07K Turbo swap any takers??

[EuroxS4]

Curious if anyone is still contemplating this swap. I am close to finishing up my big turbo 1.8T build hopefully it will be up and running before this winter. However I sold the two 2.7T engines I had and picked up a early 07K with a forged crank for pennies literally. Already have engine mount brackets ordered and oil filter block on order as well. Now its gonna come down to getting a intake manifold made, oil pan, valve cover and exhaust manifold. I also ordered a 2.5 cylinder beetle harness as the early 2006-2010 beetle ran me7.1.1 management and since i purchased pnp standalone for me7.5 all I need to do is swap 1 pin and Ill be able to utilize the same standalone ecu for the 5 cylinder. I would like to make this more of a information thread than a build thread as Im not much for build threads. I just don't have the time as it is. I will keep you guys updated. I would like to mention the following for those that are potentially interested in this swap.

For a budget build you want a 2005-2006 5 cylinder. Anything that has torx T30 securing the lower oil pan will have a forged crank.
Only 07K105101E cranks are forged,only exception to this rule is the $1500 TTRS crank.
Early 07K suffered from some timing issues because of the long service intervals. If you plan on building make sure you use good quality synthetic oil and change it every 5k miles max. That being said timing chain components cannot be swapped from later model year vehicles as the timing gear on the crank is different. There is also not way to swap that gear.

1.8T flywheels are the same bolt pattern as the 07K.

1.8T starter can be used but needs to be trimmed to fit as well as the lower timing cover.

01E transmission can be used but bell housing needs to be cut/trimmed because of the hump for the vacuum pump. Vacuum pump needs to be deleted as wel..

Your gonna need engine mounting brackets made or purchased.

Oil filter block to use for drivers side engine mount bracket is the only option.
For hydralic power steering I think the best approach is a electrci power steering pump made by TRW thats used in europe in some vw and gm cars.

Height wise the engine will fit but useing a billet valve cover wont hurt especially if running a catchcan.

Length wise theres a difference of about 4 inches. I think pulling the radiator fans and using pusher fans from other side should give you the room without modifying the rad support.
I think stock oil pan with modified subframe is the best and cheapest option.

Exhaust and intake manifolds if going turbo its your best bet for make good power.

06-10 2.5 beetle engine harness to make one hybrid harness using the stock 1.8T harness. Ideally you want to use the short ecu connector with the associated wiring and modify the pin out if needed. Having said that you will still need to use the long ecu connector with wiring from the 1.8T engine harness. Doing it this way ill take some work but will require the least amount of modification to engine harness.

Hope this helps demystify some of the things people have heard about this engine. FYI the stock forged crank should will handle more power than a 1.8T engine. I have yet to hear anyone snapping a crank.

[Gunnarrrrr]

He's really doing it 😳

[EuroxS4]

Yes it will be a process. But looking that way.






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[Spike00513]

Well Done

[EuroxS4]

Waiting on some parts. Will post updates once more is done on the engine.


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[EuroxS4]

Received and mounted early beetle accessory bracket. Everything looks good and it bolts up. Still waiting on alternator and power steering pump. Hoping to use as much of the original setup as possible. Also got the wiring harness in. Will be digging into that shortly and comparing side by side as well as what I need from the stock harness.


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[Gosser]

I walk by these motors all day long in the junk yards, I was always curious. Definitely following. There are intakes, exhaust manifolds and billet valve covers out there with longitudinal mounting in mind, so definitely doable.

[Tahoe3.0]

Well damn. Looking forward to this one.

[EuroxS4]

I walk by these motors all day long in the junk yards, I was always curious. Definitely following. There are intakes, exhaust manifolds and billet valve covers out there with longitudinal mounting in mind, so definitely doable.

Yes doable!! I already have the engine brackets on order. Intake manifold I think I will go the custom one off route. This swap is just becoming popular now into porsche 944 and various other vehicles as well. In NA form its nothing exciting but forced induction the numbers are pretty impressive. This is the route I will be going. Stay tuned I will update once more parts arrive. Currently going through the engine harness. Will be running standalone. Just easier that way. Also wil be drawing up a few parts I need in fusion 360.

[Dr.B6Banter]

Very interested in seeing the progress I can't even imagine how hard my neck would break seeing a B6 go by and hearing a 5 cylinder in it lol

I know there is a guy on youtube also doing the same swap into a B6...

