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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old February 16th, 2016, 15:05   #61
Nozzleman
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Mods, please sticky this thread.
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2003 Jetta (wifes)

2002 Ford Ranger ALH swap in progress.

1978 Ford F250 4x4 Supercab 6bta, NV4500, Dana70/60.
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Old February 16th, 2016, 17:52   #62
dremd
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Quote:
Originally Posted by Nozzleman View Post
Mods, please sticky this thread.
Please
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2013 Nissan LEAF what are these emissions you speak of?
03 Silver Premium Jetta Wagon lots of OEM goodness. 1.8T Triptronic eliminated, ALH + 6 speed manual installed in place. Emissions? Yes, a lot
2006 Sprinter long range hauler, 300+ cubic feet loaded 25 mpg.
2014 JSW (Went back to VW) Emissions? Well, about that . . .
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Old May 20th, 2016, 07:08   #63
jettawreck
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I'm subscribing so I can find this info easier, as I'm sure I will need to reference it. I'm doing a swap from my rear ended 2003 manual Jetta TDI into a 2003 manual Jetta 1.8 chassis. Both are/were complete cars, other than the 1.8 engine was toast. Both were almost identical equipment/option wise.
I have been using some instructions given by a vortex/TDIClub member who had done a similar swap. He leaves the gas chassis harness intact and swaps the 2 engine/ECU harnesses and wires in a 109 panel. He references this thread and diagrams, but my GP relay is vastly different in pin locations and numbers so I'm wondered in what wire to splice into on that.
http://forums.tdiclub.com/private.ph...m&pmid=3196879
Comments?? Help?!
I'm otherwise ready to install the engine and send my TDI cluster and ECU off for immobilizer delete.
Hope I'm going down the right path...
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2001 Jetta TDI GLS Silver-current driver (salvage)permanently vented-Panzer Plate-Sprint 520s-ScanGauge-CheckTemp III-ZeroStart heater-CAT 2 filter
2003 Jetta GLS Black w/leather (New Project Car) fixer-upper w/broken TB
2004 Cadillac SLS (wife's)
1999 GMC Suburban (It's MN-you need one)
197? Shibura 2cyl diesel 4WD tractor-loader/brushhog (very handy unit)
196? International TD340 Dozer-w/Drott 4-in-1 bucket/back ripper attachment
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Old May 23rd, 2016, 03:06   #64
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Jettawreck and I have been conversing via e-mail about his TDI install in the 2003 Jetta which had the 1.8T gasser engine.

While discussing the OBD port set-up, a thought relating to the Cruise Control Operation come to mind.

Doesn't the Cluster Out-put VSS signal of the recipient vehicle need to be tapped (spliced) and sent to the TDI ECU?

ECU Pin 20 goes to T32/3, Blue side of the cluster. This is the Output Signal circuit from the Cluster to the ECU for the Speedometer data. I have to assume the data is only used for the Cruise function only as in some conversions this circuit has been omitted and the engine did just fine.


Note: the Vehicle Speed Sensor (VSS) has three wires (switched hot, ground, and out-put to the Cluster). And, there is a VSS signal sent to the ECU from the Cluster via T32/3 to ECU Pin 20, which, as stated above, is most likely used to operate the cruise function. Thus, in order to have the Cruise Function, you may need to find the same circuit for the 1.8T Cluster and splice into it for Input Data to the TDI ECU.

Or, what are you guys doing to make the Cruise functional? My conversion was in an 84 Vanagon that did not have cruise. But, since I set-up all those bells and whistles, I do have cruise.

Also, back to the OBD function. Did you guys set-up a separate OBD port to monitor the TDI engine? Obviously, the OBD use is a must, otherwise, setting the timing using VCDS would be impossible without it.
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'84 Vanagon '02 ALH TDI engine(32 to 35+ MPGs consistently) Malone Stage 1 tune. Road trip to Nova Scotia 2013. Road trip to Alaska summer 2014 & 2016, 11k & 12k miles. 80k miles on install, Jetta Cluster odometer currently at 209k miles.
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Old May 23rd, 2016, 07:31   #65
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I just sent a text to the vortex guy that I had been following the wiring swap instructions from which used the OPs of this thread info, and he says his OBD port functioned normally after the swap.
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2001 Jetta TDI GLS Silver-current driver (salvage)permanently vented-Panzer Plate-Sprint 520s-ScanGauge-CheckTemp III-ZeroStart heater-CAT 2 filter
2003 Jetta GLS Black w/leather (New Project Car) fixer-upper w/broken TB
2004 Cadillac SLS (wife's)
1999 GMC Suburban (It's MN-you need one)
197? Shibura 2cyl diesel 4WD tractor-loader/brushhog (very handy unit)
196? International TD340 Dozer-w/Drott 4-in-1 bucket/back ripper attachment
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Old December 20th, 2016, 16:05   #66
Fix_Until_Broke
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I'm looking for the specific function of the wires in the MAP/IAT sensor if anyone knows what they are.

I know there is:
+5v power
Ground
0.5-4.5v pressure signal
RTD for temperature signal

I'm guessing that Pin 2 is the temp signal, Pin 1 is either common +5v power or common ground for the two sensors and Pins 3 & 4 are pressure signal and either common +5v power or common ground depending on what Pin 1 is.

