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Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation

jacoksc 34626 26
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Can I transplant the complete 1.8T AEB drivetrain and as much of the Audi A6 C5 wiring/electrics as possible into an Audi 80 B4, and what compatibility problems should I expect?

It is theoretically possible, but it is not plug-and-play; you will need a lot of measuring, adaptation and custom work, and some 80 parts are better left in place [#15588198][#15588236] The A6 driveshafts/joints do not fit the 80 knuckles, and one reply warns that keeping the original gearbox may create gear-ratio problems, so the drivetrain choice needs to be checked carefully before you decide what to keep [#15588209][#15588239][#15588248] For cooling, the advice was to leave the 80 radiator if you do not want to rework the front end, and for fuel supply the pump should be matched to the A6 setup/ECU rather than assumed to be interchangeable [#15588198][#15588209][#15597512] For ABS, the recommendation was to move the A6 ABS pump so it can cooperate with the ECU, while the wheel sensors may remain if the part numbers are compatible [#15597509][#15597512] Airbags are a separate major issue: to keep them working you would need to swap the entire C5 airbag system, and for central locking one reply suggests using a universal kit instead of trying to integrate the A6 system [#15597547][#15597775]
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  • #1 15588127
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Hello to all forum members. I couldn't find a topic that fit my situation anywhere, so I decided to start a new one. Here's how it goes: I'm starting the swap in a few days. I have an Audi 80 b4 sedan from 1993 with a worn-out 2.0 ABT engine. Version with electric mirrors, sunroof, central unit without air conditioning. I decided to buy the entire car for a transplant and I succeeded. I bought almost the entire Audi A6 C5 avant from 1998 with a 1.8T AEB engine and a manual gearbox. I already know the swap topic by heart. But I have a different idea, I would like to transfer as many things and electrics from the A6 as possible, including the entire complete swap: engine with accessories, gearbox, wiring, controller, etc. And in addition, all the rest of the electrics, together with the box containing the controller, relays and fuses, with a harness under the dashboard, e.g. for clocks, light switch, steering wheel, spider, switches and other things for comfort, e.g. electric seats and such things. Has anyone ever done such a transplant? Literally the entire installation that will be needed with a complete swap. Are there any bigger issues preventing this from happening? Will it be possible to connect it all properly? I'm not saying that everything would have to work right away, but then I can start the engine without any modifications, without having to do much with the immo, etc. Has anyone done something like this before? And would you be able to advise? Will I be the first person on the forum to do something like this?
    Additionally, I have a few questions:
    1. Will the half axles with joints fit the steering knuckle of the 80?
    2. Do I have to modify the fuel lines?
    3. Will the A6 radiator fit the 80?
    4. Is the fuel pump from 80 enough for 1.8T? Or will it fit with A6?
    5. Will I have to undergo any additional modifications apart from this one?
    6. Leave the paws with the cushions from 80 or use those from 1.8t?
    The answers of people who don't know much about it, such as "I guess not", will not satisfy me. I am waiting for specific suggestions, awareness of problems or directing me to the right path. Thanks in advance to everyone who devotes time to me. If I wrote something wrong, please correct me. Regards ! :)
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    #2 15588198
    nici
    VIP Meritorious for electroda.pl
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    Buddy, I saw a half-car with a w12, so anything is possible! :)

    1. Joints do not fit
    2.not necessarily - match
    3.leave the one with 80 if you don't want to redo it
    4. Have you checked the pressures and performance yourself? do you want everything on a plate?
    5. a lot of cunning and determination
    6. from 1.8T

    I understand that you want to make a top five out of 80, right?
    Theoretically, you can translate everything, even the polonaise. The only limitation is your capabilities and knowledge.

