tims944
Veteran Member
- Joined
- Jan 8, 2019
- Location
- montreal quebec
- TDI
- 2015 Golf Sportwagen TDI, 2006 mk5 tdi-SOLD 1989 944 s2 BHW swapped
So where was i, okay so pretty much sorted the main 5 possible issues, oil, coolant, steering, boost pipes and... engine mounting. bam engine is in place,
The bhw mainly uses quick connect style hoses or outlets and piping. NO THANKS
so i modified and or swapped out for simpler stuff, the rear coolant passage block is actually a BRM !, on a 944 the heater core is on the pass firewall but the outlets are only about 2" maybe apart and about 5/8" OD. and on all 944s the feed line for the core comes from the water pump or sorry maybe thats the return but regardless i cant run a line safely there because all the intake and exhaust and what not so an alternative was needed. Since i deleted the oil cooler/heater... for colder climates i didnt need to run the coolant lines to or from it, this gave me sort of spare outlets.
Now on the back of a bhw water passage i think there are normally 3 outlets, 1 down and 1 out each side, well for a brm theres only the 2, NO need to block or weld or what not that some people do... no idea why...
so i simplified it and only ran the 2, 1 of them goes directly into the heater core, and the other is actually the redirect of the line comming off the upper rad outlet, it runs through a big metal s liked shape pipe than a 90 degree rubber to the outlet.
Now also.. on a tdi the lines get plumbed to the reservoir etc, well on a 944 the line(feed) and vent for the overflow go straight to the rad and well since it has its own nice place i left the oem one in place and also modded up this pipe to only have 1 in and 1 outlet.
now the other pipe, The themostat housing also houses a metal pipe which goes all bendy curvy and ugly and this that, yuk... so annoying to plan and or calculate so screw it... i cut/ welded modified blah blah and poof this outlet now goes to my heater control valve(vacuum operated) for my heater core.
Next the thermostat plastic outlet, this usually just goes at an angle and has a quick connect hose to the lower rad inlet.. forget it.. i bought i think 4 different designs, the alh, 1.8t and even than there were different ones, if im not mistaken i chose the simple alh which goes offset at like 90' but shoots out about 4". i than built a custom aluminum crossover.
Big issue here, almost all tdis or at least the bhw has all its rad connections on 1 side.....
well that doesnt work for me, 1. the tdi rad is way too big length wise to fit(also has trans cooler... unneeeded)
2. no desire to use it...
3. the stock 944 rad has ample space and good options.
so i used the 944 one made a nice fancy cross over built some braces and boom it fits
as for alternate cooling
the Bhw normally runs a thermowhatever you call it clutch fan... well to my eyes this is just a maintenance or breakdown part... the 944 has 2 electric fans controlled solely by a relay and a thermoswitch in the rad.... DING DING DING, so simple as the bhw also normally has a sensor like this on the lower rad hose, so... off goes the clutch fan and in comes the dual electric 2 speed fans..
now that i freed up some more space i can look into belt and bracket options
The bhw mainly uses quick connect style hoses or outlets and piping. NO THANKS
so i modified and or swapped out for simpler stuff, the rear coolant passage block is actually a BRM !, on a 944 the heater core is on the pass firewall but the outlets are only about 2" maybe apart and about 5/8" OD. and on all 944s the feed line for the core comes from the water pump or sorry maybe thats the return but regardless i cant run a line safely there because all the intake and exhaust and what not so an alternative was needed. Since i deleted the oil cooler/heater... for colder climates i didnt need to run the coolant lines to or from it, this gave me sort of spare outlets.
Now on the back of a bhw water passage i think there are normally 3 outlets, 1 down and 1 out each side, well for a brm theres only the 2, NO need to block or weld or what not that some people do... no idea why...
so i simplified it and only ran the 2, 1 of them goes directly into the heater core, and the other is actually the redirect of the line comming off the upper rad outlet, it runs through a big metal s liked shape pipe than a 90 degree rubber to the outlet.
Now also.. on a tdi the lines get plumbed to the reservoir etc, well on a 944 the line(feed) and vent for the overflow go straight to the rad and well since it has its own nice place i left the oem one in place and also modded up this pipe to only have 1 in and 1 outlet.
now the other pipe, The themostat housing also houses a metal pipe which goes all bendy curvy and ugly and this that, yuk... so annoying to plan and or calculate so screw it... i cut/ welded modified blah blah and poof this outlet now goes to my heater control valve(vacuum operated) for my heater core.
Next the thermostat plastic outlet, this usually just goes at an angle and has a quick connect hose to the lower rad inlet.. forget it.. i bought i think 4 different designs, the alh, 1.8t and even than there were different ones, if im not mistaken i chose the simple alh which goes offset at like 90' but shoots out about 4". i than built a custom aluminum crossover.
Big issue here, almost all tdis or at least the bhw has all its rad connections on 1 side.....
well that doesnt work for me, 1. the tdi rad is way too big length wise to fit(also has trans cooler... unneeeded)
2. no desire to use it...
3. the stock 944 rad has ample space and good options.
so i used the 944 one made a nice fancy cross over built some braces and boom it fits
as for alternate cooling
the Bhw normally runs a thermowhatever you call it clutch fan... well to my eyes this is just a maintenance or breakdown part... the 944 has 2 electric fans controlled solely by a relay and a thermoswitch in the rad.... DING DING DING, so simple as the bhw also normally has a sensor like this on the lower rad hose, so... off goes the clutch fan and in comes the dual electric 2 speed fans..
now that i freed up some more space i can look into belt and bracket options