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06 Vr 6sp, 98 T5V 5sp
580 Posts
Discussion Starter · #1 · (Edited)
My 06 VR M66 Swap photo timeline.

So its been exactly a year since I started this project. I purchased the donor car in July of last year and since then I've
converted my 06 Vr auto to a M66 little by little. The nail in the coffin for me was when the TF80sc valve body died and I was left with either
replacing it or doing a M66 swap for the same price. The decision was easy.

The donor car was an 04 S60R with 200k on it. It ran well, but it needed a lot of suspension work and many many other small bits. I felt bad killing it, but once the motor was pulled the rest was easy.

<img src="https://i.ibb.co/JtGXgB7/20180713-200224.jpg" alt="20180713-200224" border="0">

<img src="https://i.ibb.co/jLR86HQ/20180713-224542.jpg" alt="20180713-224542" border="0">

<img src="https://i.ibb.co/dQd44v5/20180713-224825.jpg" alt="20180713-224825" border="0">

<img src="https://i.ibb.co/HDWnyDR/20180714-134814.jpg" alt="20180714-134814" border="0">

<img src="https://i.ibb.co/Mg0dvjq/20190118-190818.jpg" alt="20190118-190818" border="0">

<img src="https://i.ibb.co/Cv5fLJ3/20190119-184424.jpg" alt="20190119-184424" border="0">

<img src="https://i.ibb.co/yPmQzCH/20190119-201720.jpg" alt="20190119-201720" border="0">

<img src="https://i.ibb.co/1ZfW8xp/20190122-195208.jpg" alt="20190122-195208" border="0">

I ended up getting everything from the donor. The full wiring harness, ecu, suspension, brakes, rear sub-frame. Mostly anything that I could use for spare or I needed for
the swap. The only thing that was trashed was the interior and shell.

<img src="https://i.ibb.co/wg3LNhm/20190122-195533.jpg" alt="20190122-195533" border="0">

<img src="https://i.ibb.co/g90z8s4/20190125-142734.jpg" alt="20190125-142734" border="0">

Pulling the 06 motor.

<img src="https://i.ibb.co/b5j2zP2/20190422-212718.jpg" alt="20190422-212718" border="0">

<img src="https://i.ibb.co/pJwSywW/20190427-122404.jpg" alt="20190427-122404" border="0">

I ended up doing a lot of service while the motor was out and discovered some interesting things as well.For one I'm skeptical the motor is
original to the car, there are a bunch of orange chalk numbers written on the block and head as if they were from a parts dismantler. It's the right motor, but I don't think its
original to the car(tho I'm trying to find out how to verify this using the motors serial number). It also visually looks older than the chassis 119,000 mile reading and it has defiantly been out of the car before (some nicks and scratches that you would
only get removing the engine from the car).

<img src="https://i.ibb.co/yXVWY4h/20190427-150442.jpg" alt="20190427-150442" border="0">

<img src="https://i.ibb.co/hX7TnHd/20190427-121152.jpg" alt="20190427-121152" border="0">

<img src="https://i.ibb.co/3vtGxZx/20190427-153405.jpg" alt="20190427-153405" border="0">

<img src="https://i.ibb.co/7v06mqy/20190427-121134.jpg" alt="20190427-121134" border="0">

The oil pan was weeping a bit around the sealing surface so I took the pan off to reseal it and replace all the 0 rings wile I was in there. Turns out the spring that keeps tension on the RMS had broken at some point and a bunch
of metal from that spring ended up in the oil pickup tube screen. Super lucky nothing happened to the motor and I ended up just replacing the oil pickup tube and everything else in the area.

<img src="https://i.ibb.co/hMQn2Rd/20190503-145829.jpg" alt="20190503-145829" border="0">

<img src="https://i.ibb.co/t4LbSDJ/20190503-145736.jpg" alt="20190503-145736" border="0">

So all the seals on the bottom end, the oil cooler seals, timing belt, water pump, and a bunch of other small wear items were replaced. The interior of the motor looked clean and it runs/ran strong so I'm not too worried about it.

I didn't take a bunch of photos getting the thing back together as time was tight and I just wanted the project done. So here are the only few I got.

<img src="https://i.ibb.co/K7BCjsx/20190526-162949.jpg" alt="20190526-162949" border="0">

<img src="https://i.ibb.co/2tW88P2/20190607-125141.jpg" alt="20190607-125141" border="0">

<img src="https://i.ibb.co/xmB7Pft/20190607-184930.jpg" alt="20190607-184930" border="0">

Currently it's basically done, I'm just waiting on my final tune date.

<img src="https://i.ibb.co/B6cBKgV/20190621-182711.jpg" alt="20190621-182711" border="0">

Tho I do have a question for anyone in the know. I'm currently getting this error code. (I had the ecu flashed with the manual tune, but the CEM still needs to be flashed. I have the TCM installed currently.)

<img src="https://i.ibb.co/VTyDjn8/20190621-155454.jpg" alt="20190621-155454" border="0">

So far I have replaced the BPS, and TCV with no effect. If I unplug the BPS the error codes are different and read "values too high and values too low". I have tried just running the
turbo on waste gate pressure (by removing the waste gate vacuum line) and I can not get it to build boost. Using Vida the ecu is getting the BPS signal, but it never goes over 1010kph. It will sit around 940kph at idle
and when I rev the motor will rise to 1010kph and just sit there.

It feels like the ecu is pulling timing, fuel or throttle honestly. Does anyone see what I'm missing here, or would anyone have a suggestion to try and trouble shoot the issue before I get the final tune done?

Other than that the car drives normally and shifts well. It's so much better be a stick over that lazy auto. I would highly suggest this swap even if your on the fence.

As for the swap itself, it's really not hard. Everything from the donor car just bolts right into the auto car and most of the wiring is there, its really just the clutch position switch that you have to run wires for. Tho this being a TF80sc car you can not use the original angle gear, and since the splines one the one from the donor car were almost dust I had to source a new angle gear. Everything else I was able to use from the 04 tho, minus a little bit of
refreshing here and there.
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