1988 Scala 1.8t agu conversion

[ant]

More update on the build!

Side view of the engine with parts temporarily in place - braided fuel lines to new 8mm I/D steel fuel lines, silicone coolant pipes from engine block to header, and silicone 2.5" to 2" reducer on inlet manifold (swopped this at a later date for a 90 degree bend). On top of the inlet manifold there is a bit of braided hose and vacuum pipe, when it was fitted to the audi it used to be linked to the charcoal canister (fuel tank vapour to inlet manifold), i removed it and ran the boost gauge from it, later on i removed the brass outlet, tapped it and put a grub screw in it to smooth it over.

22. Fuel line and coolant header.jpg

Another view from the front:

21. Fuel line and coolant header.jpg

This is the intercooler pipe which originally came on the audi, before it was a different shape, it ran off the back of the turbo then at a 90 degree bend ran along the back of the engine towards the drivers side then bent another 90 degrees and ran to the bottom of the engine where it joined the pancake pipe which connected the side mounted intercooler. I chopped it down and had it welded so it just formed a 90 degree bend with one longer section, i could of bought something similar but i thought this would be a little stronger:

23. intercooler pipping 1.jpg

[ant]

A mock up of how i was wanting the intercooler pipping, 2" polished alloy pipping with silicone joiners:

24. intercooler pipping 2.jpg

A pic from the front:

25. intercooler pipping 3.jpg

Quick pic of the toyo motor sport intercooler in place, it is bolted in through the bottom and fixed in place along the top via a stainless bracket:

26. intercooler pipping 4.jpg

[ant]

Throttle cable fitted, coolant header to radiator silicone pipe fitted, braided pipe ends and clamps fitted, radiator with slim line fan fitted, and brass inlet on manifold removed and replaced with grub screw:

27. intercooler pipping 5.jpg

Rocco front end starting to go back on:

28. intercooler pipping 6.jpg

Most of the hoses clamped down, t bolts where used on all the intercooler pipes (turned the other way round so bolt was at the bottom in the end):

29. intercooler pipping 7.jpg

[ant]

I looked into what air intakes would be best to use, i originally wanted to use the original audi one with an upgraded filter but it wouldnt fit due to new mastercylinder/servo and intercooler pipework! Found a thread online (http://www.audi-sport.net/xf/threads/mu ... rs.191705/) and it recommend using a honda s200 cone filter as they where really good quality, off the shelf and reasonably well priced at £20 compared to k&N's £50, the pipe that connects to the S200 is alot larger than the intake on the 1.8t so i used a silicone 83mm to 70mm (I/D) reducer to join them:

Air intake.jpg

Side view of engine with all plumbed and wired in:

30. intercooler pipping 8.jpg

Front view of engine with all plumbed and wired in:

31. intercooler pipping 9.jpg

[ant]

I simplified the PVC (positive crankcase ventilation) system and vented it to atmosphere as i found that it reduces the likliness of boost leaks and prevents oil vapours and sludge getting into air inatke system which reduces ocatane levels... 1st off i removed all the old piping from the crankcase and the top of the oil filter housing and bunged the redundant intake manifold hole with a 19mm alloy blank off ebay! I kept the 90 degree joiner from the oil housing and bought 3 meters of 19mm braided pvc oil pipe, 1 x 19mm t piece, 1 x 19mm 90 degree bend and a 0.5L aluminium catch can with 19mm inlet/outlets and followed this guide! - http://www.audi-sport.net/xf/threads/gu ... em.118021/

Pics of mine installed:

catch can 1.jpg

catch can 2.jpg

catch can 3.jpg

[ant]

New gears stick / selector fitted, i fitted this from under the car as i didnt want to alter the inside of the car to much, i pushed it up through the tunnel under the car and set in about an inch further back than where it would originally sit (original gearstick sits further forward i think, and leans back!), i drilled new holes and bolted it in, for got to take pics from underneath but heres one from inside:

32. Gear selector fit.jpg

Added a boost gauge, tried to make it fit in as neatly as possible, drilled a large hole in the dash blank and fitted it to it, also added a new stereo:

Boost gauge 1.jpg

Boost gauge 2.jpg

[ant]

Exhaust now! Parts used - 2m 2.5" stainless, 3 x stainless 90 degree 2.5" bends (think i had to buy an extra one making a total of 4), 2.5" stainless flexi joint, free flow stainless steel back box and the old manifold mount from the previous audi exhaust...

1. Exhaust Parts.jpg

Custom manifold down pipe:

2. Downpipe 1.jpg

3. Downpipe 2.jpg

[ant]

Mid and rear section:

4. Exhaust pipe complete.jpg

Complete system:

6. Exhaust complete system 2.jpg

Exhaust system fitted:

8. System temp place 2.jpg

[ant]

Finally the petrol tank! The originall scirocco one was modified to house the audi a3 1.8t pump and swirl pot!

Tank removed the new hole marked up, it was made to the side as the tank bottom was flatter for the pump to sit on:

1. Petrol tank standard.jpg

Hole cut out:

3. Petrol tank mod 0.jpg

Circular metal piece made to be welded to the top of the tank for the pump to be fixed and sealed to:

2. Petrol tank mod 1.jpg

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Circular piece temp in place:

4. petrol tank mod 2.jpg

Fully welded:

8. Petrol tank mod 6 - fully welded.jpg

Nuts where welded around the rim so that the pump could be bolted down (a big plastic circle was made to hold it down), test fitted:

9. Petrol pump test fit.jpg

[ant]

Petrol tank was sanded down, rust treated, painted and pump fitted:

10. Petrol pump fitting 1.jpg

Close up of pump:

11. Petrol pump fitting 2.jpg

Cutting under the passenger seat to be able to access the pump:

12. Car mod.jpg

[ant]

Some pics of the engine conversion finished!

Car pick 1.jpg

Car pick 2.jpg

Car pick 3.jpg

[ant]

Car pick 4.jpg

[james butler]

exellent work ant.

great idea with the tank mod.
i tried to retrofit a plastic mk3 tank under the car but it just wouldnt fit.
carefull what you post up as you might end up with a que of people out side your door wanting you to do theirs next!

[ant]

exellent work ant.

great idea with the tank mod.
i tried to retrofit a plastic mk3 tank under the car but it just wouldnt fit.
carefull what you post up as you might end up with a que of people out side your door wanting you to do theirs next!

Cheers mate, shame about the mk3 tank not fitting, from what I hear it fits a mk2 golf but that has a different chassis.

Ha I did think that but hey it's always good to share ideas, hopefully will help someone else out. I can't take all the credit my dad did a great job helping me along the way and his welding skills where really put to the test!

Still not running quite rite yet, hopefully gunna have a play with it tomorrow once I've put a new alternator on it. Got a mate with a mk4 1.8t with same engine so can swop parts over!