Teaming up with United Motorsport we have developed a harness, tune, and hardware specifics for a complete and proper 3.6 BLV swap. With nearly a year of development we have ironed out the “kinks”.
The key features of the harness and tune are the power, see graph. Development of tuning was using a 2006 Passat BLV, black intake manifold, stock exhaust manifolds, 2.5 inch downpipes, full 3 inch exhaust. While this number may vary depending on dyno’s and if you have a variable runner or single runner intake (single runner “back intake” recommended), mileage/condition of motor, year of motor concerning camshaft profile changes, and exhaust configuration. The power numbers shown is an accurate depiction of what to expect with this swap when done proper. Drivability is second to none and mileage is very respectable.
The swap utilizes a MK4 top hung gas pedal, which makes easier fitment into MK1-MK3 chassis and the ability to be nearly 100% plug and play seamlessly.
Swap tune cost is $750
Hardware requirements:
MK4 gas pedal
All four 02 sensors (two in each respected downpipe)
2007 RS4 in tank fuel pump (TDC has weld on steel and aluminum rings available for adapting MK4/RS4 style fuel pump baskets to MK1 fuel tanks) 8E0919051CQ
6.0bar fuel filter 4F0201511E
OEM intake tube and maf sensor/housing with K&N cone filter- ABSOLUTELY NO HIDDEN MAF HARD PIPES!
Clutch and brake switch inputs (switches of choice can be discussed based on recipient chassis and are optional)
Removing the RS4 fuel pump from its basket
MK4 basket with RS4 pump install reference pictures
MK3 basket with RS4 pump install reference pictures
8mm or 5/16inch pup leader hose can be purchased easily online at stores like Summitracing or Jegs
BLV Engine Sensor Locations
Written Instructions
3.6 MK4 Plug and Play Harness Instructions
From fuse panel inside car you must REMOVE fuses 32 & 34- leave empty
From interior of car you must remove the FP relay from the relay panel above driver’s foot area #4
Also advised to unplug the LDP pump in pass rear fender well.
You must make sure fuses 43 & 28 are both 15 AMP fuses in the fuse panel- these are now the fuel pump fuses.
Make sure to ground the brown lead at ecu to a clean surface on the body in the rain tray.
Tune makes use of mk4 oem gas pedal
Hook the large lead from the relay box in harness to the fuse box above battery at posts S163, it should have a 50 amp fuse already and only this leads should be attached to the posts.
Tuning requires you modify to fit a 2007 RS4 fuel pump into your basket.
You must make sure to drill out the return line nipple on the oem mk4 basket so that the check valve is no longer present in the oem hat (looking down into the nipple on the mk4 fuel basket hat you can see a red silicon flap- this is a check valve and a small drill bit and a little drill action breaks it out and can be blown through the line and removed.
You must run a fuel filter part# 4F2021511E
You must run all four 02 sensors
You must NOT RUN AFTER MARKET INTAKES….only oem plastic intake pipe and maf with cone filter is valid for best results.
3.6 CE2 Plug and Play Harness Instructions
this harness will not work with mk2 lift pump/external pump setups!!!! you must run a mk3 gas tank or a single in tank pump!!!!! Must use 2007 RS4 fuel pump in tank
plugs g1/g2 install into fuse box, tac adaptor is pre set and should work for 4 cylinder MK2, corrodo, passat and mk3 clusters
Fuse 15 is the ignition power for the harness, and tac adaptor- if you nothing works verify this fuse is good, 15amp, and is getting power with key on and while in crank position.
A Fuel Pump module is installed into the harness. You MUST REMOVE FUSE 18 in your ce2 fuse box and leave slot empty or install the supplied “blown fuse with single spade” to Hold spot in case you forget later on in life :)
Be sure to ground the leads labeled "body-" to a solid, clean metal portion of your car.
An ECM power supply relay “109” part number 357906381A or equivalent must be installed in relay spot #3 and the stock Fuel pump relay in spot #12
YOU MUST convert the car over to run a 2007 RS4 fuel pump within your oem fp “basket” INSIDE the tank. NO OTHER PUMP WILL WORK PROPER!!!!
You must also plumb in the correct fuel filter with regulated bypass from filter back to tank for a proper “return-less feed” to fuel rail. Use fuel filter part # 4F0201511E (2005 B7 A4 3.2 is an application to look it up under) this will be a 6 bar fuel filter and have a feed, return and a pressure line to rail ( three quick connect fittings on it)
All four 02 sensor must be run, one primary and one secondary in each down pipe
Stock intake tube, maf and k&n cone filter will net good drivability and best power gains. Any “after market intake “ will create problems with fueling/idle control/ and drive-ability.
Clutch switch lead is present to run a clutch switch from mk3 #1H0927189E
It is up to you to install the hardware proper!!