I'm baaack!

pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
Haven't been here in about 10 years. Haven't seen any of you since the Grand Rapids, Michigan TDI fest. I've long since parted with that '96 Passat (B4), but vee dub runs deep in my veins. I had a wonderful 2002 passat gasser (RIP), and my son is driving a 2015 passat (too nice for a first car, but if you're married, you already know that argument was lost before it started). Anyway, I'm BACK, doing my research and preparing to grab another oil burner. The tech advancements are incredible. I feel like I'm carrying an Apple IIe and you guys are carrying quantum computers. Despite all that, I'm still hopelessly in love with the B5.5. It's VW's most beautiful design language (imho), and executed with more excitement than its sister Audi A4 of the same platform. So let us begin: Beyond bone stock, what mods would YOUR dream B5.5 tdi have, and why?
 

Zambee500

Veteran Member
Joined
Jun 29, 2008
Location
Atlanta, GA
TDI
2005 Passat TDI GLS, 2014 NMS Passat TDI SEL Premium
I'll play:

Balance shaft delete
5-speed manual conversion w/ stage 2 tune.
Recently replaced camshaft (bonus points if franko6 mk2.0 camshaft is installed)
Ceramic tints
Panzer/Evolution skid plate
Multimedia head unit with Android Auto/Apple CarPlay and rearview camera
Monster Mats
 

pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
I thought the manual tranny was available for 2004-2005? I had the Panzer on my B4. Awesome upgrade. I had several deep gouges by the time I sold the car, so I know it saved me from the tow truck.
 

Zambee500

Veteran Member
Joined
Jun 29, 2008
Location
Atlanta, GA
TDI
2005 Passat TDI GLS, 2014 NMS Passat TDI SEL Premium
I thought the manual tranny was available for 2004-2005?
Nope. Only auto-tragic sold here. There are 5-speed and 6-speed manual options available to convert to though. 5-speed conversion is a little cheaper than replacing the automatic transmission if/when that fails.

The balance shaft module is the main time-bomb that must be addressed. If the chain-driven BSM has been replaced with geared BSM, i'd probably leave it in there but just be aware that the hex key can still get worn off. But if the chain-driven is still inside, just have it removed/deleted. Deleting is cheaper and more fail-safe, resulting in a little peppier driving and maybe a hair better MPGs too. The drawback is a little bit more vibration. Tolerable to most here, but BSM delete does lose a certain amount of refinement.
 

pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
Nope. Only auto-tragic sold here. There are 5-speed and 6-speed manual options available to convert to though. 5-speed conversion is a little cheaper than replacing the automatic transmission if/when that fails.

The balance shaft module is the main time-bomb that must be addressed. If the chain-driven BSM has been replaced with geared BSM, i'd probably leave it in there but just be aware that the hex key can still get worn off. But if the chain-driven is still inside, just have it removed/deleted. Deleting is cheaper and more fail-safe, resulting in a little peppier driving and maybe a hair better MPGs too. The drawback is a little bit more vibration. Tolerable to most here, but BSM delete does lose a certain amount of refinement.
Good to know. Always something quirky to deal with on these. Any successful GLX 4-motion conversions? Marty lives within an hour of me, so I'm mulling over building my dream rather than trying to find it.
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
My favorite mod is to ditch the passat body and chassis and drop the engine in a B7 audi A4 quattro, with a 6 speed manual.
 

pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
My favorite mod is to ditch the passat body and chassis and drop the engine in a B7 audi A4 quattro, with a 6 speed manual.
You have my full and undivided attention. Would you happen to have a link to someone doing this swap? Seems like computer management would choke unless it's an engine code already used in Europe.
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
You have my full and undivided attention. Would you happen to have a link to someone doing this swap? Seems like computer management would choke unless it's an engine code already used in Europe.
I currently have 3 of them in my stable, and have done the wiring, programming and coding on probably 6 others. All are fully functional with no error codes in any module. Cruise and AC work perfectly.
 

pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
Looks like you may be in the Windsor area. I'm in West Michigan. Do you have a shop?
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
I don't have a commercial shop, but my home shop is very well equipped. I just do this for fun, I guess? I haven't posted much here lately, 'cause If I want to be assured that I'm an idiot, I generally just talk to my girlfriend...:)

Seriously though, I only do these swaps for people that can help me in some way, and not financial compensation. I like people that find me cars and parts. The B7 is literally the easiest swap ever. Start with a 2.0TFSI 6spd car, you can use the transmission (2000rpm = 62mph). Import BPW engine harness, ECU, starter and accessory bracket. Bolt all that crap together with your favorite clutch and flywheel. I use the TFSI oil pan since it has the sensor hole and it supports the windage tray that I use when I delete the BSM.

