VW/Audi 2.5 5 cylinder 07k swap

[Kdj]

Little follow up to the swap. I know a lot of you guys have done both diesel and Subaru swaps that use electronic pedals. The Mk4 VW pedal is top swing and is a popular choice. I used the mk5 pedal from a Jetta which is bottom swing like the original vanagon one. The wiring is the same even down to wire color. The plugs are different though so I just soldered a jumper loom on the the cable extension provided by my harness constructor. That was originally done for the mk4 pedal. There is a little grinding required to get pedal to fit nicely on the floor and a bracket to hold the top section. But overall a nice piece that looks fairly original.

This is how my engine cover lid ended up. Small bump.

Also if anyone is looking for an additional mattress topper this is a great value from Ikea. It will need a little trimming but has a really nice cover and is way better the the inflatable one we had been using. Price is really right too!
https://www.ikea.com/us/en/p/agotnes-foam-mattress-firm-light-blue-
10600959/
Still putting my final cost into a spreadsheet to share but overall I think this is a great swap opportunity, as these engines are plentiful and cheap. In stock form 150hp and 175 Ft lbs torque really help get the van going. All while keeping it VW. Really happy with how it turned out so far!

[Kdj]

Finally went through my stack of receipts and did a double check of what this swap cost. As I mentioned earlier came in just under $5000.00. Could you do it cheaper? Absolutely! I spent extra on things like stainless exhaust and v-band clamps. Which I still got wrong I needed new CV's and boots and purchased the lot from T3
I paid to have a wiring harness built and ecu supplied with a mapping that would start and run first time.
But overall I belive this is an accurate number of what I spent. Here's the sheet. Hope it will encourage more down this path.

https://docs.google.com/spreadsheets/d/18RAB14Mywx...p=drivesdk

[chillzombies]

[Kdj]

I wish I knew about the DAZA timing cover before I had the engine installed in the van. That is definitely the way to go. I may revisit that in the future.

I used a cover from I-5 garage. He doesn't have the best reputation on the 07k swap group, but he did come through after a little prodding! It was the cheapest one super simple just a piece of maybe 1/2" aluminum. Came with hardware and a -10 fitting. Fit fine and does what its supposed to.

[chillzombies]

Any updates? I’ve started ordering some parts like the daza timing cover and other billet parts. Found an 07k local but deal didn’t work out so I still need to find an engine but I’m hoping to make more progress over the winter. Hope to hear you’ve been driving the van and enjoying it.

[dublife13]

What MPG are you getting with this motor?

[Kdj]

Wesley is running great. I just got back from a 820 mile Kayaking trip last weekend. Being able to run the speed limit without having to worry about the up coming hills or just needing to pass when needed is what I wanted.
I did have one hiccup friday night. I installed a 40 amp circuit breaker in the main power wire feed the ignition switch from original harness. With all my lights on and climbing a long steep Pennsylvania hill the cooling fan kicked on and tripped the breaker, shutting everything down. Coasted to a stop in a dark driveway . The breaker reset and and everything came back to life and I got to camp. After a bit of diagnostic the next morning I decide to bypass the circuit breaker and hit the river. I'm going to install a 60 or 70 amp one that should solve that problem.

Also I couldn't find a muffler that would fit to quiet the drone down without modifying my exhaust system more then I wanted too. So I built my own, kinda a modified turbo design with a couple of chambers too. It was a good fabrication exercise and definitely quieted it down. Ended up being 5 1/2" round and 30 long. I had originally gone with a 4" and 5" round straight thru style, although they sounded great the drone was too much after a couple of hours.

Not sure about gas mileage. I think I got about 280 miles to a tank before I had to pee. So lets say 18+ highway doing 70+MPH