I'm checking out allroad tomorrow, i did manual 5 speed swaps on passats, should be about same on allroad, except i would not mind keeping it fwd, since its a nicer wagon then passat
Van Lee Johnson I've been driving the car for two years and 40,000kms since doing this engine swap. It has been running great. Unfortunately, I've been too busy with a major garage project to be able to do much of anything else. I'll get back to making videos soon, I hope.
I'm in London. Yes, I did the swap myself. Only parts I imported were a flywheel and clutch kit. Truth be told, I tried three different flywheels before I went with what I should have installed to begin with, a Dual-Mass Flywheel.
@@biturboaudis4 London is too far for me, but I'd love to see one of these in person. I want to do this swap, but I am just looking for an allroad right now. Ideally I want a manual with the proper gear ratios.
Great diesel conversion! Do think you would prefer a dual mass flywheel with the vibration you mentioned? Please do a final walk around video when you have it all back together. Side note, I have a 2004 A4 Avant 3.0 (less the 3.0), would this conversion be possible from the Passat TDI? Sorry, not a guru on VW/Audi chassis!
Yes, a dual mass flywheel would get rid of a lot of the vibration. Also, these particular engines (code BHW) had a balance shaft that was prone to failure at very low mileage. The combination of the two would make it much smoother at lower revs. That said, I can live with it in exchange for longevity. Your 2004 Audi A4 would be a perfect candidate for a swap like this, or a 2.7T. As a matter of fact, the flywheel and clutch kit I used in this project is made for 1.8T B6 Audi A4s.
Yah, considered a 2.7T or 4.2 swap (I'm an old guy so there's nothin like a V8!) but then you had to do your TDI swap! I had a 03 Jetta TDI back in the day and just finished my Stark Auto purchased (clean ownership) 08 Jeep CRD that I really enjoy but it's not an Audi. Anyways, just an idea, I watch all your videos and enjoy them (I'm an anal retentive car geek), would really like it if you could do a video some time (or videos) reviewing your Audi collection. Would like to see you review your B5 Avant RS4 and you never really did a review on your completed RS4 2.7T swap. I know they are time consuming but us Audi enthusiasts would appreciate it. Thanks
@@knicksallday6442 I had a spare 4.11 diff from the B7 RS4 2.7T swap (installed a LSD in that car), so I used that. Basically, the B6, B7 and C5 differentials will fit. As for the transmission, I believe I paid about 400€ on ebay.de. It came out of a Passat 4motion, code FTF.
i think that you have a problem there with engine mounts or the front snub. It should be almost the same with and without dual mass flywheel- except louder idling. Ive done a couple tdi swaps and almost every time i had to readjust, retighten the 2 motormounts. They are very sensitive for incorrect treating :) Transmission mount could also be the reason. Good luck
Thank you. I made sure that all mounts were slightly loose and only tightened them after the engine was started and shut off again. This way everything had a chance to settle. I'll have another look to be sure.
I just got my 2001 allroad TDI (bhw) on the road, but have a few items to iron out and wondering if you can shed some light on. 1) I have recoded the ABS module to 06355 (it was 06395), however, it still thinks it is an automatic as I am getting a powertrain error. It is giving the three warning lights of suspension, abs and esp. My car was originally an auto that I did a six speed swap and I wasn't having that issue prior to the TDI swap. Did you have this issue and if so how did you go about coding the ABS? 2) I went to fill up and the diesel pump nozzle won't fit LOL. Did you do anything to your car to enable the pump nozzle to fil the fill hole? 3) On the 2.7T there was a third hose with the fuel lines, did you do anything with that? Thanks in advance.
Hi, the coding change for the ABS to work needs to happen within the engine ECU. I have a couple of files with the changes, if you'd like to see them. For the fuel filler neck, yes, there is a black plastic insert clipped into the filler neck that you must remove in order for the diesel nozzle to fit. You'll see two little tabs on this insert. After you remove the insert, you need to drill out the white plastic piece, which is what would normally stop the black insert from falling into the tank. I inserted some cloths into the fuel filter neck and then drilled it (7/8" diameter if I remember correctly), and then vacuumed out the little bits of plastic. Took maybe a few minutes to do. You can leave the little metal flap in place. It is larger than the new hole and will work the same as it did previously. As for the third line, that's the EVAP purge line. I completely removed my EVAP system and charcoal canister, as those items are not used with the TDI engine.
