2003 Passat W8/BHW 2.0Tdi Swap

TDIMeister · Oct 31, 2014

Wow I'll love to see the car in person!! Except for the coal rolling (IMHO), congrats on a great build! Awesome fabrication work!

Machineman · Oct 31, 2014

Come see it !! And belive it or not it does not smoke at all when driving these pd engines are wierd i can floor it in any gear no smoke. But it nuetral free reving it will. I use to love smoke. Now i hate it. Because it make a mess of a nice car

K1Cowboy · Nov 2, 2014

Machineman said:
Two rear pipes done.

Down pipe done. All 304 SS

Mid pipe. With handmade 3" to double 2.5" split y pipe. Can buy one so i made it

Man those are some purdy welds. Nice job!

dremd · Nov 2, 2014

All looks great.
Kind of makes me wish I had held out for a Passat wagon vs my jetta wagon to swap.

nate0031 · Nov 3, 2014

An order of magnitude or so better than the welds I'm currently doing for my Audi, lol.

Machineman · Nov 10, 2014

Thanks guys That exhaust was the worst part of the swap but it was rewarding. And i love the sound. It has no drone at all. And still has a nice exhaust sound

Machineman · Nov 10, 2014

nate0031 said:
An order of magnitude or so better than the welds I'm currently doing for my Audi, lol.

You doin a commom rail on c5 platform. Are u goin standalone. I would love a common rail !!

nate0031 · Nov 10, 2014

Yes. I'm using the stock 2010 immo deleted ECU as standalone. When I first get it on the road, it won't have cruise, but the next project is building a CAN interface that lets me feed the ECU a VSS signal as it expects. That and give standard outputs for RPM etc.

For the time being, I'm keeping the stock 2.7 ECU as well. I'm feeding it data from the TDI so it thinks it's running an engine. I added a 60/2 reluctor wheel behind the damper to feed it engine position, and it'll throw codes, but survive without cam position. Once running, I'll make a how-to out of my wiring notes and post them up here.

You guys are going to get a real kick out of my turbo plumbing. I kept the stock for now, but it points the wrong direction, so I had to get a little creative.

cumminsfromthecold · Sep 12, 2015

Hey Machineman, how's the swap been? Looks amazing. Nice work!

Freeze Plug · Dec 28, 2015

nice swap, I am guessing this would be pretty much the same if starting with a V6/4motion/auto?

oldpoopie · Dec 28, 2015

http://portland.craigslist.org/mlt/cto/5354411274.html

cumminsfromthecold · Jan 19, 2016

W8 Passat to TDI

What's become of this?

Machineman, did you end up having to change any ECU pins at all for the BHW connection?

What did you end up having to fabricate (beside what's listed here on your thread already)?

I am looking at a couple of W8s right now, one sedan that's running great with 189,000 miles on it (I drove it, and drove it hard and fast), 1 owner, $2200.

The other is a wagon with 108,000 miles and is making the cam adjuster noise. Could get it for $1500 or less. That cam adjuster noise, though, is fixable. These engines - based on doing a lot of reading about them - aren't the POSs everyone says. Fitzki points out here
that they have two problems. There are more, but there are two known weak points The fixes are here: this first one is kind of amazing
http://www.w8forum.dk/forum_posts.asp?TID=1196&PN=1&title=found-camshaft-adjuster-fix
and the 2nd one is here:
http://www.w8forum.dk/forum_posts.asp?TID=1537&title=diy-thermostat

As I mull this over and read Otty's swap info and your thread here, machineman, (which I don't mean to hijack), others' input would be appreciated.

It's all a bit lunatic, but then....

mrrhtuner · Feb 23, 2016

I sent machineman a PM asking to see if he can update this. Pretty cool swap!

otty · Mar 22, 2016

Still trying to figure out why the halogen high beams won't come on on my W8 swap. One possibility just occurred to me: I used the cluster from the engine donor car, not the W8. Any chance there is something different in the W8 cluster for the dual (xenon and halogen) high beam?

Just throwing it out there.... checked the halogen bulbs, they are fine. Running out of ideas...

vwztips · Mar 22, 2016

Which light switch do you have installed, the 2 or 3 position? If it is 2 position that may be the issue

otty · Mar 22, 2016

I have the W8 switch - two positions left to right and two notches to pull out. I have also tried a euroswitch. Still no halogen high beams. I am also wondering if I am missing a relay or have the wrong relay. I know we removed some and switched some as part of the swap...

stp359 · Mar 22, 2016

otty said:
I have the W8 switch - two positions left to right and two notches to pull out. I have also tried a euroswitch. Still no halogen high beams. I am also wondering if I am missing a relay or have the wrong relay. I know we removed some and switched some as part of the swap...

From what it says in the diagrams, there is an additional relay for the high beams. Do you have access to the diagrams?

otty · Mar 22, 2016

I have the Bentley book but never had much luck reading them. A page number might help, I can't find the headlight wiring in there for the W8. Or could you send me the diagram? Thanks!

stp359 · Mar 23, 2016

otty said:
I have the Bentley book but never had much luck reading them. A page number might help, I can't find the headlight wiring in there for the W8. Or could you send me the diagram? Thanks!

No prob. Inbox with your email.

Machineman · May 5, 2016

hello everyone sorry for not replying to your questions. i havent had much time to get on here i have been very busy with my newly started business. i ended up selling the car june of 2015 . it was a great car. i just wanted a audi

Machineman · May 5, 2016

cumminsfromthecold said:
What's become of this?

Machineman, did you end up having to change any ECU pins at all for the BHW connection?

What did you end up having to fabricate (beside what's listed here on your thread already)?

I am looking at a couple of W8s right now, one sedan that's running great with 189,000 miles on it (I drove it, and drove it hard and fast), 1 owner, $2200.

The other is a wagon with 108,000 miles and is making the cam adjuster noise. Could get it for $1500 or less. That cam adjuster noise, though, is fixable. These engines - based on doing a lot of reading about them - aren't the POSs everyone says. Fitzki points out here
that they have two problems. There are more, but there are two known weak points The fixes are here: this first one is kind of amazing
http://www.w8forum.dk/forum_posts.asp?TID=1196&PN=1&title=found-camshaft-adjuster-fix
and the 2nd one is here:
http://www.w8forum.dk/forum_posts.asp?TID=1537&title=diy-thermostat

As I mull this over and read Otty's swap info and your thread here, machineman, (which I don't mean to hijack), others' input would be appreciated.

It's all a bit lunatic, but then....

i had to change some pins but noting overly time consuming some of the rain tray connector pins were changed.

i had to fabricate noting really other than a custom speedometer sending unit because the b7 audi tranny is speed via CANBUS there is no speedsensor othe than that most parts are from NA b5.5 BHW.

and no the w8s are not to bad considering the complex nature of the engine .

let me know if you have any ??

smileyboy · Jun 4, 2017

This would be my dream.. Just can't find anyone to do it

2003 Passat W8/BHW 2.0Tdi Swap

Phd of TDIClub Enthusiast, Moderator at Large

Veteran Member

Veteran Member

Veteran Member

Veteran Member - TDIClub Contributor

Veteran Member

Veteran Member

Veteran Member - TDIClub Contributor

Veteran Member

Veteran Member

Vendor

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Veteran Member

Member