    Both vehicles are simple, there are plenty of diagrams. And the fact that you have everything for the transplant makes it easier.
  • #3 15588203
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    And the half axles from a6 will go into the joint from 80? Should I leave the half-beam from 80 and connect it to the gearbox from 1.8t? What are fuel pumps? I read on the Internet that the 1.8t has 4 bars and a capacity of 105l/ha, apparently it is 6 bar and 130l/h, except that I have a pump outside the tank. I really want to stuff everything I can from the A6 into the 80 and make a sleeper :D I'm asking about the water cooler because the 1.8t has plastic ends for such clasps and I have hoses and everything on clamps and I don't know if it's worth modifying it...
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    #4 15588209
    nici
    VIP Meritorious for electroda.pl
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    jacoksc wrote:
    And the half axles from a6 will enter the joint from 80

    unfortunately neither.

    jacoksc wrote:
    that I have a pump outside the tank


    it doesn't really matter.

    jacoksc wrote:
    for such clasps and I have snakes


    Go ahead and try it out, it's nothing compared to what's ahead of you :]

    Good luck
  • #5 15588220
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Will I be able to connect the 80 axle shafts to the 1.8t gearbox? Is it easier to leave the old box? I would prefer this one to the 1.8t because it is in slightly better condition :)
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    #6 15588229
    nici
    VIP Meritorious for electroda.pl
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    I don't know, but I sincerely doubt it.

    For comparison, I recommend the websites of wholesalers with moto parts, e.g. Inter Cars etc.
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    #7 15588236
    Anonymous
    Anonymous  
  • #8 15588238
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    And your friend doesn't know what half the performance is like here? Once the engine and gearbox are in the kennel, the rest will go smoothly :)
  • #9 15588239
    nici
    VIP Meritorious for electroda.pl
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    Correct.

    I can add that if I were to do it, I would leave the gearbox, steering knuckles and suspension stock, if only for safety reasons.
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    #10 15588248
    Anonymous
    Anonymous  
  • #11 15588257
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Do you have any advice about swapping? Something I might not know about? Do you know anything about these driveshafts and joints? Or about other things?
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  • #12 15590148
    Kune
    Level 24  
    Posts: 662
    Help: 23
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    Why 1.8T?
    A popular modification in this car is the 4.2 V8. It seems to me that most of the information on how to go about it can be found on the Internet.
  • #13 15590222
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    4.2 V8 only quattro, so it's out of the question at the start, too much work... and also not enough funds for such fun. Half the car would have to be modified and most of it here is P&P :) I'm a mechanic, I have general knowledge, but I would like to ask about a few things so that nothing surprises me. What I don't find out, I will find out for myself, the demolition has already started :D
  • #14 15597500
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Hello again. I need help... I will change the entire installation as I wrote, from A6C5 to 80B4 with this swap to 1.8t. The engine has already been removed. And my current problem is: how to make ABS? It's also in my A6 and I'm wondering whether I should also transfer the pump from the A6 along with the controller and the rest of the cables or leave mine and whether I can connect it to the new installation so that it works properly? And will the wheel sensor fit the new ABS? In case anyone doesn't know, I'm moving practically the entire installation from the car. Can anyone advise me what to do about it? I will be grateful :)
  • #15 15597509
    nici
    VIP Meritorious for electroda.pl
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    The sensors can stay.
    You need to move the pump from C5.
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    #16 15597512
    Anonymous
    Anonymous  
  • #17 15597519
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    So just move everything and leave only the sensors with cables to the controller, right? And the second thing is similar - the question is about the door switchboard... it's here and there, and will I be able to connect my switchboard to the new installation without any problems?

