Late bay Gti conversion

All the advice from the t25 group is the abf head is a lot bigger and fouls the chassis rail (t25).
I'm lead to believe the agg is smaller, although I can still foresee issues in making it fit. I might end up with a different inlet manifold but I think the dizzy should be fine as I don't run the firewall (is missing) - although I am loathed to bash my new tank like the old one to make the engine fit!

 

Are yo not using the gearbox that was fitted to the diesel engine ?
I might be interested in buying it if your not .
Cheers

 

I’ve got a range of boxes, 2 3H code diesel boxes but I’m plumping for the AAP petrol box which I’ve hoarded for years as is the best ratio you can get.
3H box(es) will be up for sale at some point when I know the aap is fine


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Was it a 3H box on your 1.9 diesel engine ?
What did it go like ?

 

Yes it was. Not great to be honest.

Very high revving even with oversized rear tyres.

Took off like a scalded cat up to 50mph but not a lot of go after 60mph


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Probably the same box my son already has fitted to his T25 but we can't read what code it is.
We've squeezed the biggest tyres possible on the back but it's still revving its bits off.
Cheers anyway.

 

Slow (but some) progress tonight, a bit of a surprise when I removed the sh*t plate as it was full of congealed coolant



Though to be fair the seller of the golf did say there was a coolant leak.

So cleaned it off, fit the t25 dirt plate and replaced the coolant flame rubber which should sort the leak.

Set about to refill the gearbox with oil and find the selector rob rubber is split and perished so ordered a new rubber and cane inside as it was approaching freezing in the garage!





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The AGG is a great motor and seems to be really praised by the T3 (not T25 ) lot.
I've been looking to fit one to my caravelle to replace its 1.9WBX but i need to replace the gearbox too as its lost its 5th gear.

 

Start collecting the diesel parts now - they are only going up in value!

 

Looking at about £100 just for the 2 bars plus another £50 or so for the sump and £50+ for the mounts.
I might just fit the 150bhp 1.8T from a passat at 15 degrees instead of canted over at the jaunty 50 degree angle the T3 uses and just raise the engine hatch by 40mm with some box section steel. I would need an adapter plate though which aren't cheap but possibly cheaper than buying all the diesel bits if i could find one s/h.
I could then use the WBX engine bar with passat hydraulic mounts welded on.

 

I’ve got an adaptor plate. 091 gearbox to in-line 4 cylinder, trying to get it re-produced.
Agree with the early Passat 1.8t, I will probably do that next!


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TSR do adapter plates for VW inline4 but they're £375 for manual or £410 for autobox.
I seem to remember someone having the adapter plate as a CAD drawing. Cost about £70 to get one made from an engineering shop with the mult miliion pound tools.

 

Slight progress tonight even though it’s snowing.

Seems the fuel filler neck is worth checking along with your fuel lines



Cracked and split, glad I’d already bought a replacement.

A small tip, after realising that refitting the neck would be very difficult on my own I fit a cable tie into each hole on the neck




You can then easily pull each one through to the outer body and seat the elbow properly.




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Then progress stopped, as I realise I’ve bought the wrong hose to connect the metal pipe to the tank



Far too long! Will be on the phone to heritage in the morning and see if they will take it back and swap it for the short one


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Is it the same shape? Can you not just cut it down to size?

 

The short one changes diameter quite a lot over its 120mm length. I'll have a look later though, might be a good idea

 

@illzlee good tip on the cable ties - i need to do mine at some point over the winter (had the part for a month now though but no inclination to do out side to a frozen garage - we're forecast for -8 tonight eek!)

 

More done tonight - dug out my shop soiled fuel tank



As the underside is fitted with the secondary outlet



So drilled the nut out to accept an 8mm dia outlet




Fellows speed shop sell these, and they reckon with an 8mm outlet you can get away without a swirl pot just gravity feeding a high pressure fuel pump.
Time will tell!

So in went the tank




And then it all came out again as I couldn’t get the filler neck hose far enough into the filler pipe







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Didn’t do a lot more as got distracted taking ancillaries off the old Diesel engine to sell on.

Then remembered the shift arm rubber boot had arrived for the gearbox so swapped that over




Gonna fill the gearbox back up with oil tomorrow then hopefully mate it with the engine on the weekend


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Great thread. Especially the before and after electrics pics.