1988 Scala 1.8t agu conversion

[ant]

Before fitting the new more powerful engine i thought it would be a good idea to have better brakes, the original front brakes where refurbed and worked great so thought i would leave them for the time being, i decided as i had the a3 1.8t servo and mastercylinder why not have a go at using it as it was alot bigger? First the brake linkage had to be altered as the clutch pedal fluid inlet / outlet got in its way:

Brake 1.jpg

The altered brake linkage:

Brake 2.jpg

New brake linkage fitted:

Brake 3.jpg

[ant]

Old servo and mastercylinder with end connector unscrewed (this is needed to attach the new system):

Brake 4.jpg

The new servo and mastercylinder with a fixed ball end (push fit into a plastic conector on the audi):

Brake 5.jpg

1.8t servo and mastercylinder with the fixed ball cut off and threaded with to m10 1.5:

Brake 6.jpg

[ant]

Close up of new threaded end:

Brake 7.jpg

Amount cut off the end before threading it:

Brake 8.jpg

Scirocco connector fitted to the 1.8t servo and mastercylinder:

Brake 9.jpg

[ant]

A bracket was made up and fitted to the standard servo fixing point to hold the weight of the rear brake bias, these where fitted to the rear servo bottom outlet via new brake pipes and a brass t-piece:

Brake 10.jpg

Another brass t piece with a small 90 degree section of brake pipe was made up for the front brakes:

Brake 12.jpg

1.8t servo and mastercylinder test fitted - the fluid reservoir was removed as the air intake was going to lie across it, 2 plastic pipe inserts from a beetle VW p/n 658VG0120 where fitted (with no modification):

Brake 13.jpg

[ant]

I also bought a remote beetle brake fluid reservoir p/n 658VG0100 and a bracket was made up with stainless steel sheeting to fix it in place:

Brake 15.jpg

Brake 16.jpg

1.8t brake mastercylinder and servo fully fitted with remote fluid reservoir:

Brake 17.jpg

[ant]

Another view of the set up (you can see where the air intake is which would get in the way of the standard fluid reservoir):

Brake 18.jpg

A rear disc brake conversion was also undertaken afterwards as the drums barely worked, i used audi a3 1.8t callipers and brake pads, mk3 golf calliper carriers, mk2 scirocco/mk2 golf disc brake stub axles, mk2 golf rear discs and bearings, scirocco 16v handbrake cables and screw to banjo conversion braided brake pipes (see following link for those interested in how to http://www.edition38.com/forums/index.p ... pic=461850), forgot to take before and step by step pics!

Rear disc brake conversion.jpg

Thats enough updates for one night, looking forward to your comments!

[james butler]

looking awsome so far ant! i really like some of your mods although youre brave modding the brake linkage hopefully you wont be pressing the brake pedal too hard though with that servo upgrade.
really impressed with the remote fluid bottle idea,
looking at your pics would it not be possible to put your remote brake fluid reservoir in the scuttle? maybe it would look a little cleaner out of the bay?

[james butler]

oh yeah one more thing, did the 16v handbrake cables fit ok? i have mk3 callipers and carriers but havent got the cables yet.
ive been told cut down mk4 cables will work but havent seen proof yet of how to cut them.

edit apologies i didnt read your link 1st, it makes sense now

[dingorocco]

Wow, like very much using the audi pedal box in the rocco, very neat.
Dont agree with using the master cyl set up with front and rear split circuits, original set up with the diagonal split will allow car a greater degree of control if one brake circuit fails. Having the brake pull rod with the offset step in it may cause some issues as well I would think but definitely interested to see how it all works out.

Keep going, top job !!

[ant]

James butler yes the handbrake cables fitted fine however the calipers have to be fitted upside down, ive turned mine the right way round and trying to find a way to route them while I'm having the running issues I mentioned to you when I saw you the other day. Will keep you updated with that! Unfortunately with the fluid reservoir I couldn't as the outlets come out the bottom and the pipe just wouldn't bend enough for it to do so, will be looking to tidy up bay at a later date so will prob have to find a different shape or size.

Dingrocco I agree however with the Audi set up its so much newer it should prove to be more reliable, also with the fluid reservoir its split which will always hold fluid in the other compartment if loss of fluid happens one side always leaving me with brakes.

With the brake linkage my dad is a very experienced welder fabricator so have full trust In his abilities, I wouldn't want any old welder doing it as its always risky playing with brakes. Also he used to fit hydraulic systems in lorries so has been with me each step of the way with the new system and thinks it will work well, which it does as the car is stopping very well with it now its running! Will see with time how it goes of course.

[james butler]

we will have to meet up some time ant and show me what this car can do, it must be savage!

[ant]

we will have to meet up some time ant and show me what this car can do, it must be savage!

Yeah definitely! Once the limp mode issue is sorted anyway, although to be fair it still shifts ha. Should be getting the part this week so hopefully be sorted, will drop you a text when I'm going to be over your way again.

[ant]

Next i started on prepping the engine ready for it to be fitted, 1st off i decided to spray the inlet manifold silver with a high temp spray as it looked a little tatty, this is a temporary fix as i want to get another to polish it along with the rocker cover:

Before:

1. Manifold Prep.jpg

After:

2. Manifold Paint.jpg

I replaced the coolant sensor from the original 1.8t to a mk3 golf black one as this will work with the 1.8t ECU and the standard scirocco cluster:

3. Water Temp Sensor Swop (MK4 to MK3).jpg

[ant]

I replaced the standard 1.8t low oil pressure switch (black) situated on the right hand side of the oil filter housing, i also added a high oil pressure switch (white) as the 1.8t for some reason didnt have one, this was added above the oil filter housing (to the left) where there was a spare hole blanked off by an allen key bolt. Both switches are standard from a mk1 golf or scirocco mk2, unfortunatley fogot to take pics of them in but got one of the parts when they where delivered (on the left):

4. New oil and coolant sensors.jpg

I bought some engine mounts from epytec in germany that would make the engine and gearbox a direct fit to the scirocco, i looked in to making some but for the cost it just wasnt worth it, something i found out with the rubber inserts is to push them in with the bolt hole at the top otherwise the engine sits to high and the bonnet doesnt close! - this happened to me as i believed standard fitment was with the bolt hole at the bottom and went with it.. I painted them with etch primer and then with black high temp spray paint.

5. Conversion Mounts Standard.jpg

Here is a pic of the side of the engine before the new cambelt and different tensioner was fitted to allow for the engine mounts. Originally the 1.8t has a sprung tensioner and the mounts had legs which bolted in through gaps in the cambelt cover:

7. Engine Cambelt Before.jpg

[ant]

After pic, the standard sprung tensioner was replaced for a 16v fixed tensioner p/n 051-109-243 from heritage, the cambelt was replaced for a standard 1.8t one and the water pump was done at the same time. This then allowed for the mount to be fitted (note rubber insert should be other way round, doh!). Later on the power steering pump was removed and a smaller auxilary belt was fitted which was a 6pk 923:

8. Cambelt and Pully Change.jpg

Pic of new driveshafts, 100mm end to fit the 1.8t agu gearbox flange and standard spline to fit scirocco wheel hub - brand new off ebay (not re-manufactured):

11. New converted Driveshaft 1.jpg

Driveshafts in place temporary as they where removed for engine fitting:

13. New converted Driveshaft 3.jpg