B5 V8 Swap

[king84]

Yeah, I wish I had started the thread as "B5 V8 ABZ Swap" instead.


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[king84]

It was a busy night for me.

V6 connectors for the electronic box plenum chamber was my first task. Took out the male and female ends to verify the wiring in its current configuration. .



Once I verified pin locations, I reinstalled the male and female connectors and its plastic holder within the plenum. I only had to replace one damaged connector housing after separating my 01A trans harness from the V6 harness. I picked up spare male ends from a junk yard B5. Made sure there was enough slack for the male end to splice and extend.




I started splicing in extensions using wires from V6 harness and my spare V8 harness. Kept it color coordination with a few exceptions.



So far....




I made sure to have male&female end splices on the splicing points to ensure I have an easy option to relocated or replace if need be. This is while using drawings from Alldatadiy for my 97 A4 2.8 (ACK). Not expensive in comparision to Bentely.

Anyway, I'll update later when i go after the ECU harness, which may include partially removing the engine to reposition the harness. In a perfect word, Im looking to get it running by this week.


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[king84]

Its always good to not have to worry about renewing registration without an emissions test this year.


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[Wrath And Tears]

How does emissions work for you 4.2 guys? I know a fair amount live in non emission states. Would hate to have to try that in CA.

[king84]

It's every other year in WA for cars made between 1991 to 2008. The oldest falls off the list eventually. I took care of it before the tear down.

www.emissiontestwa.com/e/faq.aspx#2




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[bhusted]

How does emissions work for you 4.2 guys? I know a fair amount live in non emission states. Would hate to have to try that in CA.

I think that my swap would be CA legal. The engine is newer than the chassis it is installed in and I retained *most* of the original emissions equipment. I eventually removed the combi valves and got rid of the associated ECU codes. I'm also in WA and the state emissions test only consists of plugging into the OBDII port and checking readiness monitors. I pass that with flying colors...

[king84]

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[king84]

Perfect world scenario didn't go as planned when it came to get ting the ABZ started..... two year-old birthday party and spending time with family. On the other hand, the little time I did have I had to partially remove engine to reroute harness and gain extra slack. Wrapped harness again and attached to keep it in place. Took care of some plumbing as well.



I just need to remove the 55pin connector and associated excess. ABZ plenum connectors will be simple and easy to deal with




Combed through layout to match drawings. Note, it isn't precisely accurate.

AUDI B5 (ACK) .....verified with drawing and current configuration of my 1997 A4 2.8 V6 Quattro w/ 5-speed 01A.

T10M/(x) – BLACK PLENUM CONNECTOR (10-point)
1. Empty
2. GREEN/BLUE: ECU TO CLUSTER
3. WHITE/GREY: OIL PRESSURE SWITCH (F1)
4. BLUE/WHITE: ENG OIL TEMP SENSOR (G8)
5. BLUE/RED: REVERSE LAMP/Connector (REVERSEL AMP) IN INST PANEL WIRING HARNESS SEE T10/5.
6. BLUE/YELLOW: ENG COOLANT LEVEL WARNING SWITCH (F66)
7. BLUE/BROWN: ENG COOLANT TEMP TO INST CLUSTER
8. Empty
9. BROWN/RED: VEHICLE SPEED SENSOR (VSS) G68
10. YELLOW/RED (Switched to RED/YELLOW): ECU TO DIAG FOR FUEL SYSTEM.

T10/(x) – TAN PLENUM CONNECTOR (10-point)
1. Empty
2. es/ge to ws/ge, es/ge to white/yellow: ECU to Diagnostic pump fuel system.
3. YELLOW: Auto check system: Automatic transmission only*
4. BLUE: Generator to Instrument panel.
5. BLACK/BLUE: (A70) Conn (15amp, fuse 231) in instrument panel wire harness. See T10m/5.
6. BLACK/YELLOW: ECU to Conn (30 pin, Idle boost) instrument panel
7. YELLOW/BROWN: ECU to Malfunction Indicator Lamp, CEL.
8. BLACK/GREY: ECU to A/C control head.
9. WHITE/BLUE (switched to BLUE/WHITE): ECU to cluster
10.