One wire needs to be re-routed from bulkhead connector to fuse block to power the cooling fan module in the proper sequence. Eliminate the fuel pump driver module and pin the leads directly to the pump (which gets replaced with the BHW unit). Drill out suction pump orifice to .050". Eliminate gas filter. Use the canister purge line as a return (TFSI is returnless). Hurl cannister and associated plumbing in dumpster. Attach leak test pump filter to tank vent. Bash out filler neck restrictor.

Immo delete and Reflash ECU to get rid of DPF, aux heater and engine mount solenoid codes. Also change gear ratio tables for the gas transmission and add your favorite tune. Code engine 172, ABS 4529 (which is not technically correct, but diesels only came with 1LE brakes so you have to code it that way regardless of the brakes on the car. Not to worry, I have tested the ESP extensively, it spoils your fun just as it should...:cool:. I usually order a euro cluster for 20 bucks, pull the gage faces and throw the rest in the garbage, I then edit the cluster EEprom to correct the tach scaling. Haven't had a lot of luck using European clusters (or any immo related stuff) in a north American car. They seem to be slightly different immo versions, or my tools suck, or my skillz. Whatever the case, I bricked some clusters and finally gave up. Alarm still goes off if wrong key is used and immo light is out, so it's fine.
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2012 Tiguan TDI/DSG 2005 Audi A4 6MQ 2011 BMW X5 35d
Hey QuickTD, does the B7 intercooler use the same fittings as the Passat BHW.

This is very interesting. My son has a B7 TFSI that supposedly has been rebuilt. When (not if) it takes a dump, may talk him into converting it with the Passat I just picked up with a bad transmission.

Did they import a B7 Avant 2.0 and manual to the US?
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
Hey QuickTD, does the B7 intercooler use the same fittings as the Passat BHW.

This is very interesting. My son has a B7 TFSI that supposedly has been rebuilt. When (not if) it takes a dump, may talk him into converting it with the Passat I just picked up with a bad transmission.

Did they import a B7 Avant 2.0 and manual to the US?
B7 2.0TFSI intercooler piping is all gear clamped. The BHW piping adapts pretty easily though. I cut the turbo outlet coupler from a blown BHW S-hose (I have a bunch of those...) and clamp it to the B7 turbo to intercooler hose. On the left side, I cut the intercooler coupler off of a BHW hose as close as possible and clamp it on the B7 intercooler. It all works out very well, sizing is good. I use the TFSI airbox with the BHW MAF, bolts in. I then use the BHW airbox to turbo hose. It's a bit short. You need to stretch it a bit to get the airbox fastener in place but it relaxes after a while...

We have B7 manual wagons here, I suspect the US got them as well.

I just bought another passat as well, 193000km, rare low mile car. Body is rusty and has a bad auto. I'm looking for a real nice B7 A4, maybe an S4 or RS4. Most B7's are getting pretty rusty here, so finding a summer driven RS4 might be my last hope for another B7 swap. On to the B8's and common rail I guess...
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2012 Tiguan TDI/DSG 2005 Audi A4 6MQ 2011 BMW X5 35d
Yeah I was just looking on Autotempest and there are a few here and there. More than I want to pay since they are running.

I have moved on to the Tiguan and putting TDI's in them. The sedan/wagon thing is too low for me, haha. Just looking for a a project to put the BHW in. Have a complete 6 speed set up from a 2004 S4. I realize the gearing is a little high for the BHW. It does have a 3.89 rear diff. Easier to find an automatic car. Will the B6 drivetrain interchange with the B7. If yes, could pick up a B7 6 speed manual and mate up with the axles, prop shaft and rear diff I have now if it has a 3.89 FD ratio,
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
B7 trans and shifter box will fit a B6 and vice versa. B6 and B7 are pretty close drivetrain and mechanically. B7 uses a different rear diff style (shorter pinion/nose on the B7), so driveshaft length may be an issue, I have "adjusted" the driveshaft length on a few allroads, it isn't really a huge problem... Biggest difference between B6 and B7 is the electronics. B6 rejects EDC16, B7 loves it.

I have my first tiguan coming soon, not mine. Doing the wiring and tuning for another guy. FWD 6spd manual, so it should be pretty straightforward. I'm just not ready for an SUV myself. I still love a low slung, tight handling car.
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
When you mention Audi B7 A4 Quattro, what years are you referring to? 2005-2008?
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
should we look at 2004-5 only for a BHW swap? I've seen a bunch of S4 manuals for sale. The V8 probably kills mating a BHW to those manuals, huh?
 
