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FrankensTTein 2.0 FWD > Audi TT Mk2 3.6 AWD

164K views 1K replies 46 participants last post by  IPG3.6 
#1 · (Edited)
:mrgreen: :mrgreen: Hey all.

Been here a while and have dabbled in the Mk1 side of things and recently acquired the most recent project car(s). You will see why the title is called so.

TABLE OF CONTENTS
  1. FWD 2.0L BWA to 3.6L VR6 BWS conversion
    1. ECU pinout
    2. Floorpan information
    3. Engine bay fusebox labelling
    4. Engine bay large fuses labelling
    5. Electrics discussion - ECU, IMMO, CECM/BCM
      - CANbus malfunction = car death (VIDEO)
    6. Exhaust comparisons 2.0 vs 3.6
      - Exhaust experiment - no rear mufflers (VIDEO)
    7. Fuel tank mount points (AWD), AWD fuel tank wiring info
      - Coding for AWD fuel tank (VIDEO)
      - Fuelling issues and remediation
    8. Haldex wiring loom info
    9. Manual conversion parts
    10. Propshaft brackets part number (requirement for AWD conversion)
      - Propshaft tunnel material and measurements info
      - Propshaft removal & bushing / guibo part numbers
      - Propshaft brackets welded in pics
      - Propshaft bolted in pics
    11. Servicing VR6 engine (applicable for 3.2 and 3.6)
    12. VR6 blue coilpack covers (applicable for 3.2 and 3.6) (VIDEO)
    13. 2.0 BWA removal pics
    14. 3.6 BWS installed!
      Swap from 2.0 to 3.6 1/3 (VIDEO)
      Swap from 2.0 to 3.6 2/3 (VIDEO)
      Swap from 2.0 to 3.6 3/3 (VIDEO)
  2. DRIVETRAIN AND HANDLING
    1. ABS module removal and installation (VIDEO)
      ABS coding error rectified (VIDEO)
    2. Brakes, springs & swaybars comparison - FWD vs AWD vs Passat R36
    3. KW v3's coilovers installation w/suspension torque values
    4. Mechtronic DSG issues and swap (VIDEO)
    5. Rear subframe w/rear differential and suspenion assembly removal (VIDEO)
    6. Rear subframe full assembly installation (VIDEO)
    7. Rear trailing arm bush upgrade to polybush (VIDEO)
    8. Steering rack upgrade gen2 to gen3 info and pics
    9. SuperPro 26mm rear sway bar upgrade
    10. Suspension components comparison
    11. 17Z brakes for Audi TT Mk2 pics, more pics
      17Z Brembo brakes rebuild (VIDEO)
      17Z Brembo brake upgrade and Forza two piece rotors installed (VIDEO)
      17Z Brembo brake upgrade - master cylinder swab & VCDS brake bleeding guide (VIDEO)
  3. EXTERIOR/BODY MODIFICATIONS
    1. AFS Headlights info (upgrade from halogen to bi-xenon LED cornering lights)
      Headlight upgrade (VIDEO)
      AFS cornering lights output test (VIDEO)
      AFS sub CANbus wiring discussion
      AFS conversion parts list
    2. Alarm module upgrade - need to scroll down the post (VIDEO)
    3. Auto power folding, Auto dimming, auto reverse dip, Dynamic sweeping indicator wing mirrors (DIY VIDEO)
    4. Badges logo placement (rear)
    5. Bumpers removal (rear w/PDC wiring)
      Front bumper installation (VIDEO)
    6. Carbon fibre front lip pics
    7. Centre brake light removal and upgrade guide (VIDEO)
    8. Doors - complete removal and installation (VIDEO)
    9. Headlight level sensors upgrade w/wiring info
      - Rear level sensors info
      - Rear arm rivets for level sensors
      - Cross compatibility rear level sensor info + basic settings
    10. Headlight mounting bracket repair using headlight tab repair kit
    11. Number plate lights upgrade to LED units
    12. Parking sensors (PDC) information
      - Parking sensors wiring info (rear)
      - Parking sensors wiring (front)
      - Front PDC sensors installation into front bumper pics
    13. Side skirts upgrade and parts
      Side skirts removal and installation (VIDEO)
    14. TTRS wheel arch brake vents upgrade (VIDEO)
    15. Undertray fittings (VIDEO)
    16. Wind whistle issues and best fix guide (VIDEO)
    17. Wheels upgrade - Neuspeeds vs BBS two piece (VIDEO)
  4. INTERIOR MODIFICATIONS
    1. Door seals - replacing torn and damaged seals guide (VIDEO)
    2. Fire extinguisher install - Kap Industries (VIDEO)
    3. Glovebox swap (due to broken hinges)
    4. Gear shifter comparison, gear shifter assembly swap (VIDEO)
    5. Headlight switch wiring diagram
    6. High beam assist (HBA) rear view mirror upgrade (VIDEO)
    7. Homelink interior light upgrade & modification (VIDEO)
    8. Interior boot lid rim removal guide
    9. Puddle light "quattro" projector LEDs install guide (VIDEO)
    10. R8 slotted, LED ambient handles upgrade (VIDEO)
    11. Seats swap - manual seats w/electric lumbar to fully electric
    12. Soundpipe installation and review - gen1 Soundaktor (VIDEO)
  5. IN CAR ENTERTAINMENT, CONVENIENCES
    1. Airbag reset, boost/oil temp/lap timer, needle sweep, cluster LED configuration, AFS lights demo mode
    2. Alpine Halo9 9" head unit (VIDEO)
      Time alignment settings
    3. Amps and speakers
      - Clarion 4 channel amp install - hooking into factory plug's power
      - Adding third 4" speaker to non-Bose amplified system
      - Rainbow German Audio 3-way speakers: 8" woofer, 4" mid, 1" tweeter
      - Modifying OEM speaker housings for Rainbow woofers and mids
      - JL monoblock subwoofer amp install
      - MTX slimline subwoofer pics
    4. Bluetooth module for OEM stereo upgrade (VIDEO)
    5. High Beam Assist (HBA) rear view mirror pics and wiring
    6. Instrument cluster mods
      TT Mk2 8J Instrument cluster pinout information (for ColourMFA)
      ColourMFA for Audi TT Mk2 instrument cluster test (VIDEO)
      Cluster modifications for ColourMFA
      ColourMFA installed in TT 8J cluster test (VIDEO)
      ColourMFA boost gauge test 1, boost gauge test 2 (VIDEO)
      ColourMFA installation overview in Audi TT 8J 1/2 (VIDEO)
      ColourMFA installation overview in Audi TT 8J 2/2 (VIDEO)
      ColourMFA in Audi TT Mk2 (long) Review (VIDEO)
      ColourMFA debug features: PDC OPS display, climatronic, launch control (VIDEO)
      Instrument cluster swap: red to white LEDs (VIDEO), IMMO OFF (VIDEO)
      Red instrument cluster w/ needle sweep + lap time (VIDEO)
      White LED broken backlights repair, detailed pictures
    7. Wireless charger pad installation + double USB 3.0 ports (quick charge)

