Just making a running thread that I will update the front page with new information on the swap as it comes by me or if anybody posts it up. If you have any new information on parts, part numbers, where to get parts, or anything about a build let me know and i'll get it on here. Pics to come soon.
Things like engine management, turbos, etc will not be listed as that is all a basic turbo/engine build and has nothing to do with the swap itself. Also as of now there is no way to use the stock management to power the VR6 from an Audi. I will only mention if certain turbo manifolds do not fit as that information becomes available. As far as I know every manifold works currently except for the Kinetic manifold but I'm not 100% sure on this. I think the Kinetic manifold hits the passengers side strut tower.
Apparently a starter from a VR5 will work. I don't know what model car it is, I think it's from the B5 VW Passat in Europe. Same with the flywheel. Two options I did not know about before. Might be able to cut down the price of the swap by a few hundred bucks if you can get those parts from across the pond but that's person specific. I'll get more info on that as I find more.
I'm just putting these here for temp sakes until I can get all the info but there is a guy in Europe who has made a spacer/flywheel adapter to use an Audi 5cyl 7A flywheel in conjunction with a stock VW/Audi/Bosch starter. The starter is from the European VR5 Passat. I have contacted the guy and he said in one of his posts that he'd give out the plans for the spacer/adapter. After I get those plans from him I might have a few made up for us over here in the US in case anybody has access to European parts or people want to shop on ebay.de for the parts. I'm sure the VR5 starters are all over ebay along with the flywheels. In fact you'd probably want to get a L/W flywheel made here in the US that way the only european part is the starter. Starter part numbers are... VW: 012911023 BOSCH: 0001107070. This will be added to the list once I get the rest of the information on the spacer/adapter. The OEM starter also makes it so you don't have to cut/shave anything off for clearance.
Images for the items listed in the last paragraph.
Adapter plate - Touareg/ European Phaeton VR6 Adapter Plate, European VR5 Passat Adapter Plate, - 022103551А, 071 103 551A
- 034 - Single Disc - This flywheel uses stock Audi B5 Flywheel Bolts - M10x1x43
- 034 - Tilton Style/Multi-disc
Clutch - 034's Single Disc Flywheel works with the Audi I5 20v clutches, engines 7A/3B/AAN/ADU.
Starter - 034
Timing Chain Cover - MK4 Lower Timing Chain Cover
- MK4 Plastic
- MK3 Aluminum with one end chopped and welded shut
- VR6 Phaeton from Europe - VAG-CAT : The Phaeton pan bolts up and clears everything.
- Modified Touareg w/Modified Sub-Frame - Touareg pan needs to have the bottom cut and welded shut to be not as low and needs the sub-frame to be trimmed on the top. The Touareg pans can be had for 200-300 bucks used from Junkyards/LKQ/Car-Part.com.
Intake Manifold - Any short runner should work but I'd recommend the following two
- SPA makes a cast one that has a nice output direction and is the same price. Find it on ebay.
Application Specific Parts
034 Motor Mounts or Custom Mounts - 034 Mounts are direct to the chassis and do not have any vibration dampening so if you want a smoother ride then you will need to make a set. Also the 034 mounts do not allow for an A/C compressor.
Oil Dip Stick - If using the stock Mk3 dip stick you'll probably encounter problems with the mounting tab with a short runner. I used another left over VW bracket I had and brazed it onto the stock Mk3 dip stick after grinding off the original and it bolts to the oil filter housing.
Starter Mounting - Two places need to be clearanced for the 034 starter to fit. First is the block casting by the lower bolt hole. There needs to be some block ground away so that the starter can swing enough to engage all of the teeth. 2nd, the block casting needs to be clearanced near the oil pan just a little to allow the main power nut for the 034 starter to come off. The VR5 starter shouldn't need this as the connection points are on the solenoid, but I'm not sure on the lower mounting hole.
Depending on your motor mounts you'll have to shave/cut/hack up your front radiator support a fair amount to clear the engine/pullies. Custom fit fans will need to be had.
Motor Mounts - Stock Mount from Touareg/Q7, not 100% sure
You might be asking why a few of these parts are listed. The Mk4 items are for ease of installation. The Mk4 valve cover clears the hood unlike Mk3 ones and requires no modification. The Mk4 timing chain cover has a notch where it bulges out and it doesn't have the extra framing support. The reason why these are removed is because the 01A/01E transmissions won't mount flush if the notch isn't there. You can be cheap and shave part of your transmission off to cut the cost but timing chain covers are cheap. The reason for the new oil pan is to clear the sub frame and to bolt to the transmission. The transmission has two or four bolts that go through the bottom, the Touareg/Phaeton oil pan allow for these to be used.
Somebody got the stock hood latch to work with the swap. I'll see if I can look up that information on that too. I think most people just go with hood pins though for ease of the swap.
After you are done everybody needs to get this from 034.
034 Starter + Bolted Up
Differences in the two timing chain covers. Notice notch that goes in where the timing chain cover bulges out.
Modified MK3 Timing Chain Cover to fit
Modified Transmission Bell Housing to fit Mk3 Timing Chain Cover
The two valve covers, Mk4 first then Mk3
Phaeton Oil Pan - Really hard to source here in the states. Being sold for 400+ by two places currently. if anybody has any connections over seas let us know.
Clearance at the bottom of the pan from the stock sub frame
Modified Touareg pan to work for the application. These can be had for 200-300 bucks used.
Sub frame had to be modified to fit the Touareg pan if I am correct. Not 100% sure that it HAD to be modified or not. Either way it's a pretty simple and straight forward change.
SPA's Intake Manifold. Click the 034 link above to view theirs.
034's Engine Cradle/Mount Pics
The following are custom mounts made by others who have done this swap. Some harder and more complicated than others.
24v OEM Mounts used in this application on a 24v motor