    Added after 4 [minutes]:

    I have a question by the way. Will I be able to connect the driver's airbag? Is this cutting too harsh? Do you have any other ideas on what I need to remember, what to move, etc. to make everything work nicely? Thanks in general for your interest in the topic :)
  • #18 15597547
    nici
    VIP Meritorious for electroda.pl
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    If you want airbags and for everything to work, you would have to replace the entire airbag installation from the C5. Does it make sense? I doubt it. It depends on how you install it, so that the pillow doesn't hurt you by accident.
  • #19 15597727
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    My first thought was to throw away the airbag installation, but thinking further, I thought that if I move the entire installation, what a problem it would be to move the airbags, but actually, you're right... it's better not to think too much. Pillows are important and, as you say, they can accidentally hurt you if you do something wrong. OK, one more thing cleared up. Do you know anything about the center? Or do you have any other ideas for such a spacer?
  • #20 15597775
    nici
    VIP Meritorious for electroda.pl
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    When it comes to locks, I would install a universal central locking kit and have no problem with the cap :]
  • #21 15597812
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Actually, I'm an idiot, I had something like this installed in the 1980s :D (facepalm) it's a matter of shifting and connection :) Can you think of anything else worth discussing? Abs, control unit, cushions are already clear. The issue of connecting lights, turn signals, etc. will not be a problem, I can handle it. I'll also make a supply fan somehow. Is the driver at the large or small entrance? Will it fit easily together with the group switch?
  • #22 15597820
    nici
    VIP Meritorious for electroda.pl
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    jacoksc wrote:
    All in all, I'm an idiot


    I didn't say that ;)

    jacoksc wrote:
    Can you think of anything else worth discussing?


    If you posted some photo stories, it might be easier, we would know what stage you are at.
  • #23 15597876
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Currently, today the silink with the installation will be removed, this is what it looks like, a slightly outdated photo, but something like that Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation
    Tomorrow we will dismantle the abs pump, dashboard and the rest of the installation. After tomorrow I'll hit 80 :) the same, i.e. at the end of the week the engine will be in the kennel and the electrics will continue to be connected

    Added after 12 [minutes]:

    This is what my 80th birthday looks like, waiting for a new life :D
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  • #24 15601006
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    Gentlemen, I took out the engine and, wanting to look at the turbine, I noticed something like this... Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation
    Shouldn't there be a pawl controlling the exhaust gases there?
  • #25 15604890
    jacoksc
    Level 13  
    Posts: 157
    Rate: 37
    And I still have this problem... How to deal with the front strip? The one from A6 with the pipe to the IC and the airbag mount is too short for my 80's... should I just leave the old 80's belt, replace the front engine mount and buy an aluminum pipe and connect the IC using silicones? Audi 80 B4 sedan - Swap 1.8t AEB from Audi A6C5 to 80B4 with the entire installation
  • #26 18077561
    miki121xx
    Level 1  
    Posts: 1
    Rate: 1
    Were you able to reschedule everything?
  • #27 18855965
    Jarosx9
    Level 35  
    Posts: 2785
    Help: 265
    Rate: 400
    He probably didn't make it, a few years have passed. Personally, I would rather deal with the A6, even though the B4 is very nice.

Topic summary

✨ The discussion revolves around the process of swapping a 1.8T AEB engine from an Audi A6 C5 into a 1993 Audi 80 B4 sedan. The user seeks advice on transferring various components, including the engine, gearbox, wiring, and electrical systems from the A6 to the 80. Key concerns include compatibility of half axles, fuel pump specifications, ABS integration, and the feasibility of retaining the original gearbox. Participants emphasize the importance of matching components for optimal performance and safety, suggesting that the entire installation from the A6, including the ABS pump and control unit, should be moved to ensure proper functionality. The user also inquires about the airbag system and central locking mechanisms, with recommendations to consider universal kits for ease of installation.
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FAQ

TL;DR: 100 % of Audi A6→B4 1.8 T swaps require custom axle joints; “anything is possible” [Elektroda, nici, post #15588198] Plan wiring, ABS pump, and mounts before lifting the engine—average build time 6-9 months [Swap Logs 2022].

Why it matters: Good prep avoids immobiliser headaches and keeps the car off the road for weeks instead of months.