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QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
No. Avoid the B6. 2005 was a transitional year, if it has a 2.0TFSI you're good, 1.8T bad. I would go 2006-2008 for a swap. The B6 is a nightmare, though I have swapped a few. B6 requires EDC15P electronics, no way around it. The B7 will work with BPW ECU and harness imported from europe. B7 2.0T has a transmission suitable for a diesel as well. It runs 2000rpm@ 60mph. OK for autobahn but, according to many here, not US freeway use.
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
So we could use the 2005 passat TDI engine, harness and reflashed ecu in a 2006-2008 Audi 2.0TFSI and avoid everything else including any Audi S4 since they had a V8? I did some research on the TFSI. It's basically a hybrid gas engine with direct injection like a TDI which makes it ideal for a BHW replacement. Demon Diesel has a nice build thread in the conversion forum. So Audi made and imported 2.0 T and 2.0 TFSI to the states or only Canada?
 
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pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
The Audi 2.0 TFSI with a tdi and seats from the s4 would be close enough for me.
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
I was looking through classifieds and every 2006-2008 Audi 2.0T was also an FSI. Looks like lots of donor cars out there for a swap. I'm down for one!
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
So we could use the 2005 passat TDI engine, harness and reflashed ecu in a 2006-2008 Audi 2.0TFSI and avoid everything else including any Audi S4 since they had a V8? I did some research on the TFSI. It's basically a hybrid gas engine with direct injection like a TDI which makes it ideal for a BHW replacement. Demon Diesel has a nice build thread in the conversion forum. So Audi made and imported 2.0 T and 2.0 TFSI to the states or only Canada?
There is only one 4cyl engine for the US and Canada, and it is the 2.0TFSI. Most A4's have this engine, as do most VW's of the era. Finding one with a stick is usually the problem. The V8 and V6 cars have no intercoolers or piping, different rad support, wrong transmission ratios, the list goes on. suffice to say a 4cyl car is a much easier swap.

The passat has more in common with a C5 A6 than a B7 A4. The electronics compatibility with the A4 is not good. The A4 has ECU controlled cooling fans, serial bus cruise control and CAN based AC compressor cutout and load sensing. The passat has none of those things, and the ECU lacks the hardware on the circuit board, so a reflash is not possible. Like everyone else that does this swap successfully, I use a BPW ECU and wiring harness. I reflash to get rid of the DPF and a couple of annoying fault codes (engine mount solenoids and aux heater) and add a bit of a tune.
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
Have you had any problems getting the BPW ecu and harness? Frans a good source for them? Malone is good for the reflash and stage 2 tune? Is the C5 A6 a good swap candidate? I like the longer wheelbase of the A6. Did Audi put the 2.0TFSI in them with manuals or were they all 3.2 v6 or other? Didn't Audi put a TDI 4 cylinder engine in them as a base diesel? Probably never imported to the states if they did. I've never seen one.
 
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QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
Have you had any problems getting the BPW ecu and harness?
No.

Frans a good source for them?
I don't know, I use ebay.

Malone is good for the reflash and stage 2 tune?
What is "Malone"?, I tune them myself.

Is the C5 A6 a good swap candidate?
I don't know, I've done a few C5 allroads, they're pretty easy, and have been covered a hundred times here. I don't know offhand if there was a 2.0T A6 manual, maybe in europe, probably not here.
 

pharmerman

Veteran Member
Joined
Mar 28, 2001
Location
I-94
TDI
1996 Passat, maroon (gone but not forgotten), 2002 Passat GLX v-6 Manual
I've had enough experience w/ diesel to know that's what I want, but not enough time, tools, or energy to do it myself. Is there anyone out there that would do the swap for me if I showed up with a car, the necessary parts and cash?
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
That's pretty awesome, QuickTD. I can reflash my ECU in my Mercedes diesel swap I did a few years back but only because of the aftermarket ECU I'm using with tuneable software I got from Baldur in Iceland. what software do you use to flash the TDI's?
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
MPPS for flashing, WinOLS for tuning. I also use VAG eeprom programmer for cluster flash modification (to rescale the tach for diesel gauge faces). I use FVDI for immo deletes.
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
Impressive. If we go with this swap, can we send you the ecu for reflash and tune?
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI, 2007 A4Q 6spd 2.0 TDI
I'd rather you didn't. You would be disappointed with my service.
 

50harleyrider

Veteran Member
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
(y). I don't want to hijack pharmermans' thread so we could PM. There are a lot of these 06-08 quattro six speeds in the mid atlantic and southeast US. If you're looking for one seriously, PM me and let me know how much you want to spend and any other particulars and I'll help you find one.
 
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