B6 2.7 Twin Turbo B5 Engine Swap

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AudiS3-Turbo

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Hello ...well i sold my S3 as i was needing a avant for the little one,got hold of a 1.8t quattro sline,2004 nice and clean for the right money after a while i got bored with the 1.8t and wanted more looked into Big turbo,rods mapping etc but it put me off the cost and potential lag which i hate so desided to fit the b5 S4 2.7 motor,plenty have done this in the states,they often take the V8's out !!

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So when i picked the avant up!
pickingtheavantup_zpsa68a2182.jpg


at home



So that was followed on by H&R springs,19" LM reps





Added tow bar to pull my bike around



And the 2.7 when i got it.



After a good clean off!



Replaced all the top end seal,cambelt kit,water pump etc... Painted the rocker cover wrinkle red to jazz it up!



The wife was not best pleased lol








This is what map is on the ecu....nice!



out with the perfectly good bex lol





Thats as far as im at and i will update as i go along !
 
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nice, someone on here was looking for a BEX engine, might be worth searching (unless you've already sold it?)
 
audi upgrades
been a few.... but mainly the wiring and had daft things like gearbox bolts needed to be longer to fit the spacer plate the 2.7t requires to fit the gearbox to name but a few :keule:
 
Starting off with the 1.8t there is no heat shields on the passenger side so all that had to be added.





Th spacer plate needed to fit the gearbox



Also made up some extra heat shields for the manifolds,cant have to many lol



Bought some xs power downpipes,they fit the B5 but not the B6 due to the gearbox cradle,some cutting and 6" flexi joints sorted that.





 
Also the 1.8t box has multi-hole fittings for all engines but one of the starter bolt holes were just a small cast hole,this needed to be oped up.







and to add a bit of spice......

 
Also the S4 has a twin fuel line system,one to rail and returns back,the b6 is regulated by the regulator in the fuel filter,so instead of rigging up another line the fuel rail regulator was substituted for a nice cnc blank



also some 350mm b8 brakes to go on at some point.

 
Not done much, got a 2.4 ac compressor mount to fit the 1.8t swish plate compressor, also adding a second ac pressure switch as the original switches the fans on by ecu (Herts) and I cannot replicate that, so a 2.7 rs4 fan control module will work the engine/ac fans

Fitted some eBay intercoolers, utter crap but they are going in until I can source some good quality rs4 replacements
 

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Well its finished and runs well.



The exhaust temperature sensors were faulty so replaced them with two after market ones from Poland,works great now! saved like over 400 quid!!

Old one have some odd glue/gel...horrible crap covering them,gets everywhere!!! aaarrgggh!!



new VS old



Swapped out the front springs for the over 1450kg (fat lads) front springs as the under 1450kg sat on the bump stops lol




Made the front section of the system to match B6 S4 milltek system,non resonated 2.5" to 2.25" dual...got a lovely burble to it .








S4 Brakes fitted upfront and the stock 17" rim goes over them...just ! stops very well,plenty pf power,next will be to do the rears and swap them out for 300mm rears



Dumped the ebay intercoolers and got some proper RS4 intercoolers,so nice,big! made up the brackets and trimmed the ducts to fit,took some time but worth it! Avg temp around doors are 36 deg c and foot flat goes below 30 deg c ,awesome!









Had to flatten the ridge on the chassis leg on each side to clear the hoses.







The AC/coolant fans were switched by ecu,no longer available now,so the b5 rs4 fan control unit is a stand alone unit,works fans,after run fan and switches the ac fan on when the condensor gets to hot but in order to use that i had to add a second early switch so now had the standard and additional switch to work ac



Only issues is the clutch is heavy,it came with the motor and looked good,going to swap it out at some point ,the EPC light is always on,this is due to the instruments not been able to communicate with the B5 ECU so the only resolve was to remove the LED bulb.

Also fault code engine coolant short or open to ground,yet again this is instrument issue,as it looks for signal from ecu to bump idle up when AC load is on,this is not available on the b5 ecu as its manual,atho the temperature gauge works fine and temperature ready in live date from instruments and temperature coolant rise like normal as its not mapped in like later cars
 
Good effort, i bet it gave you a few sleepless nights ! What sort of power is she running at the moment ? Are the 1.8T gear ratios good enough match for the 2.7TT engine ? What sort of rpm's you have at 100 Mph ?
 
Love this build! Them A4 Avant sports are really nice looking motors!
 
