Manual swap B5 TDI Passat

caffeine

Veteran Member
Joined
Jan 4, 2021
Location
B.C., Canada
TDI
03 Allroad w/04 BHW/02X conversion, 00 ALH Jetta
I used a stock TDI 240mm DMF/clutch on my BHW swapped Allroad w/bellhousing spacer. Just used a B7 2.0T pilot bearing and put a single washer behind it in the crank; gives lots of pilot bearing engagement and has been solid for about 18k kms now.
 

krook

Veteran Member
Joined
Jan 13, 2021
Location
Hungary
TDI
A4 B5 AWX, A4 B5 AFN
I used a stock TDI 240mm DMF/clutch on my BHW swapped Allroad w/bellhousing spacer. Just used a B7 2.0T pilot bearing and put a single washer behind it in the crank; gives lots of pilot bearing engagement and has been solid for about 18k kms now.
that also needs another starter. with 228mm setup you can keep the gasser starter!
 

d24tdi

Veteran Member
Joined
Jan 6, 2019
Location
MT
TDI
96 B4V
Keeping the factory US BHW starter (I think that's what the poster above meant to say, rather than gasser :)) was one of the selling points of the Whitbread SMF for me, as it allows the 228mm starter to work.

However, since then I have concluded that the Euro starters that are compatible with the 240mm FW are so easy to find and cheap overseas that it's not a worthwhile concern. Grab two of them if you are worried enough to want a spare.

If I could do it again a 240mm DMF would be the way I'd go. I'm happy with the Whitbread HD setup and the Stage 1 Southbend clutch that came with it, it does exactly what it's advertised to, but pedal weight and engagement smoothness are (as expected) not factory level from the beefed up smaller diameter clutch. There are enough good factory options that living with those tradeoffs is unnecessary.
 

caffeine

Veteran Member
Joined
Jan 4, 2021
Location
B.C., Canada
TDI
03 Allroad w/04 BHW/02X conversion, 00 ALH Jetta
Where to get a tune now?
Used ecm from a old swap?
I found a modified BGW tune (DPF delete) on the ecuconnections forum that I am still using in my Allroad. Runs the engine pretty well, but is not compatible with ESP or ASR. I flashed it with a BDM100 I bought on Aliexpress (to the original BHW ECM).
 
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