This was the first car to have secured. Running perfectly but with a little too much damage for a cost effective repair.
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So luckily another happened to pop up, albeit a little higher mileage, but for a relatively good price.

Now the build thread, which I wish to document here (as the Australian forums are abysmal), is planned out to go something like this
- swap out FWD drive train for the S-Lines' Quattro (gen4) and 10mm lower suspension
• brakes and 19" wheels
- swap out the rest of the trims that are up-specced from the S-line such as
• red FIS to updated facelift cluster
• power seats
• steering wheel
• exterior trim (these are what I can think of straight up but pretty sure there's more)

Once all that is fine and dandy (yes I know you're already thinking should just buy one in Quattro spec! But that's not the point here! And the price was too good) - then the focus turns getting this in and running.

So yes, this is a little crazy in that it'll be a full conversion but it'll keep me busy, I feel like it'll be the best way for me to learn this platform that I'm relatively new to (although not that much of a stranger to the 8L/8N platform), and put the 3.6 into a chassis that a little more agile than a Passat.

From the content I've stumbled across in this group I should have most of what I'll need to make this happen. The latter part of the build, there's not so much info, but hey we all need to start somewhere right?

JULY CORONA SPECIAL UPDATE: The R36 engine swap IS complete and running - very well i might add! If you've read this far you deserve to skip to the juicy part by clicking here. Audi TT 3.6 swap link
 
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#4 ·
I've thought before that it would be a good project to put the 3.6 in the TT. I'll be interested to see how you get on
 
#5 · (Edited by Moderator)
MT-V6 said:
I've thought before that it would be a good project to put the 3.6 in the TT. I'll be interested to see how you get on
It is definitely possible - the hardware side of things will be the easy part as the 3.6/3.2 are virtually the same size on the outside. It's been done before in America, and this one is a manual conversion too (which is my end goal - sorry DSG fans!)
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And i have been working on the pin outs between all the different cars so when the time comes i know where to look when looking for why things don't work. I can upload this once it's tidied up.
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#6 · (Edited by Moderator)
First delete to definitely do!!!