[EuroxS4]

Very interested in seeing the progress I can't even imagine how hard my neck would break seeing a B6 go by and hearing a 5 cylinder in it lol

I know there is a guy on youtube also doing the same swap into a B6...

yes the 5 cylinders do sound good!!!

[nefkntym]

Looking forward to seeing the progress of this. I thought about it years ago, but I decided against it.

[EuroxS4]

Looking forward to seeing the progress of this. I thought about it years ago, but I decided against it.

I was a skeptic myself mostly because of the amount of custom parts and costs needed just to fit the engine longitudinally into these cars. But recently mounting brackets became available as well as some more information on the the swap in particular. Some smaller parts will be designed by me as I now have a 3d printer to prototype some of the smaller pieces that will be on the engine. The goal is to use as much of oem parts as possible as space allows. Long story short I think there is enough data available as far as potential with this engine to have a go at building a 6-700+whp budget engine with some goodies. That being said alot of performance parts I already have for the big turbo 1.8T engine will swap over to this 5 cylinder engine. Ideally I only need to go through the whole engine,purchase fasteners and new bearings and timing chain components and perform some necessary upgrades. But the engine management is already checked off, as is the flywheel and clutch setup as well as the starter and transmission,turbo and intercooler. This leaves accessories which will be all stock vw beetle accessories as they had a hydralic power steering pump, custom oil pan, custom exhaust manifold and custom intake and plenum and injectors, Will most likely be using a 80 or 85mm throttle body.

[Spike00513]

Did you know

VW Teramont in Chinese market
has 2.5L VR6 turbo stock

I wonder what those engines go for

[EuroxS4]

Did you know

VW Teramont in Chinese market
has 2.5L VR6 turbo stock

I wonder what those engines go for

Well aware of that engine being in the VW parts bin. VRT has been done before. VW has a 3.0l Turbo vr6 they have yet bring to the market. Its supposed to come in the new Arteon R. Wether that happens well see. Numerous sources tell me yes. However FSI injection I am not a big fan of. More of a KISS approach is better if you ask me. Engine room is already a premium in our cars. That being said 5 cylinder engines have a special unique sound. That being said I love Vr's as well but 12v vr sound better than 24v in my opinion,5 cylinder 20v sound like pure sex when done right.

[EuroxS4]

Waiting for some parts to arrive to test fit. Started designing the rear coolant flange. Still not finished,but will be soon. Then ready to 3d print and test. Should be a nice piece to use with the factory heater core hoses.

Coolant flange v1.png

[JoshDub]

I'll go ahead and subscribe to this. If anyone is finally going to get this done, it'll be you. The b6 is begging for a 5pot

[EuroxS4]

I'll go ahead and subscribe to this. If anyone is finally going to get this done, it'll be you. The b6 is begging for a 5pot

coolant flange v1c.png

Coolant flange is coming along. I still need to figure out what im gonna do with the end and if Im gonna curve it or not. Then I will print and tweak as needed. The next thing to address is gonna be the piping for the water pump. Looks like im gonna have to design another block possibly to fit the map controller thermostat. We will see. I already have a 07K intake manifold flange drawn up and some other goodies I was working on for a friend over seas we will see if I could use any of it. Stay tuned for the updates. Also currently looking for rods. Would like to stay with 21mm pins or bigger to be able to take the power. Time will tell what the options are.

[Spike00513]

Well aware of that engine being in the VW parts bin. VRT has been done before. VW has a 3.0l Turbo vr6 they have yet bring to the market. Its supposed to come in the new Arteon R. Wether that happens well see. Numerous sources tell me yes. However FSI injection I am not a big fan of. More of a KISS approach is better if you ask me. Engine room is already a premium in our cars. That being said 5 cylinder engines have a special unique sound. That being said I love Vr's as well but 12v vr sound better than 24v in my opinion,5 cylinder 20v sound like pure sex when done right.

B5 5.2L V10

[EuroxS4]

Definitely cool as well. How ever no room to do anything and limited to 450hp I’m shooting for more than that. But nice to know others are still swapping engines into these older cars. Personally I feel like the B6 were the last generation that we’re still made to last but I’d buy a b5 avant if one came my way as well.


