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Go Back   TDIClub Forums > VW TDI Discussion Areas > Upgrades (non TDI Engine related)

Upgrades (non TDI Engine related) The place of handling, lighting and other upgrades that do not relate to the performance or economy of the TDI engine. In other words upgrades to your TDI that don't fit into TDI Fuel Economy & TDI Engine Enhancements.Please note the Performance Disclaimer

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Old October 27th, 2006, 13:52   #61
alphaseinor
 
Join Date: Jul 2006
Location: Denton, TX
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Get one from a TDI, the gear ratios are better suited for the TDI. If you get one from a gas engine, the RPMs will be much too high on the highway (like 3500 RPM) likely dropping your mileage to what the automatic had on the highway.
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Old October 27th, 2006, 14:09   #62
Water4fire
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TDI(s): 02 Jetta TDi
Fuel Economy: 38
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What about a Automatic from a gas?
Sorry to ask, but going to auction to get the parts car and only gas VW's are there.
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Old October 27th, 2006, 14:11   #63
alphaseinor
 
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The automatic will be the same problem, Mine had a gasser automatic, and it's top speed was about 90 MPH @ 4,600 RPM... at 75 MPH the tach was stuck about 3700RPM when it should be closer to 2500 RPM
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Old October 27th, 2006, 14:12   #64
alphaseinor
 
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You should look on car-part.com
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Old October 27th, 2006, 14:28   #65
GdB
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Default Final Wiring Diagram?

Quote:
Originally Posted by alphaseinor
You should be able to match up a connector for the transmission range switch so you can have an easier swap... I think the IP connector is similar, but I haven't tried it... Don't forget to unplug your TCM in the plenum
Why not just use the old TR connector (cut) from the auto harness?

Where did these schematics come from? It would be nice to know if they also apply to 2002 and 2003, so no surprises come up.

[IMG]file:///D:/Temp/moz-screenshot.jpg[/IMG]After reading, looking... I figured out what you mean and made some notes:

Before "Auto to Manual Swap":



Ignore this:



Remove and cut:



Finish:



Does that look right?
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2002 Golf TDI, ONCCV, cat2 filter, 14lb flywheel, 0.658, 5 speed swap HOWTO:
http://pics.tdiclub.com/data/500/GdB...D_VERSION2.doc

Last edited by GdB; December 11th, 2006 at 18:47.
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Old October 27th, 2006, 14:30   #66
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Default Clutch Switch

I forgot to mention the steps:

alphaseinor Wiring for auto to manual swap (know to be good for 99.5 Golf TDI)

1. Connect the 12v (green/black) from the TR switch to the reverse light switch (on tranny)

2. Connect the other wire on the reverse light switch to the blue/yellow wire on the TR Switch

3. Connect the two wires: red/yellow to grey/red


Correct me if I am wrong, but the only thing needed to get the clutch switch in here is to splice the clutch switch in series into the ignition switch wire.

I like having the clutch switch for safety.
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EV's: 2019 Hyundai Kona Electric 2012 Mitsubishi i-MiEV, 2016 e-Golf
2002 Golf TDI, ONCCV, cat2 filter, 14lb flywheel, 0.658, 5 speed swap HOWTO:
http://pics.tdiclub.com/data/500/GdB...D_VERSION2.doc
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Old October 27th, 2006, 14:36   #67
alphaseinor
 
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The clutch switch when it is "in" (no foot on pedal) is closed, when it is out it is open.

So you would need some sort of relay/transistor to flip the order of the pedal... I didn't use my clutch switch because of this limitation.

The TR connector connects directly to the TR switch, I was just thinking you could make a connector that extends the harness and leaves the other wires "floating".

No clue if this will work for a 2002 or 2003...
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Old October 27th, 2006, 14:38   #68
alphaseinor
 
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essentially you will need to connect red/yellow to grey/red to simulate neutral or park... unfortunately if you connect it to the clutch pedal streight out, you will have the starter work with your foot off the pedal, and if you put your foot down it won't.
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Old October 27th, 2006, 14:40   #69
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overall for my car that would be correct... Your mileage may vary, so bring a continuity checker...
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Old October 27th, 2006, 22:17   #70
GdB
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Default 2002 Golf TDI Auto Checks Out! Almost?

alphaseinor,

Did you ever do the VAG-COM adaptation?

I checked out my 2002 Golf TDI Auto for some things:

[yes] 3 studs for clutch pedal mount

[yes] master cylinder nipple ready to cut

[no] narrow brake pedal
My brake pedal has one more diamond in width (5 total), about 1/2" I guess. I don't think it will be a problem. The pedals appear seperated enough in your pic:
[IMG]file:///D:/Temp/msohtml1/01/clip_image001.gif[/IMG]
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2002 Golf TDI, ONCCV, cat2 filter, 14lb flywheel, 0.658, 5 speed swap HOWTO:
http://pics.tdiclub.com/data/500/GdB...D_VERSION2.doc
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Old November 6th, 2006, 13:49   #71
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The coding is here....

http://en.openobd.org/vw/golf_1j.htm

I didn't do this since I got mine chipped, and jeff already set it... but it should go something like this... engine, coding (not sure about login???), the it should be set to manual 04000,

If anyone has more to add, since I'm still working on my harness issues, please post if this is the correct procedure on recoding...
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Old November 6th, 2006, 14:08   #72
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Woops... wrong engine.... Mine's an ALH... I'll get this sorted out soon enough...
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Old November 6th, 2006, 15:44   #73
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Default harness issues?

I thought you were done. Are these "harness issues" related to the swap?
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EV's: 2019 Hyundai Kona Electric 2012 Mitsubishi i-MiEV, 2016 e-Golf
2002 Golf TDI, ONCCV, cat2 filter, 14lb flywheel, 0.658, 5 speed swap HOWTO:
http://pics.tdiclub.com/data/500/GdB...D_VERSION2.doc
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Old November 6th, 2006, 15:53   #74
alphaseinor
 
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nope, I was having problems with the harness that is on the little connector on the ECU that feeds the IP junk... there are some bad ground wires that are black from corrosion... so I just ordered a new one instead of rerunning all of those wires (there has to be about 20-30 wires there...

Outside of that... the swap went extremely well, and It's much more fun to drive

Last edited by alphaseinor; November 6th, 2006 at 15:55.
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Old November 7th, 2006, 02:08   #75
Fortuna Wolf
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Sounds good alphase,
When I get the money I'll consult thee.
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2002 Jetta Sedan ALH-01M: 2 um Cat FF, Wingnut-3 CCV filter, polyurethane fuel lines, 5 brake light mod, Ventectomy, Polysiloxane vacuum tubing, Pioneer DEH-3800MP w/ KFC-1389ie, Panzer Plate, EGT+Boost+Oil Temp Gauges, Boost Valve, KERMA Line Pressure Mod, LED Lighting, HC-12a refrigerant, Optima 75/35 AGM, .187 nozzles, Hawk HPS pads.
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