3.0 30v swap in a tip
 

Hi guys, i promised to start a build thread, but its going kind of slow.

The engine is '04. ASN from A4 3.0 30v 220hp v6 automatic. Good thing about it is, it is using 5hp19 trans , as seen in 986 tiptronic.

Custom engine cradle is fabricated for both side engine mounts, and the stock porsche mount is connected to the front engine mount. The engine now sits firmly and the hood locks in perfectly.

Car is 1997. tiptronic, with cable throttle, so i will be using stock ECU, TB etc.

Previously we made a 3d printed TB adapter, but ... Stock 3.0 manifold can not be rotated to face the throttle forward, and behind there is virtually no space to make a sensible intake (maf etc.) piping.
So i bought the 2.8 30v manifold, that has recesses on both sides, still it can not be rotated to avoid the coolant pipe on the front.

Only option left is the most dissapointing 2.7tt manifold You can see on the picture.

Possible consequence of this might be a rear mounted turbo... but we'll see... :)

More pics to come, later!

Cheers

Nice work, hope you get the manifold how you want it.
Are you driving it now?

Aren't the ports much smaller on that manifold? It's not going to make the 220bhp.

Did not get the manifold how i wanted, but the only way i could. Thats why the thing is probably going to get a turbo, since its cheaper to build boost then to find a RS4 intake (big port) manifold.

It is taking some time....

I guess i made a mistake with engine choice :( looks like the 2.7tt fits more easy then anything, but i could not live with the 1.8t :)

A lot of smaller things to sort, trans oil cooler is in the way of exhaust, throttle cable is short, coolant hoses are just a bit short , fuel rail needs rewelding etc.

I did however modify the stock ecu to run VAG COP active coils and it was pretty straight forward job, just to see it fire and i will post on how to do it.

I will also test if stock ecu hardware runs with 996 3.4 software (bigger maf, mapping for 300hp etc)

Cheers

Not too late to swap it to a 2.7tt, it's the same basic engine. I've got one in my Boxster.

I know You do ECSY, You are my inspiration :)

2.7tt engine is very unpopular in my country, it is overtaxed :( And its also very popular in the tuning circles, so very few in parts market :( I had one B5 S4 for a family car, but beeing a 2000. MY car , it was a major headache when it started to brake down... On the other hand 2.8 and 3.0 are not a tuners engine at all, so plenty of cheap cars at the brakers. I run a tuning garage for quite some time (since 2004) and i kind of run away from the mainstream stuff... For example Honda B series is unobtanium these days, but a 3.0 30v engine is about 100-150euros, 2.8 is even cheaper :D

Back to the build,

The engine fired up. VAG COP conversion works.
Fuel rail is heavily modified, for stock fuel lines, works well.
Most of sensors are ok or close enough, only the oil level sensor is kind of uncompatible.

Throttle adapter contraption thingy is still in the works, dreaming of a 3d printed intake manifold.....

Some pics:



http://986forum.com/forums/uploads02...1649061058.jpg
http://986forum.com/forums/uploads02...1649061078.jpg
http://986forum.com/forums/uploads02...1649061091.jpg

The thing ia alive !
https://youtube.com/shorts/_1QiztzNmTI?feature=share

I was on the edge of my nerves, when i finally found a low miles 2.7tt auto with all the accesories 😁 but rather gave another try and it is up and running.

Engine coolant temperature sensor is the 4 pin type just like the audi one. Further more it is in the same resistance range, both for ecu and instrument panel. BUT, pinout is NOT the same 🤕

Took a while to find it out

Next stop exhaust system....

did you finish this?

Had a family trouble for a year or so, and the boxster just did not reach the top of my priroty list :(.

Long story short, it works. :)

Even had a spin around the block for a few times.

The engine got exchanged for a low miles one that i stumbled upon for cheap, but ... it turned out to have a HG failure, that i discovered after the installation in the car. Now i need to reinstall the old engine i could swore will die during the process , but did not...

Fuel pump died, then a short on the fuel level sensor fried my instrument cluster. Now i am completing a virtual one using realdash app as it turned out to be a cheaper solution then a second hand one.

Also had a fight with stock motronic dme, but eventually i won. Found all the necessary stuff needed to make it run like a dream on a 3.0l engine. Injector constant etc.

Even did a few dyno runs... power wise , nothing spectacular, hoping to touch 200whp.

Will post some pictures and clips later.

P.S. It sounds wicked

It does sound wicked :D Congratulations!

:cool::cheers:

We need more pics, infos, videos…

Had trouble accessing the forum from my home... Seems that my ip address got filtered somehow.
But it works from my work , so here we go !

http://986forum.com/forums/uploads02...1731582053.jpg

https://youtube.com/shorts/jT02Ztn4qKI?feature=share

Then the fuel pump died, then the dashboard died and finally the engine died...

http://986forum.com/forums/uploads02...1731582602.jpg
http://986forum.com/forums/uploads02...1731582646.jpg
http://986forum.com/forums/uploads02...1731582675.jpg
http://986forum.com/forums/uploads02...1731582695.jpg
http://986forum.com/forums/uploads02...1731582717.jpg
http://986forum.com/forums/uploads02...1731582755.jpg
http://986forum.com/forums/uploads02...1731582778.jpg
http://986forum.com/forums/uploads02...1731582801.jpg

Backup option

http://986forum.com/forums/uploads02...1731582836.jpg

https://www.youtube.com/shorts/pt3VWw7e3r0

This is the electronic part of the dashboard:
http://986forum.com/forums/uploads02...1731583581.jpg

arduino mega, with brakeout board, and some resistors and optocouplers to pick up analog and digital signals from the car, since we do not have can bus on our grand dads...

Anyway, the engine is out
http://986forum.com/forums/uploads02...1731583691.jpg

and the new one is in
http://986forum.com/forums/uploads02...1731583865.jpg
still hanging by a thread, but getting there , closer every day
http://986forum.com/forums/uploads02...1731583886.jpg
and some bird nest in the trunk
http://986forum.com/forums/uploads02...1731583909.jpg

took the whole unit from the b5 passat , engine code APU, small port DBW engine with automatic 5hp19 boasting mighty 150hp.
Had to swap axle hubs from the porsche gearbox, and while i was there, i counted the teeth on the drive gears. the passat final drive is quite a bit longer (or porsche one shorter)
could not determine output shaft sensor type so i went with the engine and gearbox alltogether.
only thing needing modification are the 3 threaded holes for the oil cooler mount. and axle hubs as said earlier.


Currently i am sorting out the cooling system. it is quite a bit different then the f6 and v6 engine.
http://986forum.com/forums/uploads02...1731584430.jpg
https://www.youtube.com/watch?v=rmGTuoqcx-w

Passat does not have trans oil cooler like the porsche, i have to figure out where to connect it...

also both radiator hoses are on the same side of the engine , badly oriented, which required a lot of hose, or modification of the water routing under the car which i did, and will explain later...


http://986forum.com/forums/uploads02...1731584591.jpg

Nice. There is a company in the UK that sells bits for a 1.8t swap. https://www.986booster.com/

You beat me to it!
Would seem to be a far better use of time and money, with a better payoff. More power, lighter: why do anything else?