View Full Version : Project C4 / C5 / D3 “Crossbreed” V8 077-Series Content.
Nollywood
04-13-2019, 12:27 AM
G’day ladies and gents!
I just thought I should document a new project, which I have undertaken for a client.
A 1996 C4 A6 2.5 TDI I5 Quattro Avant, which is having a 4.2 V8 swap.
Now many would say, why not just buy a C4 S6 Plus? These were available with the V8 motor, right? And you’d be kind of right - problem though is these cars were very limited production, and secondly, this car is being built with a difference. I’ll let the pictures do the talking. Please feel free to ask questions!
It won’t be a super fast project, as this car is in the UK, and I’m not...I fly in every other week to work on it.
Nollywood
04-13-2019, 12:35 AM
The teardown:
https://i.imgur.com/NZ5G0Xw.jpg
https://i.imgur.com/qA4ue20.jpg
https://i.imgur.com/oFHtv7e.jpg
https://i.imgur.com/iKcnaTg.jpg
https://i.imgur.com/b1Uj6a8.jpg
https://i.imgur.com/2Nfiw7Z.jpg
https://i.imgur.com/rOGZDab.jpg
https://i.imgur.com/1QH3frW.jpg
Nollywood
04-13-2019, 12:38 AM
The heart:
https://i.imgur.com/rBheFGZ.jpg
https://i.imgur.com/NxjiFEg.jpg
https://i.imgur.com/stdKjbX.jpg
https://i.imgur.com/G2HlwAL.jpg
Nollywood
04-13-2019, 12:43 AM
The donor #2:
https://i.imgur.com/In3wM5q.jpg
https://i.imgur.com/nWnOFps.jpg
https://i.imgur.com/PJk5qzp.jpg
https://i.imgur.com/V1NCDHT.jpg
- - - Updated - - -
The C4, as she currently sits:
https://i.imgur.com/hLNFxfH.jpg
Nollywood
04-13-2019, 12:50 AM
The owner can certainly afford a brand new RS6, just in case anyone brings this up - why such an extensive build on a 23-year-old Audi? And the answer?
Because, he can.
His other cars are a 2017 Volvo V90 2.0 D5 Estate, and a 2018 Audi S8, just visible in some of the background shots. The S8 is mapped, and makes 714hp! So he’s no stranger to fast cars. He’s also an aero engineer.
Dirtyb5
04-13-2019, 05:14 AM
Nice! I’m going to watch this one. Love v8 swaps
Nollywood
04-13-2019, 05:32 AM
Nice! I’m going to watch this one. Love v8 swaps
Thanks bud!
This goes way beyond a regular V8 swap though.
neilpaku
04-13-2019, 09:31 AM
Nice one Nolly - C4 is my favorite - mine is a '95 2.8 wagon on the original engine/trans - it delivers all day every day despite having eaten two deer and one other car.... Up to 235k miles currently.
Nollywood
04-13-2019, 10:44 AM
Teardown continues:
https://i.imgur.com/bbMHXU6.jpg
https://i.imgur.com/IIpOaHn.jpg
Nollywood
04-13-2019, 10:47 AM
Semi-gutted:
https://i.imgur.com/qphP4B5.jpg
https://i.imgur.com/eV02XuB.jpg
https://i.imgur.com/scT7Svw.jpg
https://i.imgur.com/XkvFq3c.jpg
Nollywood
04-13-2019, 10:51 AM
Main harness:
https://i.imgur.com/chxtvdq.jpg
C5 guts:
https://i.imgur.com/6NzePQO.jpg
https://i.imgur.com/Wb9Eq18.jpg
https://i.imgur.com/ooOAtPB.jpg
Dirtyb5
04-13-2019, 01:17 PM
Wanna send me those avant bumpers 🤣
Nollywood
04-13-2019, 01:22 PM
Wanna send me those avant bumpers 🤣
Everything on this C5 is for sale. 👍
What will you be using from the c5?
Nollywood
04-13-2019, 09:48 PM
What will you be using from the c5?
The complete wiring, and all controll modules.
Airbag.
Convenience.
ABS / ESP.
Instrument cluster.
The complete C5 A6 dashboard and centre console/s.
landfill
04-14-2019, 10:45 AM
Cool, but why not machine the 2.5
for the 20v head and run a big ass
turbo. The stroker I5’s are a dream
and will make power a lot easier than
any 4.2.
I hear you on the s6+ but it is definitely
one badass ride if you can find one. There
was one for sale up in Canada a few years
back.
