Syncro engine swap - DJ to AGG

[BAYVELLE]

Engine crane down nr Glastonbury if you want to borrow it? I'm not using it at the moment.

[syncropatrick]

Darren, I'll call you tonight.

[syncropatrick]

Try to avoid having a donor with aircon - its a faff to manoeuvre that system out the way (you can't release the gas into the world), plus I recall reading that the aircon alternator bracket has to be swapped for a non-aircon one to fit under the van engine hatch.

[silverbullet]

Except that if you have a system leak then the gas leaks out anyway... R134a is non-CFC isnt it?

[ELVIS]

non aircon bracket + alternator body is different IIRC chap so would possibly need matching alternator

[adyjoad]

Alternator bracket you need is 028 903 143 AD and yes you need a matching alternator.

[jes*b]

Patrick ... I might have both of those ...let me check this evening .

[syncropatrick]

If I'm buying an alternator can I fit a 120A one?
My battery alt->bat charger can be driven up to 120A . Its to charge the 220Ah leisure bank as well as starter.

Jes, I'm interested.

[syncropatrick]

Slow day dismembering the Golf. Many unfamiliar terms in the Haynes,such as EGR valve, and lots of reading, looking at diagrams and scratching of head.

Todays anointment - CV grease.

Best tool of the day - my decent set of CV bolt bit sockets, and more Plus Gas.

I reckon another day of mechanical dismemberment and then onto loom pulling.

[ELVIS]

No EGR on yours chap.

When you take loom out, go under dash, pull all of the plugs off the relay board, You dont need any of the plugs that go to the relay plate so just pull the wires back through the bulkhead(from the engine bay side) as much as you can and chop all the plugs off.

Immobiliser is up under dash, you will see it if you look under from drivers footwell towards the transission tunnerl side of the steering wheel.

Give me a bell if you get stuck with loom, done three now in last 8 days

[syncropatrick]

No EGR on yours chap.

When you take loom out, go under dash, pull all of the plugs off the relay board, You dont need any of the plugs that go to the relay plate so just pull the wires back through the bulkhead(from the engine bay side) as much as you can and chop all the plugs off.

Immobiliser is up under dash, you will see it if you look under from drivers footwell towards the transission tunnerl side of the steering wheel.

Give me a bell if you get stuck with loom, done three now in last 8 days

Thanks, that saves me some effort.

[badgerfax]

If I'm buying an alternator can I fit a 120A one?
My battery alt->bat charger can be driven up to 120A . Its to charge the 220Ah leisure bank as well as starter.

.

Hello chap, I'm in the process of doing the same conversion. If you locate a 120A alternator that fits can you let me know the part number.
I have had to change the alternator bracket too and the alternator I scavenged from scrappy is only 70A.

Also I have found that water pipe part number 037121053H is perfect fit from water pump to flange on cylinder head.

I have found supplier of pa66 gf30 hose connectors, they do a 16mm x 16mm x 8mm T piece which I plan to use to connect the 8mm throttle heater pipe to below expansion tank. I have not yet placed order for this and the other connectors as until I get the agg in the van I am unsure how many other will be required. Let me know if you want to double up on the order as they are european company.

Cheers
Gary

[syncropatrick]

Gary, thanks for hose tip.
I'm not sure what a pa66 gf30 hose connector is. Had to google it. I've no idea how many or where these are needed. Until I've got to that bit of reassembly, I don't think I'll have a better answer. What is the company, in case they have other goodies we might need?

Spent the day running errands and acquiring more toolage, including some 11mm OSB so the wheeled implements can traverse my knobbly parking bay. Got to go to work for a few days, so back on this on Saturday.

[silverbullet]

I was the originator of that little snippet in Mechanical:

I would look for PA -GF30 or similar. PA is polyamide aka nylon, the GF30 means glass fibre reinforced @ 30%
Pretty close to what VW still use for plastic coolant parts afaik

Two days ago. Still no thanks though...

[badgerfax]

I was the originator of that little snippet in Mechanical:

I would look for PA -GF30 or similar. PA is polyamide aka nylon, the GF30 means glass fibre reinforced @ 30%
Pretty close to what VW still use for plastic coolant parts afaik

Two days ago. Still no thanks though...

Terribly sorry Silverbullet, please accept my apologies and many thanks for the hose info.