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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.

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Old April 9th, 2017, 19:38   #1
nitec
 
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Default Eurotrash Motorsports: W8 4Motion to BHW swap

Folks,

this has been a long time coming...The W8 base belonged to a long time TDiclub member - Fitzski...I've been on his case to sell me his W8 4Mo 6spd wagon for at least 3 years before he finally crumbled under the pressure. It then took me 2+ years of sorting out other projects before I found a suitable donor...long story short we started this project today and I`m really excited about it

The plan is fairly straight forward - complete BHW swap out of a B5.5 using all stock setup swapped into the B5.5 Wagon using the OEM O1E manual transmission - that's it. I'll build this for my mom or to sell so no Holset madness on this project

I've noticed there really isn't a good W8->TDi thread so hopefully this will help document the process a little better...

on with the pictures:

Here's the W8







Here's the extremely clean donor (short of a leaking valve cover gasket)



intercooler bracket needs to be moved over



this is where we stopped today



only things left to do before we pull it all out tomorrow are disconnect the driveshafts and the transmission shifter
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Old April 10th, 2017, 19:19   #2
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BHW's out...



it's a chain drive BSM - I think the consensus is the leave it alone?



I've got a few gaskets to replace and then it's ready to be dropped in...the W8 is coming out next...

realized pretty quickly that the BHW AC will not work in the W8 so I`ll have to figure out a way to mount the W8 AC compressor to the BHW - perhaps using the BPW bracket from the Audi will work?
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Old April 10th, 2017, 19:26   #3
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For the chain drive - the consensus is to delete it using an ALH pump.

What are you using for a clutch?
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Old April 10th, 2017, 19:29   #4
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oh yeah? the BSM works fine for now - I`ll look up the procedure...it is just a matter of unbolting it and bolting up the ALH pump? there was some hole that needs to be plugged right?

clutch is likely going to be single mass Valeo kit...works great on my B7 so no reason not to use it...I was thinking of getting a dual mass but can't seem to find a reasonable kit for it...
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Old April 10th, 2017, 20:25   #5
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is the BHW sprocket unusable? I've got the whole BRM assembly but don't feel like pulling the sprocket if I don't have to
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Old April 10th, 2017, 21:01   #6
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You have to
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Old April 11th, 2017, 03:39   #7
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Sprocket is different. Original design is weak on the chain/sprocket/guide, as well as the hex shaft which drives the oil pump - both will trash your engine. Guide here:

http://pics.tdiclub.com/data/3419/BH...eplacement.pdf

that guide is for replacement with a ($$$) geared module, same procedure to install the delete kit shown here:

http://www.cascadegerman.com/product...ft-delete-kit/
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Old April 11th, 2017, 12:47   #8
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Watching with interest! Still a few wiring issues with my swap but some may be different than yours given the AVF engine/ECU in mine.
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Old April 12th, 2017, 09:57   #9
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hmmm...the engine is really clean so I was hesitant to get into big tear down exercises but I think this is worth doing...I've already got a few oil pumps kicking about so should be ok - will need a new sprocket though that's for sure...

My parts list is shaping up like this:

- front and rear crank seals
- oil pump sprocket
- BRM (or BEW or 1.8T oil pump)
- Valeo 228mm SMF clutch
- 1.8t pilot bearing
- valve cover and tandem pump gaskets
- oil filter housing gasket

that's about it...was thinking of taking the intake and turbo off to chance gaskets there too but again - everything looks new so I`ll leave it at that...

am I missing anything in the "while in there" category?
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Old April 12th, 2017, 10:43   #10
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otty - I'm curious...what did you do about your AC?
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Old April 13th, 2017, 12:46   #11
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AC is not working currently. It is somehow not wired correctly and I haven't figured it out...
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Old April 13th, 2017, 14:22   #12
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Quote:
Originally Posted by nitec View Post
realized pretty quickly that the BHW AC will not work in the W8
Can't you just swap everything under the hood from the BHW in to the W8 body - pipework, condenser, drier & compressor? The point where the lines enter the cabin is standard so as long as you swap everything it should all be fine surely?

The AC controller in Audis can be coded to either mag-clutch or internal valve so I would assume the Passat one is exactly the same if thats the issue?
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Old April 13th, 2017, 17:26   #13
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Single mass flywheel clutches are documented to destroy 01E synchros in short order. Good luck with the build. Do something mad with the leftover W8 engine. A straight exhaust alone brings out the single plane V8 Ferrari-like sound. Search YouTube to see/hear what I mean.
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Old April 13th, 2017, 19:42   #14
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yeah I read about the SMF 01E situation...not sure how I feel about it - my B7 uses the same style transmission and it runs like a charm with the 228mm SMF...I find it a little hard to believe the "strongest" Audi transmission that people use behind all of their high HP turbocharged motors with SMFs fails just because it's mounted to a diesel engine where an O1A apparently doesn't...I dunno - every other option costs twice as much so I'm pretty sure I'm going down that path anyways...I wonder how many O1Es/SMF sets have actually failed and how long each one took...

MJ - interesting...I wouldn't think you can do that with VCDS? I've got a few different brackets to try out over the next few days to see if I can get the W8 AC mounted to the BHW the same way I did it in the B7...there's no issue mounting it the same way that the BHW was mounted - the only problem is the clutch activation so if you think that can be adjusted then it may be pretty straight forward...

otty - do you have a pic of your AC setup? I suspect the previous owner kept the BHW setup, which doesn't work with the W8...perhaps MJ will help us with out with this

Last edited by nitec; April 13th, 2017 at 19:54.
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Old April 13th, 2017, 21:09   #15
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One of these in your straight-piped W8 engine would be simple mental.
http://www.ebay.ca/itm/291973493410
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