Amazing!! Very impressed with the quality of work especially on the exhaust looks like it should have come like that from factory.

If you don't mind me asking give or take how much roughly it cost you including all the nigly bits that needed to be sorted etc! And considering you did most of the work your self what did you need to get specially made like the exhaust etc?

Got am1.8t Quattro saloon would love to have a go at this one day
 
Stickystuff said:
Amazing!! Very impressed with the quality of work especially on the exhaust looks like it should have come like that from factory.

If you don't mind me asking give or take how much roughly it cost you including all the nigly bits that needed to be sorted etc! And considering you did most of the work your self what did you need to get specially made like the exhaust etc?

Got am1.8t Quattro saloon would love to have a go at this one day
Click to expand...


thanks bud, as for cost it's around 3 grand doing it yourself, probably cheaper but I did splash out for a few extras
 
adamss24 said:
Good effort, i bet it gave you a few sleepless nights ! What sort of power is she running at the moment ? Are the 1.8T gear ratios good enough match for the 2.7TT engine ? What sort of rpm's you have at 100 Mph ?
Click to expand...


power is around 360 and plenty of torque to boot, it's got great midrange pull!

gearing, 100mph is 4200rpm so is spot on for me, acceleration is what I'm after not top speed
 
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audi a4 2.7 bi turbo swap:

it sounds great on the move, for now I'm enjoying it, next year, much bigger turbos, heads etc..
 
audi upgrades
This is awesome, can this be done with b7 2.0tfsi? Id love to swap out my 2.0t for the 2.7t
 
Well the weather has been getting better so i dealt with a few issues,the front wings were rusty so replaced them and had the front end repainted with some extra stuff to do at a later stage







The additional switch for the AC was leaking so i replaced the condenser and made a y joint ....works a treat



Also delt with the engine mounts,it moved so much it rubbed a hole in my ns bi pipe! so off the old mounts a 034Motorsport street density mounts,what a difference !!





And some snowfoam,,,,,,

 
Nice to find a thread on this, fatboy rowan told me about it and sent me to your instagram account to have a look.

I've been looking to see about doing this in the future but would be keeping my car as an auto (I like it being lazy plus I have a paddle shift steering wheel to fit) Only thing that concerns me is I quite like the v6 3.0 in the car atm, it sounds good even when taking it easy, the turbo's would probably quieten it down too much.

How much did the downpipes set you back?
 
It's not quite, it's got a lovely burble and when driving around like normal, on boost its a different animal!

As for the downpipes, parts aprox 100 quid

Or you could use a combination of 3.0 and 2.7 and make a hybrid 3.0 Turbo...
 
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using the 3.0 with the other bits? I have thought about this but wasn't sure on how well the internals would take it, i'm not after massive power with it tbh as I doubt the autobox could handle above say 340-50
 
Yea the 3.0 has a alloy block, so use 2.7 heads with 3.0 litre or visa versa had been done, it's not the power that's a issue but the torque, lots and lots of it!
 
yeah i've heard and been in a couple of cars with 2.7's taken out to 3.0's that went well. Just heard the bottom end on a 2.7 has more strengthening stuff
 
Got to say impressed to see the swap, it has inspired me to build my own it's been a long time but got everything mounted the wiring is another issue. I have all the throttle working also ABS everything is there but having issues with injectors short to ground car turns over on key it is not immobilised! It would be great if you could get involved also will pay. Agen good thread thanks
 
I've had the s5 350mm front brakes for a while, but they overheat fast as the rears are stock... I know!

So I've bought custom drilled discs, porsche style, 350mm front and 300mm s4, got new s4 back plates, s4 caliper carriers and new rs4 calipers.

I'm ditching the steel rear knuckles in favour of the s4 alloy knuckles to save some weight and retain that stock look.

Going to use ebc red stuff pads all round.

Also... The good bit awe stage 3 kit, ecu already adapted to b6 with giag tuning software, 4" billet maf housing and bosch big Green injectors.... Just need to get the k04 turbos.

Uploadfromtaptalk1432376151319

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audi upgrades
New look RH ALURAD 18" 8.5 all round with et 52 5x130 with 20mm adapters takes it to et 32...


8723fb33db59dd818120f4f6b8c8fcf3.jpg
 
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this is so much win, have engine envy but you did the hard work for it!
What brand of adapters you go with?
I have always been a little hesitant to take the dive as all the ones that aren't reported to crack are allot of dollar (but I guess you pay that to keep your wheels attached!)
 
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