@@biturboaudis4 Nice! I have a M6 tap. For the main hole did you use a hole saw? Will doing this with the engine in the car be a pain? One last question, can I send you an email for the ECU files? Malone did my tune and immoblizer work.
The coating on the bumpers is nothing special. It's just matte paint. I sanded them like would normally be done for painting. It's almost 2 years later and they still look good.
@@biturboaudis4 Thank you! I'm in Ottawa and this car gonna be my sailboat towing car with 2.7t engine. When you tow something do you turn your air suspension in specific setting?
@@st.k.4528 I usually keep the car at level 2 while towing, but only because the rear of the car is low, and I only have one receiver adapter for pulling trailers.
IPP I have one question. Does your AUDI has automatic or manual gear box? When I was watching and hearing I really did not understood which gear box has your car. Hi from Georgia(საქართველო)
@@biturboaudis4 newer years of this engine. Its PD is it? It looks like a AVF/AWX. Probably a US only version as 2.0tdi in Europe were only introduced witch CR in the B6 passats and B7/C7 Audis.
@@oofol Correct, this PD engine was offered in the B5 Passat, 2004 and 2005, North America only, and only with an automatic transmission. It's an 8 valve engine.
@@biturboaudis4 Ya I can see its 8v and it is a drilled out AVF most likely :) I wasnt aware of this engine as I live in Europe :) I would put in a X muffler to get a bit smoother ride thou
I want to build one of these!
I want a TDI allroad SOOOO Bad!!!!
Bud!!! This is your project !! Allroad is only one ☝️!!!
I'm checking out allroad tomorrow, i did manual 5 speed swaps on passats, should be about same on allroad, except i would not mind keeping it fwd, since its a nicer wagon then passat
Bro can you show us an update on this All Road? I’m about to purchase one and would love to see you the end result on yours?
Van Lee Johnson I've been driving the car for two years and 40,000kms since doing this engine swap. It has been running great. Unfortunately, I've been too busy with a major garage project to be able to do much of anything else. I'll get back to making videos soon, I hope.
Koje je zapremine to jest koja je kubikaza motora u ovom audiu?? Pozzz
Where in Ontario are you located? Did you do the whole conversion yourself? How many parts did you have to import?
I'm in London. Yes, I did the swap myself. Only parts I imported were a flywheel and clutch kit. Truth be told, I tried three different flywheels before I went with what I should have installed to begin with, a Dual-Mass Flywheel.
@@biturboaudis4 London is too far for me, but I'd love to see one of these in person. I want to do this swap, but I am just looking for an allroad right now. Ideally I want a manual with the proper gear ratios.
Great diesel conversion! Do think you would prefer a dual mass flywheel with the vibration you mentioned? Please do a final walk around video when you have it all back together. Side note, I have a 2004 A4 Avant 3.0 (less the 3.0), would this conversion be possible from the Passat TDI? Sorry, not a guru on VW/Audi chassis!
Yes, a dual mass flywheel would get rid of a lot of the vibration. Also, these particular engines (code BHW) had a balance shaft that was prone to failure at very low mileage. The combination of the two would make it much smoother at lower revs. That said, I can live with it in exchange for longevity. Your 2004 Audi A4 would be a perfect candidate for a swap like this, or a 2.7T. As a matter of fact, the flywheel and clutch kit I used in this project is made for 1.8T B6 Audi A4s.
Yah, considered a 2.7T or 4.2 swap (I'm an old guy so there's nothin like a V8!) but then you had to do your TDI swap! I had a 03 Jetta TDI back in the day and just finished my Stark Auto purchased (clean ownership) 08 Jeep CRD that I really enjoy but it's not an Audi. Anyways, just an idea, I watch all your videos and enjoy them (I'm an anal retentive car geek), would really like it if you could do a video some time (or videos) reviewing your Audi collection. Would like to see you review your B5 Avant RS4 and you never really did a review on your completed RS4 2.7T swap. I know they are time consuming but us Audi enthusiasts would appreciate it. Thanks
Did you keep the AWD with the tdi swap??
Yes. Wouldn't have it any other way.
