4.2L V8 Swapped B5 A4

[4Loops]

I just got done installing the rs6 sandwich plate and external cooler on my avant, the car has been running much hotter than i want it to. After driving it late last night, it seems to be running about 10-15 degrees cooler(maintained 205 and when id get on it a couple times it would get closer to 210) but i havent yet driven it in the las vegas heat. From here, if this doesnt cure the 220-225 degree temps, its changing the mkiv radiator(2 row) out for 3 or 4 row and possibly deleting the ac if that takes up too much room.

So to the sandwich plate install. I ordered an entire upper engine mount bracket with the sandwich plate from germany, I got it for $120 shipped which is pretty awesome, especially vs prices here in the states. I had bought an aftermarket sandwich plate with a thermostat and it wouldnt fit over the 4.2 m24×2 thread size and the machinist i took it to drug his feet for over a month so i got fed up and ordered oem, and im glad i did. The rs6 version has a 2 step thread size for the sanwich plate which youncan see in the pics, this unthreads from the housing so you can do this without pulling apart the whole side of the engine and having to drain coolant etc with the cooler being inside the bracket.

Hey Audihere!, you said you ordered an RS6 upper engine mount bracket/oil cooler with the sandwich plate. It sounds like you simply removed the sandwich plate and the threaded pipe from the RS6 engine mount bracket/oil cooler, and installed them to your engine's mount bracket/oil cooler -am I right? So all you really needed here was the sandwich plate and the threaded pipe?

-If that's the case, I was considering doing the same, but I have found an oil cooler/engine mount with the sandwich plate and the threaded pipe holding these together, from a 4.2 Toureg. I'm thinking this should still be fine, since I should expect this oil cooler should be the same as the RS6's oil cooler mount -with a removable threaded pipe, long enough to hold on the sandwich plate.
http://www.ebay.com/itm/Olfiltergeha...0AAOSwSlBY0tSi

What do you think about this plan? Nollywood, do you think this is a good way forward? I could keep my oil cooler that's already on my engine, and replace the threaded pipe and add the sandwich plate. -I hope this will work, as the mount/cooler from the toureg is half the cost -or less- than the RS6 specific mount.

[Audihere!]

Yep, thats exactly what i did but when the engine was out I did change out the plastic coolant tube to the billet one so I had zero reason to remove the entire bracket again. I did have to order additional fittings to go with the external cooler etc but that is exactly what I did

[4Loops]

Awesome! Great to hear, I'll give that a shot then.
Yea, I also changed out the coolant tube with a gruven aluminum pipe while the engine was out.
Do you know remember what size fittings you got to fit the sandwich plate fittings? -I've got to order an oil cooler and lines too. Any recommendations?

[Audihere!]

The sandwich plate fittings are m22-1.5, i used 10an fittings for my set up so ordered a set of those and then got the external cooler off ebay(came with the cooler, braided lines, and a sandwich plate that youll not use), its the cheapest route i could find. I'll also be receiving the fabbed aluminum core support for mine soon too so ill have more room for the coolers(have matching coolers for oil and power steering). The size of cooler i used required removing the fog lights on the s4 bumper

[Ephry73]

The sandwich plate fittings are m22-1.5, i used 10an fittings for my set up so ordered a set of those and then got the external cooler off ebay(came with the cooler, braided lines, and a sandwich plate that youll not use), its the cheapest route i could find. I'll also be receiving the fabbed aluminum core support for mine soon too so ill have more room for the coolers(have matching coolers for oil and power steering). The size of cooler i used required removing the fog lights on the s4 bumper

Good info. Wonder if a fan with a thermoswitch would help in this case or maybe even a bigger cooler.


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[4Loops]

Excellent, I'll check out that route too.
Wish I could find an S4 bumper. Sure would help with airflow. That, and it looks a bit better.
So did you find that the stock power steering cooling pipe just wouldn't do the job? -Or did you install a finned P.S. oil cooler as a 'just in case'?

[Midnightblkb5]

good stuff bro! hard work pays off


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[pee quu]

I just did the same exact thing!

I had ordered an rs6 oil cooler plate and it came with the motor bracket and the oem hard lines off the cooler to the plate. worked out great. I actually got my set up with the help of Nolly. I have also noticed a 10-15 degree drop in oil temp. It hasn't gotten super hot here in NY but I have noticed the difference on the oil temp gauge

[4Loops]

I just did the same exact thing!

