www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You

Order your TDIClub merchandise and help support TDIClub


Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

Reply
 
Thread Tools
Old October 1st, 2019, 15:11   #1
Roadkil4
Newbie
 
Join Date: Sep 2012
Location: Old Town Maine
TDI(s): Mk4 Golf
Fuel Economy: 35-42
Default B7 A4 2.0T to BRM TDI

Going right off the deep end here as I don't have much experience with the BRM motors (explicitly ALH) but I picked up a pretty clean 2007 Audi A4 with the 2.0t the previous owner disassembled. This is the second 07 A4 i've owned, and aside from the insurance, I love these cars.
-Black heated leather
-AWD goodness
-At 6'6" tall it's comfortable
-6-speed (more on that later)
-and a pretty spacious engine bay compared to what's out there

I found with my last B7 A4 2.0t, the gear ratio in 6th is similar in rpm to my ALH wagon in 5th with the A4 turning slightly slower. The BPY block is EXTREMELY similar to the BRM, so bolting motor mount brackets should be the same. I already know I need a different accessory bracket, but I have a few found.

A few things I know little about: Fuel delivery. The 2.0t is a return-less system with only one line being ran from front of the car to the rear, pressure either being done by a pressure regulator in the back or PWM to the pump...since I didn't find the PWM module mentioned in other forums about the 2.0t, so i'm not as sure. I may have been looking in the wrong area. I did pull the Jetta fuel pump for Frankenstein play later.

Boost and exhaust plumbing will be Frankenstein/custom.

A few things I know NOTHING about, that the stock gas ECU talks to, I.E. ABS, Airbags, CC, etc. and what those systems need from the ECU. I assume fan control is a big one and from a few forums i've been reading, ABS.

So far, I have the car and the engine+ECU+some of the wiring needed.

Thanks for sticking around through this random thought vomit, here's some pics as your reward:

Towmaster 2500:


Needs a good cleaning




Pine cones add flavor


The BRM with mated DSG


A few questions for the hive mind:
Clutch? Was thinking of bolting the gas 2.0t one temporarily for fit up, but not sure what to run permanently. Was thinking the 4.2l v8, as I would already be using its starter (same or similar i've read).

Pedal? Same pedal in the Audi as the TDI?

ECU? Was planning on running the stock one out of the 06 Jetta I pulled everything out of, but I already know this won't be a great idea. Standalone, at best.

More to come as I find the time.

Last edited by Roadkil4; October 1st, 2019 at 15:29.
Roadkil4 is offline   Reply With Quote
Old October 1st, 2019, 15:33   #2
Roadkil4
Newbie
 
Join Date: Sep 2012
Location: Old Town Maine
TDI(s): Mk4 Golf
Fuel Economy: 35-42
Default

Just found this link, gonna lurk for a while

http://forums.tdiclub.com/showthread.php?t=353866
Roadkil4 is offline   Reply With Quote
Old October 1st, 2019, 15:38   #3
mogly
Veteran Member
 
Join Date: May 2003
Location: Sarnia, ON, Canada
Default

Cool project.

The BRM came in a Mk V which is transverse mounting. The A4 is longitudinally mounted.

Likely your easiest route is the BHW in regards to engine hardware and the engine wire harness.
mogly is offline   Reply With Quote
Old October 2nd, 2019, 12:13   #4
Roadkil4
Newbie
 
Join Date: Sep 2012
Location: Old Town Maine
TDI(s): Mk4 Golf
Fuel Economy: 35-42
Default

Don't think that will matter. Friend came with an A4 came at with me with a broken TB in his A4, was able to swap one in from a Passat. The blocks are borderline identical with some major exceptions being the hard pipe coming out of the water pump area. All the mounting bosses are there between the two blocks, just not all of them are used.
Roadkil4 is offline   Reply With Quote
Old October 2nd, 2019, 13:20   #5
mogly
Veteran Member
 
Join Date: May 2003
Location: Sarnia, ON, Canada
Default

Not being discouraging. Just stating that the mounts, cooling system, accessory bracket etc on the BHW are what you need.
mogly is offline   Reply With Quote
Old October 3rd, 2019, 15:39   #6
Roadkil4
Newbie
 
Join Date: Sep 2012
Location: Old Town Maine
TDI(s): Mk4 Golf
Fuel Economy: 35-42
Default

Absolutely! I found that BKE is the 1.9 TDI which came in the B7 A4 in Europe, Accessory bracket on the watch list, waiting to hear back on shipping cost. Hoping the motor mount brackets are the same, but ready to hunt those down if need be. Cooling will be a Frankenstein snake of pipes until I can get a proof of concept going. Intercooler will be all Aluminum tubes unless I hunt down that pipe too.

