Show Posts
1
Diesel Swap Tech and FAQ / BEW into 2002 Weekender
« on: November 18, 2016, 10:57:42 pm »
Yes, I'm a little insane 
. My goal is to build a manual transmission (4motion if possible!) TDI Eurovan for camping and road trips from parts that are accessible in the US as much as possible. This will make findings replacement parts and spares potentially easier and much more tolerable than having to pay for and wait for shipping from Europe or the rest of the world.
I found a 2004 Passat with the 134bhp BHW motor that had a busted transmission and was able to get the whole car for about what used motors alone were going for around me so I jumped on it. The motor ran well, and I was able to ride around the block once I got it home on the flat roads. I just finished doing the balance shaft delete procedure and changed the water pump and timing belt, waiting on some parts from the BEW (1.9 PD in the jetta/golf/beetle) to remount the accessories on the front of the motor since the passat has the AC compressor on the back. I also found a used 02m from an Audi TT that I'm having an adapter plate made so I can clock to motor to the correct orientation and still use the quattro/4motion transfer box eventually. I still need to reorient my oil pickup tube and I've got a steel oil pan on the way to notch out as necessary with the new motor orientation. The cars have the motors at -15* towards the firewall and the 4 cylinder vans have the motors mounted at +27* which comes out to 42* difference in mounting angle. Unless I can figure out a smooth way to overlap the bolt holes it looks like I'm going to have to rotate a few more degrees forward to 35*, or about 50* total, to properly clear the gearbox bolt holes and give enough material for the new block mounting points. I think the VR6 motors are mounted at 34-35* forward, so I'm not so worried about the angle. Some of the Vanagon swaps have TDIs mounted at 50* from vertical and they run well. And based on eyeballing some of the euro T4 and T5 transmissions it looks like I'm going for about the same mounting angle that they come with on the 02B/D/G/Z gearboxes. I have an uprated southbend clutch and a 240mm flywheel that will fit in the 02m bellhousing nicely.
I'm not sure what the intake side will be yet, but post compressor wheel I'll use custom piping to go out front to a Sprinter FMIC and the back on the driver's side to the intake. Downpipe is going to have to be a custom job since the turbo exhausts on the driver side, but I think a U bend to mate up with the O2 sensor section and flexpipe back into the van's exhaust will work nicely. I think that some of the Volvos used a set of slim line fans that I may have to try out if space becomes an issue with the stock radiator fans as well.
There are some guys on the UK T4 site that managed to swap an 02m into their T4s with the 1.8t motors, I haven't been able to find anyone that has done it with a TDI yet. At this point I'm going through the wiring diagrams to figure out what can stay and what can go, but I have the entire Passat harness which makes things nice. I think I'll be able to swap over the Passat cluster and use the immo deleted ECU with a tune, likely from Malone as they are one of the only tuners I've found that can convert the BHW ECU to manual. The only thing I'm still not sure of with the ECU wiring will be the ABS, I'm not sure if I'll be able to use the van's ABS controller/ECU or if I'll have to use the Passat one and swap it over onto the van's ABS pump. I'm going to swap over the wiper and turn signal stalks from the Passat to be able to use the MFI on the Passat cluster and hopefully will make using CC easier. We shall see. I've been looking at the Malone stage 1.5 or stage 2 tune for 150-160ish bhp and 250-290lbft of torque, and I want to use the dynamic EGR feature they have. I like the idea of keeping the environmental features intact as well as keeping the EGR cooler for faster heating up when it's cold.
I think I'm going to pick up a set of 5 speed axles from a 95 eurovan since they are the same length and make an adapter for the passenger side of the gearbox to extend out to the passenger side axle. I may be able to cannibalise the VR6 intermediate shaft for this since it will have a mount already on it. Not sure yet. I've got the TT shift box and an extension on the shifter so the cable shifter should work nicely. It reportedly mounts fairly easily in the tunnel once you drop the gas tank, you just have to drill a few mounting holes into the floor. Speaking of which, I'm hoping the passat lift pump and fuel pump will work in the Eurovan tank and I'll just have to redo the soft lines for diesel compatible ones. I haven't looked much into this yet, I suspect I'll be tackling it once I get to it. There are a few hurdles to clear first.