I had ordered an rs6 oil cooler plate and it came with the motor bracket and the oem hard lines off the cooler to the plate. worked out great. I actually got my set up with the help of Nolly. I have also noticed a 10-15 degree drop in oil temp. It hasn't gotten super hot here in NY but I have noticed the difference on the oil temp gauge

Wow, that setup looks fabulous. Pretty genius place (and way) to fit the oil radiator. Shrouding looks good. Wish I were ok-ish working with aluminum.

Say, what fans are you using there, Mr. Pee Quu? I can assume they keep your temps well in check? This is my next (and hopefully last) bottleneck.

[pee quu]

My buddy does all the fab work I just help with the ideas. Yeah we wanted the air to be guided into the fan once it went through the oil cooler

Fans I honestly couldn't tell you, my buddy ordered them. They work great temp stays planted in the middle. Only time it ever creeps is sitting in traffic in the middle of July and Aug, but it only goes past the half way mark MAYBE half way to the next line on the gauge and once you get moving it goes back to normal.. That or if I really beat on the car, I'm talking red line every gear and getting the speed past 100mph it will creep to the same point and once I get back to normal driving it will go back down. I have yet to meet anyone with a 4.2 swap who hasn't said the temp creeps in the same situations. Even my cousin who works at audi says the 4.2s are knows to creep a little in the dead of summer. its been this way over the last 3 years. at first I was a little iffy with it but I'm ok with it now. I did the oil cooler in attempt to help this, not sure if it will even do anything as far as motor temp, but we will see once summer fully kicks in

[Nollywood]

Looking great, guys.

To help with engine bay / under hood temperatures, I've ordered a spare hood. I'm actually getting Audi Sport Quattro-style vents stamped into it.

[Audihere!]

When i did my swap i added a smaller and longer cooler for the PS behind the grille but have found that i needed to relocate it to the driver lower front like a sidemount IC so i could configure my fans in a staggered set up. Ill be custom mounting an eaton m112 ford cobra supercharger so need to save room and run as cool as possible. The fabricated core support should free up a decent amount of room.

Side note, i have a silver s4 bumper available if you're lookin

[pee quu]

Looking great, guys.

To help with engine bay / under hood temperatures, I've ordered a spare hood. I'm actually getting Audi Sport Quattro-style vents stamped into it.

I have thought about doing a second hood with a custom cowl or tracking down a carbon fiber hood that doesn't look to ricer. Than I question water getting into the vents and falling on the motor/electrical parts.

[pee quu]

Ill be custom mounting an eaton m112 ford cobra supercharger

what else are you planning on doing to the motor to go along with this? I have seen a lot of guys make custom intak manis and slap s/c under them and call it a day. I have thought about this but if I did do a custom blower I want it to be super reliable for the long run.

[Audihere!]

Ill either be using a ctsv liquid intercooler or a cobra intercooler in the manifold, a killer chiller to refridgerate the intercooler(it splices into the ac, also off a cobra), ill either be using rs6 pistons or stacking gaskets/decompression plates to lower the compression(another guy is tryin this on his now with a single turbo set up so we'll see how that pans out), and possibly going to e85/e50 fuel with larger injectors.

[Audihere!]

My hoods vented now, engine bay gets a lil dusty but rain hasnt been a real issue sonce the vents are over the edge of the valve cover above the exhaust manifolds so the coil packs arent being drenched but I also live in las vegas so rain isnt a big issue here

[4Loops]

Interested to see how these vented hoods look. I've seen bhusted here in his thread working on installing vents, but I don't think I saw the finished product.

Very excited to see a charged v8 in the b5! How do you plan on tuning the ECM for all these changes?

Your bumper is not the one with the shark-gilles on the sides is it? I am not partial to that look myself, a bit too aggressive for me. -At least for my current style liking.
I'd have to see how much Greyhound freight or the "bicycle shipping" services would cost to ship, to see if it's worthwhile having it shipped a third of the way across the country, or if I should just keep my eye out for one locally. Hopefully paint wouldn't kill me on price, too. But afterall, I have considered getting the hood and front quarters resprayed anyway..

[Audihere!]

I put up photos of my vented hood on this thread a ways back, pesonally i like it a lot. Tuning so far was done by Daz but he has since passed away so id be likely using the guy that has done his best to replace him named Mirza.

The bumper is an actual b5 s4 oem bumper, the ones with the shark gills are usually rs4 knock offs but the oem rs4 bumpers are quite nice but very expensive since rs4 wasnt available in the states. Greyhound would cost about 100 bucks to ship, ups etc are likely well over 300.

[4Loops]

I saw your pics earlier of the cuts on the blue hood, the vents in the primered black hood, but I just haven't seen what they look like as a finished product -on the car, with the whole car assembled. I imagine they look quite at home.

