TDIsyncro
Veteran Member
'99 Audi A4Q/2.0TDI Conversion - in Progress
OK guys, time to start my thread. I have been accumulating parts and info for around 4 months now.
I bought this car specifically to create a TDI powered AWD luxury car for my daily use. After research for about 2 months, I concluded it could be done and I did an intensive search to find a B5 Audi A4 in mint condition. I ended up finding the perfect unit in Vancouver, BC, Canada. No road salt. All dealer service records. Owned by a family guy and proffesional. 102,000km (63,000 miles)
My original plan was to drop an ALH into it, but ended up finding a BHW for a really good deal. After recieving the BHW, I realized I had stumbled into the perfect engine configuration for this swap. The Passat B5.5 and Audi B5 A4, being both longitudinal mount and sharing mainy parts are a perfect match. The deal sealer is the fact that it will be producing around the same factory hp as the 1.8T, but much more torque (155ft-lbs vs 300 ft-lbs). The A4 is also an amazingly compact car for the luxury it holds, lending it to good fuel economy and performance when combined with a diesel power train.
Project Specs:
Chassis: '99 Audi A4 Quattro. Sport Package. Factory S4 Interior Upgrade. 2.8V6 Gas, 112,000km
OEM Power: Edit -190HP/207ft-lbs Torque
OEM Transmssion Specs: 5 spd, 01A (DWM). 3.89:1 Differential Gears
1st - 3.5:1
2nd - 1.94:1
3rd - 1.3:1
4th - .94:1
5th - .789:1
Factory Rims & Tires - 225/16/50 ZR
Speed/RPM: 2650RPM @ 100KPH
Donor Power Train Specs:
Engine: 2005 Passat 2.0TDI (BHW), under 60,000 km (local wrecker)
OEM Power: 134hp/254 ft-lbs
ECU - EDC15P and 40 Pin Harness from Euro ARL Code (PD150). Custom tuning specs set for roughly [EDIT 175HP/320 ft-lbs ??] (Supplied and tuned by VWMikel)
Other Harness: 2002 ALH 1.9TDI 80 Pin Harness (local wrecker)
Euro Tranny Specs:
01A 5spd Variant (EEP), 3.89:1 Differential Gears, 70,000km, Supplied by Scott Dewitt
1st - 3.5:1
2nd - 1.94:1
3rd - 1.22:1
4th - .83:1
5th - .66:1
Estimated Speed/RPM: 2166 RPM @ 100KPH - optimum would be 1900 for this engine, but I get what I get.
Before I get to much further into this thread, I would just like to make special thanks to Rexking414, who has helped a lot in digging up information. Also would like to thank VWMikel for providing guidance on ECU/harness related issues, and Scott D. for sharing his knowledge on all things mechanical. I think I was picking Scott's brain for a month before I even bought my Audi, and four months before I bought any parts from him.
I am very busy with projects in my profession right now, however, it's time to start kicking this project into high gear, so I will update and discuss things as I go.
Project Status/Major Milestones:
'99 Audi Car Purchase - Dec 11, 2007
BHW Engine Purchase - Jan 06 2008
EDC15P & 40Pin Harness Purchase - Jan 31 2008
ALH Harness Purchase - April 22 2008
ECS Tunning - RS4/1.8T Adapter Flywheel and RS4 Clutch/Pressure Plate (ES - 5486) - May 8, 2008
1.8T A/C Pump, Front Cross Tube & Misc Purchased - April 16 2008
Been slowly working towards new Blance Shaft Chain, Chain Tensioner & T-Belt Kit - done
Spent 12 hours this weekend going through wire diagrams for AHA, ALH & ARL.
Created spread sheets for pin-outs.
Tagged ALH wiring.
Hooked up most of the ARL 40 pin harness to BHW engine.
Generated a list of harness issues to deal with. (which I will list below)
OK guys, time to start my thread. I have been accumulating parts and info for around 4 months now.
I bought this car specifically to create a TDI powered AWD luxury car for my daily use. After research for about 2 months, I concluded it could be done and I did an intensive search to find a B5 Audi A4 in mint condition. I ended up finding the perfect unit in Vancouver, BC, Canada. No road salt. All dealer service records. Owned by a family guy and proffesional. 102,000km (63,000 miles)
My original plan was to drop an ALH into it, but ended up finding a BHW for a really good deal. After recieving the BHW, I realized I had stumbled into the perfect engine configuration for this swap. The Passat B5.5 and Audi B5 A4, being both longitudinal mount and sharing mainy parts are a perfect match. The deal sealer is the fact that it will be producing around the same factory hp as the 1.8T, but much more torque (155ft-lbs vs 300 ft-lbs). The A4 is also an amazingly compact car for the luxury it holds, lending it to good fuel economy and performance when combined with a diesel power train.
Project Specs:
Chassis: '99 Audi A4 Quattro. Sport Package. Factory S4 Interior Upgrade. 2.8V6 Gas, 112,000km
OEM Power: Edit -190HP/207ft-lbs Torque
OEM Transmssion Specs: 5 spd, 01A (DWM). 3.89:1 Differential Gears
1st - 3.5:1
2nd - 1.94:1
3rd - 1.3:1
4th - .94:1
5th - .789:1
Factory Rims & Tires - 225/16/50 ZR
Speed/RPM: 2650RPM @ 100KPH
Donor Power Train Specs:
Engine: 2005 Passat 2.0TDI (BHW), under 60,000 km (local wrecker)
OEM Power: 134hp/254 ft-lbs
ECU - EDC15P and 40 Pin Harness from Euro ARL Code (PD150). Custom tuning specs set for roughly [EDIT 175HP/320 ft-lbs ??] (Supplied and tuned by VWMikel)
Other Harness: 2002 ALH 1.9TDI 80 Pin Harness (local wrecker)
Euro Tranny Specs:
01A 5spd Variant (EEP), 3.89:1 Differential Gears, 70,000km, Supplied by Scott Dewitt
1st - 3.5:1
2nd - 1.94:1
3rd - 1.22:1
4th - .83:1
5th - .66:1
Estimated Speed/RPM: 2166 RPM @ 100KPH - optimum would be 1900 for this engine, but I get what I get.
Before I get to much further into this thread, I would just like to make special thanks to Rexking414, who has helped a lot in digging up information. Also would like to thank VWMikel for providing guidance on ECU/harness related issues, and Scott D. for sharing his knowledge on all things mechanical. I think I was picking Scott's brain for a month before I even bought my Audi, and four months before I bought any parts from him.
I am very busy with projects in my profession right now, however, it's time to start kicking this project into high gear, so I will update and discuss things as I go.
Project Status/Major Milestones:
'99 Audi Car Purchase - Dec 11, 2007
BHW Engine Purchase - Jan 06 2008
EDC15P & 40Pin Harness Purchase - Jan 31 2008
ALH Harness Purchase - April 22 2008
ECS Tunning - RS4/1.8T Adapter Flywheel and RS4 Clutch/Pressure Plate (ES - 5486) - May 8, 2008
1.8T A/C Pump, Front Cross Tube & Misc Purchased - April 16 2008
Been slowly working towards new Blance Shaft Chain, Chain Tensioner & T-Belt Kit - done
Spent 12 hours this weekend going through wire diagrams for AHA, ALH & ARL.
Created spread sheets for pin-outs.
Tagged ALH wiring.
Hooked up most of the ARL 40 pin harness to BHW engine.
Generated a list of harness issues to deal with. (which I will list below)
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