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I was wondering what that strange noise was when driving the 3.2 for the first time. Sounds TOO fake to me.
 

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#7 ·
I imagined they would we physically similar

Do you have a link for that US one?

The TT looks nicer with the aluminium engine cover, would be good if you could retain that somehow?
 
#8 ·
No links on that red one sorry. Stumbled across them on Facebook and not much info was given hence the homework.

Also the 3.6 in all it's forms only come in the plastic cam cover... so sad

With the only difference in the inlet manifold which is 2 piece vs 1 piece
 
#10 ·
The oil filler cap is on the other side of the engine to the 3.2, strange
 
#11 ·
MT-V6 said:
The oil filler cap is on the other side of the engine to the 3.2, strange
Yeah there have been some upgrades on the exterior of the motor - there are no aluminium coolant pipes or thermostat housings yet available for 3.6.

The 2 piece inlet manifold is the best so you can gain access to the cam cover without having to remove the front of the car.
 
#13 · (Edited by Moderator)
This is where i'm pretty sure there is one universal body.

Looking at all the different pics online and part numbers - there is one floor, and one rear end. Whereas earlier models or hatchbacks of the same gen have obvious different depths in boot height.

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#14 · (Edited by Moderator)
And comparison of a 2.0 FWD vs. 2.5 AWD
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No difference in depth. How ever mounting points under the vehicle might be a different story...
 

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#15 · (Edited by Moderator)
Both TT's cleaned and project FrankenTTein almost ready for the green light!
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It's amazing what a clean can do...
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Cover off and gave under there a blast with compressed air and a wipe down
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The final product ... which will be replaced
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#16 · (Edited by Moderator)
Just a few more shots before things start getting a bit more involved!

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But we made it and it was time for a wash before having a well deserved rest.

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Currently getting tools together to help with swapping electronics.
 

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#17 · (Edited by Moderator)
Have to get everything working so i can get registration and plates for the car.

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Relatively simple job with the hardest thing being to move the wheel arch liner enough to get to the motor.

This next job isn't important but i like the "fan" spray pattern that is on the older TT's and some VW's. These units are from an R36.

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They are a perfect fit (can you tell which one it is?)
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... however it looks like the electrical connector needs to be wired up as they weren't squirting anything (just a dribble) when activated. Something to work on.
 

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#18 · (Edited by Moderator)
Some background work before starting
Fuse Box.jpg


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In my experience, being prepared (especially for such a "big" swap) is the best way to go. Knowing the above information and more importantly the below will be helpful in diagnosing when systems aren't working throughout the process.

Notice something? (file available on request)
 

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#19 ·
Isn't the coolant pump for the V6 mechanically driven? I didn't think it ran with the engine off?
 
#20 ·
MT-V6 said:
Isn't the coolant pump for the V6 mechanically driven? I didn't think it ran with the engine off?
Are you referring to J151?

That's the after-run pump - same thing on turbo cars that acts like a turbo timer. The pump runs to keep coolant circulating after ignition off. Secondary to the main water pump which is belt driven and the impeller is in the block.

After run is located to the left of the dipstick tube (when looking at the engine as if you're standing in front of it)
 
#21 ·
Cool, never knew it had that!
 
#22 · (Edited by Moderator)
Here you can see it nestled in between the ancillaries bracket and the dipstick tube (mk4 setup) -
The 8J pump is a smaller unit but in a similar spot.
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#23 · (Edited by Moderator)
Still in the planning stages and resource gathering for the 3.6 swap. Meantime there's a lot that i would like to transfer over from the newer car over to the regoe'd one.
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Now to dispel some online arguments. There is NO DIFFERENCE in the floor pan between Quattro and FWD in the 8J platform. The space under there will be viable for adding the Haldex and rear diff. assembly without having to cut and weld like the 8N platform.

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Back to retrofitting trims...

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Starting the car up again and these errors stick!
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But a quick drive made them go. Am assuming it was because the steering wheel was changed.

Next is to install electric front seats so will need to obtain wiring runs from the donor car and all associated fuses/modules.
 

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