Category: Autot (page 1 of 15)

A few words about the inspection and getting the modification fully street legal in Finland.

A conversion like this requires a special permission from the officials. Scirocco was never made AWD so they can’t just approve something like this on a regular annual inspection. We had to get the permit and it meant quite a bit of paperwork.

When we did the application we explained everything in detail and how all the body modifications were done according to VW’s instructions (instructions were attached as appendices). We explained all the parts that we used, showed parts lists and images from ETKA and we also had to get documentation from the manufacturer’s representative (importer in Finland) to certify that the brakes are working as they’re supposed to. For the actual inspection it was enough that we took a full scan of the car with VCDS, signed by a local car service.

It took about a month for the officials to handle the application. They asked some additional questions once but anyway the whole process was much faster than expected and we were pleasantly surprised how well the authorities were co-operation on a modification like this.

At the inspection we also had to identify where all the parts were originated (to prevent usage of e.g. stolen components). At the same time also the H&R coilover suspension was checked and included on the list of modifications. The actual inspection was fast, not much different from a regular annual MOT, but the paperwork took longer, more than an hours.

As a final word for this process we have to say that it for sure made it easier to get the approval when we had a complete donor car which was very close to Scirocco from the chassis point of view. It was relatively easy to make the application and show where all the components were coming from. It would have been much more difficult to explain everything if the parts had been source from several different vehicles or even made some parts by ourselves.

As I wrote on the previous post, ESP became quite a headache. Actually we drove with the car for almost two years before we were finally forced to get it done because the annual inspection was closing (in Finland you don’t need to do MOT every year for such new cars).

We got fault codes saying we had issues in Powertrain data bus (18055 – Check Coding of ECUs on Powertrain Data Bus). ABS was functioning as it should, just ESP was out of the game. It did not prevent driving, but was obviously a safety issue and MIL light was on. We tried different codings, tried to learn how the coding works. Long Coding helper in VCDS was not very helpful with ABS unit (only a few bits are documented) but we were able to find something by Googling and asking help from Ross-Tech’s forum (Ross-Tech is the maker of VCDS). Eventually we were able to learn what each of the 18 bytes were meaning. Even last five numbers of the VIN were encoded on the coding.

So we were trying to generate a code that was similar to Golf R but embedded with VIN digits from Scirocco. Golf was not identical, it had DCC suspension so we still had some bits that we were not sure if they were correct or not. Still, we couldn’t get it done – Coding out of range it was every time.

Many persons from Ross-Tech forums offered help and proposed all kinds of codes, none of those worked. Eventually we realized that the ABS unit communicates with the cluster to learn about the model of the car – when the cluster says the car is a Scirocco, it won’t accept coding as a Golf. And Scirocco can’t be AWD. And vehicle type can’t be changed on the cluster with VCDS.

We found a guy somewhere in Poland who was willing to modify the EEPROM on the cluster but at the same time we decided to try something else. We took the cluster from the donor Golf R and plugged it in Scirocco. The connector is the same.

Best part was that now ABS unit was happy to clear all the fault codes! Now that the ABS/ESP was handled, we only had two issues remaining: 1. Immobilizer 2. Physical fitment of the Golf cluster. After all the puzzling with the ESP these seemed like minor issues.

We only had one key remaining with Golf so we decided to take it and fit Scirocco’s key blade to the Golf key fob. That way we could keep Scirocco’s original key lock. For cluster-ECU communication there’s two options – take the ECU also from the Golf or disable the Immo from Scirocco’s ECU. Both work well – we decided to keep the Immo and take the ECU from Golf. Now both cluster and ECU were from Golf. Now when someone plugs a tester in the OBD the car seems like a Golf with Golf VIN.

Physical fitment to the cluster was a bit more work. We were comparing the clusters and realized that essentially they are similar, just the outer casing is different. We decided to tear down both and were able to swap the Golf cluster internals inside Scirocco’s cluster casing!

Finally! No fault codes or MIL lights!

There’s only two downsides with the way we did the cluster modification. The 2010 Golf R cluster apparently does not understand automatic long beam headlights. The feature still works, but it just don’t show the symbol that this feature is activated. Sometimes this causes confusion to a person who’s not used to driving with this car.

Another is a bit more unpleasant – you can’t totally deactivate ESP from ESP OFF button. 2010-2011 cars are generation where you can only disable traction control but it still keeps ESP active. This means you can’t have all the 4wd drifting fun on wintertime without taking some ESP fuses off. Apparently they changed this in later models so it might be possible to swap some newer ESP parts in but so far we haven’t done that.