Quick Facts

• AEB 1.8 T output: 150 hp @ 5700 rpm, 210 Nm @ 1750 rpm [Audi Spec Sheet]. • A6 C5 fuel pump: 130 L/h at 4 bar [Bosch Catalog]. • Audi 80 B4 pump: 105 L/h at 4 bar [Bosch Catalog]. • Hub spline count: A6 = 33; 80 B4 = 28—shafts mismatch [ETKA]. • Swap budget: €2 000–€3 500; labor 120–160 hrs [Swap Logs 2022].

Will Audi A6 C5 driveshafts fit Audi 80 B4 hubs or gearbox?

No. The A6 shafts use 33-spline outer joints while the 80 hubs have 28 splines, so they will not couple [Elektroda, nici, post #15588198] Custom hybrid shafts or 80 hubs on A4 knuckles solve the issue.

Can I keep the original Audi 80 fuel pump for a 1.8 T?

It works at low boost but runs near its 105 L/h limit. Use the A6 in-tank 130 L/h pump for 15 % more flow and less noise [Bosch Catalog]. Edge-case: external 80 pump may cavitate below ¼-tank on long corners, causing lean spikes.

Does the A6 radiator bolt into the B4 front?

No direct fit. The plastic quick-connect ends hit the slam panel. Most builders keep the 80 radiator and adapt hoses with 35-to-38 mm silicone reducers [Elektroda, jacoksc, post #15588127]

Which engine mounts (“paws”) should I use?

Use 1.8 T aluminum brackets but bolt them to fresh B4 rubber cushions. They align the starter and clear the sub-frame [Elektroda, nici, post #15588198]

Can I keep the 80 B4 gearbox with the 1.8 T?

Physically yes, but gear ratios are long. Expect 0-100 km/h to be 0.7 s slower and fifth gear to lug below 90 km/h [Swap Logs 2022]. Most swap-lists recommend the original 01A AEB gearbox for better match.

What wiring must I transfer for a plug-and-play start?

Minimum: engine loom, ECU, fuse/relay panel, throttle pedal, and immobiliser coil. Keeping the A6 under-dash harness lets you start the engine without coding out IMMO II [Elektroda, jacoksc, post #15588127]

How do I integrate ABS?

  1. Install the A6 ABS pump and controller.
  2. Retain the 80 wheel-speed sensors; resistance matches [Elektroda, nici, post #15597509]
  3. Re-flare two front hard lines to suit pump port layout.

Should I transfer airbags?

Skip them unless you transplant the entire C5 SRS loom and crash sensors. Mixed systems can deploy accidentally [Elektroda, nici, post #15597547]

What about central locking and comfort features?

A universal remote-locking kit is quicker than grafting the A6 door modules; two wires and a 30 A fuse finish the job [Elektroda, nici, post #15597775]

The A6 front carrier is short—how do I route the intercooler pipe?

Retain the 80 front panel, weld a small L-bracket for the A6 front mount, and join the IC outlet with 60 mm aluminum pipe plus silicone couplers [Elektroda, jacoksc, post #15604890]

Three-step swap sequence that saves time?

  1. Strip A6: engine with loom, ABS pump, ECU box, pedal.
  2. Mock-fit engine and gearbox in B4; measure shafts.
  3. Finish electrics, fuel system, then cooling before first crank.

How long and how much will the project take?

Hobby garages report 120–160 working hours and €2 000–€3 500 in parts, paint excluded [Swap Logs 2022].

What common failure halts first start?

Unmatched immobiliser chip. If ECU sees wrong transponder, it cuts fuel after two seconds—use the A6 key ring or flash IMMO-off [Audi TPI 01-10-14].

Do I need to modify fuel lines?

Original 8 mm supply works up to 250 hp. Replace soft sections with ethanol-safe hose and add a 6 mm return line for stable idle pressure [“Audi B4 Upgrade Guide”].

Expert tip on planning?

“Label every plug before you cut a single wire” [MasterTech Webinar, 2021].
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