ALH ECU swap - MSA15 to EDC15

Well I got the ECU in and it won't start. I have a few codes. Maybe someone can help?

I am missing some wires regarding pedal sensor and MAF but I want to see if I can at least get it to start. I don't know if I fried this ECU on the bench a while back by plugging in the wrong plug

I was able to read out the ECU with my flashing tool at least though

Pics:



Thanks guys

Well the plug wasn't in all the way. I fixed it and now I have less codes:

Saturday,07,January,2012,16:56:54:46862
VCDS Version: Release 11.0.0

Address 01: Engine Labels: 038-906-012-AGR.lbl
Control Module Part Number: 038 906 012 BD
Component and/or Version: 1,9l R4 EDC G100AG 2507
Software Coding: 00001
Work Shop Code: WSC 06103

5 Faults Found

16764 - Glow Plug/Heater (Q6) Circuit: Malfunction
P0380 - 35-10 - - - Intermittent
17655 - Needle Lift Sensor (G80): Open or Short to Plus
P1247 - 35-00 - -
17762 - Modulating Piston Movement Sensor (G149): Electrical Malfunction
P1354 - 35-00 - -
18047 - Accelerator Position Sensor 1/2 (G79/G185): Implausible Signal
P1639 - 35-00 - -
17971 - Quantity Adjuster (N146): Lower Limit Reached
P1563 - 35-00 - -

Readiness: 1 5 0 0 1

Looks like a few things are not wired correctly. I would double check the wiring.

Really want to do this swap with my 99.5 if its not too bad.

Are you using a 919 or 920(can) cluster?

there is a difference in how the 'earth' or 'common' wires are attached...
the MSA has some of them all attached together...
the EDC doesn't accept that...
I had to run several of the common wires from the sensors directly to the EDC
because these wires are connected somewhere in the harness of the car....

JW

turbocharged798 said:

Looks like a few things are not wired correctly. I would double check the wiring.

Really want to do this swap with my 99.5 if its not too bad.

Are you using a 919 or 920(can) cluster?

Click to expand...

Making that adapter will be your worst nightmare. I had help making it.
I'm using the stock cluster for now. I will eventually get a MFA sport cluster.

struikie said:

there is a difference in how the 'earth' or 'common' wires are attached...
the MSA has some of them all attached together...
the EDC doesn't accept that...
I had to run several of the common wires from the sensors directly to the EDC
because these wires are connected somewhere in the harness of the car....

JW

Click to expand...

Crap. I did not want to hear that. Which ones did you have to do that?

I really don't think the ECU is fried... Does anyone know what pins go to the N146, G149 and G80? I think that's why the car is not starting. When I get back to the shop I'll check for RPM's with VCDS.

struikie said:

there is a difference in how the 'earth' or 'common' wires are attached...
the MSA has some of them all attached together...
the EDC doesn't accept that...
I had to run several of the common wires from the sensors directly to the EDC
because these wires are connected somewhere in the harness of the car....

JW

Click to expand...

That makes no sense. It does not matter how "earths"(or grounds we call it in the US) go together as they all go to the same place anyway.

DJ: I am not worries about the adapter(I can spend plenty of time with that on the bench), what I am worried about is compatibility issues with some of the components and wiring.

turbocharged798 said:

That makes no sense. It does not matter how "earths"(or grounds we call it in the US) go together as they all go to the same place anyway.

DJ: I am not worries about the adapter(I can spend plenty of time with that on the bench), what I am worried about is compatibility issues with some of the components and wiring.

Click to expand...

It does matter if the ecu needs to have the circuits connected to grounds through pins of the ecu which are not connected at all at the moment.

I see now, it needs to ground THROUGH the ECU. Gotcha.

That's what is keeping me from trying to swap, I do not start rewiring my car.

Mannnnn I just want to fix this as soon as possible. Does anyone know which wires to the N146, G149 and G80? I think that's all I need to get this car started at least.

The fastener that goes on the small plug DID break, so I took it off. I think I'm just not getting a good connection. I double checked the excel spreadsheet I found against the Bentley book and everything looks correct. I'll give it a shot again on Monday. I am NOT giving up.

Well it runs!
I had some green pins on the adapter harness so I cleaned them up and it fired up!
It idles rough though. I still need to add wires for the gas pedal and MAF but does anyone know what pins go to the MAP sensor?
Which of these fault codes would make the car idle rough?

