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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old January 4th, 2020, 14:34   #1
russx
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Location: Ukraine, 45400 Lutsk
TDI(s): A8 d2
Default Audi A8 D2 3.7 to 2.5 r5 tdi VNT 200hp cheap swap

Hi guys, i am from Ukraine(east europe) and i bought 2000 a8 d2 without engine for swap r5 tdi 2.5 engine with VNT turbo and 01e quattro manual gearbox. All parts I am buing in Poland on junkyard.


I bought
- engine volvo s80 I 2.5tdi 1j (same 2.5 AEL 140km) 200$

- 01е quattro gearbox passat 5.5 2.5tdi v6 glx 3.88 150$
- gearbox mounts а8 2.5 v6 manual 60$
- engine mounts a6 c4 5cyl
- driveshaft right audi s8 manual 20$
-- driveshaft right audi a6 c5 manual for left side 20$
- Ecu edc15vm+ octavia a4 for remap 10$
- engine loom octavia a4 edc15vm+ 10$

- pedals A8 D2 v6 tdi manual 60$
- clutch singlemass 240мм r5 tdi aat 50$
- turbo gtb1756vk 2.7tdi bpp 180km 150$

- gear selector а6 с4 01e 20$


Last edited by russx; January 11th, 2020 at 12:30.
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Old January 4th, 2020, 16:15   #2
russx
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Location: Ukraine, 45400 Lutsk
TDI(s): A8 d2
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Sorry for my english
Bought new parts for swap

1 531027430 INA tensioner
2 235381 ELRING gasket for cylinderhead
3 234560 ELRING gasket for oilpump
4 G2664 FRECCIA valve sleeve
5 12014584 CORTECO rings for valves
6 5323XS GATES timing belt
7 800001110000 KOLBENSCHMIDT piston rings
8 NRF radiator audi a6 c4
Total cost 170$


Last edited by russx; January 4th, 2020 at 16:19.
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Old January 6th, 2020, 14:37   #3
russx
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Location: Ukraine, 45400 Lutsk
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I started to make the wiring looms. EDC15VM+ has 2 connoctors on ecu. Shorter I used with looms from Skoda Octavia 2002 1.9AGR. I have only connected T14a connector.
The pins of T14a
1: gn/sw big --- to T32/10gn/sw at cluster
2: sw/gn --- pwr frm fuse 7 - 10A powers vss at trans
3: gn --- to T32/28 gn at cluster - speed signal from ECU
4: li --- to T32/18 li at cluster - coolant temp
5: ro/li --- pwr from fuse 32 - 30A
6: ge/sw --- pwr from fuse 34 - 10A
9: br/ws --- ground for sensors - splice with cluster grounds
10: gn/sw (small)- to load reduction relay - from ECU T121/88
The longer connector I made new looms
Pins of connectors in electronic box of A8 D2
t10 blue
1 2.5blk-yel 2glow plugs
2 speedometr
green gnd for starter relay
7 grn-red oil
10 clutch switch
t10c green
3 ac d3
5 wht-red f47 brake switch
6 кр-чор f brake switch
8 2.5yel-blk no need
t10d red
1 red-wht 2glow plugs
4 can
6 can
8 can
10 ac d4
t10a black
1 2.5red 30power
3 brown temp g62
4 2.5blk-grn 15power
6 grey-yel temp g62
9 wht-blu no need
10 grey-blk f1 oil pres
t6e brown
2 brwn-grn glow plug control
6 diagnosis
t10w white
1 cruise pin1
2 gas pedal pin4
3 gas pedal pin6
4 cruise pin2
5 cruise pin3
6 gas pedal pin1
7 gas pedal pin3
8 cruise pin4+6
9 gas pedal pin5
10 gas pedal pin2

My loom has also preheating of by glowplugs, tnis is diagram

Last edited by russx; January 6th, 2020 at 15:01. Reason: new photo
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Old January 7th, 2020, 21:32   #4
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Very nice!
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Old January 8th, 2020, 13:35   #5
ej666
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I made split connection AEL ecu to edc at box of old ecu on a6c4qua, if you need conversion table - may put it this
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Old January 8th, 2020, 14:08   #6
russx
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Quote:
Originally Posted by ej666 View Post
I made split connection AEL ecu to edc at box of old ecu on a6c4qua, if you need conversion table - may put it this
I dont need any AEL diagrams because ael has very old ecu and my engine 2.5d volvo already has 10pin fuel pump like 1.9 ALH and diagrams are the same ALH only flash program is another in ecu
Pinout AEL MSA11 to EDC15VM+ who need
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Old January 10th, 2020, 18:48   #7
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Quote:
Originally Posted by russx View Post
That's not an R5 engine.
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Old January 11th, 2020, 11:38   #8
russx
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Quote:
Originally Posted by Scott_DeWitt View Post
That's not an R5 engine.
this is volvo 2.5 tdi d5252t r5 engine
https://en.wikipedia.org/wiki/List_o...5_TDI_85-103kW
I have disassembled it to replace piston rings and crankshaft. The oil pan is from A6 c4 2.5ael



airspace to the pan about 3cm

Last edited by russx; January 11th, 2020 at 12:05.
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Old January 11th, 2020, 11:49   #9
russx
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bought facelift instruments v6 tdi, it works by can
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Old January 11th, 2020, 12:01   #10
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I will use starter from volvo is better than a6 c4 its on permanent magnets and uses less amp
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Old January 11th, 2020, 17:18   #11
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okay I thought you meant Toureg R5 engine.
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Old January 17th, 2020, 14:07   #12
russx
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Got new rims 18'' Avus 3 from s4 b6, need to repaint because some one painted them to black. The price was 150$ in Poland
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Old January 20th, 2020, 06:42   #13
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Making vacuum conversion a4 b8 gtb1756vk



I used tesa for wiring looms
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Old January 21st, 2020, 08:28   #14
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Impressive looking work so far, looking forward to watching this come together.
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