Audi Allroad 1.9TDI with 6spd. - Project Thread

Probably the best/easiest option for someone doing the swap. I just didn't feel like buying another pedal and waiting, lol.

vwztips said:

I used the pedal from a Passat. 3 bolts then plug and play

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I have the passat BHW pedal and the allroad auto pedal. Neither give me proper values in VAGCOM. That's where I stopped at forever ago.

Anyone else have an issue getting proper 0-100% out of their pedal?

What year is the AR?

02 AR with 05 passat BHW swap using passat BHW ecu.

Scott_DeWitt said:

How are you going to handle the lack of speedometer sender on the trans?

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Scott
You asked about the vss. I'm back in the conversion mood, didn'touch the car for long time, any way. Engine is running, i will have many questions about some alh to allroad clima signals and the VSS. Someone suggested to get a signal from the ABS module, well that didn't work. It seems i have to put a speed sensor on the axle bolts and use a dakota signal converter.
I am open to any suggestions.
Also you may have the answer that many people are confused about :The 0A3 6 speed manual seems about 1 1/8 to 1 1/2'' longer than the 01E. Can you change the tail ends or any known audi driveshafts shorter? Some people are talking about 4.2 Allroad driveshaft with an 1 1/2'' adapter.

Not much left now! Installed the tune from KERMA yesterday and it feels very, very good! And the QLoader software is very straighforward and makes life pretty easy!








The main issues are:

1) Need to get speedometer working.

2) The car takes a long time to start up when the engine is at normal operating temperature. It's almost 5 seconds of cranking before it takes. Any thoughts?


Otherwise there's small odds and ends that I need to chase down to wire and take care of various electrical issues and warnings that I'm getting ( for example, headlight range light is up on the dash)... but we're getting there!

love the project, I can dream about doing this someday!

Probably not your issue, but my 99 golf had the hard to start when engine is hot. I was told a tune would fix it but I switched the transmission coding from manual to auto and that fixed it but I now have a check engine light. I'll live with that until I can afford a tune.

How long did this swap take you?

deecee said:

love the project, I can dream about doing this someday!

Probably not your issue, but my 99 golf had the hard to start when engine is hot. I was told a tune would fix it but I switched the transmission coding from manual to auto and that fixed it but I now have a check engine light. I'll live with that until I can afford a tune.

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I've heard the same thing, so I'm hoping it might be a "simple" tuning issue, too -- waiting to hear back from Charlie @ Kerma to see if there's anything that can be done!

vplukas101 said:

How long did this swap take you?

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Well, I started the thread April 2015, so I guess around a year and a half! But this project was never a priority of mine, so it was a very casual endeavor!

Not too worried about the boost issue. I found (and repaired_ that one of my hoses was loose toward the intercooler i'm using (off an '15 A4 TDI) and leaking air, so I'm assuming once I clear it won't come back.
Anybody have and idea about the airbag light? That's what I'm most worried about now.

Picked up speed off the axles.

No thoughts on the codes?

Also, and recommendations on what I could use as an "output" for the GLOW PLUG light for when it's cold out?

I have a 2001 AllRoad that I installed a 2004 BHW and DQT gearbox in. It also has a larger turbo and stage 3 tune.

I initially had similar codes with my Airbag and ABS unit. Basically it appears that the controllers were looking for a handshake with the ECU on start up but not getting the proper signal. Mike at TDTuning worked with me to get rid of the codes. Everything still functions as it should.

As for the glow plug light, I found a cluster from England from a TDI and showed MPH. It was plug and play. So now I have the GP light and the correct tachometer scale.

Well, Charlie@Kerma was able to take care of the airbag error for me

There's only 3 more easy errors left for me to take care of, and I should be golden!

#1) Glow-Plug Harness. I'm going to wire those myself so I never have to use the cheap/brittle harness that VW makes that goes bad every other year.

#2) Front-Left Ride Height Sensor. I'll take it apart and clean it. That's seems to be a common issue on these.

#3) Headlight Range warning on the cluster. As a result of the faulty ride-height sensor, I'm sure

Car seems ready to eat up the highways. With cruise control set to 80MPH, i'm doing about 2100 RPM's in 6th gear.



I think this project is just about wrapped up.

Thanks for those who chimed in, and big thanks to KERMA TDI for their knowledge and tuning help with blazing fast response times.

....now, maybe a tacoma TDI swap next???

That is sweet! I'm considering doing a PD swap into an Allroad, since I need the larger cargo space for me, 2 teenagers, and 2 large dogs.

Jake

I am finishing up on the last of the work on my 1.9TDI allroad and really love it. It is really the right combination of engine and comfort for me at least. I am wondering how many of these swaps have been done. I count 5 or six on this forum.
At some point I will post pics and discussion of my swap. that is once I finish my Passat MT swap.
Chris

I have a 2001 with a 2.0 BHW and DQT. Nice car and fun to drive.

Have a 2003 AR Cobalt blue with a bad 2.7, trying to decide if I will keep it a gasser or convert it.

I have the 5 speed ready to go in. Will get after it next week. Who did you use for your reflash? My allroad conversion was all Europe sourced parts including the ECU so If you can recommend a tuner that would be helpful. Am thinking of just getting a MT reflash and IMMO delete. The 2.0 with stock tune should be plenty when all the power gets to the wheels vs my AT with its TC lockup issues

I have used Mike at TDTuning for all my conversions.

MKIV I just noticed your comment about doing 80mph @2100 rpm. Which gearbox did you install and what ratio is 6th gear as well as the differential ratio?

MKIV_TDI said:

Well, Charlie@Kerma was able to take care of the airbag error for me
There's only 3 more easy errors left for me to take care of, and I should be golden!
#1) Glow-Plug Harness. I'm going to wire those myself so I never have to use the cheap/brittle harness that VW makes that goes bad every other year.
#2) Front-Left Ride Height Sensor. I'll take it apart and clean it. That's seems to be a common issue on these.
#3) Headlight Range warning on the cluster. As a result of the faulty ride-height sensor, I'm sure
Car seems ready to eat up the highways. With cruise control set to 80MPH, i'm doing about 2100 RPM's in 6th gear.

I think this project is just about wrapped up.
Thanks for those who chimed in, and big thanks to KERMA TDI for their knowledge and tuning help with blazing fast response times.
....now, maybe a tacoma TDI swap next???

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