Audi B5 420-R: The Build

Post any info regarding parts for conversion and swaps.
and any posts regarding swaps help.

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Nollywood
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Post by Nollywood » Fri Apr 29, 2016 9:59 am

My left-hand side engine bay cover arrived this morning:

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2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Nollywood
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Post by Nollywood » Fri Apr 29, 2016 4:43 pm

Manual D2 S8 ECU installed, of course, immobiliser is active, so the engine fires up for a couple of seconds, then shuts down. New ECU will be matched to the instrument cluster tomorrow.

I replace the rusty headlamp retaining bolts and washers with fresh stainless versions, gave the lock carrier the same treatment. I ordered a brand new lock assembly, which was delivered today by Audi. I'll tackle that replacement over the weekend.

I also need to order the appropriate lock carrier stickers. I hacked mine about way too much, it was a mess. I ordered and modified a replacement, which came off a 2001 1.9 TDI, so it has the wrong label attached. I also intend to order the A8 D3 4.2 specific sticker, which usually sits besides the one with the electric fan caution.
2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Nollywood
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Post by Nollywood » Fri Apr 29, 2016 4:45 pm

New stainless steel headlamp and lock carrier retaining bolts, and washers:

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This sticker's got to be replaced. Why do B5 hood lock assemblies rust so bad? This one's pretty crusty:

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OEM replacement hood lock assembly:

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2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

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ChrisJC
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Post by ChrisJC » Sat Apr 30, 2016 5:55 pm

It does look bloody good I have to say.

Chris.
--
Series IIA 4.6 V8
R/R P38 4.6 V8

Mark
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Post by Mark » Sat Apr 30, 2016 7:56 pm

Looks like it came from Audi like that 8)
302 V8 Sierra 5 door sleeper under way

Nollywood
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Post by Nollywood » Mon May 02, 2016 2:56 pm

I replaced the crusty hood latch, and discovered the latches for I4 and V6 cars are different, they also differ between aircon and non-aircon.

For the first time in 6 months, the car is on the driveway, and I hosed down, and washed off months of dust. She looks pretty good. All that's left is to have the new S8 manual ECU matched to my instrument cluster, connect the 3 fans and coolant pipes, replace bumper.

And of course, get the aircon charged up, and the car tested and taxed.

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2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Nollywood
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Post by Nollywood » Wed May 04, 2016 9:52 pm

Tomorrow, the radiator will have the angle on the top outlet altered. I will then fit the 12" curved-blade inner (puller) fan, then fit the radiator for good, with the top retainers in place.

I am running an OEM B5 S4 pusher fan in front of the radiator, with a 10" 120W curved-blade slimline beside it. The OEM S4 pusher, and the inner puller are being controlled by a B5 RS4 harness and matching controller. I will run the front 10" pusher independently.
2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Nollywood
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Post by Nollywood » Thu May 05, 2016 8:37 pm

My radiator is done, no more clearance issues.

But more importantly, the car now runs the way it should. I had the immobiliser coded with VCDS. This meant pairing the new S8 manual ECU with my instrument cluster (after extracting the SKC / PIN).

I could have gone with a simple immobiliser defeat, the issues with this are a flashing immo warning. This will be stored in the cluster as a DTC, which will certainly prevent any sort of future coding. I'm stoked!

I'll post a quick video later.
2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Mark
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Post by Mark » Thu May 05, 2016 9:29 pm

What's VCDS ?
302 V8 Sierra 5 door sleeper under way

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stevieturbo
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Post by stevieturbo » Thu May 05, 2016 9:47 pm

Basically VagCom, VW group specific diagnostic software for the laptop, although it's aftermarket, not supplied by VW
9.85 @ 144.75mph
202mph standing mile
http://www.youtube.com/watch?v=XgWRCDtiTQ0

Nollywood
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Post by Nollywood » Fri May 06, 2016 7:51 am

Thanks guys!

It's been one hell of a journey. To my knowledge, there is no other B5 A4 of any year, with a BFM V8 engine swap. It's been more Research & Development, a journey of discovery. Hopefully by next week, I can book the car in to get it tested, and back on the road.

My B5 A4 2.5 V6 TDI Quattro Sport is next. As the motor is up for sale, as soon as it's paid for, stripping of the car will begin.
2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

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stevieturbo
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Post by stevieturbo » Fri May 06, 2016 8:25 am

Nollywood wrote:Thanks guys!

It's been one hell of a journey. To my knowledge, there is no other B5 A4 of any year, with a BFM V8 engine swap. It's been more Research & Development, a journey of discovery. Hopefully by next week, I can book the car in to get it tested, and back on the road.

My B5 A4 2.5 V6 TDI Quattro Sport is next. As the motor is up for sale, as soon as it's paid for, stripping of the car will begin.
Glutton for punishment !!

Would a Q7 V12 diesel fit ? lol
9.85 @ 144.75mph
202mph standing mile
http://www.youtube.com/watch?v=XgWRCDtiTQ0

Nollywood
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Post by Nollywood » Sat May 07, 2016 11:51 am

Update: 7th May, 2016:

After listening to the Audi A8 D3 power steering vane pump whining and groaning, and frothing the fluid, I was convinced it was not compatible with the B5 A4's rack, and I was quite prepared to put the front end in service position, and replace the pump.

I decided to give it another bleed this morning, and after about 2 minutes of loc to lock action, it gave a load gurgle, spat up a bit of fluid, then became quiet as it was in my D3 A8. I made an extension to the fluid reservoir, so I could put in more than the usual amount of fluid, without losing any. It worked, so that's all well.

I tested the alternator output with a digital multimeter, and it's dead. Hopefully, I'll be able to replace the combined voltage regulator and brush assembly with the alternator in situ, otherwise, service position calls.

I have been running the engine with the C5 RS6 oil cooler sandwich plate inlet and outlet take offs bridged with a loop of rubber hose. It came off while I was getting to grips with a nice, quiet PAS pump, so I shut the motor off pretty quick. I might as well do an oil change, so I ordered a genuine C5 RS6 oil filter, and Audi's Quantum Longlife Fully Synthetic oil. The oil has been delivered, though the filter won't be with me until Tuesday.

I also purchased some genuine Audi G13 concentrate coolant, though I have been running the motor with plain water. I would be pretty narked if I had to lose the expensive stuff, if the front end had to go into service position. The cooling system will be filled up and bled, once I'm satisfied the alternator doesn't need to be pulled.

I'm a bit of a stickler for OEM, and the incorrect Turbo Diesel sticker on the lock carrier bugged me. I got the part number for the sticker that would have been on the D3 A8, ordered it, and it was delivered. I removed the incorrect one, and carefully applied the correct one.
2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Nollywood
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Post by Nollywood » Sat May 07, 2016 12:50 pm

Up on axle stands, just after I bled the power steering. I'll have a shot at replacing the alternator voltage regulator while it's in this position.

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Power steering fluid, Audi G13, Audi Quantum Fully Synthetic and the defunct Turbo Diesel sticker from the lock carrier:

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Much happier with the correct sticker:

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2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

Nollywood
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Post by Nollywood » Sat May 07, 2016 1:08 pm

A quick teaser. No more whining, groaning power steering pump. Note method used in extending the fluid reservoir capacity during the bleeding process, highly recommended to prevent fluid loss:

2000 Audi B5 420-R, Pelican Blue:Work In Progress.
2000 Audi B5 420-R DTM, Santorin Blue: Work In Progress.

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