T6Z/(x) – RED PLENUM CONNECTOR (6-point)
1. BLACK/BLUE: (A20) Wire Conn (15amp) in instrument panel.
2. EXTRA NOT IN SPEC
3. RED/BLACK: Starter to PNP
4. RED/GREEN: Oxygen Sensor to fuse
5. RED: ECU to fuse
6. Empty

T10Z/(x) – YELLOW PLENUM CONNECTOR (10-point)
1.
2. GREEN/BLACK (Switched to GREEN/RED): From ECU to Instrument Panel, K Diag. Connector.
3.
4. Empty, S/B RED/BLACK.
5. BROWN: Engine coolant to cluster temp
6. RED/BLUE: ECU to fuel pump relay.
7. GREEN/BROWN: ABS to ECU
8. GREEN/YELLOW (Switched to BROWN/WHITE): Fuel pump relay to fuse to ECU
9. S/B GREEN/BLACK, but its BLACK/GREEN: ABS to ECU
10. BLACK/VIOLET to VIOLET/BLACK:ECU to center console.



AUDI D2 (ABZ) per drawing. Will verify harness later.

T6A/(x) – VIOLET PLENUM CONNECTOR (6-point)
1. From Z29 (Oxygen Sensor Heater O2S) as BROWN/RED to Connector T6a/1, to ECU pin E4 as BLUE/RED.
2. From Z30 (Oxygen Sensor Heater O2S) as BLUE/GREY to Connector T6a/2, to ECU pin E8 as BLUE/VIOLET.
3.
4.
5. From V144 (Leak Detection Pump) pin 3 to D80 (87A for EVAP solenoid, along with N80/N212/N156) 
****?????
6. From V144 (Leak Detection Pump) pin 2 to ECU pin D8 
****?????

T6E/(x) – TAN PLENUM CONNECTOR (6-point)
1. From A2 (Plus15 terminal) fused S6 (10A) to F125 (multi function trans switch) pin1 as BLACK/YELLOW. 
2. From J17 (FP Relay) 29/S to ECU pin A4 as BROWN/GREEN.
3.
4.
5.Instrument panel ground connection (E113) to T6e/5 as BROWN, then to J217 (TCM) as BROWN/WHITE.
6. From cluster to A76 (K-wire with ABS/TCM/AC) to T6e/6 connector as GREEN/RED, to ECU pin A7 as GREEN/BLACK.

T10/(x) – BLUE PLENUM CONNECTOR (10-point)
1.
2. From G22 (Vehicle Speed Sensor) Pin 2/G to T10/2 as YELLOW/WHITE, to then G21 (Speedometer) as YELLOW/WHITE.
3. K (Data Link Connector(DLC) Rapid Data Transfer to K-Diagnosis wire in instrument panel (A76) as GREEN/RED, to T10/3 as GREEN/RED, to J217 (Transmission Control Module(TCM)) pin 88 as GREEN/RED.
4. From 87A fused S3 (20A) to Z19 (Oxygen Sensor Heater) as BLACK/RED.
5.J217(TCM) to T10/5 as YELLOW/ GREEN, then to T10g/7 as YELLOW/GREEN
6.

7.

8. From F125 (multi function trans switch) pin 8 to back-up lights as BLUE/RED.
9.

10.

T10A/(x) – BLACK PLENUM CONNECTOR (10-point)
1. RED: BATTERY to E20 (Plus connection (30), in Motronic Multiport Fuel Injection (MFI) wiring harness) to T10a/1 Conn to D50 (Plus connection (30) in engine compartment wiring harness, to Fuse for control module – Auto transmission, which goes to ECU as RED/GREEN to pin D9 (need to verify).
2. E45/5 (Cruise Control Switch) to T10a/2 as BLACK/WHITE to go through Z40 (Plus connection (15) in cruise control wiring harness and split to J217 (TCM) & F125 (Multifunction Transmission Range Switch as BLACK/BLUE.
3. From G82 (Engine Coolant Temp Sensor on Engine) pin 2 as BROWN to T10a/3, then to E123 (Trip Odometer Reset Switch and L&R (K65&94) turn signal.
4. From A2 (Plus15 connection) fused S115 (20A) to 15 pin on ignition coil 2,4,6, BLACK/GREEN.
5. From S3/15 as BLACK to T10a/5, to split in two as BLACK/YELLOW to J217 (TCM #54&55).
6. From G82 (Engine Coolant Temp Sensor on Engine) pin 1 as GREY/YELLOW to T10a/6, then to G3 (Engine Coolant Temperature Gauge) & J218 (Instrument Cluster Combination Processor) as GREY/YELLOW.
7. E105 (BROWN ground connection in instrument wiring panel left) to F8 (Kick Down Switch) to T10a/7 as BROWN/WHITE, to ECU as BROWN.
8.

9.

10. From F1 (Oil Pressure Switch) to T10a/10 as WHITE/BLACK, to then K3 (Oil pressure light) as GREY/BLACK.

T10B/(x) – YELLOW PLENUM CONNECTOR (10-point)
1. BROWN: From 102 (Ground on Trans) to E113 (ground in instrument panel)
2. RED/BLACK: from Break Light switch to T10B/2 connector to ECU.
3.