Here is the codes so far:

Tuesday,10,January,2012,14:49:57:46862
VCDS Version: Release 10.6.0

Address 01: Engine Labels: 038-906-012-AGR.lbl
Control Module Part Number: 038 906 012 BD
Component and/or Version: 1,9l R4 EDC G100AG 2507
Software Coding: 00001
Work Shop Code: WSC 06103

5 Faults Found

18047 - Accelerator Position Sensor 1/2 (G79/G185): Implausible Signal
P1639 - 35-10 - - - Intermittent
18000 - Altitude Sensor / Boost Pressure Sensor: Implausible Correlation
P1592 - 35-00 - -
16764 - Glow Plug/Heater (Q6) Circuit: Malfunction
P0380 - 35-10 - - - Intermittent
17569 - Manifold Temp Sensor (G72): Open or Short to Plus
P1161 - 35-00 - -
18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
P1650 - 35-10 - - - Intermittent

Readiness: 1 5 0 0 1

Click to expand...

Have you wired in a new map sensor?

m1ketdi said:

Have you wired in a new map sensor?

Click to expand...

I need a new MAP sensor?

Hmm maybe linearisation of the old maf is differnt to what is in your new ecu....

MAF sensor isn't wired in yet. At least the one that I have to add in below:

Can anyone tell me where these wires go (highlighted):


Also where is the intake temperature sensor?

By tomorrow, my car will RUN! No and's, if's or but's.

IAT sensor is located on the MAP sensor. Its a combo unit that has both sensors in one.

turbocharged798 said:

IAT sensor is located on the MAP sensor. Its a combo unit that has both sensors in one.

Click to expand...

Awesome. That makes sense. Thanks

I'm fixing the IAT and the Pedal sensor tomorrow. That should be enough to get it to work

Well I got the gas pedal working but it still idles rough as heck.

I'm still missing some wires but I only get these codes:

Wednesday,11,January,2012,19:33:59:46862
VCDS Version: Release 10.6.0

Address 01: Engine Labels: 038-906-012-AGR.lbl
Control Module Part Number: 038 906 012 BD
Component and/or Version: 1,9l R4 EDC G100SG 2507
Software Coding: 00002
Work Shop Code: WSC 06103

4 Faults Found

16764 - Glow Plug/Heater (Q6) Circuit: Malfunction
P0380 - 35-10 - - - Intermittent
18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
P1650 - 35-10 - - - Intermittent
17553 - Mass Air Flow Sensor (G70): Short to Plus
P1145 - 35-00 - -
18044 - Powertrain Data Bus: Missing Message from Airbag Controller
P1636 - 35-10 - - - Intermittent

Readiness: 1 3 0 1 0

Click to expand...

Any help?

Sort the maf problem, or change to map based smoke limiter...

I just flashed a tuned file. With the MAF unplugged I shouldn't have a smoke limiter.

It just idles erratically and I can't get it to rev past 4000 RPM's. Oh, and I started it a few times inside the garage and got covered in soot

Here is a video of my issue:
http://www.youtube.com/watch?v=nSRyhNn0Iuk

I don't wanna keep running it like this. Any ideas?

Wonder how hard it would be just to swap the engine harness with a immo2 harness? A few connectors will be different, but that's easy to fix with a good terminal extraction tool.

This is still easier... Adding 4-5 wires vs swapping the entire harness...

New scan. MAF is unplugged.

Thursday,12,January,2012,15:20:10:46862
VCDS Version: Release 10.6.0

Address 01: Engine Labels: 038-906-012-AGR.lbl
Control Module Part Number: 038 906 012 BD
Component and/or Version: 1,9l R4 EDC G500SG 2507
Software Coding: 00002
Work Shop Code: WSC 06103

3 Faults Found

18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
P1650 - 35-10 - - - Intermittent
17552 - Mass Air Flow Sensor (G70): Open or Short to Ground
P1144 - 35-00 - -
18044 - Powertrain Data Bus: Missing Message from Airbag Controller
P1636 - 35-00 - -

Readiness: 1 1 0 1 1

Click to expand...

Have a look at the timing in vcds maybe?

m1ketdi said:

Have a look at the timing in vcds maybe?

Click to expand...

No. Let me know what block I should be looking at and I'll take some logs if needed.

did you also look at the file about pins that I uploaded ?
it has some info on the wires that I ran directly to some components....

JW

struikie said:

did you also look at the file about pins that I uploaded ?
it has some info on the wires that I ran directly to some components....

JW

Click to expand...

I didn't see it. Can you please link me?

DJGonzo said:

No. Let me know what block I should be looking at and I'll take some logs if needed.

Click to expand...

If you have full vcds then go to measuring blocks, group 0 then click basic settings. Then click tdi-timing. If not then I'm not sure on the numbers.

DJGonzo said:

I didn't see it. Can you please link me?

Click to expand...

http://forums.tdiclub.com/showpost.php?p=3491009&postcount=48

JW