And it begins...TDI Passat 5 speed

[CrazyAndy]

Please post the reflash details on getting the ECM to 'forget' the TCM; see about it 'forgetting' the EGR as well!   And I've got access to ElsaWeb; just let me know if you need any wiring diagram info to take care of the cooling fan stuff.  Hope you kept the old manual box reverse lamp plug so you could spice it in.

Sounds like your project is near endgame; excellent job.  Good luck with all the miles you'll spend with it!

[QuickTD]

I will let you know about the reflash stuff. I'm in no great hurry to send away the ECM, I'll get all the other stuff cleaned up and make sure I have no other codes/issues before proceeding. Runs great now, just has an annoying light

 Thanks for the offer, but I'm hooked up pretty well as far as the drawings go. It also appears that the BHW fan harness is sort of a retrofit. The 3 speed/after-run setup was only used on the diesel and is more or less a plug-in affair. The ECM is really only looking for the after-run relay, the other 2 speeds are thermal switch controlled. I have the stuff so I figure it might as well work properly. I just need to pull the harness out of the junker and stick it into the new car. A fellow VW enthusiast has already snatched the 1.8T but it's not far away. He just wanted some internal bits, so I can still snag the reverse light switch connector from the harness.

Looks like I'm in the home stretch.
 

[andy2]

I'll mabye have to get a ride in this beast sometime to verify its quickness with the 5 spd 

[QuickTD]

 Andy, I'm not sure that you are capable of being a fair performance judge of any "stockish" VW... The land yacht does move out though. We'll see after the chip tune...

 The car is now mechanically and electrically done. No fault codes other than the auto trans coding related stuff. I've decided to go with TD tuning for the ECM reflash. Would have liked to have used Malone but he seems busy?... TD tuning got back to me right away and Mike has done other cars of the same configuration with great success. Nothing like a sure thing.

[andy2]

Yes, I attemted to contact malone with no luck.He is likely very very busy and might need to expand his services.  

I have driven/worked on a couple stock passat 2L tdi's

[MrDave]

Please post the reflash details on getting the ECM to 'forget' the TCM

I'm not sure about the B5, but on the A4/mk4, on the ALH anyway, it was a simple 'recode' on the ECU to switch programs between 5spd and auto.

00001 = auto
00002 = 5spd

I think 00003 was for AWD/Haldex.
Tuners can load 2 or 3 programs into the ECU that you can switch between via a simple click of the recode button in VCDS/VagCom.


Just a thought.

-Dave

[QuickTD]

Please post the reflash details on getting the ECM to 'forget' the TCM

I'm not sure about the B5, but on the A4/mk4, on the ALH anyway, it was a simple 'recode' on the ECU to switch programs between 5spd and auto.

00001 = auto
00002 = 5spd

That would be a happy thought... Unfortunately, the BHW engine was never sold in any other configuration anywhere in the world. VW only saw fit to load one program into the ECM from the factory.   

[MrDave]

Sorry to hear it's not an easy fix.

I suppose a tuner like Malone can deal with it for you, once they figure it out.

In the mean time, what sort of alarms and bells do you get when you leave the TCM installed without the auto-trans installed?

You should probably turn the auto-trans off in the can-gateway, if you haven't already. That might clear things up a bit.


-Dave 

[QuickTD]

I never transplanted the auto trans controller. Its wiring was completely independant of the rest of the engine wiring. I have already turned it off in the can gateway. The remaining codes are,

ECM -18034 missing message from TCU

ABS - 18055 check coding of ECU's on powertrain data bus

Cluster - 01315 missing message from TCU. It also has a code in it for missing multi function steering wheel controller

I'm not sure how to code the cluster for my setup I have it at 07335 from 15345 which matches the equipment currently installed. I see nothing in the coding info about manual/auto or the multi function steering wheel. The MFA and cruise both work fine with the stalk controls though. I have tried multiple codings, even just some random stuff, no dice. Maybe there is something in adaptation that is not documented or maybe I have to use VDS Pro and work at a lower level? It doesn't set any lights so I'm not that worried about it.

[QuickTD]

The car is now officially on the road. I have to drive it to Toronto to get the ECM reflashed, so I figured it might as well be legal. I put about 60 km on it this afternoon and it continues to impress me, loads of torque. 5th gear roll ons from 50km/hr are awesome, shoves you back in the seat. With the mazda 5th gear roll-ons just changed the sound of the exhaust...

[CdnVWJunkie]

The car is now officially on the road. I have to drive it to Toronto to get the ECM reflashed, so I figured it might as well be legal. I put about 60 km on it this afternoon and it continues to impress me, loads of torque. 5th gear roll ons from 50km/hr are awesome, shoves you back in the seat. With the mazda 5th gear roll-ons just changed the sound of the exhaust...

Great thread.  Nice progress too.  Curious what flywheel and clutch set up you ended up using.  I read solid FW but didn't notice other details.

[QuickTD]

As I was registering the car, I noticed the date I bought it, Sept 28. Not too bad for less than two months only working on it weekends and the odd evening. Had a few 1-2 week delays for parts in there as well. Helps a lot to have a complete wreck to pull all the parts from. I am pretty happy with the way this has turned out. So happy, in fact, that I may fix up another passat for the better half. Possibly a gasser, but if the right parts were to come along... I really like the way the B5 passat is put together. It seems like a very high quality car.

I am using a valeo 228mm single mass conversion kit for the 1.8T. I believe it is also possible to use 240mm V6 parts on the diesel, though I didn't know it at the time... So far the clutch shows no sign of slipping whatsoever. As I recall it is rated at ~300ft/lb, so it may start to give trouble with a hot tune. The car is plenty quick already and it's a daily driver so I'm only going with TDtuning stage 1. I don't forsee any problems.

[CdnVWJunkie]

Absolutely good turn around.  Interesting about the 1.8T clutch set up.  I have the DMF set up and mines apart.  Tempted to upgrade now while it's out and sitting on the shop floor.  Please post comments after you have it tuned.

[theman53]

Let us know if you find out the V6 clutch would work. Nice work.

[JFettig]

I am running a Southbend Stage 2 endurance on their billet flywheel for a 1.8T in my Passat. Trans chatters like crazy but it holds good. Engagement is pretty grabby but its not too bad.

I inquired about that Valeo setup, one of the places told me that VR6 pressure plates and clutches work on the flywheel, you might want to verify but it would be a good setup for more torque if you get an upgraded VR6 setup.