BHW Turbo Upgrade

chickensoup2180

Veteran Member
Joined
Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
Hello all. I was wonder what options I have for turbo upgrades for thew BHW PD engine? I did a search but only found 1 option.

Basically, I'm open to swapping headers, but I would like to use the stock cold side plumbing.
I have lots of room thankfully, as the egr is gone, and its longitudinal.
thanks
 
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adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Probably easier to get a bv43 from pd170 Audi A4/a6 and swap a CR bv43a chra in it…fits plug and play and supports up to 200 wheel horse power. If you’re into fabrication anything will fit with adapter plate from Darkside and/or tubular manifold ! Few of our colleagues have fitted the gtb2056vl from Volvo d5 with just a simple adapter plate and even they retained electric actuator…decent response and looks stock !
 

chickensoup2180

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Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
Yeah the bv43 is what I was looking at. My question tho is would I be replacing the turbo and header with the bv43? Because when I shop for them, I only see them integrated onto the exhaust manifolds.
 

adamss24

Veteran Member
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Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
You need the turbo Off the european Audi A4/a6 170 Bhp, it’s separate of the manifold…you got it on your existing manifold !
 

chickensoup2180

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Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
You need the turbo Off the european Audi A4/a6 170 Bhp, it’s separate of the manifold…you got it on your existing manifold !
Ah. Thanks for the clarification.

Will the US spec integrated turbo and manifold, bolt onto my bhw? Or is it a different port and stud pattern.
 

adamss24

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Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
It won’t work, the turbo with the integrated manifold is orientated differently and much bulkier than the bv43 from the longitudinal platform. You either need the gtb1749vc, bv43a chra/bv43 housings or some sort of hybrid made of your existing garret turbo. I believe you can fit gtb turbos as well with adapter plate from darkside developments, they have been made solely for longitudinal platform or you can spend a bit and get their billet tubular manifold that will take any gtbxxxxvk turbo !
 

Mongler98

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Joined
Mar 23, 2011
Location
COLORADO (SE of Denver)
TDI
98 Jetta TDI AHU 1.9L (944 TDI swap in progress) I moved so now i got nothing but an AHU in a garage on a pallet.
nice plate... looks sweet... unlike that hacksaw nightmare blockoff plate below! LOL
 

chickensoup2180

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Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
i should have mentioned that this is a US spec car with the Borg Warner vtn17 turbo.

AT this point, recomend me a turbo that allows up to 220hp range that can be bolted to the exhuast manifold or with an adapter. thanks
 

chickensoup2180

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Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
Ok, I did some more research. I want to gtb2060vk.

I literally just replaced my cam and lifters. But I want to have it reground to a stage 2 profile. Either have it dfl coated or hardened and polished.

I'll probably just buy a new set of lifters. They are cheap enough. What brand should I buy?

Also, will the 2060vk bolt to my exhaust manifold of does it need an adapter? Thanks

Edit- oh, what nossles?
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
None of the above turbos will bolt onto your manifold, you need to get adapter plate or weld flange to the turbo’s hotside.
 

Mozambiquer

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Mar 21, 2015
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Versailles Missouri
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1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
Ok, I did some more research. I want to gtb2060vk.

I literally just replaced my cam and lifters. But I want to have it reground to a stage 2 profile. Either have it dfl coated or hardened and polished.

I'll probably just buy a new set of lifters. They are cheap enough. What brand should I buy?

Also, will the 2060vk bolt to my exhaust manifold of does it need an adapter? Thanks

Edit- oh, what nossles?
I'd go with a Franko6 cam. Colt is decent, but I've seen several of them that are worn out. Obviously I don't have the full story, but it makes me a bit hesitant...
Injectors, well the ones in there are good for 180+ hp, I'm not sure where it maxes out. Obviously if you're still auto transmission, you'll probably need to budget for a manual swap if you're running that much power...
I know x-man turbos has several different turbo options for the BHW. I'd look at what he has as well.
 

MEgearhead

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Aug 6, 2016
Location
Virginia
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B5.5, 4L, 4G
Send x-man and gotboost messages.

X-man has a couple plug and play options gt1752 and gt1756. He also has a gt1856 with the vnt20 compressor housing, but that will require a increaser silicone 90 and clamps in place of the stock outlet hose. (Check out 50harleyrider's bv43 thread).

Gotboost will make a gtd1752 with the longitudinal manifold flange. You will need to rework the down pipe to accept a v-band, and the compressor outlet will require something similar to the vnt20/Bv43.

I wanted to go with the gtd for better spool, but decided I didn't have time for anything that was not plug and play. I went with the x-man gt1756. I have it installed along with his 260 bew cam. We don't have the tune yet so really can't report on performance.

