MK1 AGU

Hello All,

I have a MK1 golf 20VT AGU that i am having some problems with as its my first project, i have attached some pictures to help show you what im talking about.

Firstly this is the engine as it stands (bit of a mess)

Where does this connection need to be joined to from the throttle body?

The connection on the end of the inlet goes to the servo? (i think?) but i am not running a servo on this car? also there are two vacum connections on the bottom of the inlet, where do the connect up to?

Any ideas where the line off the circular part on the end of the fuel rail connects up to?

as i am running after market intercooler pipes where do the connections on the dump valve need to end up? also the vacum line on the top?

lastly the airmass? i want to run a cone filter but i have no idea how to run this airmass as it is huge!? Please keep in mind i want to keep the engine bay as shaved and tidy as poss!

Many Thanks

block off all the unused vacuum ports, with the bigger one on the round thingy not sure a 20v expert should hopefully be along shortly.

with the airmass you need to find the correct housing to fit it into, if the oem one for your engine isnt suitable swap the airmass unit for the correct one to fit the correct housing.

if its a bosch one post up any part numbers on there, this will help us ID it.

also have you got the ecu that this engine was running from before it was removed? If so its probably been mapped to match the airmass, so you'll need to find the right housing to use it or get a remap to suit the replacement airmass.  the VR6 housing is a common upgrade for 20v owners, they use that as its bigger than stock but swap the original airmass into it so the ecu is happy

So when you say "block off all vacum ports, with the bigger one on the round thingy" do you mean connect all the ports to the "round thingy" on the turbo pipe?

I have looked at my airmass and it is bosch with a number of "965 12 1A"

The engine and ecu came all together in one bundle.

I just mean any spare ports you have left over, cap off.

with the round thingy I meant 'dump valve', didn't read your text properly

I shoudl have just opened ETKA and had a look yesterday sorry! looking at it the fat end of the dump valve should be plumbed into the side of the rubber pipe, yours is custom and hasnt got this connection as you say. With it capped off like that I would assume this makes your dump valve useless? probably not a great plan…? smaller vac line on the valve goes direct onto the turbo.

the metal thing on the end of the fuel rail is the fuel pressure regulator, the pipe from that goes to the left nipple on the inlet manifold on the passenger side near the big one for the brake servo if that makes sense?

Thats great! that makes sense to me about the vacum line of the fuel pressure regulator,i take it that means the other port on the bottom of the inlet needs blanking off as im not running a servo? what about the vacum line on top of the dump valve?

By the sound of it i need to buy a custom intercooler pipe which comes out the turbo at 90 with a port for the dump valve?

Any ideas on the airmass?

aye both the unused nipples on the inlet cap off, and as i say the vac line on your dump valve runs to the turbo itself.

not sure on the fat dump valve pipe connection to inlet, though yeah i would assume it would be best to plumb it in as per factory

as for the maf, google comes up empty so no idea what it is

Think your 'dump' or recirc valve should be controlled by manifold pressure/vac as mine is.  I have run a vac pipe from a spare nipple on my inlet directly to the recirc valve.  Recirc valves are used on these engines as the air has already been metered as on an AGU it relies on MAF not MAP i believe. The recirc valve can be plumbed anywhere on the boost pipework (some use hot side, some use cold side of the intercooler) then recirced or dumped back to before the turbo on the Turbo intake pipework anywhere after the MAF. Hope this helps! 

Firstly, the two connections you mentioned underneath the inlet manifold, one goes to the fuel pressure regulator and the other goes to the recirc valve.  You will need to plump in some pipes for the recirc valve into your pipework, the side pipe needs to go somewhere in the pressure side of the system you will need to make/buy a t piece for it, needs to be there to release pressure when you let off the gas to prevent turbo stall.  MAF you need a housing for it to sit in and go straight after the air filter and onto the turbo inlet pipe.

aaahh I see where I went wrong. the N75 is the one which has a vacuum line direct to the turbo nipple, the recirc/dump is on the other nipple on the inlet manifold as said

The ETKA picture shows the N75 as being round like the recirc/dump valve, which it is not in real life

Yeah the N75 has a line direct into the intake pipe, one to the turbo actuator and one to the pressure side of the boost system, it then controls the boost pressure by alternating the n75 valve between the pressure side and the intake (atmospheric) side.  There is no map sensor on an agu though so it calculates it through MAF/TPS/IAT/other wizardry!