b6 s4 2.7t swap - Advice Needed

[Fuzzy27]

Hi guys, almost finished with all the adaptations needed for an APB 2.7t and I have a couple questions for you guys.

Background on the project:

Donor car for the 2.7t was my daily 2000 a6 with an 01E trans, 186k on it but well maintained/ babied driving by previous owners
mostly original except for a stage 2+ daz tune, 3" downpipes, 710N DV's and a single mass flywheel/clutch kit about 20k ago

picked up a 2004 s4 that was being parted allegedly because the timing chain skipped a beat, even though it apparently still ran..lol
Bought as is with no seats, side mirrors or door blades. Intake manifold was gone, timing chain covers were off and it was bad, obvious that some noob tried a crack at it.
no other known problems. aside from the stupid ass lowering springs. Previous owner lived in a city in MA. GENIUS IDEA BRO.

I began to consider the swap when I had my engine pulled out to upgrade to bigger RS6 Hybrid Turbos when my stock drivers side turbo broke.
Stumbled on the s4 being parted when i was looking for rims on craigslist, the guy selling it was happy to sell it whole as he knew I would resurrect it.

Progress:

Power steering line from a6 is hooked up, ready to go
New turbos hooked up, all the hoses in place
Radiator from a6 fitted into bumper support/shroud, tubes hook up w/sensors
fan clutch and AC Compressor removed, cover over belts and new serpentine belt installed
all ac lines/hardware removed from the firewall out, inlet/outlet capped off
New OEM Lower engine mounting brackets (2.7t style)
034 motorsports density line motor mounts installed
b6 smic brackets removed, old 2.7t brackets ready

As it stands, the engine is ready to bolt up to the trans once i install the custom harness that is in progress by a local specialty shop.
About the harness: Using the 2.7t harness -
plugs for updated coils
Programming the ecu to communicate with ABS for speedo input to overcome the 5k limiter

The outstanding work at this point is converting the fueling to a return system.
So far the idea has been to use an '01 1.8t jetta filter for the fuel feed from pump to fuel rail
(tank->Pump->jetta filter->rail->fpr->custom return line->fuel tank)
I have prepared the car to install a fuel return line, but would like some input for size, strength and anything else I should consider
That's the easy part.

So far I just have the line from the N80 valve from the 2.7t to the charcoal canister figured out..
I literally just need someone to tell me what to do with the two remaining hose fittings at the fuel filter so the charcoal canister and fueling will function properly.

any additional advice would be greatly appreciated. photos will be updated here: https://goo.gl/photos/m2HPPWGK4tPvkQdW8
Thank you for reading!

[jr1415us]

There are a few members over on quattroworld who have carried out this engine swap, maybe they can advise you:http://forums.quattroworld.com/s4b67/msgs/28828.phtml

[mnthny4]

Just go with a Lexus sc430 engine swap fits like a glove and runs like hell with a few mods

[Bonz099]

Just go with a Lexus sc430 engine swap fits like a glove and runs like hell with a few mods

Ummmm Really? This is the first ive heard of this.....

[Fuzzy27]

If anyone could explain the routing on the fuel filter it would be greatly appreciated!!

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[blitz2190]

I believe a b6 3.0 filter still fits the fuel lines, at least I've seen it on some of the b7 A4 swaps, then either run a coated steal line back or, I'm not sure if it would be the same but on the b6 which shares a lot of similarities the 02 3.0 return line fits for an oem look.

[Fuzzy27]

Thank you!

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[Fuzzy27]

This is helpful but i really need to know more about the fuel filter. There are two sets of connections. The one i have figured out is tank->filter->fuel rail. I need to know the path of the other line that passes through the filter

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[melomandn]

q_dubz converted to a return system, try PM'ing him

[Fuzzy27]

Cool thats what im aiming to do, using a jetta 1.8t filter

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[blitz2190]

This is helpful but i really need to know more about the fuel filter. There are two sets of connections. The one i have figured out is tank->filter->fuel rail. I need to know the path of the other line that passes through the filter

Sent from my SM-G920V using Audizine mobile app

The third on that goes back to the tank from the filter is the return line, you would connect the return from the engine bay to this when you run it.

edit
So i thought originally this was a b7, you can swap the 3.0 return line in and use the 3.0 filter for an oem setup. The 3.0 filter clips right into the 2 center hoses and the third one offset on the back would connect tp your return line.

Where in MA are you, I may still have a return line and im about 15 minutes from haverhill if you needed an oem one.