S50 conversion - brake servo question

Post Sat May 27, 2006 11:30 am

OK, as mentioned in the post about fitting smaller master cylinders and servos to alow the fitment of M50's, S50 engines aren't covered..

I am starting this post to hopefully highlight the differences between this and fitting an S50 engine.

I have an S50B32 to fit into my 318is and would like to know if using the parts given in the other thread will mean I have room for the plenum of my engine?

Will I have to make any other mods than fitting the Audi master cylinder and VW servo? Will it still need moving over? What parts/how has this been done before?

Many thanks guys.

I'm hoping to get all the brakes and suspension done this month. I'll need to buy 17"s and tyres though so not going to be a cheap option. Bummer.

Jai

Post Sat May 27, 2006 4:21 pm

Basically the VW servo will fit in the same way as with the M50 conversion, but the plenum on the S50 is bigger, so it wont be a direct fit.

The corner of the S50 plenum needs cutting to fit around the servo and by using the VW servo (smaller diameter), less plenum needs cutting. I originally cut my plenum to fit around the E30 servo, but it was just to tight a fit and would of restricted the airflow to No.6 cylinder.

The servo (VW) and M/cyl can be moved over by about an inch IIRC and this will mean less plenum needs cutting again. Moving the servo over will also give more clearance between the rubber intake boot and M/cyl. I havent moved my servo because my plenum was already cut.

I also cut my plenum a little more around the bulkhead end to give some more room for the heater matrix pipes.

I have kept the E30 M/cyl, but my plenum was also 'narrowed' by about an inch to help with the clearance issue between the end of the M/cyl and the rubber intake boot.
Using the shorter Audi M/cyl will help with this clearance issue, so the plenum should not need narrowing - one of the guys with the Audi M/cyl will be able to confirm this.

Post Sun May 28, 2006 3:43 pm

The E30 servo can be moved across about an inch, so the Golf servo should be able to be moved considerably more. Maybe enough to use an unmodified E34 pull rod.
Limiting factor will be the fluid resevoir fouling the reinforcement for the suspension tower.

Post Tue May 30, 2006 11:59 am

Brianmoooore wrote:Limiting factor will be the fluid resevoir fouling the reinforcement for the suspension tower.

Well it doesnt have to be,

From a E23 745i

Andrew

Post Tue May 30, 2006 8:28 pm

I thought someone would come up with an alternative remote reservoir!
That's S50 inlet problems sorted then. Must be enough room now.

Post Tue May 30, 2006 8:33 pm

how would you go about moving the lever the pull rod acts on? cut it off and weld it on further across?

Post Tue May 30, 2006 9:37 pm

Jhonno wrote:how would you go about moving the lever the pull rod acts on? cut it off and weld it on further across?

I've done this on my own M50 conversion.
Removed the whole mounting bracket inside, re-drilled it to fit further across, cut the hole in the bulkhead in the appropriate place, made a reinforcing plate for the engine bay side, and an extension piece for the brace to the tunnel.
All reassembled, and finished off with a cut down E34 pull rod.

Post Tue May 30, 2006 9:40 pm

any pics of how it looks now?

Post Tue May 30, 2006 10:26 pm

All hidden behind the glovebox now. There's nothing complicated about it; the whole assembly is just moved 25mm to the left, looking from inside the car.

Post Wed May 31, 2006 1:38 pm

Brianmoooore wrote:I thought someone would come up with an alternative remote reservoir!
That's S50 inlet problems sorted then. Must be enough room now.

I havent got mine fitted at the moment, but thats basically what Ive done.

Ive used the S50 power steering reservoir that mounts down on the alloy engine arm (below the plenum) and the E30 brake reservoir is mounted in place of the E30 PAS reservoir.

Post Wed May 31, 2006 1:46 pm

Any pics in situ?

Also, are you putting the S50 into the touring in your sig now?

I can't keep up

Post Wed May 31, 2006 2:21 pm

No pics of it intstalled in mine yet - has been trial fitted but took it back out to make space to work in.

No, the S50 is still in the Sport.
The touring is my run around (or was until the engine gave up

), havent decided whats happening with the touring yet, but there are a few options

Post Thu Jun 01, 2006 1:37 pm

Many thanks for the replies guys.

Next thing is to find the correct master cylinder, servo and bits and bobs then...

Going to hold off the engine swap for a while due to funds (moving house end of June) but might as well sort the chassis mods and make the engine bay ready to fit it. Plus it'll give me time to get used to the car with the new suspension and brakes before levering in a massive nutter of an engine!

Pictures of an installed cylinder/servo or someone doing the swap would be cool.. Anyone got any?

Jai