(Edited to correct typo I went with a gt1756 not a gt1856)
 
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Joel451

Member
Joined
Aug 3, 2020
Location
Oliver Springs, Tn
TDI
2004 Passat 2.0
I know this is an older post but wondering how MEgearhead and chickensoup218 made out with their turbo upgrades, are you happy with them ? I'm getting ready to replace my bhw turbo and would love to hear your feedback.
 

jimbote

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Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Probably easier to get a bv43 from pd170 Audi A4/a6 and swap a CR bv43a chra in it…fits plug and play and supports up to 200 wheel horse power. If you’re into fabrication anything will fit with adapter plate from Darkside and/or tubular manifold ! Few of our colleagues have fitted the gtb2056vl from Volvo d5 with just a simple adapter plate and even they retained electric actuator…decent response and looks stock !
Details on retaining electric actuator?
 

MEgearhead

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Aug 6, 2016
Location
Virginia
TDI
B5.5, 4L, 4G
I am satisfied with the X-man GT1756, but if I were to do it again, had more time to work on it, and didn't have to worry about e-checks, I would try to use a more modern turbo like a GTD####vrk series, or I would go with the GT1752. My decision to use the plug and play GT series options was based largely on having to pass biannual emissions inspections. Other options are actually visible if the inspector looks closely.

The GT1756 spools rather slowly. It doesn't reach 20 psig until around 2100 rpm. It's makes full 27 psig boost at 2500. The GTD vrk units are reported to spool nearly as fast as stock.

If you are up to a little DIY fitting like welding an exhaust v-band flange on the downpipe, and fabbing a custom boost hose, and don't need an option that looks very close to stock, I'd go with a newer style like the GTD, but I have no experience with them.

If you want plug and play that looks exactly like stock, the X-man GT options are great options. If you're retaining the stock injectors I'd go with the 1752 for the quicker spool. You won't be able to support the fuel required for the full boost potential of the 1756 anyway.

Either the 1752 or 1756 should work with the stock 3 bar sensor, but I'd recommend changing to a 4 bar if going with a 1756 to give you a little bit of margin for spikes. I had spikes well over 3 bar when we were trying to dial in the tune, and that was with an initial 2.6 bar target. We've got it cleaned up pretty well and with the current 2.9 bar target spikes are just below 3 bar. Consult your tuner, and take their recommendation seriously even regarding turbo options. You are marrying them.

Since my previous post I think Darkside has additional options, but I really haven't researched them.

I don't think chickensoup ever did a turbo upgrade. I believe he sold the car. Good kid though.
 

chickensoup2180

Veteran Member
Joined
Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
I choose not to do the turbo upgrade because I uhh.... took the car off roading with my homies and drove it 30 miles with a punctured intercooler. Then the BSM tensioner broke again.
Soon tho, Ill be pulling the engine to do the BSM delete. Ill do a turbo upgrade then. and probably get a 4 motion body tbh.

Also, I wouldnt recommend a turbo upgrade if youre gonna beat on it with the factory auto. My TC started unlocking at random speeds after trashing it with just a tune and exhaust.
 

chickensoup2180

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Nov 1, 2021
Location
Ga
TDI
2005 Passat Wagon (BHW)
If you want an actually fast car tho, dont bother with the TDI. Anything is possible with lots of money but... you know
 

Joel451

Member
Joined
Aug 3, 2020
Location
Oliver Springs, Tn
TDI
2004 Passat 2.0
Thanks for the updates. I'm leaning towards the xman GT1752 and retaining the stock injectors. Currently have a colt stage 2 cam and am hoping to get appox 170hp and 300ft/pds with this setup and a tune from Kerma(I might be overly optimistic about this). The engine is in a Jeep tj so looking for more low end power.
 

Dasilzar

Active member
Joined
Oct 16, 2017
Location
Michigan
TDI
2005 Passat TDI
Thanks for the updates. I'm leaning towards the xman GT1752 and retaining the stock injectors. Currently have a colt stage 2 cam and am hoping to get appox 170hp and 300ft/pds with this setup and a tune from Kerma(I might be overly optimistic about this). The engine is in a Jeep tj so looking for more low end power.
Just ran across this thread and wanted to throw some more info out there for you if you haven't done any upgrades yet. My BHW gets just over 170hp and 300ft/pds with just a Stage 2 Malone. If you wanna upgrade beyond that I've seen a lot of people go with a bv43a turbo as it bolts right on. I think Cascade German has a kit, or I'm pretty sure that Frank06 has some occasionally, but not certain on that one. You do need to delete EGR and possibly the EGR cooler for it to fit. I've seen some people saying they get around 200hp with that setup. If you want anymore power than that make sure you don't have the slushbox that came stock with the BHW (although I doubt you do if you have the engine in a Jeep. Stock injectors are rated for up to 240hp IIRC so not much need to mess with those.
 
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