New TDI swap

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Hello everyone, I’m new here and was hoping for a couple pointers. I recently received a 2005 Passat wagon with a TDI 2.0L automatic with the transmission burnt out and I would like to learn the basics of prep and removal of engine, harness and ecu for the purpose of swapping into a 1992 Jeep Comanche 4x4. Any pointers are welcome and appreciated.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
Keep engine harness uncut, de pin from the ECU box. Cut 18 inches from pedal harness plug.

Now make spaghetti!!!!
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
No machine work needed. Cam should be inspected. Balance shaft should be deleted if chained.

If you were on the proper coast I'd be talking you into selling me that shell.

You will need to retune the ECU and delete the immobilizer
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
No machine work needed. Cam should be inspected. Balance shaft should be deleted if chained.

If you were on the proper coast I'd be talking you into selling me that shell.

You will need to retune the ECU and delete the immobilizer
Well the shell will be for sale once I get the engine and related components out, clean title etc. I’m sure someone would be interested on here but yes I am located near Tacoma WA
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Removal is underway, I can’t imagine why the transmission went out the oil looked and smelled just like engine oil :oops: I guess these transmissions go out between 200-300k miles without a transmission service lol
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
Those transmissions are lucky to make it past 125k without regular service intervals.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
No machine work needed. Cam should be inspected. Balance shaft should be deleted if chained.

If you were on the proper coast I'd be talking you into selling me that shell.

You will need to retune the ECU and delete the immobilizer
I was meaning to ask about this immo delete, is it necessary if I am planning on using the truck side ignition system? I know this probably sounds really green but I’ve yet to do a swap to such a dissimilar vehicle before and I want all of my facts straight. Thanks for info on this
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
When you send the ECU off they will handle all the immob delete. Even if you purchase a diy immob delete stuff she'll still rev hang between gears without a retune, great if you like to grind gears. She needs to be retuned to a manual transmission.

@burpod has started doing tunes, he might be able to help you out. There are a few other active members who provide tunes that I cannot recall the names of so hopefully they'll chime in or others can provide them.

I used Matt Whitbread for my first go around then David at fast forward for my 4Runner build. David provided my custom harness. Not cheap. I had great luck with both. Will try to make my own harness on the next go project
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Thanks for clarifying. I had my eyes on whitbread for some of the mechanical mods, I think ill try my hand with the harness fingers crossed I don’t screw anything up lol. Are there any inputs from a manual transmission that I need to include in the harness (probably not since the ecu is from an auto and there won’t be a tcm) just figured I would ask. Thank you for your insight on this.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
The harness in the BHW Passat is pretty simple to get everything out. Just take your time and look it over, don’t forget the OBD data port
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I think the only signal you might need trans/power train wise is a vss sensor.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
So what’s the best recommendation for a service manual Haynes, Chilton or others? Maybe a VW/Audi factory service manual, tell me what has worked best for you guys. Keep in mind I will mostly be referring to it for the tech specs on the 2.0 TDI BHW. I do have AllData at the shop but I love having the old school paper backup book on hand.
 
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PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
The BHW is so simple and well documented I wouldn't fool with a manual. For wiring purposes you can request someone share a pin out for you, I used to have it saved on my email but lost it many years ago.

Cam replacement, replacing timing belt, injector removal/reinstall, balance shaft delete, etc all have well documented threads and YouTube videos
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
If you are looking to get a paper manual, the Bentley is the one you want.
But you can get all the same info on this forum.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Sad to see a clean looking wagon taken apart like this. Bummer you couldn't find a crashed sedan for it!
I know it’s a shame but hopefully someone shows interest in the body once I’ve pulled what I need. I own other VW/Audi vehicles that have not been molested so please don’t judge me too harshly lol. This has been something I’ve wanted to do for quite some time and the previous owner was days from sending it to the cruncher so at least I grabbed it before then.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Can someone give me the names of the necessary/critical inputs or sensors for the ecu that should be kept during the swap? I have a pretty good idea I just wanted to be sure I wasn’t missing anything. I would like to keep most of the engine and systems oe on the engine side including a/c, charge piping/w intercooler etc. unless it would provide great benefit not to. Thanks guys
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
You don't want to use the Passat intercooler system. An all aluminum with a larger fmic will be far superior and more reliable.