Nollywood
04-14-2019, 10:50 AM
Cool, but why not machine the 2.5
for the 20v head and run a big ass
turbo. The stroker I5’s are a dream
and will make power a lot easier than
any 4.2.
I hear you on the s6+ but it is definitely
one badass ride if you can find one. There
was one for sale up in Canada a few years
back.
It’s not my car, I’m building it for a client.
Besides, as I’ve always said, it’s not always about the power, it’s also to do with the sound. I personally don’t like oil burners, with their limited rpm range and noise / smell.
Nollywood
04-14-2019, 10:53 AM
This is also going to be a C4 with a difference. It’s not just having a V8 slapped in.
It’s literally going to be a C5 in a C4 shell, or a C4 with C5 modern systems, including the entire dash, cluster and switchgear. There won’t be a single C4 controller left.
landfill
04-14-2019, 12:12 PM
I didn’t mean to keep it diesel.
The 2.5 blocks are used as a base
for stroker I5 20vt gasoline builds.
You are able to run a 95.5mm to
100mm stroke with the 10mm increase
in deck height.
You can run them at about 2.65L
safely versus the 2.2 with AAN, 3b,
and etc.
Nollywood
04-14-2019, 12:31 PM
I’m aware of the 2.5L diesel block being used as a stroker base for the 2.2L. This was what I did with my old 3B-engined ‘87 Coupé quattro back in 1998. It was a blast to drive!
landfill
04-15-2019, 07:15 PM
^^^ Wasn’t sure my bad. A lot of
people in N.A. doing diesel swaps
lately.
Since you’re across the pond now
have you seen any s6+ in person?
Nollywood
04-15-2019, 11:51 PM
^^^ Wasn’t sure my bad. A lot of
people in N.A. doing diesel swaps
lately.
Since you’re across the pond now
have you seen any s6+ in person?
I’ve only ever seen 2 in person - one was actually an 1992 Ur S4 Plus in the UK, the other was a 1995 Ur S6 Plus in Frankfurt, Germany.
Nollywood
04-15-2019, 11:56 PM
The next step will be to pull the motor and trans, together with the front axles, driveshaft, rear differential and axles. Then remove:
- Rest of the C5 harness.
- ABS module.
Then the shell can be thrown out, giving me space to start pulling the C4 dash, harness and controllers.
rah253
04-17-2019, 02:55 AM
This is actually a very cool build in my opinion, that V8 in the C4 will be great! Will the exhaust be ugraded and is he going for a manual gear box? can't wait to see more on this.
Nollywood
04-17-2019, 04:24 AM
In response to Rah’s query, the spec of this C4 will be:
POWERTRAIN:
Audi A8 D3 4.2 V8 40V (BFM).
MANAGEMENT:
Audi S8 D2 ECU (AVP).
DRIVETRAIN:
Audi A6 C5 6-speed manual (01E).
TTV 0883 single-mass flywheel.
Audi RS4 B5 clutch.
Audi A4 Quattro B5 OEM clutch slave cylinder (metal).
Audi A6 Quattro C4 front Axles.
Audi A6 Quattro C4 driveshafts.
Audi A6 Quattro C4 rear axles.
Audi A6 Quattro C4 rear differential.
BRAKING:
Audi S8 D2 pre-facelift front calipers.
Rear brakes: TBC.
CHASSIS:
Front: TBC.
Rear: TBC.
Wheels: Audi 8.0” x 18” Ronals (Euro C5 RS6-style)
WIRING:
Audi A6 Quattro C5.
SWITCHGEAR:
Audi A6 C5 dash switches.
Audi A6 C5 combinatiaon / stalk switches and ignition lock / switch.
CONTROLLERS:
Audi A6 Quattro C5 airbag controller (under HVAC unit).
Audi A6 Quattro C5 convenience module (under passenger front floor).
Audi A6 Quattro C5 YAW module (under rear bench).
Audi A6 Quattro C5 climate control.*
Audi A6 Quattro C5 ABS module / unit.
Audi A6 Quattro C5 instrument cluster.
INTERIOR:
Audi RS6 Avant C5 electric and heated seats in cream leather.
Audi RS6 C5 dash / fascia with centre console and armrest.
Audi A6 C5 dash support / crash bar.
Audi A6 C5 steering column.
Audi A6 Quattro C4 new carpet.**
Audi A6 C4 / C5 hybrid door cards.