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[Kevin C]

Waiting for some parts to arrive to test fit. Started designing the rear coolant flange. Still not finished,but will be soon. Then ready to 3d print and test. Should be a nice piece to use with the factory heater core hoses.

Coolant flange v1.png

Once you get past your fit check parts do you know what process/ materials your going to use for your functional parts?

[EuroxS4]

Once you get past your fit check parts do you know what process/ materials your going to use for your functional parts?

Yes I do. Most likely going with aluminum. I have a friend that might be able to do these on his 5axis cnc mill however I am also looking at powder bed metal printing as well. This part could also be cast. I havent decided yet but those are my only options. First need to print in plastic to check fitment make sure it all correct. As of right now I was contemplating using the factory map controller thermostat but space is a premium with this enigne as it was never designed to be mounted longitudinally. So as of right now I am not sure if the factory thermostat will even be an option. It would be nice however I am still waiting for the power steering pump,alternator and ac compressor so I can see if there is sufficient room to try and cram the factory tstat somewhere under the intake.

[Kevin C]

Yes I do. Most likely going with aluminum. I have a friend that might be able to do these on his 5axis cnc mill however I am also looking at powder bed metal printing as well. This part could also be cast. I haven't decided yet but those are my only options. First need to print in plastic to check fitment make sure it all correct/

For work we have gone with low cost FDM printed parts for fit checks and functional test and transitioned to 3D printed metal where heat requirements justified it. FDM printing was a great way to verify before spending a bunch on the final part. The 3D metal ducts we made were pretty large and the cost to print was staggering ($5000 a set). I'm kind of curious what smaller parts cost to have done. That was a project from two years ago so I'm sure the pricing has come down, the end parts were amazing. A friend with a CNC is a really good option. At work we are seeing a lot of interest in lasers for 3D metal, that market seems to be really taking off. I'm really curious to see current costs info on parts like the T stat housing. Obviously if you 3D metal print you can design parts that cant be made by machining. Nice for optimizing flow.

[Steve Bassen]

Yes I do. Most likely going with aluminum. I have a friend that might be able to do these on his 5axis cnc mill however I am also looking at powder bed metal printing as well. This part could also be cast. I havent decided yet but those are my only options. First need to print in plastic to check fitment make sure it all correct. As of right now I was contemplating using the factory map controller thermostat but space is a premium with this enigne as it was never designed to be mounted longitudinally. So as of right now I am not sure if the factory thermostat will even be an option. It would be nice however I am still waiting for the power steering pump,alternator and ac compressor so I can see if there is sufficient room to try and cram the factory tstat somewhere under the intake.

If it's anything like the 1.8T map controlled thermostat then hopefully finding an off the shelf conventional one to put in its place and then coding it out in the ME7 should be fairly straightforward. I found the maps for the target/actual temps and flattened them and coded out the error for having the electric thermostat unhooked for the 518AF back when I was gearing up to do my 1.8T build years ago with a conventional thermostat (using B5.5 1.8T water pipe and housing).

[EuroxS4]

If it's anything like the 1.8T map controlled thermostat then hopefully finding an off the shelf conventional one to put in its place and then coding it out in the ME7 should be fairly straightforward. I found the maps for the target/actual temps and flattened them and coded out the error for having the electric thermostat unhooked for the 518AF back when I was gearing up to do my 1.8T build years ago with a conventional thermostat (using B5.5 1.8T water pipe and housing).

Yes b6 a4 1.8T have a map controlled tstat. Right now it doesn’t look like the room is there. I think the map controlled Tstats over complicate the system without any real benefit. I think a regular tstat is the way to go.


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[EuroxS4]

For work we have gone with low cost FDM printed parts for fit checks and functional test and transitioned to 3D printed metal where heat requirements justified it. FDM printing was a great way to verify before spending a bunch on the final part. The 3D metal ducts we made were pretty large and the cost to print was staggering ($5000 a set). I'm kind of curious what smaller parts cost to have done. That was a project from two years ago so I'm sure the pricing has come down, the end parts were amazing. A friend with a CNC is a really good option. At work we are seeing a lot of interest in lasers for 3D metal, that market seems to be really taking off. I'm really curious to see current costs info on parts like the T stat housing. Obviously if you 3D metal print you can design parts that cant be made by machining. Nice for optimizing flow.