4.
5.

6. J217 to T10b/6 as BROWN/RED, then to T10g/6 as BROWN/BLACK
7. J217 to T10b/7 as YELLOW/BLUE, then to T10g/8 as RED/ GREEN
8.

9. Y6 (Transmission Range (TR) Selector Lever Display (from red 26pin connection)) as YELLOW to T10B/9, then to ECU as BLACK/WHITE. Shorter explanation: From J219 (TCM) to Y6 (Gear Selector)
10.

T10C/(x) – GREEN PLENUM CONNECTOR (10-point)
1.
2. J217 to T10c/2 as RED YELLOW. Then same color to T19g/3
3.
4.
5.
6.
7.

8.

9. From J104 (ABS) pin 47 to ECU Pin A12****?????
10.

[king84]

A little update:

Translating ABZ drawing to harness isn't hard at all. It's not having the time to look into that makes it take so long to apply.


Hm, my ABZ doesnt have an oil temp sensor, not even on the oil pan. Thinking of installing it


I did spliced in the fuel level sensor, starter/generator, coils, and injectures.


Putting the shifter back in took longer than I wanted to, but its in.



Starter will engage, but there's a few things I still need and want to put in.




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[Nollywood]

Install the oil temperature in its default location. My AHC S8 32V motor has it as standard.

[king84]

Noted. Did you replace the throttle cable from a 4.2 or picked up one with proper length?


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[Nollywood]

I used a stock B5 1.8T cable with slight modification.

I've never bothered trying to use a D2 V8 cable, the pedal and cable route are completely different, so is the distance between the gas pedal and throttle body.

[king84]

I would like to smack the cheapskate idiot who decided to make it standard to install a PLASTIC clutch slave cylinder on a B5 when it started with a metal one in 96 (I have a 97). It would probably be the same one who said yes to a plastic thermostat housing on an 01 Allroad when the same engine is shared with a B5 S4 that carries a metal version. Can't bleed it if its easily rounded. . Nollywood, oh yeah....I know....Metal slave is on its way.






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[king84]

On a lighter note, I installed the downpipes and handled a few plumbing issues in regards to the power steering pump and oil cooler. I need to shorten the studs on top side of the downpipes to allow the O2s to screw into place. Had to install a longer grounding cable that attaches near the starter and bond to the frame.

I need to make sure the coils, sparks, and everything else are good to go in order to fire it up. I know its getting fuel, but no spark....yet. To be continued tomorrow.

,


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[Tanzimur]

great read, great build! Im in the mist of a bigger turbo transplant and might have to do the clutch soon so my question is instead of unbolting the slave from the trans cause i hear its a pain to get it back in, wouldnt it be easier to remove that quick disconnect on the metal line going to the slave and go from there?

[king84]

It would be easier to remove the quick disconnect (don't lose the retaining clip), but you would have to bleed it. If you can deal with being delicate with the plastic clutch slave when trying to bleed it, great and good luck. I however now prefer to have the metal clutch slave instead.


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[Tanzimur]

It would be easier to remove the quick disconnect (don't lose the retaining clip), but you would have to bleed it. If you can deal with being delicate with the plastic clutch slave when trying to bleed it, great and good luck. I however now prefer to have the metal clutch slave instead.


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lol gotcha! idk i might have the upgraded one never pulled trans or looked into it pulled the engine once.

[GOODBYNAAIR]

I went metal slave with SS lines makes a big difference. I also did the gravity bleed method worked really well.

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[king84]

$3 bucks later and I'm able to pick up a 1.8 throttle cable from a local yard. Interesting, seems like it's best to have a V6 shell for the ABZ swap in terms of subrame and assocaited assemblies for fitment. On the other hand, it's helpful to source from a 1.8 for some small essentials such as hoses, radiator, cross member, etc. Some things will probably need a little modification just so it can fit perfectly. Anyway, will continue on later....


#B5v8ABZswap
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[king84]

Out with the old and waiting on the new.


9" socket.


Vise-grip pliers did the trick







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[Tanzimur]

I went metal slave with SS lines makes a big difference. I also did the gravity bleed method worked really well.

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WHat kind of diffrence we talking here?

[king84]

Clutch slave was suppose to be in yesterday, but the post office forgot to drop off. Hopefully it comes in today. Went in to recharge my 10 month old battery at Oreilly's and found out that it went bad. lol. Welp, 3 year warranty swaps it out with a new one.




#B5v8ABZswap
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[Turbo_B5]

took me two months to get my battery warrantied by Bosch. I cutup the car for parts before I got the replacement battery.

Hurry up and finish this project!

