Vw 2.0 AGG conversion

[Ameer]

Howsit guys,

So I’ve decided to ditch my trial of building a 2.0 8v from scratch, and went with buying a import engine

See pictures below,

The engine is going into a 2005 citi mk1

Could you assist in creating a list of things that would need to be done to get the motor installed in the car?

What would I need to change? What would I need to get?

I have the original 1.4i mp9 setup, currently removed from the car with all OEM parts.

FFZ gearbox is what I have,

Would I need to change mountings?

I have taken a picture of the current motor, engine bay and import engine

Thanks in advance for all assistance


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[missioner]

Right first up you will need the 210mm clutch and flywheel set, anything else will slip as soon as you go over half throttle.

I would also (strongly) suggest the 280mm front brake kit from GW Delaney. A Citi doesn't stop well to start with, this kit goes a fair way to remedy this. It requires 15" wheels, and it's race proven with various options.

Post more pictures of your progress

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[missioner]

Use as much of the original ancillaries to simplify the build.

Parts that don't need modification to fit and work are more reliable.

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[175SBU]

How much did it cost for the import motor?


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[blou_poot]

Agreed with above.

210mm flywheel and clutch for the 1.8 the 2.0 clutch will need the bigger CV cups.

Use the standard 1.4 intake with map sensor, get the mp9 flashed for 2.0 and bobs your uncle...

[Ameer]

Thanks for the input missioner,

Do I just ask for a 210mm kit and will that come with the right flywheel or do I need to do scrap yard searching for the right flywheel?

Also what all would need to be done for the brake upgrade? Is a complete new brake setup?

I was told the mountings would need to be changed? Do I need to cut on the body and reposition the mountings? A friend of mine suggested doing this, not sure if it’s the correct method...

I am hoping to swap whatever I can from the original motor onto the new motor, another fellow also mentioned changing the dizzy?

I paid 8k for the motor, bought it about a month ago

So project should be kicking off very soon


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[Ameer]

I have a remapped polo cup box which I will be using, got it done by a guy in Hout Bay..




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[Ameer]

Will the clutch kit work directly with the ffz gearbox?


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[blou_poot]

Mountings are the same... Unless you want solid mounts...

Clutch and flywheel will fit in box get clutch that works with flywheel.

Goldwagen has the complete kit.

Allen from houtbays ecu flashing is great should work.

[amstel18]

You will also need a Distributor from a late model golf 3 gti. The one that comes with the AGG is single window and you need 4 window for mp9 to work. You can mod it, but it's less hassle to buy a new one. You can't swop in the old one as the gears are different sizes.

on the mountings. If you disassemble the AGG motor's cambelt covers, the 4 holes are there to use your existing mount from your old motor. You can just cut the covers to refit around the mounting, or leave the covers off. I prefer having a cover to protect the cambelt.

To use the new alternator setup on the AGG you need a Polo without AC's ribbed belt. Can't recall the part number, but most spares shops should be able to sort you out.

[175SBU]

Thanks guys, this is informative indeed.
Kudos


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[missioner]

I was gonna reply but all the questions are answered.

Seems my work here is done.

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[missioner]

Oh rechecked not quite done....

The brakes from GW Delarey consist of a pair of 280mm rotors, pads for vented discs and adapter's to space the calipers correctly. It uses the original caliper without any modifications and comes with all the necessary hardware.

The prices vary depending on what kind of discs and what spec pads you choose. For your setup the mild street option with the Ferodo DS pads should be perfect. The car won't be used as a track beater so more stopping power isn't needed.

VS the stock 232mm brakes, these will make you need tissues in the car, so you can clean the mucus off the windscreen after each time you stamp on the pedal. Anything not strapped down will be lying on the dash including the passengers.

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[Ameer]

Will be calling GW tomorrow for the clutch and brake cost, shall update pricing on here

Blou mentioned about mounts being solid, would that be referring too these mounts in the pictures.

Numerical order 1. Down.

Which of these would you be referring too? Only the mounts that support the motor? Or could we do the bushes and rubber parts of the control arms in something more solid?

What would best be advised?

What would be the pros/cons to solid mounts?

Any specifics I would need to ask the mouldings company? Are they supposed to fit the metal sleeve inserts etc in the mounts, for the bolt to go through?

Thanks






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[missioner]

Yup all of those you pictured.

Personally I would only replace the engine mount rubber with the polyurethane one. You are not chasing power or doing a turbo build, the rest of the stock rubber mounts should do fine. It ain't broke...

If at a later stage they break then look further into the polyurethane mounts.

GW Delarey can also supply the poly rubber kit. Ask for the centre bushed engine mount kit, as some have experienced issues with the offset one.

Look up #PapaJo's Caddy thread for more details regarding the poly engine mounts.

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[Ameer]

Thanks missioner

Only going to do the engine mount and gearbox mount in poly..

Been struggling to get the original engine mount off the 1.4 motor, any quick tricks?

I have loosened the 2 bolts on the LH side of the mount, but cannot seem to find another bolt or a method to remove the covers, without removing the pulleys.

Help needed,

Thanks again


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[Ameer]

After some struggle, managed to locate & remove the 4 bolts holding the engine mount on the 1.4 engine.

Phew, it’s tight without removing the the covers properly but done.

Now off for Poly




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[Ameer]

Side view Sunday of 1.4i mp9 with engine mount removed


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[Ameer]

Side view Sunday of 2l with engine mounts removed




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[Rourke]

Great informative build here

keep them coming

Nice thing is you are not scared of sharing pricing here .

Many have done countless conversions ,but not including pricing and that being that some have been done a while ago.

Updated pricing will give some1 looking into this a better perspective before trying to go at it.

A q from me if i might?

the 2L AGG Engine , i see some golf 3.5 cabrios have them in .
What are the differences to mp9? what is mp9 Exactly ?
Does this AGG engine not use Map Sensor ?


Cheers

[Ameer]

Thanks Rourke

Yeah 100% agreed, all the other build threads seem to be a bit outdated, and it’s always a plus to have some documentation to the build

Makes it easier for the next person,

So I’ve sent the mountings away to, to get polyfied, with some 65% polyurethane

Will share prices and pictures once collected at the end of the week,

I will leave the questions to be answered by the more knowledgeable guys, as I’m interested to see the response..



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[Ameer]

I’ve created a list of things to do and will be adding too it, as the build continues

Check it below,

Feel free to comment if you see I need to add things or have advice on any of the points, will be greatly appreciated..




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[175SBU]

Great info, much appreciated, this will make it so much easier for the next person; i could be that next person


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[Ameer]

Managed to find a kamei rear boot spoiler,

Took me sometime to get my hands on it, but nonetheless I have finally got it

Will be saving this for the finishing touches




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[Ameer]

Can somebody confirm if this is the correct flywheel I purchased?

Managed to get it from a second hand shop




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