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1984 1.9DG to AGG Conversion

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club joker 84 View Drop Down
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Joined: 21 Jul 09
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Post Options Post Options   Thanks (0) Thanks(0)   Quote club joker 84 Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jul 18 at 20:50
Voltage regulator I think you just measure between the two connected pins and you should get about 10v.  https://www.thesamba.com/vw/forum/viewtopic.php?t=609208&start=0

I only found it because I had tried everything else.  New sensor, checking fan function, checking thermostat, etc.  Wasted hours!  For the cost of the part, it would probably be one of the first things I looked at if it ever happened again.

I ended up using the JX dipstick and tube following the method that Gary D recommends in his notes.  It took quite a lot of fiddling to stop it leaking though.  I then extended the JX dipstick by welding in a bit from the AGG dipstick.  It is still not ideal and weeps slightly.

If I did it again, I would probably use the AGG dipstick and just shorten in to get under the hatch.  You would probably need to move the collar up it a bit so that it came to the right level with the JX sump on, but much less likely to leak.

What did you want to know on the air intake?  There is quite a lot of information out there about the different ways people have done it.  I was trying to keep it looking factory, so re-used the DG air box.  There are two types of DG air box though.  I don't think that my method would work with one of the round ones.  

I aimed to keep the original tubing between the MAF and throttle body, as I thought that these would be the most important bits.  Other than that it is just a matter of getting clean, cool air to the MAF.  My intake might be a bit restrictive maybe, but the DG filter was quite a bit bigger than the AGG original, so seemed ok to me.  Feels fine to drive, but not tried any others to compare.  It is nice and quiet if that is important to you.  In one of my posts above, there is a link to a guy on retro rides (I think) who managed to re-use the original AGG air box.

You will probably need an adaptor to join the MAF to any aftermarket intake hose / filter etc.  I used this one http://www.autosiliconehoses.com/air-inlet-adaptor-vw-golf-mk2-mk3-mk4-jetta.html.  It was a bit off when it came, as it was square inside, so I cut this out with a hacksaw and Dremel.


Edited by club joker 84 - 05 Jul 18 at 20:59
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bmouthboyo View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote bmouthboyo Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jul 18 at 08:50
That is great thank you, I will have a little look about and check it's not the timing on my older Gti engine and then check regulator.

Regarding the air intake, I like your idea of using the intake hoses running to the OS snorkle. What do you use after the airbox up into the snorkle box? I have a diesel snorkle header part but I don't think it will fit in the OS box. How does yours prevent water ingress?

Cheers
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club joker 84 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote club joker 84 Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jul 18 at 23:49
Hi,

No snorkel on mine, just the airbox sitting in the engine bay. Intake faces toward the vent area, but not had any problems with water intake. Pretty sure you could join up to a snorkel if you were offloading a lot. Mine stays on the road, and I have not had any water ingress issues.
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