I'll have to keep Mirza in mind. I've discovered that the intake I ordered from the A8 is a two stage manifold, where my motor wants the 3-stage -and I think Daz's tune for the 4.2 in the B5 w/ manual was for a 3 stage. So I'll have to get that sorted out.

Didn't know the RS4 wasn't offered here. Figures. All the really good stuff never seems to come here. The wide body definitely completes the B5's sleek look to give it that proper aggressive look.

Yea, I guessed shipping would be somewhere in that ballpark. I'm trying to budget funds for this project more tightly as of late. The bumper's not a complete necessity at this point, but I'm curious what price you have in mind for it. -I could PM you on this I suppose. Maybe I should also price out the cost of a respray, to see if it's in my best interest to look for an in-tact and in good shape s4 bumper from a black car.

[Audihere!]

The s6 and s8 have 2 stage intake manifolds and a6/a8 have 3 stage. The tune can be adapted to you particular set up, my tune is a euro s6 manual trans file that Daz wrote the CEL into because euro didnt have it at the time.

S4 bumpers generally cost between 450-600 for decent to great condition, anything cheaper will be a basket case and/or missing lots of items like washer caps, filler plate, and grilles etc Id be lookin for 500 for mine(just parted out an s4 so have the spare)

[4Loops]

Looking great, guys.

To help with engine bay / under hood temperatures, I've ordered a spare hood. I'm actually getting Audi Sport Quattro-style vents stamped into it.

Which vents? The nostril-type vents of the sport quattro, the single one on the side (maybe doubled, one on each side?), or the vents on the rear of the hood? Or all of 'em? Would certainly look neat!

[4Loops]

The s6 and s8 have 2 stage intake manifolds and a6/a8 have 3 stage. The tune can be adapted to you particular set up, my tune is a euro s6 manual trans file that Daz wrote the CEL into because euro didnt have it at the time.

S4 bumpers generally cost between 450-600 for decent to great condition, anything cheaper will be a basket case and/or missing lots of items like washer caps, filler plate, and grilles etc Id be lookin for 500 for mine(just parted out an s4 so have the spare)

Yep, I was thinking they would be up there. I'll surely have to hang around for the right time for this part. I'll just be happy to get it back on the street!

[Nollywood]

Which vents? The nostril-type vents of the sport quattro, the single one on the side (maybe doubled, one on each side?), or the vents on the rear of the hood? Or all of 'em? Would certainly look neat!

The vent in one side, but I'll have a mirror image vent on the opposite side, too. The vents above the grille as well.

[GoFundMyGas]

Looking at your message, I am guessing the ECU from the 2002 S6 AT 4D0907559B will not be compatible?

[zatta]

Anybody have any recommendations for downpipes for the 4.2 swap? Seems like if I’d like to go catless the only option is something custom at this point


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[nekodynamo]

No one makes downpipes from 4.2 as far as I can see. I'll be seeing what I can do with 2.7t downpipes.

[Fattyalx]

No one makes downpipes from 4.2 as far as I can see. I'll be seeing what I can do with 2.7t downpipes.

Can use factory downpipes for a 4.2 or 2.8. I used S8 downpipes and modified them to fit on my swap.

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[Cactus Avant]

Got the DTS installed and it does make a difference. Under power before I could feel the transmission squirm around now it seems to totally stay put. There is of course some additional NVH, but really only at idle and I can live with it.

Today I also installed the correct clutch switch for the new ECU. How much of a difference could a switch to tell the ECU if the clutch is in or out make? Major improvement! I don't know how to describe how it was before other than "jerky". It made me feel like I didn't know how to drive. Now it's much smoother. For the record, If you're running the ME7.1.1 ECU, the switch needs to be "normally closed". I wrongfully assumed that the switch from the 2.8 would work, but it is "normally open". I ended up using a brake light switch I got from the pick-n-pull.

Last few things on the list to do before buttoning it back up:
- hook up CEL wire. This had to be removed for the new ECU, but I'd like to get it figured out for future reference.
- figure out which of the vacuum solenoids is activated by the ecu. The new ECU only actuates one of the intake manifold flaps.
- move the VSS signal to the proper pin on the ECU. The cruise control stopped working after the ECU swap and I think it's a VSS issue.

I realize this was over 9 years ago, but do you remember how you got your check engine light to work again? I have an ART engine and harness and did the same thing as you, installed an AWN ECU into the car. I have a code P1650 - "Powertrain Data Bus Missing Message from Instrument Cluster".

Did you hook the check engine light up using the same pin from the ART ECU, or did you somehow get the CAN BUS communication working? Thanks!