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-   -   Audi Allroad BHW TDI conversion. (http://forums.tdiclub.com/showthread.php?t=421678)

Wing_man August 18th, 2014 13:13

Audi Allroad BHW TDI conversion.
 
This has been my ongoing project over the last few months, I'm currently driving the car, it's an absolute dream! Enjoy the pictures.

The donor car. 2005 Passat TDI, blown auto trans, Balance shaft delete
Alh oil pump mod, New turbo Cams and lobes, healthy little engine.

http://i295.photobucket.com/albums/m...ps11548076.jpg

The project car, 2002 audi allroad 2.7TT 6spd from California.

http://i295.photobucket.com/albums/m...ps714555e2.jpg

http://i295.photobucket.com/albums/m...psd00ebd19.jpg

And it begins...

http://i295.photobucket.com/albums/m...ps9060f229.jpg

http://i295.photobucket.com/albums/m...ps7ac77b4f.jpg

http://i295.photobucket.com/albums/m...psbb135ae0.jpg

Made sweet shop chair from Passat seat...

http://i295.photobucket.com/albums/m...ps21486995.jpg

Modified front cross member from Passat, notice the front stabilizer mount.

http://i295.photobucket.com/albums/m...psfc688896.jpg

http://i295.photobucket.com/albums/m...psfd29afa4.jpg

Now the front cross member with added Passat radiator mounts.

http://i295.photobucket.com/albums/m...psb9b78471.jpg

Wing_man August 18th, 2014 13:14

Downpipe.

http://i295.photobucket.com/albums/m...ps9139fb0c.jpg

http://i295.photobucket.com/albums/m...ps799fb73b.jpg

http://i295.photobucket.com/albums/m...ps460c20f9.jpg

Clean donor.

http://i295.photobucket.com/albums/m...ps6c7fb815.jpg

Engine's in.

http://i295.photobucket.com/albums/m...psd249432b.jpg

http://i295.photobucket.com/albums/m...ps34baade8.jpg

http://i295.photobucket.com/albums/m...ps133ab82a.jpg

http://i295.photobucket.com/albums/m...psa2ed2b3e.jpg

http://i295.photobucket.com/albums/m...pscce4b432.jpg

Cruising speed in 6th with the euro gearbox.

http://i295.photobucket.com/albums/m...ps13c343f3.jpg

Hasenwerk August 18th, 2014 14:09

Great work!

Anything that you would do differently if you had to do it again?

riddleyo August 18th, 2014 17:10

Awesome project, great job. How about a video!?

96cali August 18th, 2014 23:46

Very nice and thanks very much for sharing! That's my dream car right there. ;)

How did you handle the AC lines and air suspension? Could you have used any stock exhaust components instead of all that fab work?

Wing_man August 19th, 2014 04:50

Quote:

Originally Posted by 96cali (Post 4595970)
Very nice and thanks very much for sharing! That's my dream car right there. ;)

How did you handle the AC lines and air suspension? Could you have used any stock exhaust components instead of all that fab work?

The stock Passat downpipe would have been okay, some fabrication is absolutely necessary if you want to re-use the original audi cat back system. I made a new downpipe that gave the transmission a lot of clearance, that way when ever I have to remove the transmission I don't need to bother with removing the downpipe first. :D

Scott02 August 19th, 2014 05:17

Damn, I've been beaten!
Mine still looks like your "clean donor" pic...

Congrats!

Please be sure to report back mpg figures, as that's the reason for doing all this work, after all.

mannytranny August 19th, 2014 09:00

Passat engine bolts up easily to Audi trans?

Scott_DeWitt August 19th, 2014 10:19

Quote:

Originally Posted by mannytranny (Post 4596150)
Passat engine bolts up easily to Audi trans?

Certain Audi transmissions yes.

Wing_man August 19th, 2014 14:01

Yeah, I believe the O1E transmissions will bolt up to the vw 4 Cyl diesels. It's just a matter of getting a transmission with proper gearing ratio's. The transmission I used is from a 1.9 European probably AFN tdi out of an a6 Quattro or something like that, transmission code is FTF... I had to swap out the original audi Allroad transmission cv flanges into this transmission, and replace my rear differential with one that had the same final drive as my FTF transmission... 4.11 final drive I believe it was.

vwztips August 19th, 2014 15:09

Did you have to add what looks like a couple of 3/4" diameter tubes to the turbo crossover pipe? Was it something the Audi needed?

otty August 19th, 2014 17:15

Notice you have a Euro cluster (only KM/h). I do too. Mine came from the Euro AVF TDI donor car. Why do you have one? Just curious.

Looks like a sweet ride :)

Wing_man August 19th, 2014 20:31

Quote:

Originally Posted by vwztips (Post 4596484)
Did you have to add what looks like a couple of 3/4" diameter tubes to the turbo crossover pipe? Was it something the Audi needed?

Yes, that's how I mounted the lower part of the Passat rad. The bottom part of the Audi rad support needs to be cut in order to fit the crossover pipe... I suppose you could also just add an after market intercooler pipe and leave the front end as-is... Mind you the way I did it looks more original.

Wing_man August 19th, 2014 20:33

Quote:

Originally Posted by otty (Post 4596559)
Notice you have a Euro cluster (only KM/h). I do too. Mine came from the Euro AVF TDI donor car. Why do you have one? Just curious.

Looks like a sweet ride :)

Thanks, It's not euro, I'm canadian KM/H haha.

jonlowe August 19th, 2014 21:32

How's the power? The all road is about 600 lbs heavier than the Passat, according to the figures I've found. Does the engine have a tune?

Did you get your climate control electrical issues sorted out?

What did you have to do to the fuel system to work with diesel fuel?

I'm very impressed.

Sent from my Nexus 5 using Tapatalk


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