My largest concern is fuel delivery from the tank.

I'm hoping the wiring harness is similar, because the euro ones stretch all the way to where the cabin filter would be here in NA. Not opposed to re-pinning or cut/splice, but would rather I didn't.
Roadkil4 is offline   Reply With Quote
Old October 9th, 2019, 12:24   #7
Koehn
Member
 
Join Date: Oct 2018
Location: Vancouver, BC
Default

I can't speak from B7 experience, but the 2.0T fuel delivery system is likely the same as what was in my late-model B6 1.8T with the updated tank. Fuel filter mounted on the passenger side of the tank (just forward of the rear wheel) is also a pressure regulator so there's a return line back to the tank there.

What I and others have done is remove and bypass the filter for the fuel feed line and then use the hard evap lines that parallel the fuel line under the body of the car as a return line. I salvaged connectors from the evap system as I scraped it which made everything click together nice and easy with just a few short runs of fuel hose.

For the pump there's generally two options:
  1. run a diesel lift pump (BHW, BEW, or really any PD lift pump can be removed from the plastic carrier and inserted into your 2.0T's with some modification with a grinder), or
  2. keep the gas system as-is and run a fuel-pressure regulator set at ~11 psi (?) with bypass.

If you can get the longitudinal engine mounts from a NA Passat or international A4, those should bolt to the block fine and will definitely fit the chassis.

I'm still working out the kinks from my swap, but I also kept my gasser 6-speed. Mine is a GJW 02X, not sure what yours is. 6th is nice and high for cruising, and my only real complaint is that 1st is too low and 2nd is too high. Idle in 1st is close to ~5kmph which doesn't get you far off the line before you have to shift.

I believe the clutches from the either the 2.0T or the 4.2L won't work with the diesel crank but I can't say for sure as I don't know much about the BPY. I ended up going diesel-oem with a 240mm DMF from an AVF diesel. This combo was only for 6-speeds and requires a specific euro-only starter. Whitbread Performance also makes a pretty trick 240mm SMF that can use the standard BHW starter. There might also be some more options for B7's, but I think they are the same as the B6's in that regard.

For wiring I think you'll likely want a BKE/BPW/etc wiring harness and ecu (I think that's an EDC16). If you get one from a RHD car you'll have about four feet of extra wire to deal with, so try to source a LHD harness. The connectors between chassis and engine are likely all the same, but there will almost certainly be some repining and reworking required. The gasoline system has circuits that the diesel doesn't and vice-versa.

The accelerator pedal is different for TDI models, so you'll have to source the correct one. I don't think there is a difference RHD to LHD for this.



All in all, it's a really fun process and I look forward to seeing what you put together!
Koehn is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
2009 A4 2.0T to CR140 - need some help with part numbers nitec TDI Conversions 0 December 13th, 2018 17:10
2.0T TDI motor swap into B7 Audi A4? tbone1989 TDI Conversions 3 April 6th, 2013 21:29
2007 audi a4 2.0t quattro tdi ptcz TDI Conversions 5 February 10th, 2012 16:19
Timing belt procedure: BRM vs 2.0t gasoline robbinsresort VW MKV-A5 Golf/Jettas 3 January 10th, 2011 07:20
A4 B7 2.0 TDI 140 Clutch Judder r0nn13 VW MKIV-A4 TDIs (VE and PD) 0 July 1st, 2008 04:13


All times are GMT -7. The time now is 11:59.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.15077 seconds with 12 queries
[Output: 82.39 Kb. compressed to 72.22 Kb. by saving 10.16 Kb. (12.34%)]