@@biturboaudis4I'm not sure if you mentioned it but which rear diff did you use also how much was that transmission from germany
@@knicksallday6442 I had a spare 4.11 diff from the B7 RS4 2.7T swap (installed a LSD in that car), so I used that. Basically, the B6, B7 and C5 differentials will fit. As for the transmission, I believe I paid about 400€ on ebay.de. It came out of a Passat 4motion, code FTF.
i think that you have a problem there with engine mounts or the front snub. It should be almost the same with and without dual mass flywheel- except louder idling. Ive done a couple tdi swaps and almost every time i had to readjust, retighten the 2 motormounts. They are very sensitive for incorrect treating :) Transmission mount could also be the reason. Good luck
Thank you. I made sure that all mounts were slightly loose and only tightened them after the engine was started and shut off again. This way everything had a chance to settle. I'll have another look to be sure.
I'm looking to get rid of my egr , same exact car same exact engine as you, im in toronto who can do the tune for the egr delete?
I just got my 2001 allroad TDI (bhw) on the road, but have a few items to iron out and wondering if you can shed some light on. 1) I have recoded the ABS module to 06355 (it was 06395), however, it still thinks it is an automatic as I am getting a powertrain error. It is giving the three warning lights of suspension, abs and esp. My car was originally an auto that I did a six speed swap and I wasn't having that issue prior to the TDI swap. Did you have this issue and if so how did you go about coding the ABS? 2) I went to fill up and the diesel pump nozzle won't fit LOL. Did you do anything to your car to enable the pump nozzle to fil the fill hole? 3) On the 2.7T there was a third hose with the fuel lines, did you do anything with that? Thanks in advance.
Hi, the coding change for the ABS to work needs to happen within the engine ECU. I have a couple of files with the changes, if you'd like to see them. For the fuel filler neck, yes, there is a black plastic insert clipped into the filler neck that you must remove in order for the diesel nozzle to fit. You'll see two little tabs on this insert. After you remove the insert, you need to drill out the white plastic piece, which is what would normally stop the black insert from falling into the tank. I inserted some cloths into the fuel filter neck and then drilled it (7/8" diameter if I remember correctly), and then vacuumed out the little bits of plastic. Took maybe a few minutes to do. You can leave the little metal flap in place. It is larger than the new hole and will work the same as it did previously. As for the third line, that's the EVAP purge line. I completely removed my EVAP system and charcoal canister, as those items are not used with the TDI engine.
@@biturboaudis4 In regard to the ECU files, yes that would be helpful. Thanks for the input on both the fuel filler neck and the EVAP.
@@biturboaudis4 Did you add an oil level/temp sender to the bottom of the pan?
@@jaygardner3666 I did. The pan is cast with it, so I drilled it out and tapped the holes to M6.
@@biturboaudis4 Nice! I have a M6 tap. For the main hole did you use a hole saw? Will doing this with the engine in the car be a pain? One last question, can I send you an email for the ECU files? Malone did my tune and immoblizer work.
Did you send bumpers before painting? How you removed that rubber coat from them?
The coating on the bumpers is nothing special. It's just matte paint. I sanded them like would normally be done for painting. It's almost 2 years later and they still look good.
@@biturboaudis4 Thank you! I'm in Ottawa and this car gonna be my sailboat towing car with 2.7t engine. When you tow something do you turn your air suspension in specific setting?
@@st.k.4528 I usually keep the car at level 2 while towing, but only because the rear of the car is low, and I only have one receiver adapter for pulling trailers.
IPP I have one question. Does your AUDI has automatic or manual gear box? When I was watching and hearing I really did not understood which gear box has your car. Hi from Georgia(საქართველო)
Hi. Manual gearbox.
@@biturboaudis4 OK
მადლობა
All wheel drive still work?
Yes, no changes to the quattro system apart from an updated gearbox with gear ratios more suited to the TDI engine.
Which engine code
One thing - this is a 1.9tdi not a 2.0 ;)
It is indeed a 2.0TDI. 2005 VW Passat, BHW engine code, North America only.
@@biturboaudis4 newer years of this engine. Its PD is it? It looks like a AVF/AWX. Probably a US only version as 2.0tdi in Europe were only introduced witch CR in the B6 passats and B7/C7 Audis.
@@oofol Correct, this PD engine was offered in the B5 Passat, 2004 and 2005, North America only, and only with an automatic transmission. It's an 8 valve engine.
@@biturboaudis4 Ya I can see its 8v and it is a drilled out AVF most likely :) I wasnt aware of this engine as I live in Europe :) I would put in a X muffler to get a bit smoother ride thou