B5 V8 Swap

[bhusted]

There is another version of the metal pipe on ebay for ~$20.

[king84]

Just got done grinding to make a bracket for the alternator. Took me 30-45 minutes. I still need to find a large tap bit for the hole in the corner.



Installed bracket.


Installed alternator back on with more space and clearance to deal with the mount and cooling set up.




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[bhusted]

It looks like you're intending to use the V8 alternator. The V6 unit will fit and is smaller. I chose to use the V6 one as I'm not sure you could remove the V8 one with the engine installed in the car. Just something to consider.

[Nollywood]

With my 32V and remote oil filter set-up, I had a freeze plug machined to plug the hole in the block.

[king84]

With my 32V and remote oil filter set-up, I had a freeze plug machined to plug the hole in the block.

Yeah I saw that idea with one of your prior builds. I like the work you've done with the 420-R project.


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[king84]

It looks like you're intending to use the V8 alternator. The V6 unit will fit and is smaller. I chose to use the V6 one as I'm not sure you could remove the V8 one with the engine installed in the car. Just something to consider.

It's the alternator from my old 12v V6.


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[bhusted]

It's the alternator from my old 12v V6.

I didn't realize that the 12v alternator had the air duct to it like the V8 one. I don't think the alternator from my 30v has that duct.

[Nollywood]

My 30V alternator was ducted too.

[wolfe2118]

Don't bother tapping the coolant hole, just stick a freeze plug in it. I just went to NAPA and got a 1/2" or possibly 3/8" steel freeze plug and drove it in with red locktite. Once it's in there, it will never come out without plenty of effort.

[wolfe2118]

Locating sensor. Couldn't fully install since I can't find my tap and die set.






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Just catching up on this. You may want to rethink your RPM sensor location. It appears that you are in the wrong location and it also looks like you are trying to line it up with the starter ring teeth. Trying to get timing information using the starter ring will not work. You need to be running off the other ring that you can see through the existing hole.

[king84]

With my 32V and remote oil filter set-up, I had a freeze plug machined to plug the hole in the block.

Correct me if Im wrong, you used the heater core coolant feed from the rear of the engine with it's matrix removed?


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[Nollywood]

Correct me if Im wrong, you used the heater core coolant feed from the rear of the engine with it's matrix removed?

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I'm not sure what you mean.

[king84]

Nevermind. I found the info I was looking for. I was going to ask about the directional pathway of coolant flow in regards to the heater core hoses. I found my answer.


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[king84]

Progress, but still working on wiring. I'll up date later.







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[king84]

No real updates besides ordering oil cooler, sandwich plate, heater core (went bad before the build), and a few hoses. Been busy with life and work. Has anyone else done anything lately with their B5 V8's?


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[Xoct]

I'm on my way of making FSI coils instead of original ones. Waiting for your commutation ABZ harness and A4 one:)))


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[king84]

You reminded me on one thing. I did split open the B5 harness and separated the two connector bundle that hooks into the 01A trans before setting the ABZ in the B5.

Note: It helps to print out the diagrams from Vagcat.com (part catalog) and compare them with schematics from Bentely. Gives an idea where to lay everything in its place.


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[Nollywood]

Remember, it's all too easy to separate the original B5 transmission connectors (reverse lamp and VSS connectors) from the engine harness. This will certainly get you a working speedo.

Just remember the ABZ ECU needs that same signal too.

[wolfe2118]

No real updates besides ordering oil cooler, sandwich plate, heater core (went bad before the build), and a few hoses. Been busy with life and work. Has anyone else done anything lately with their B5 V8's?


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What is the sandwich plate for? You are using the 034 relocation plate so you will need a oil filter relocation kit, you will have no need for a oil filter sandwich plate. Get a oil bypass thermostat if you can afford it. I installed my oil cooler this past summer and the engine never spiked temperature afterwards but the issue I ran into as soon as it got cold is that it would take a very long time to get up to operating temperature, a thermostat would take care of this. As of now(because I like heat), I have the oil cooler wrapped with cardboard so the engine warms up quicker.

[king84]

I should have clarified. I picked up a Mocal 80°C THERMOSTAT Oil Cooler Sandwich Plate. The Mocal oil cooler sandwich plate with a built-in thermostat will have the oil bypass the cooler until it reaches 80°C. This stops the oil getting too cold for safe road use. When the oil reaches 80°C, the thermostat will allow the oil to pass through the cooler. I'm going with the dual set up of air and water cooled. Temp outside is sitting around 37deg right now in WA state, but we've had three digit temps in the past, or at least close to it in some areas during the summer. I wanted to make sure my annual 6 hour summer drive to Spokane wont end up with me stuck in the middle of nowhere.


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[king84]

Got the oil cooler today. Hoses came in yesterday. Working on making mock-up mounts. I've seen cardboard with tape used to figure out clearance and make a set, but I might try wood instead.


Ran into a small issue that costed me 6 hours of searching. Lost the retainer clip for the clutch slave cylinder. Luckily, I was able to get one from a local salvage yard.