Yes powder bed 3D metal print uses laser to make the part. This technology is booming right now. It open lots of capabilities that weren’t available before. I think 5axis cnc in my case may be the best option however time will tell. I finished the flange yesterday. Not sure if I’m gonna print the whole flange. I may just print the connections ends to make sure they all fit as needed. Although even a plastic printed part would be good for pressure testing and making sure not leaks are present. I will keep you guys posted. Waiting on some accessories should have them this week. I already have a intake manifold flange drawn up as well as a exhaust flange. A friend of mine also sent me a 3D model of a Lamborghini flange from the 5.2 v10. We’ll see.


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[Steve Bassen]

Yes b6 a4 1.8T have a map controlled tstat. Right now it doesn’t look like the room is there. I think the map controlled Tstats over complicate the system without any real benefit. I think a regular tstat is the way to go.


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Yeah they're just for emissions so they can run the motor hotter during cruise and part throttle, pointless for a performance application.

[EuroxS4]

Yeah they're just for emissions so they can run the motor hotter during cruise and part throttle, pointless for a performance application.

Wouldn’t be surprised if the map for the tstat and the way it’s calibrated I regards to temperature is the main cause behind Coscast heads cracking #2 combustion chamber faces.


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[Steve Bassen]

Wouldn’t be surprised if the map for the tstat and the way it’s calibrated I regards to temperature is the main cause behind Coscast heads cracking #2 combustion chamber faces.


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Yeah I'm 100% convinced of that.

[MetalMan]

AWM heads can crack on B5s, too... don't necessarily need a mapped T-stat to make it happen either! (My old '01.5 head developed a crack between cooling jacket & valve seat, that would only make itself known when under high load and the engine was in use 30+ minutes)

[EuroxS4]

AWM heads can crack on B5s, too... don't necessarily need a mapped T-stat to make it happen either! (My old '01.5 head developed a crack between cooling jacket & valve seat, that would only make itself known when under high load and the engine was in use 30+ minutes)

I havent seen one on a B5 unless it was badly overheated. Then again most of the ones I've seen were AEB engine codes which didnt suffer from this issue.

*Update* Engine mount brackets finally got cut, still need to get formed and welded. Pics coming soon I hope. I will try to update as much as I can. Kinda hard juggling home life,work,a business and personal projects at home. Stay tuned.

[Dr.B6Banter]

I havent seen one on a B5 unless it was badly overheated. Then again most of the ones I've seen were AEB engine codes which didnt suffer from this issue.

*Update* Engine mount brackets finally got cut, still need to get formed and welded. Pics coming soon I hope. I will try to update as much as I can. Kinda hard juggling home life,work,a business and personal projects at home. Stay tuned.

We'll be here! Always neat seeing crazy stuff still happening on this aging platform, and definitely gives me the motivation to finish the odds and ends on my B6.

[EuroxS4]

Yeah I have 3 b6's currently. I think I may chop the front end from one to use as mock up while I finish other projects.

[EuroxS4]

I’ll just leave this here for now. I’ll write more I. During the day when I have time guys.


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[Dr.B6Banter]

Nice fab work! I also notice that little 3d printed price. It's great for custom applications like this to check fitment before you make the part out of metal.

[EuroxS4]

3D printed part is a template used to cut the bell housing on a 01E transmsision so it clears the rear 07K timing cover.The parts finally arrived from canada, the brackets and 3d printed template are made by race3 and oil fitler block is from issam or iabed industries. Iabed also now has a oil pan but with low cost volume parts its alot of money. Roughly 2 grand for oil pan and pickup tube. I will be cutting the stock pan and possibly casting my own alloy pan. Currently this project is on hold, I just got the parts in so I figured i'd update it. I will update as I progress. Stay tuned!!!

[avant1987]

Excited for additional updates and progress!

[EuroxS4]

Progress Is slow currently as other thing have priority. But I am selling alot of my big turbo 1.8T parts in order to get things rolling on this project more quickly.

[Seerlah]

Out of curiosity, what do you plan on doing with your 1.8T build? I assume both these motors are for the same car?

[Leafy1]

You have to make the pan a front sump right? I wish they made the upper pan steel like the lower pan.

Do those mount brackets use factory mounts?