BHW/01E 6 Speed Swap

[QuickTD]

Hello, what did you end up doing with the turbo support? I finally got all the pieces together and we’re currently intalling a DQS with the 240 clutch into my 2004 Passat but the starter and the turbo support don’t like each other.

Remove it.

 

[QuickTD]

This isn't true, after 2002. later engines have bolt patterns that have different bolting patterns.

Which engines are different? I have (luckily?) not encountered any, but it would be nice info to have.

 

[Uberhare]

I can't remember to be honest, it was so long ago now! I suspect I just ran without one. I'll be taking the car apart this winter so I can have a look then.

 

[Windex]

I left mine off. I think Uberhare did as well

 

[yahmon]

Hello, what did you end up doing with the turbo support? I finally got all the pieces together and we’re currently intalling a DQS with the 240 clutch into my 2004 Passat but the starter and the turbo support don’t like each other.

Made a new one mounted on top off the engine mount

 

[GoremanX]

I haven't had a turbo support for 3.5 years, and I'm running a bigger, heavier turbo than stock on an OEM manifold

 

[MILESB]

Hi, we took the advice of leavin it off. Project is just about complete. It’s drivable, needs the tune. It took a long time getting all the pieces for the conversion. The list in this thread is not complete but very, very helpful I had a bunch of questions but got it figured.
I only made two screw-ups. One was getting the wrong timing kit for the AVF, as it was from an 2002 Audi and the tensioner was the old style and the other was the wrong clutch stainless braided hose.
My car is a 04 Passat wagon tdi with a toasted auto trans, got it for $700. Brought in an AVF motor (200k Kms) from UK which has the manual crank, no pilot bearing worries. Also, no balance shaft crap. the gearbox from Germany is a rebuild DQS 6 speed and hooked up to a 240 clutch.
All the other bits came from eBay, Poland and other former eastern block countrys, very reasonable prices and before COVID hit, shipping costs to Canada were reasonable. Completely insane shipping costs now.
I need to thank my friend Peter, the Mechanical genius that put the bits and pieces together into my car, I helped but most likely made more work for my buddy. also, the many members here that provided their expertise answering my very many questions, Thank you all.

 

[Uberhare]

Let me know what is missing from the list & I'll update it.

 

[yahmon]

Hi, we took the advice of leavin it off. Project is just about complete. It’s drivable, needs the tune. It took a long time getting all the pieces for the conversion. The list in this thread is not complete but very, very helpful I had a bunch of questions but got it figured.
I only made two screw-ups. One was getting the wrong timing kit for the AVF, as it was from an 2002 Audi and the tensioner was the old style and the other was the wrong clutch stainless braided hose.
My car is a 04 Passat wagon tdi with a toasted auto trans, got it for $700. Brought in an AVF motor (200k Kms) from UK which has the manual crank, no pilot bearing worries. Also, no balance shaft crap. the gearbox from Germany is a rebuild DQS 6 speed and hooked up to a 240 clutch.
All the other bits came from eBay, Poland and other former eastern block countrys, very reasonable prices and before COVID hit, shipping costs to Canada were reasonable. Completely insane shipping costs now.
I need to thank my friend Peter, the Mechanical genius that put the bits and pieces together into my car, I helped but most likely made more work for my buddy. also, the many members here that provided their expertise answering my very many questions, Thank you all.

Need help with that tune let me know.

 

[Uberhare]

Go with Malone for a tune. Very smooth, gobs of torque and almost no smoke.

 

[yahmon]

Go with Malone for a tune. Very smooth, gobs of torque and almost no smoke.

And the inevitable Malone advertising campaign has started

 

[zzdiesel]

Worked for me.

 

[QuickTD]

And the inevitable Malone advertising campaign has started

Could be worse, kerma and dbw fans are much more aggressive...

 

[yahmon]

Could be worse, kerma and dbw fans are much more aggressive...

Yep it get's hilarious when they all start defending their pricey tunes that started from the same pyramid scheme.

 

[Windex]

Paid my money to Malone, on my 6spd swap, got a tune that performs exactly the way I want - turns off all the autobox warning lights and stage 2 power - take your concerns to the vendor thread.