Yes, I'm insane. But I'm excited about the van when it gets to the running stage. Updates to follow... Questions and thoughts are welcome.
. My goal is to build a manual transmission (4motion if possible!) TDI Eurovan for camping and road trips from parts that are accessible in the US as much as possible. This will make findings replacement parts and spares potentially easier and much more tolerable than having to pay for and wait for shipping from Europe or the rest of the world. I found a 2004 Passat with the 134bhp BHW motor that had a busted transmission and was able to get the whole car for about what used motors alone were going for around me so I jumped on it. The motor ran well, and I was able to ride around the block once I got it home on the flat roads. I just finished doing the balance shaft delete procedure and changed the water pump and timing belt, waiting on some parts from the BEW (1.9 PD in the jetta/golf/beetle) to remount the accessories on the front of the motor since the passat has the AC compressor on the back. I also found a used 02m from an Audi TT that I'm having an adapter plate made so I can clock to motor to the correct orientation and still use the quattro/4motion transfer box eventually. I still need to reorient my oil pickup tube and I've got a steel oil pan on the way to notch out as necessary with the new motor orientation. The cars have the motors at -15* towards the firewall and the 4 cylinder vans have the motors mounted at +27* which comes out to 42* difference in mounting angle. Unless I can figure out a smooth way to overlap the bolt holes it looks like I'm going to have to rotate a few more degrees forward to 35*, or about 50* total, to properly clear the gearbox bolt holes and give enough material for the new block mounting points. I think the VR6 motors are mounted at 34-35* forward, so I'm not so worried about the angle. Some of the Vanagon swaps have TDIs mounted at 50* from vertical and they run well. And based on eyeballing some of the euro T4 and T5 transmissions it looks like I'm going for about the same mounting angle that they come with on the 02B/D/G/Z gearboxes. I have an uprated southbend clutch and a 240mm flywheel that will fit in the 02m bellhousing nicely.
I'm not sure what the intake side will be yet, but post compressor wheel I'll use custom piping to go out front to a Sprinter FMIC and the back on the driver's side to the intake. Downpipe is going to have to be a custom job since the turbo exhausts on the driver side, but I think a U bend to mate up with the O2 sensor section and flexpipe back into the van's exhaust will work nicely. I think that some of the Volvos used a set of slim line fans that I may have to try out if space becomes an issue with the stock radiator fans as well.
There are some guys on the UK T4 site that managed to swap an 02m into their T4s with the 1.8t motors, I haven't been able to find anyone that has done it with a TDI yet. At this point I'm going through the wiring diagrams to figure out what can stay and what can go, but I have the entire Passat harness which makes things nice. I think I'll be able to swap over the Passat cluster and use the immo deleted ECU with a tune, likely from Malone as they are one of the only tuners I've found that can convert the BHW ECU to manual. The only thing I'm still not sure of with the ECU wiring will be the ABS, I'm not sure if I'll be able to use the van's ABS controller/ECU or if I'll have to use the Passat one and swap it over onto the van's ABS pump. I'm going to swap over the wiper and turn signal stalks from the Passat to be able to use the MFI on the Passat cluster and hopefully will make using CC easier. We shall see. I've been looking at the Malone stage 1.5 or stage 2 tune for 150-160ish bhp and 250-290lbft of torque, and I want to use the dynamic EGR feature they have. I like the idea of keeping the environmental features intact as well as keeping the EGR cooler for faster heating up when it's cold.
I think I'm going to pick up a set of 5 speed axles from a 95 eurovan since they are the same length and make an adapter for the passenger side of the gearbox to extend out to the passenger side axle. I may be able to cannibalise the VR6 intermediate shaft for this since it will have a mount already on it. Not sure yet. I've got the TT shift box and an extension on the shifter so the cable shifter should work nicely. It reportedly mounts fairly easily in the tunnel once you drop the gas tank, you just have to drill a few mounting holes into the floor. Speaking of which, I'm hoping the passat lift pump and fuel pump will work in the Eurovan tank and I'll just have to redo the soft lines for diesel compatible ones. I haven't looked much into this yet, I suspect I'll be tackling it once I get to it. There are a few hurdles to clear first.
Yes, I'm insane. But I'm excited about the van when it gets to the running stage. Updates to follow... Questions and thoughts are welcome.