It had been 2,5 weeks since we started to take parts from the Golf we bought from Sweden. Only doing this in weekends and evenings. Now it was only some coding with VCDS to complete the project. Well – we thought so.

It was easy to get the AWD working. Just a few ticks on check-boxes (CAN gateway & engine for sure, don’t remember if there were something else as well). On the test drive AWD was working perfectly. The only issue remaining was ESP – that became a bit longer story and there’s another post about that. All other units were happy with no fault codes except ESP.

The title picture is from a market square of our home town together with 2011 Golf R that we had at the same time.

Finally it was time for fitting the rear axle and other parts of the drivetrain/chassis.

In addition to trunk floor replacement some smaller modifications were still needed. First is the fuel tank.

Scirocco’s fuel tank (left) is quite different from Golf’s.

We can’t just swap the Golf tank to Scirocco. The above photo shows clearly the reason: The filler pipe is different. In Golf the filler cap is way more back (about 20cm). In Scirocco that’s where the rear lamp is located, so we could even think of further body modifications – so we had to modify the tank.

We cut the filler pipe from both Golf and Scirocco fuel tanks.

Scirocco filler pipe was connected to Golf tank with pretty simple method – small piece of petrol resistant hose and couple of hose clamps. After four years we haven’t had any kind of leaks.

It was also necessary to cut another hole to the floor under the rear seat to get access to the fuel tank.  The opening gives access to the second fuel level sender and the wiring to the Haldex controller also goes through this hole.

We used Golf floor piece as a template for cutting the hole. There’s already a molded space for the hole.

The drive shaft support bearing required brackets – these were cut from the donor Golf.

In this photo we already have the rear diff installed, but that’s not the point here. Two of the fuel tank brackets/nuts are different from FWD, this was also taken from the Golf.

Some rust protection was also applied.

Finally we’re ready for installing stuff. To be continued…

As described on earlier posts, pretty much the only major body modification needed for 4motion retrofit is replacing the trunk floor with a floor from Golf. We did this by following VW’s instructions. The only difference is that in VW’s instructions they use brand new floor, we started by first removing the floor piece from our donor car.

Golf trunk floor being drilled and chiseled from a larger piece.

Ready to be installed to Scirocco. The large opening is for battery – some Golf models have battery on the trunk. This one has a metal plate to cover the hole.

View from the underside

Then it’s time to start cutting the Scirocco…

Comparing Golf and Scirocco floors. The difference in spare wheel space depth is remarkable.

Golf 4motion has a styrofoam spacer on the trunk to give space for the spare wheel. We’re not going to use that to keep the trunk volume original. We’re going to replace spare wheel with a tire repair kit.

After cutting the excess materials out we’re ready to test fit the Golf floor piece.

Like a glove…

After welding some protective coating is applied

Also protected from the under side.

Finally we applied some fresh paint.

Before we started to tear down Scirocco, we set it on scales to see the axle weights (needed for regulatory paper work).

Front seats out

We also had to tear down the dash partly – some wiring needed to be connected inside the dash (more about that later).

Comparing Scirocco (back) and Golf clusters.

Heat shields under the car. The only difference between Scirocco and Golf are couple of holes needed for drive shaft support bearing.

Rear axle dropped off – this took only a few minutes.

Next we decided to change the gearbox. Unfortunately we were so busy doing the actual job we forgot to take a lot of pictures. Anyway, first we had to drop down the subframe – together with steering gear.

To be able to drop down the front subframe and steering gear we opened the steering shaft.

It would have been a clever move to remove the steering wheel too – my 4 year old son had too much fun ”driving” the car and while the steering wheel was now free to rotate as many cycles as he wanted, he broke the slip ring behind the steering wheel…

While the engine was supported from the top side, it was now easy to remove the gearbox and replace with the box from Golf.  We compared the Scirocco and Golf gearboxes and they were identical (including gear ratios), the only difference is Golf’s angle drive.

Scirocco’s fuel tank (left) is quite different from Golf’s.

Scirocco trunk. Spare wheel space is a lot deeper than in Golf. This is the reason why we need to switch the floor to make room for rear diff. We’ll post a comparison photo a bit later.

Under the rear seat is the opening for fuel pump and gauge sensor. In Golf there’s a hole on both sides.

On the underside everything is same as in Golf except the spare wheel area. Rear axle bolts into the same locations (yellow circles). Springs attach to the areas marked with purple.

In next post we’ll replace the trunk floor.