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[Nollywood]

I would advise you run a metal slave cylinder, if that isn't your current setup.

[king84]

I would advise you run a metal slave cylinder, if that isn't your current setup.

That's on the summer "wish list" with a reinforced stainless steel line. Probably through USP motorsports.

[king84]

Needed to grind out more for space.

A little better.


Good for now. Still need to deal with mounts as well.



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[king84]

Parts came in the other day. My central hollow threaded tube from my 97' 2.8 12v V6 oil filter fits with the dual set up.









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[king84]

I only got a chance to spend an hour on the wiring earlier this morning.



Three part ABZ wire diagram
helped a ton.


Identified each connector and wire going to the ECU in reference to the ABZ wire diagram.


All ECU connectors accounted for except for one, which probably stayed behind with the A8 body shell. I noticed both ABZ harnesses in hand didn't have the one connector, which I believe is a brown 24 pin connector. Either way, my V6 harness is a good donor.



On a side note, I did play around with a wooden mockup of a passenger side mount. Cardboard helps with aligning holes, but couldn't give me that solid feel of how it should sit with a good amount of thickness. I want to make the starter terminals accessible. I added small pieces bit by bit to ensure fitment and take advantage of space. I need to cut out two pieces to match the curvature and framing of prior examples. Driver side won't be as much of a challenge since I plan to partially hack off the end of the factory mount to have it bulked up and extended out to align with the V6 subframe.

Note: Pics on the right are NOT mine.


Driver side example.




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[Nollywood]

The missing ECU connector is part of the A8's dash harness. It's tan coloured, and essential. I bought one off eBay for like $6.

[wolfe2118]

The only thing you "need" off of the C connector is C10(RPM signal) and C13(VSS signal). The engine WILL start and run without it but your off idle response will suck and yiur tach will not work. I went without mine for the first few weeks that I had mine running. The connector is the same as the others just with different guide pieces, just file off the plastic pieces so it fits. Find my schematics that I posted, wire it up the same way and you will be up and running all without needing to send your ECU out.

[king84]

The only thing you "need" off of the C connector is C10(RPM signal) and C13(VSS signal). The engine WILL start and run without it but your off idle response will suck and yiur tach will not work. I went without mine for the first few weeks that I had mine running. The connector is the same as the others just with different guide pieces, just file off the plastic pieces so it fits. Find my schematics that I posted, wire it up the same way and you will be up and running all without needing to send your ECU out.

Yeah. I have the schematics. I was just diving into it right now with the spare ABZ harness.





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[haliceaa4]

Yeah. I have the schematics. I was just diving into it right now with the spare ABZ harness.





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Where did u get those schematics?

[king84]

WIRING?

Where did u get those schematics?

I got them all over. Google helps. Also, fellow V8 swappers and threads have a good amount of info as well. I've pretty much subscribed to most B5 V8 threads and bookmarked other ABZ swap projects from other models and forums. Everything won't be a perfect fit, so be aware of attention to detail.

A few wiring links:

http://jmp.sh/b/lWzjkfUkr9NVqzRyBHF0

http://12v.org/urs/1997_Audi_A6_Syst...g_Diagrams.pdf

http://www.elektroda.pl/rtvforum/download.php?id=530004

http://www.mitchell-auto.ru/UserFile...audi-s8-wd.pdf

http://www.volkspage.net/technik/ssp/ssp/SSP_161.PDF

http://www.kpematop.com/S6/V8-5VEngine.pdf

http://www.tbfh.org/wp-content/uploa...StudyGuide.pdf


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[haliceaa4]

Lol I have some I just like how they are large sheets put together in one page

[haliceaa4]

But ty for the posting

[king84]

Lol I have some I just like how they are large sheets put together in one page

Makes a ton of difference rather than flipping through a bunch of pages.


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[king84]

But ty for the posting

Yep! You're welcome.


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[king84]

WIRING?




I got them all over. Google helps. Also, fellow V8 swappers and threads have a good amount of info as well. I've pretty much subscribed to most B5 V8 threads and bookmarked other ABZ swap projects from other models and forums. Everything won't be a perfect fit, so be aware of attention to detail.

A few wiring links:

http://jmp.sh/b/lWzjkfUkr9NVqzRyBHF0

http://12v.org/urs/1997_Audi_A6_Syst...g_Diagrams.pdf

http://www.elektroda.pl/rtvforum/download.php?id=530004

http://www.mitchell-auto.ru/UserFile...audi-s8-wd.pdf

http://www.volkspage.net/technik/ssp/ssp/SSP_161.PDF

http://www.kpematop.com/S6/V8-5VEngine.pdf

http://www.tbfh.org/wp-content/uploa...StudyGuide.pdf


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This use to be my fear wiring a German vehicle. Now I know better.



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[king84]

Pt2 of drafting a mock up of mounts.








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[haliceaa4]

Can I ask y u customized mounts?

[king84]

ABZ engine mounts wont line up or fit with the V6 subframe.


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[haliceaa4]

Oh ur using abz sry I should have looked before commenting sry looks amazing btw