I recently purchased a 2007 VW Passat 2.0T Wagon ... with a blown 2.0T engine. The guy wanted $800 ... I offered $600 and he took it.
Apparently, when he purchased it, it had the dreaded HPFP problem ... cams were destroyed and the head was junk. He replaced all those parts ... but failed to check the engine oil pump. When he got it all together, the engine ran all of ... 1 minute! The NEW cams and head are now destroyed ... again!
Fast forward to today. After doing MUCH research on the 2.0T FSI engine, and all of it's problems ... I had SERIOUS doubts about even fixing it ... again. The LAST thing I wanted was a car that would require constant fixing! Then I began reading about VW's 2.5L 5-Cylinder engine ... VERY reliable (although a little less powerful).
Then I came across a local shop who buys wrecked late model VW's ... fixes them, and resells them. He just so happened to have a 2010 Jetta 2.5L 5-Cyl. engine with only 70 thousand miles ... for only $50! Why so cheap? Because he takes the intake manifolds, the vacuum pumps, and other accessories off and sells them ... at great profit. And he's left with these engines. Apparently, the intake manifolds and dip stick tubes are a hot commodity since that's one of the first things to get destroyed in a front-end collision. This particular car was read-ended ... so there was no damage to the engine.
So, I did some more research. Was it feasible? Would the 2.5L bolt to my transmission? Would it even fit in the engine bay? Turns out it's actually quite feasible. I told the guy that had the 2.5 what I was planing to do, and he also sold me the 2.5L engine wiring harness and ECU ... so, I got the engine, the ECU, and the wiring harness for $100! ... and NO High Pressure Fuel Pump to worry about!
I pulled the whole front end off the Passat (nice feature! ... the front bumper, radiator, front support, all come off with about 12 bolts!) ... I pulled the seized 2.0T out ... and began to measure.
The engine will bolt right up to the transmission ... the torque converters are the same (I'm still trying to determine if the 2.0T and 2.5 converters are the same internally) ... and the passenger's side motor mounting is the same, so the 2.5 mount will bolt right in place. The only modifications I'll have to make are the exhaust routing, and the radiator and heater hose routing.
The only other potential problem I foresee is ... the engine immobilizer. I called the local VW dealership and stated my plans ... a 2010 VW Jetta 2.5L engine into a 2007 VW Passat 2.0T Wagon ... could they program the 2010 Jetta ECU to work with the 2007 Passat key and ignition? They said they've never done it before, but they could try ... for about $60! Sounds good to me! The other possible solution, if the dealer can't program it ... is a place in Colorado called KermaTDI ... you send them your ECU, and they'll reprogram the ECU to delete the immobilizer feature ... for $155.
Anyone here ever tried this before? Any tips or potential problems that anyone might think of ... anything I might be missing ... let me know. I'll keep you posted with the progress.