Very cool project. How much fabrication do you foresee to get the c5 interior and electronics working?
Nollywood
04-17-2019, 01:24 PM
Very cool project. How much fabrication do you foresee to get the c5 interior and electronics working?
The electronics is the easy bit - electronics is my thing, I love and understand wiring diagrams, should I need to refer to any.
The main fabrication will be the dash support frame / bar, with the C5 HVAC unit tucked behind it.
Nollywood
06-19-2019, 07:42 AM
With me purchasing a second BCY engine, my buddy decided he wants my old motor.
And he also decided a smaller VAG chassis was best. As luck would have it, a pretty clean 1995 B4 80 2.6 V6 12V Quattro sedan turned up local to him. And I drove it to his place, the C4 A6 Avant Quattro had been picked up earlier in the day (16th June, 2019).
This will be having my old C5 RS6 engine, with a few modifications and timing belt service.
https://i.imgur.com/T3rj2pN.jpg
https://i.imgur.com/lRFSkCJ.jpg
https://i.imgur.com/y4NCgX6.jpg
https://i.imgur.com/pNeFNMJ.jpg
https://i.imgur.com/XBkOU15.jpg
https://i.imgur.com/BpwyxNv.jpg
Bodywork and respray plans after engine swap. 😎
The electronics is the easy bit - electronics is my thing, I love and understand wiring diagrams, should I need to refer to any.
The main fabrication will be the dash support frame / bar, with the C5 HVAC unit tucked behind it.
I’m a little crazy, but I like figuring out the electronics.
My ming s6 I 2.7 swapped was a 2003 and I used a 2000 harness, which was a mistake. Everything worked, but there was a lot of rewiring and repinning due to differences in how things were powered. These engines are really pretty simple to get running.
Looking forward to seeing everything fit together.
SlvrArrw
06-23-2019, 09:08 PM
I think you are a whiz. Sounds great.
I have a 1.8T to put together ,1st time ever.
I think I caught the bug, so now planning what to do next after the B6.These are such great cars!
Sent from my SAMSUNG-SM-G935A using Tapatalk
landfill
06-23-2019, 10:10 PM
Man the euro 80/90’s are so
much cleaner than stateside.
Euro bumpers, lighting, and
the three spoke sport wheel
we never got. The bumpers
on ROW 80’s & 90’s Audi’s are
much shallower than the NA
versions too.
Should be cool with a 6 speed
4.2tt swap.
jolio1994
08-06-2019, 06:39 PM
Going to bump this, bookmark it if you will, going to try and shoot some ideas off you later this week.
Nollywood
08-09-2019, 11:49 AM
Well...
My client has changed his mind - again! 😈
A new car. I won’t post any more, until I’ve torn into it enough that he can’t change his mind. 😎 But rest assured, the replacement car is a mint barn find, and has not been started for 4 years, and has been in the same place for over 10 years.
You’ll have to wait to find out what it is. I spent last Thursday freeing the very seized and rusty brakes. I also replaced the tyres - they had all gone flat, and perished. None would hold air, despite all being 6mm tread. 😆
Watch this space.
Nollywood
08-09-2019, 11:52 AM
Going to bump this, bookmark it if you will, going to try and shoot some ideas off you later this week.
No worries bud. 👍
jolio1994
08-11-2019, 08:00 PM
So, if one was to swap in a BCY engine and use the stock engine harness/ecu, in your opinion would it be easier to:
A. Retain all the stock URS6 in-car wiring and integrate the ECU into it.
B. Buy an entire A6 2.7t 6sp manual car and take the dash, in-car wiring, and all necessary controllers and put it into the URS6/
I know for a fact I'm going to be using the A6 throttle pedal and with that will just use the entire pedal assembly from the A6. The fabrication can be done on my end, but integrating the obd2 into the obd1 harness is going to be the tough bit for me.
Feel free to message me
Nollywood
08-12-2019, 05:40 AM
So, if one was to swap in a BCY engine and use the stock engine harness/ecu, in your opinion would it be easier to:
A. Retain all the stock URS6 in-car wiring and integrate the ECU into it.
B. Buy an entire A6 2.7t 6sp manual car and take the dash, in-car wiring, and all necessary controllers and put it into the URS6/
I know for a fact I'm going to be using the A6 throttle pedal and with that will just use the entire pedal assembly from the A6. The fabrication can be done on my end, but integrating the obd2 into the obd1 harness is going to be the tough bit for me.
Feel free to message me
I’ll send you a PM.