I was just cruising youtube when I came across one Coty Built's builds, and thought, "man thats schweet!" I started emailing back and fourth with them, and once I started asking questions that were deeper than "I want to spend $7k on your starter kit" they stopped corresponding. Right about then, EVGuy started selling his adapter kits. It occurred to me that I should be able to piece together my own setup that wasn't so questionable. My primary concerns with the Coty setup is the truss. The truss, while it places all of the accessories in the correct position to retain stock parts, looks like it would make wrenching difficult, and these engines do have a sub 100k mile timing belt.
I started with most of a BEW out of a Jetta, a BHW (Passat) ECU and harness, and a couple blown turbos from a handful of vehicles. I popped the head off of the "running" BEW to find that the compressor inducer had removed considerable material from cylinders 1 and 2.
Found the BEW I picked up on Craigslist for $600 with about 180k miles on it in Victoria, BC. The prior owner helped me hoist it into the back of my XJ, and I brought it home!
I got ahold of a reputable machine shop (franko6) and found out I was looking at needing a rebuilt head and atlest some block work thanks to the cylinder walls being scored. Also, it had considerably uneven piston protrusion. The cost of this rebuild pushed me to look for a different engine to start with before I dumped too much in the smaller of the TDIs in the USA.
Using an EBay ECU bench I was able to dump the ECU and remove the immobilizer. Once I get a running engine, ill start it up before getting anywhere near the Jeep.
At this point I sold off the parted out BEW components that aren't ruined and building a used low mile BHW. The BHW has 2mm of extra bearing journal surface, better pistons, larger injectors, and a slightly lower compression ratio for better ability to take boost. Its weakness is this miserable piece of German overengineering called a BSM (Balance Shaft Module) that tends to die and take out the oil pump, but fortunately the BEW's robust oil pump will move right over to the BHW.
I want to retain the AC, Defroster, high idle, and the cruse controls. My plans for those are to use a VW AC module to run a VW compressor for both defroster functions and AC. I plan on using the documented (but unused on anything VW published or in bentley) high idle ECU pin. For the cruise, I will have to run an arduino to translate button presses on the resistor ladder to individual IOs the EDC16 (Bosch ECU) expects, while I am doing that I wouldn't mind having some media buttons on the steering wheel... so I'll be looking for either a ZJ, WJ, or KJ steering wheel to butcher up.
As I said, I've been working on the CANBUS aspect, and thats promising for some info, but the speedo data is crap at being on a scale of 1-254 of an unknown unit. VW decided that the ECU shouldn't send distance to the cluster, so they pass the VSS through the cluster and condition the signal received by the ECU, so I need to replicate that signal and track distance at the cluster. I have two options there: 1) analog gauges - I like the VDO Viewline Onyx series in a auto meter 5381 panel or 2) drive a stock dash's air core gauges using another arduino. McNeil has been working on just that for his Wrangler but I'm leaning towards the VDO stuff.
My wife got me a 30 gallon genright for the project and I have read conversions like these get between 25 and 35 MPG... so after I've spend untold thousands, I should be able to go almost anywhere without fueling up!
I picked up a BHW (2.0L - 134HP stock) out of a 2005 Passat off EBay. Now the work begins
I started with most of a BEW out of a Jetta, a BHW (Passat) ECU and harness, and a couple blown turbos from a handful of vehicles. I popped the head off of the "running" BEW to find that the compressor inducer had removed considerable material from cylinders 1 and 2.
Found the BEW I picked up on Craigslist for $600 with about 180k miles on it in Victoria, BC. The prior owner helped me hoist it into the back of my XJ, and I brought it home!
I got ahold of a reputable machine shop (franko6) and found out I was looking at needing a rebuilt head and atlest some block work thanks to the cylinder walls being scored. Also, it had considerably uneven piston protrusion. The cost of this rebuild pushed me to look for a different engine to start with before I dumped too much in the smaller of the TDIs in the USA.
Using an EBay ECU bench I was able to dump the ECU and remove the immobilizer. Once I get a running engine, ill start it up before getting anywhere near the Jeep.
At this point I sold off the parted out BEW components that aren't ruined and building a used low mile BHW. The BHW has 2mm of extra bearing journal surface, better pistons, larger injectors, and a slightly lower compression ratio for better ability to take boost. Its weakness is this miserable piece of German overengineering called a BSM (Balance Shaft Module) that tends to die and take out the oil pump, but fortunately the BEW's robust oil pump will move right over to the BHW.
I want to retain the AC, Defroster, high idle, and the cruse controls. My plans for those are to use a VW AC module to run a VW compressor for both defroster functions and AC. I plan on using the documented (but unused on anything VW published or in bentley) high idle ECU pin. For the cruise, I will have to run an arduino to translate button presses on the resistor ladder to individual IOs the EDC16 (Bosch ECU) expects, while I am doing that I wouldn't mind having some media buttons on the steering wheel... so I'll be looking for either a ZJ, WJ, or KJ steering wheel to butcher up.
As I said, I've been working on the CANBUS aspect, and thats promising for some info, but the speedo data is crap at being on a scale of 1-254 of an unknown unit. VW decided that the ECU shouldn't send distance to the cluster, so they pass the VSS through the cluster and condition the signal received by the ECU, so I need to replicate that signal and track distance at the cluster. I have two options there: 1) analog gauges - I like the VDO Viewline Onyx series in a auto meter 5381 panel or 2) drive a stock dash's air core gauges using another arduino. McNeil has been working on just that for his Wrangler but I'm leaning towards the VDO stuff.
My wife got me a 30 gallon genright for the project and I have read conversions like these get between 25 and 35 MPG... so after I've spend untold thousands, I should be able to go almost anywhere without fueling up!
I picked up a BHW (2.0L - 134HP stock) out of a 2005 Passat off EBay. Now the work begins
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