What's in the workshop? Its manual swap time!

[MikkiJayne]

Limited progress over the past couple of evenings as the cam chain tensioners needed changing which took a while.

Flywheel on - this is a custom lightweight unit from TTV Racing. Its a little over half the weight of the stock one, and a little over half the price! It also takes a nice cheap B5 RS4 clutch.





Gearbox going on.



This is from a C5 A6 2.5TDI quattro. The ratios look 'plausible' and they're relatively easy to come by.



Always the little details



Engine and gearbox bolted together



The manual ECU files which I've obtained from Vera and Goran (thanks both!) have the secondary air injection coded out, which is handy because its pointless and just adds weight and plumbing.

Pulled all this rubbish from the engine, and I'll remove the pump from the airbox before it goes back in.



Made up some blanking plates for the ports on the back of the heads



I pre-modified a spare engine harness, removing all the automatic gearbox and ecu wiring and also the SAI stuff. Still some work to do for the sensors on the manual gearbox - I couldn't do the reverse switch and speed sensor until I had the gearbox attached so I could check the wire lengths so I'll sort that tomorrow.



Where I finished tonight:



20 hours.