[king84]

Finally arrived.




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[mignogna114]

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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what adapter for the oil cooler is that?

[getslideways]

very cool read. I may have to bribe you for a ride once you get her all buttoned up.

[bhusted]

Are you going to have this thing ready for Leavenworth this year? Would be fun to have a pair of V8 B5's on the way there.

[king84]

mignogna114,

It doesn't have to be the exact same parts. There are other brands out there. Oil cooler from my V6 along with it's threaded 3-4in tube.






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[king84]

Are you going to have this thing ready for Leavenworth this year? Would be fun to have a pair of V8 B5's on the way there.

I can only hope so. I originally planned to finish this project next year, but I'm now cramming to get it done before the end of April, or at least May.


#B5v8ABZswap
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[king84]

Metal clutch slave is in. Should of had it installed before setting the engine within the body.





The old metal line wouldn't flex enough to get out because I couldn't completely pull it forward since theres space constrants. I had to partially loosen parts of the clutch pedal assembly within the cabin itself to gain an extra half inch or so....



Note: I've come to realize that the spacer was too much. Had to grind off 1/3 or 25% of it off. Without it all together had the end of the sensor rubbing.




Old pic of my 01A. I didnt have to drill any new hole to mount. Just used an existing set to secure it.







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[king84]

Pop Quiz!!!!


What is the importance of Power Output Stages.....AKA Ignition Control Modules??!?!?

Laughing at myself.




Will pick up a pair tomorrow early in the morning. I should have it fired up by then before I get busy with life. I'm pretty confident to include a loaded video as well.



Borrowed pic. just examples.
.

















http://forums.quattroworld.com/s4s6/msgs/15284.phtml


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[wolfe2118]

Pop Quiz!!!!


What is the importance of Power Output Stages.....AKA Ignition Control Modules??!?!?

Laughing at myself.




Will pick up a pair tomorrow early in the morning. I should have it fired up by then before I get busy with life. I'm pretty confident to include a loaded video as well.



Borrowed pic. just examples.
.

















http://forums.quattroworld.com/s4s6/msgs/15284.phtml


#B5v8ABZswap
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Basically just a high speed solid state relay.

[king84]

B5 V8 ABZ (32v) First start.

Sorry for the delay. Yeah I know, my throttle cable broke apart on me. Had to compensate for the time being.
Mounts are not in as well.

Youtube



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[king84]

I wonder if a radiator coolant flange/coupler can fit a typical B5 radiator. Part numbers I'm looking into.... 3B0122291C & 1K0122291L.







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[king84]

Picked up those couplers from a jetta or gti in a local yard the other day. They fit the 1.8 radiator just fine. Found another 1.8 throttle cable as well, but I need to mod it a little. I decided to swap in the 4.2 power steering hose instead of dealing with my v6 pair that screws into an extended metal banjo. Bending the metal V6 hose to reach the power steering pump took up more space than I wanted and it was awkward. I ran the engine last light and noticed a little smoke coming from driver side. I figure the exhaust was burnig off the little spillage I had with the steering rack. I just hope it won't leak from the steering rack itslef from hear on out. It was a little challenging to access without all my tools. Im good on radiator hoses, but i need some couplers that step up/down to different size.


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[Xoct]

Could you take some pictures of how the heater pipes held and where connected to the engine?


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[king84]

Not enough space to get a good pic. I kinda closed up the area. Trans is already hooked up and mounted while attached to the engine. I think it would have to be partially removed to get a good view, but I'll see if it can be taken from one of the wheel wells. I do need to check to see if the high pressure power steering hose is leaking from the steering rack.

It's all on your own preference on how you want to connect them, but keep in mind which one is the feeder and return hose in relation to the V8 engine water hoses.

I grinded off connecting ends from my V6 piping to avoid having to replace or cut the hoses leading to the heater core. It took a bit to slide on the hoses onto the V6 pipe ends with the engine partially installed. You could cut off the couplers/flanges off, but I'm not sure if it could reach to slide into place.


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[king84]

Update.

Engine brackets dropped off to be worked on.



Decided to use and measure both OEM brackets for fitment. The add-ons will have at least a 1/4 inch thickness of metal added, which will be a little more than the current brackets. Passenger side is more of a challenge. Expecting them to be done this week....hopefully.


Oh, and yes I plan to use new V6 mounts. Test fit was done with the old pair.






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[king84]

A better vid of the ABZ running. Note,smoke in the end is from the the downpipe burning off a little powersteering fluid.


Youtube



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[GOODBYNAAIR]

WHat kind of diffrence we talking here?

Much better peddle feel and more crisp engagement. with some after market PP the stock slave gets tired its not speced for a larger PP.