I went with a BRM intake so the charge pipe enters the same side as the turbo, less pipes under the hood. I deleted the ASV and EGR. Find the tuner you're going to use and what emissions if any you need to pass before you decide on deleting anything. I also had the MAF deleted, came with the tune/custom harness.

Im running all the VW accessories including ac compressor in my 87 yota.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Got the engine pulled and trans separated, engine on the stand. I started labeling all the inputs on the engine side harness, removed all the plugs and pulled the ecu. Disconnected all of the plugs in the bottom of the ecu box so I could remove the engine side harness then went to take a look on the inside where they came in through the firewall and dang theres a ratnest of wires up under the dash. Should I just unbolt the entire contents of the car side harness and pull all of it? (Looks like the data link harness is intricately woven into the center of the mess) it would be nice if I could pull only the engine control and monitoring portion plus a/c out of it but from what I am looking at that might not be possible.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
The AC is a simple 12v + ground. Mine is run off of two 30 amp relays and the factory 87 Toyota light up blue ac button.

The +12 activation switch for both relays runs through a trinary aftermarket sensor that installed in the high pressure line. It will kill the power if pressures drop below about 125 psi or above about 450 psi

One relay controls the ac clutch, the other activates the 12v fan.

No need for any ECU wiring in the ac system with the BHW.

Inside the cab you need about 18 inches of harness up from the throttle pedal.

Then get as much harness as you can from the obd port.

You don't need anything else inside the cab other than pedal unless you want to run the Passat gauge cluster.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
The AC is a simple 12v + ground. Mine is run off of two 30 amp relays and the factory 87 Toyota light up blue ac button.

The +12 activation switch for both relays runs through a trinary aftermarket sensor that installed in the high pressure line. It will kill the power if pressures drop below about 125 psi or above about 450 psi

One relay controls the ac clutch, the other activates the 12v fan.

No need for any ECU wiring in the ac system with the BHW.

Inside the cab you need about 18 inches of harness up from the throttle pedal.

Then get as much harness as you can from the obd port.

You don't need anything else inside the cab other than pedal unless you want to run the Passat gauge cluster.
This is some outstanding information, thank you sir. When you say 18” from the pedal do you mean cutting the harness 18” from the pedal or should I just run the length of the pedal wires to the plug? I thought I remember seeing somewhere that the orange plug in the bottom of the ecu tray tied into the pedal, of course, I could be mistaken.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
You'll need a pin out.18 inches of wire is about All you can get before it enters a larger loom of wire you don't need.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I should note im running the Passat cluster in my set up. No emissions so the asv, EGR and MAF are deleted. I think I'd get better mpg if the MAF was still in there but I'm not a tuner, I wouldn't have deleted that but I wasn't asked my the tuner nor did I request to keep it so it is what it is.

Because of these issues my wiring will vary from yours a bit.
 

Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
Well I thought I was going with a Toyota Tacoma but plans change I guess. Couldn’t pass on the price so I ended up with 1991 sorry correction “Jeep” Comanche 4x4 lol
 
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Myst69

Member
Joined
Apr 11, 2024
Location
Pacific Northwest
TDI
2.0 BHW
I pressure washed the engine after letting some degreaser sit on it for awhile, it was pretty caked on. So the engine ran fine it’s whole life and was meticulously lubed and serviced by the dealership the major downside I guess would be that it had exactly 300k miles on it and I need to build it to last another 300k any suggestions would be much appreciated. So far I’m planning on a counter balance shaft delete, new cam and lifters/seats the timing belt was just replaced so I’ll hold on that also whatever block machine work that may be necessary possibly crank and bearings depending on wear and of course new seals all around. Upgrades that I am considering would be a slightly larger turbo that doesn’t spool up quite is fast, egr delete etc etc. thanks for helping me out guys
 
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