Has anyone mapped this out to this level of detail so I can fill in the below?

Frustrating that they don't provide this level of detail in the wiring diagrams.

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03 Jetta, Cat 2u, DG Steel SP w/MOGolf Mod, 3"DP, 4"EXH, EaBP100 Bypass, Euroswitch, ECodes, Driving Light, PD Lift Pump, R520's, RC5,RC6, TDTuning, Malone, ScanGaugeII, 3" TIP, 2" TOP, HE221W Compounded with GTC1444VZ, 6 Bar MAP, VR6 MAF, Vented Fender Liner, Battery Cover Mod, 11mm, Monster Mats, 215/55/17 (27.9/53.0/75) Monthly MPG Links, Euro Trunk Latch, IDParts RSB, SDI or ALH Intake, ARL Ceramic Pistons, Rosten Rods, DRW, Wavetrac, SBC, FSD's, Beef Springs, Rebuilt Head, Recaro's, Colt II, DG Sigma 6, RMT200
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Old January 14th, 2017, 16:51   #67
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I pinned this out today...

Pin 1 = Ground
Pin 2 = Temperature - voltage goes up as temperatures go down - Has 5v pull up
Pin 3 = 5vdc Supply
Pin 4 = Pressure - voltage goes up as pressure goes up - Has ~55k ohm pull down resistor
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03 Jetta, Cat 2u, DG Steel SP w/MOGolf Mod, 3"DP, 4"EXH, EaBP100 Bypass, Euroswitch, ECodes, Driving Light, PD Lift Pump, R520's, RC5,RC6, TDTuning, Malone, ScanGaugeII, 3" TIP, 2" TOP, HE221W Compounded with GTC1444VZ, 6 Bar MAP, VR6 MAF, Vented Fender Liner, Battery Cover Mod, 11mm, Monster Mats, 215/55/17 (27.9/53.0/75) Monthly MPG Links, Euro Trunk Latch, IDParts RSB, SDI or ALH Intake, ARL Ceramic Pistons, Rosten Rods, DRW, Wavetrac, SBC, FSD's, Beef Springs, Rebuilt Head, Recaro's, Colt II, DG Sigma 6, RMT200

Last edited by Fix_Until_Broke; January 15th, 2017 at 18:45. Reason: Added more info
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Old March 30th, 2017, 14:16   #68
EvilLawnGnome
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I'm working on an ALH swap into an Early Westy Rabbit. I'm keeping the early cluster, as it looks fantastic. I'm curious if there is a good way to trigger the glow plug relay light and the CEL using anything that's on the ALH engine harness. Thoughts?
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Old April 10th, 2017, 20:05   #69
tgray
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Default Using proper ground wire connection point in your wires

I have not seen any mention of this in the write ups and the understanding is not always obvious so I am going to try to explain why the VW original plan should be followed if possible. This is important when you are doing a conversion because it is tempting to find a ground wire and splice it into another ground wire without understanding why there are so many running all over the place.
Back in the old days before computers all you needed to do was bolt down a ground wire to the frame and splice in where every you wanted with no problems. Now, with computers it is a different world. Wires have resistance and so do grounding points. Resistance in long runs adds up and to make the problem worse, the sensors often are read on voltage drops or resistance. So just that in itself will cause problems if they are not hooked up right. The other part of the problem is what is called a ground loop. A ground loop is where there is a potential difference between one ground point and another. The path of the current will start going places you don't want or even will know if things are not on the common plane of reference. Wires switched on and off will create pulses that induce stray voltages back into other wires that affect the computer system. When you see the twisted pair wires (this is to help stop induced voltages from the pulses), these are for the CAN Buss system that send digital messages and a stray pulse or 2 will really mess your ECU communications up. This is not good because how do you troubleshoot something like that?
I have pulled apart the MK4 wire harness and see many small ground wires lugged together into one big ground wire before it goes to the grounded lug. The purpose of VW designers is to bring the grounds together to one common point to keep resistance as equal as possible to one common plane between the critical components. Things like lights and horns can be just bolted down where it is works the best.
Can you ground a wire anywhere in your conversion and find the car will start and run. Probably so, but keep in mind that VW didn't just pull wires all over the car and bundle them together when they could have easily found a closer ground point for less expense and hassle.
If grounding is confusing try to think in terms of landing a common point with other wires rather than going where it is quick and easy. If you do need to splice a wire in without being sure, it is always better to splice a little wire into a big wire that goes to the ground. At least the resistance will not go up so much. I haven't verified it but I think VW uses tracers on some of the more critical grounds that should be lugged together at a common point.
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Old April 21st, 2017, 15:41   #70
jhax
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http://pics.tdiclub.com/data/517/Golf_4.pdf I found a pinout for sensors on the intewebs and uploaded the PDF on the site. Makes it a little easier to visualize.

Cheers,
Justin
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Old August 7th, 2017, 16:59   #71
zspace
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can anybody send me the pictures from the first page i am in the midle of a swap thank you
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Old August 12th, 2017, 07:40   #72
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i have found the picture dont know how to post them anybody needs them send me a pm with your email adress i will send them to you
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Old September 18th, 2017, 14:48   #73
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I need them. I pm u my email. If anybody else has them and can repost them please do
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