Let the build begin - Plushed/Bagged VR6

[C Chis]

Well, today was a good day!

10am this morning I had a working van!




By 2pm the engine was out and sold, gearbox plonked on the shelf. No going back now!



By 5pm Diesel tank out, some rust treated and a quick lick of paint for the rear axle. Very temporary paint job, will do something different in a bit.

Broken bolt to remove from the RHS ARB mount, grrrrr!



Rear shocks have seen better days, replacements ready to fit.



New PETROL () tank, charcoal filter, fuel regulator and a hybrid Audi Quattro/Caddy fuel pump fitted.



Tomorrow should see the tank, shocks, ARB fitted and some poly bushes installed, oh, and the electric power steering and VR6, yessss!


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[Jeffers76]

How did you find sourcing the petrol tank, I have found 2 part numbers with a slightly different price for each and there both on back order


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[C Chis]

[mention]Jeffers76 [/mention] got very lucky with the tank, bought it from Sean as he needed a maxi tank and this was a SWB one.

The part number for this tank is 2K0 201 051 P and is the same shape, etc as my Diesel one but with the additional vents and the brackets for the charcoal and fuel filters.

I had a wait of 70ish days for the fuel feed and vapour return lines from the OEMVWShop website.


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[Lister79]

Nice to see you fitting the proper fuel tank/piping, so many of these conversions are let down by people bodging up the diesel fuel tank and trying to justify that it’s fine to do. Keep up the good work, looking forward to seeing the updates.


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[C Chis]

[mention]Lister79 [/mention] cheers! Yes, I prefer OEM if at all possible, just makes it look and feel right.

Tank up and strapped in along with new anti roll bar and drop links, Replacement shocks on order too





Yay! It’s in!

Day Two…

Engine, gearbox, drive shafts, electric rack(with wiring harness) and poly bushed mounts now in and torqued down



Day 3 tasks…

Next on the list along with measuring up and fabricating the exhaust closure piece to mate the new down pipe to the vans back box is the wiring harness changes and battery relocation. Time to find out if my spreadsheet is correct

Books of knowledge have proved useful on both days.




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[Sean1066]

Awesome work there buddy.
It will be nice to see this up and running keep up the hard work.

[Alex mc]

@ C Chis

Nice work there mate. enjoying reading your thread . hat off to you and I look forward to seeing it out on the road. Your research and book of knowledge is paying dividends already.

What shocks did you go for on the rear ?
My ARB finally arrived . Did you use standard rear drop links when you fitted yours Colin ?


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[C Chis]

[mention]Sean1066 [/mention] thanks bud! Getting there with the conversion, 3 full days into it now, I’ve not worked as hard in 2 years! Wiring changes today The fuel tank is a perfect fit too

[mention]Alex mc [/mention] cheers, we’ll need to organise a small meet!
Yeah, having the information to hand and laid out in order has saved a few hours as well as letting me add notes for the future.

Today is all about ticking off the individual loom wires as I repin them to the new ECU or to the vans modules, etc.

I’ve went for standard B4 Bilsteins and standard length drop links on the centres on the rear as my suspension is running standard height (can’t get over the pavement into my drive when it’s lowered ) however, starting to look at options for swapping to air. I’ve now got a few boxes of poly bushes that I won’t need, oops!


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[C Chis]

Days 4 & 5…

Wiring mostly….



Contemplating changing the engine bay electronic panel from my caddy one to the Audi one.

Took a little break from the wiring spaghetti to fit the final poly bush to the lower mount, not the easiest one to squeeze in



Home for a spot of dinner and chill before heading back through to work out the motronic current relay wiring/position


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[C Chis]

A quick update….

Engines in, scanned and I only have 2 error codes, so far…

1. Steering angle sender - no communication. Most likely because I haven’t installed it yet!

2. Accelerator position sender G79 and G185 signal too low, quick check and I found I’d wired them up wrong, quick swap and a rescan, down to 1 Accelerator position sender, G79 still faulty. Resistance values are very low, most likely I’ve caused damage from sending 12v to them, going to replace the complete Caddy throttle assembly tomorrow with the one from Audi.

Fingers crossed it”s G79 that’s stopping the engine from firing up

All being well then I just have this mess to tidy up and wrap




Does like like it belongs though



Also welded up the exhaust system and gave it a quick paint to tidy it up. I did route the sensor wires correctly after the photo was taken




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[Sean1066]

That engine looks awesome in there buddy well done.
All that hard work is paying off now
When you start it for the first time (by the looks of it it will be soon) you will have a big grin form ear to ear

[Doc]

Nice work, it's an achievement to get to the point where there are no nasty fault codes. First start is alway a big grin moment.

[C Chis]

Thanks guys!

Tossed and turned all last night, every time I woke I thought, “is it time to head to the garage and fit the pedal!”

Just having a coffee before heading through.


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[Papa Bear]

Fantastic work.
All your planning and research seems to be paying off.
Top job!

[C Chis]

Cheers [mention]Papa Bear [/mention]

Cleared the G79 & G185 errors to be met with a few more errors, a bit of fault finding later and I’d missed a power wire to some of the engine harness!

IT’S ALIVE, ALIVE I TELL YOU!

Engine is now running, for a short period of time… low fuel pressure due to having a 6.6 Bar filter/regulator and a pump that’s only capable of 4ish Bar, need to source a lower pressure filter/regulator to match the original VR6 pump.

Tomorrow is loom tidy up day along with refitting the front end with the Touran Bi-xenon headlights


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