S6 minus ... V8 swap project + much more

[priba]

Ok ... let's do this

started to tune my c4 tdi back in 2007 when I bought it

stock .... 2.5 TDI AEL quattro

first things first .... suspension, Eibach and KYB
17" RS6 replica wheels and some cosmetic touch ups


chip and K&N of course

than I find out Bosio nozzles and ran to CZ to buy a set


since I had enough diesel pouring in the cylinders next step was more air
custom fitted VNT from V6 c5 2.5tdi
had to adjust the turbine side angle respectively to the bearing housing and had to convert compressor side to be able to connet with existing pipes
I know ... not much of a upgrade but it worked just fine
aditionaly, needed to make interconnecting flange between turbine housing and downpipe


meanwhile, there was a urgent need to upgrade the breaks
S6 front strus with HP2 setup + S6 rear subframe with anti sway bar and rear vented discs


replaced the master brakes cilinder for bigger one from S and replaced front anti sway bar with 28mm type ... added strut bar


interiour ... nice sporty seats from, you guessed it, S6 ... Nardi wheel with new leather and LED dash lightning ... wipers interval regulator with 4 speed setting
some wierd instruments ... those were taken out from original housings and placed in one hand made with red plexiglass cover


then I faced the wall ... for the propper controll of VNT I had to find limited version of VW T5 ECU produced in 1 1/2 year period for I5tdi with VNT

[priba]

Swap

after some time I got my hands on V8 ABZ and started with the real deal



one of the first things done was petrol pump instalation
as I said, that car should have been petrol powered but at a last moment someone decided to make it diesel so it had prewiring for pump
combination of c4 and d2 parts and voila


finding V8 parts and specialy flywheel took some time so I had opportunity to deal with some other issues
replaced springs for new ones, sorted out brakes, brake cables and pipes


then a packages started to arrive in from quattro-zentrale ...
first batch - exhaust manifolds, engine brackets/mounts, rubber door trims ...
next batch - flywheel and clutch set, tie rods, US blinkers ...
next batch - interior parts, S6 strut bar, water hoses, wheel arch liners ...
so the party could start

flawheel had to be combined with auto tranny flex plate ring
I didn't think about sensor placement, to put it in original place on the tranny, so it ended in same position as on auto tranny ... note the red line


installed V8 style tie rods (I know, they are upside-down on this picture ) , charcoal filter, drilled new holes on the driver side of a block for engine mount

[dragonlfc]

nice project there
still see lot of nice a6 c4 and 100s in croatia when i go home
i am from osijek
pozdrav zemljak
i will send you a pm

[priba]

ABZ upper oil pan part have a "bump" that's in the way for c4's front subframe so I had to cut it out


done some rearangement to the bolt patern for exhaust manifolds


then a bit harder thing to overcome ... oil filter/cooler is in the way for engine mounts and filter can't be replaced 'cause of the subframe ... V8-c4 engine bracket can't be used 'cause the bolt patern is not identical and contact surface is angeled to the block respectively
did some smal repairs along the way .... new slave clutch cylinder and reverse light switch


solution to the filter - mount issue ... cutting off the filter/cooler housing and installing external one
be aware, filter/cooler housing is in one piece with alternator bracket so you have to leave front and lower part


some aluminium brackets for air and oil filter and spark coils amplifiers
engine mounts ... customized bracket, made of ABZ and AEC parts

[priba]

some additions ... new expansion tank, brake hidraulic reservoar to go along original strut bar, replaced radiator and fan crowl


complete new fuel line installation made of 10mm plastic pipes


that wiring look scary ... a friend of mine helped me with those


finalising installation ... connecting water piping, installing heat shields
had a clearance issue with ABS pump so had to move it a bit out


S6 instrument cluster with BC, S6 wings, fired it up and in that state I took her to a meeting

[UrS4boy]

Still seems to be that someone swapping a V8 into a C4 chassis would be better off using an ABH or AEC block with later ABZ heads, etc. Mounting the block would be much easier.

But hey, good work to make the ABZ fit in the C4.

[priba]

after some time ... V8 44 rear torsen diff came in and did the oil change in gearbox and diff, replaced CV joint boot


interior refreshment with help of my son


exterior ... went to Germany to get a mint front bumper, painted it and wings


final touches

[priba]

https://www.youtube.com/watch?v=5vlQITf6dx4











some other things installed at that time ... including a new clutch set from Sachs

[priba]

pending jobs

soon she'll get new paint job
flat fives are here ... gonna go for black color
black details S6+ stile ... grill and chrome
new dual pipe exhaust
castor/camber plates replacement (made by Thuppu)
powerflex controll arm bushings (inner and outer) and rear diff mount
front subframe rigid mounts and bushing
maybe rear subframe alu bushings
tailgate S6 lights
short shifter from 034motorsport
ECU tweak to manual transmission

[priba]

nice project there
still see lot of nice a6 c4 and 100s in croatia when i go home
i am from osijek
pozdrav zemljak
i will send you a pm

hi mate ... iliti zemljak
tnx

pm replied

[priba]

Still seems to be that someone swapping a V8 into a C4 chassis would be better off using an ABH or AEC block with later ABZ heads, etc. Mounting the block would be much easier.

But hey, good work to make the ABZ fit in the C4.

yep, you're correct UrS4boy
if I would go down that road I would combine old V8 lower part and AHK/AKH upper part and ECU, that would be a 330-340HP blast
but when you get an engine literally for free than there's not much to choose
this ABZ came in with 110ish k km with big service made so I didn't even had to open the toothed belt cover

thanx mate, it's doable as you can see
easier than tracking V8 flywheel

[macspring]

soon she'll get new paint job - Grand.

flat fives are here ... gonna go for black colour - Mk1 S8s looked fine.

black details S6+ stile ... grill and chrome - Thank goodness.

new dual pipe exhaust - No, don't do it. Looks wrong.

castor/camber plates replacement (made by Thuppu) - Await feedback.

powerflex controll arm bushings (inner and outer) and rear diff mount - oem rubber for everyday use on real roads

front subframe rigid mounts and bushing - oem rubber for everyday use on real roads.

maybe rear subframe alu bushings - oem rubber for everyday use on real roads.

tailgate S6 lights - Yes.

short shifter from 034motorsport - If you want.

ECU tweak to manual transmission - Of course




Good work to make it a V8q

Enjoy.

[priba]

thanks macspring

"flat fives are here ... gonna go for black colour - Mk1 S8s looked fine."
gone, to a friend of mine .... I had them for quite some time and got tired of them ... wanted something a bit wider
wheels are easy replaceable

"new dual pipe exhaust - No, don't do it. Looks wrong."
NOT left and right side of the car ... probably wrong expression, I ment two pipes running all the way


"oem rubber for everyday use on real roads. "
I'm aware of this but want to have her more tight since rubber is busted
this is not a daily driver any more ... project and pure fun
luckily wife and I drive company cars

I'll give my feedback on the suspension here

[macspring]

Replies noted. The exhaust now makes sense. All good so.

Looking forward to further updates in due course.

[priba]

camber/castor plates

this morning those were still in the post office




in the afternoon ...











not sure if I got this right




only passenger side is finished, driver side tomorrow, hope so

find out I'll have to buy new control arms ... ball on this one is busted, probably the other one too
hope to see my powerflex bushes in a day or two so I can put her back on the wheels