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




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 August 18th, 2014, 13:13   #1
Wing_man
Member
 
Wing_man's Avatar
 
Join Date: May 2011
Location: Trenton on
TDI(s): Allroad BHW
Default 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.



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





And it begins...







Made sweet shop chair from Passat seat...



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





Now the front cross member with added Passat radiator mounts.

Wing_man is offline   Reply With Quote
Old August 18th, 2014, 13:14   #2
Wing_man
Member
 
Wing_man's Avatar
 
Join Date: May 2011
Location: Trenton on
TDI(s): Allroad BHW
Default

Downpipe.







Clean donor.



Engine's in.











Cruising speed in 6th with the euro gearbox.

Wing_man is offline   Reply With Quote
Old August 18th, 2014, 14:09   #3
Hasenwerk
 
Hasenwerk's Avatar
Default

Great work!

Anything that you would do differently if you had to do it again?
__________________
David Marshall
Fast Forward Automotive
TDI Stand Alone Wire Harness Manufacturing | Signal Converters, Gateways, and Processors | Vehicle Speed Sensors | Malone Tuning
Hasenwerk is offline   Reply With Quote
Old August 18th, 2014, 17:10   #4
riddleyo
Member
 
riddleyo's Avatar
 
Join Date: Jul 2009
Location: Dayton, Ohio
Default

Awesome project, great job. How about a video!?
riddleyo is offline   Reply With Quote
Old August 18th, 2014, 23:46   #5
96cali
Newbie
 
Join Date: Jan 2013
Location: Saint Paul, MN
TDI(s): Passat
Default

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?
96cali is offline   Reply With Quote
Old August 19th, 2014, 04:50   #6
Wing_man
Member
 
Wing_man's Avatar
 
Join Date: May 2011
Location: Trenton on
TDI(s): Allroad BHW
Default

Quote:
Originally Posted by 96cali View Post
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.
Wing_man is offline   Reply With Quote
Old August 19th, 2014, 05:17   #7
Scott02
Veteran Member
 
Join Date: Jan 2006
Location: near Youngstown, OH
TDI(s): Too Many
Fuel Economy: 51/45/41
Default

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.
__________________
2015 GSW DSG - 27kmi, Kerma engine tune
2011 JSW DSG - 160kmi, Malone DSG tune - Buyback done
03 Jetta Wagon TDI 5MT - 175kmi, 2.5"F 2"R lift, 215/75r15 tires, self tuned
02 allroad TDI 6MT - 150kmi, current project, getting a BSM deleted BHW and euro TDI geared 01E quattro
Scott02 is offline   Reply With Quote
Old August 19th, 2014, 09:00   #8
mannytranny
Veteran Member
 
mannytranny's Avatar
 
Join Date: Oct 2003
Location: CA
TDI(s): 02 Jetta
Default

Passat engine bolts up easily to Audi trans?
mannytranny is offline   Reply With Quote
Old August 19th, 2014, 10:19   #9
Scott_DeWitt
 
Scott_DeWitt's Avatar
 
Join Date: Apr 2004
Location: Texas USA
Default

Quote:
Originally Posted by mannytranny View Post
Passat engine bolts up easily to Audi trans?
Certain Audi transmissions yes.
__________________
www.advancedautomotion.com
Scott_DeWitt is offline   Reply With Quote
Old August 19th, 2014, 14:01   #10
Wing_man
Member
 
Wing_man's Avatar
 
Join Date: May 2011
Location: Trenton on
TDI(s): Allroad BHW
Default

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.
Wing_man is offline   Reply With Quote
Old August 19th, 2014, 15:09   #11
vwztips
Veteran Member
 
vwztips's Avatar
Default

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?
vwztips is offline   Reply With Quote
Old August 19th, 2014, 17:15   #12
otty
Veteran Member
 
otty's Avatar
Default

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
__________________
Malone tuned stage 1 and loving it!
otty is offline   Reply With Quote
Old August 19th, 2014, 20:31   #13
Wing_man
Member
 
Wing_man's Avatar
 
Join Date: May 2011
Location: Trenton on
TDI(s): Allroad BHW
Default

Quote:
Originally Posted by vwztips View Post
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 is offline   Reply With Quote
Old August 19th, 2014, 20:33   #14
Wing_man
Member
 
Wing_man's Avatar
 
Join Date: May 2011
Location: Trenton on
TDI(s): Allroad BHW
Default

Quote:
Originally Posted by otty View Post
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.
Wing_man is offline   Reply With Quote
Old August 19th, 2014, 21:32   #15
jonlowe
Veteran Member
 
Join Date: Aug 2012
Location: Northern AL
Default

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
jonlowe 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
2002 Audi Allroad ALH Conversion Dirty_Al TDI Conversions 45 June 2nd, 2018 08:07
02 Allroad BHW swap w/ euro TDI 6MT Scott02 Other TDI/Diesel Picture Gallery 23 August 21st, 2014 10:13
Looking into an BHW swap into an 2001 allroad arjax TDI Conversions 7 July 14th, 2014 21:06
Audi Allroad Diesel Conversion Dirty_Al TDI Conversions 14 October 14th, 2013 22:41
Audi 3.0 TDi Allroad donDavide TDI News/Tech 20 June 20th, 2007 08:34


All times are GMT -7. The time now is 06:31.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2018, 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 0.21798 seconds with 11 queries
[Output: 131.08 Kb. compressed to 110.01 Kb. by saving 21.07 Kb. (16.08%)]