The swap still isn't 100% complete, but here's a few more pics and steps leading closer to where I am now.
I have a wiring issue that I think is common to a couple fault codes I'm throwing - I attached the VCDS fault log in case anyone has some advice! As well, my injection timing is still off, I'm going to replace these stanadyne injectors that are commonly problematic around 100k km, but I also think the injection timing is being affected by the engine coolant temp fault. You'll also notice the brake switch and ABS control module coding faults - still haven't resolved those either, I'll update on this as I get it resolved.
Friday,28,December,2018,10:01:07:30156
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 18.9.0.2 (x64) HEX-V2 CB: 0.4436.4
Data version: 20180927 DS296.0
www.Ross-Tech.com
VIN: WV2MB47001H118692 License Plate:
Mileage: 154040km-95716mi Repair Order:
Chassis Type: 70 (7D - VW Transporter/Multivan (1996 > 2004))
Scan: 01 02 03 08 15 17 18 19 22 25 35 37 56
VIN: WV2MB47001H118692 Mileage: 154040km-95716miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: Redir Fail!
Part No: 074 906 018 B
Component: 2,5l R5 EDC 0000SG 2519
Coding: 00002
Shop #: WSC 25900
VCID: 15773D8EBC96CA6F5D3-4B7A
3 Faults Found:
18062 - Please check DTC Memory of Instrument Cluster
P1654 - 35-10 - - Intermittent
17664 - Engine Coolant Temp Sensor (G62)
P1256 - 35-10 - Open or Short to Plus - Intermittent
16955 - Brake Switch (F)
P0571 - 35-00 - Implausible Signal
Readiness: N/A
-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 7D0-907-379.lbl
Part No: 7D0 907 379 D
Component: ESP 5.3 T4 FRONT V26
Coding: 06912
Shop #: WSC 25428
VCID: 323DE6122D383D57581-5160
4 Faults Found:
00526 - Brake Light Switch (F)
36-00 - Open Circuit
01203 - Electrical Connection between ABS and Instrument Cluster
31-00 - Open or Short to Ground
18256 - Please check DTC Memory of Engine Controller
P1848 - 35-00 -
01044 - Control Module Incorrectly Coded
35-00 - -
-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: None
Part No: 7D0 907 040
Component: CLIMATRONIC 0003
Coding: 00032
Shop #: WSC 02743
VCID: 5F9B5FA60E2AC03FC7F-25A6
2 Faults Found:
00799 - Coolant Temperature Sensor (G110)
30-00 - Open or Short to Plus
00792 - A/C Pressure Switch (F129)
35-00 - -
-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1J0-909-60x-VW3.lbl
Part No: 1J0 909 603 BM
Component: AIRBAG VW3 - V04
Coding: 16973
Shop #: WSC 02743
VCID: 75B71D0E9CD66A6FBD3-4B5C
No fault code found.
-------------------------------------------------------------------------------
Address 17: Instruments Labels: 7D0-920-xxx-17.lbl
Part No: 7D0 920 803 B
Component: T4-KOMBIINSTR. VDO V25
Coding: 01151
Shop #: WSC 00186
VCID: 2313135662C2A4DFA37-513C
2 Faults Found:
01039 - Coolant Temperature Sensor (G2)
30-10 - Open or Short to Plus - Intermittent
00562 - Sensor for Oil Level/Temperature (G266)
30-00 - Open or Short to Plus
-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00000
Shop #: WSC 00000
VCID: 70B92C1AE3B44F476E5-513C
1 Fault Found:
01044 - Control Module Incorrectly Coded
35-00 - -
-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 6X0-953-257.lbl
Part No: 6X0 953 257
Component: IMMO 0008
Coding: 00001
Shop #: WSC 40301
VCID: 7DA7052EA4E6322FF53-4B3C
WV2MB47001H118692 VWZ1Z0A1207766
No fault code found.
-------------------------------------------------------------------------------
Address 35: Centr. Locks Labels: 7D0-959-800.lbl
Part No: 7D0 959 800 C
Component: Funksteuergerát 0001
Coding: 00001
Shop #: WSC 02743
VCID: 2D07F56E340662AF053-4B1E
No fault code found.
End----(Elapsed Time: 02:32, VBatt start/end: 12.2V/12.2V. VIgn 0.0V)------
Before I moved the motor in, I did a refresh on the linkage - the balls were dry rotted and cracked, and I figured I'd never have better access than right now -
https://drive.google.com/open?id=1dfxSgtIXEX5K-4TfzNnZ28bWIMePXg5S
Motor bolted right up, no need for motor mount mods like some other swaps require - just the two mounts up front on driver/psgr side, and the pendulum mount towards the rear.
https://drive.google.com/open?id=1GEkUVGcbWS3-ZqSlgiduX7mj7LeVYHy0
There were a few modifications I had to make in regards to the intercooler - firstly I ended up with an intercooler that is wired for the 2 pin sensor + air temp sensor vs the 4 pin sensor seen in the later model T4s. My motor and ecu is wired for the 4 pin sensor, so I ended up placing the sensor inline in the intercooler hose -
https://drive.google.com/open?id=1SS-U9arXo2CHTmfgRjk8eVImizvoTl9z
2 pin sensor still in place with the temp sensor port plugged (since this function is integrated in to the 4 pin sensor) -
https://drive.google.com/open?id=1ABc9LgkTt3Nz9Gu7y6pY5Pkt15l3S-Af
Also, the T4 TDi is equipped with a coolant reservoir/N75 bracked integrated in to the firewall - I ended up mounting the reservoir to my rad (like all the VR6 EVs are set up), and mounted the N75 to the underside of the intercooler bracket. I may try welding that bracket in to the firewall eventually, since the coolant hoses don't quite have the factory look...
https://drive.google.com/open?id=1Ez6shGGIkrbR4sFBwE-WWYeItcchqkqi
T4 bracket -
https://drive.google.com/open?id=1lJTAbHjz5NnjpQkJ6hGR92cDxor-ftfQ
New home for the N75 on the Eurovan -
https://drive.google.com/open?id=1CfK64ZazKK1v-3Lnw5InrRSO-pVk0kX-
On an earlier post I mentioned the rad/coolant line compatibility issue - because of the short nose/long nose mismatch between donor and recipient, the secondary water pump doesn't quite sit in a "factory position" - sourcing some long nose coolant hoses would remedy the situation, since these short nose hoses don't quite reach the rear of the bumper frame assembly -
https://drive.google.com/open?id=1JhDOpaYwh36xksLDnFsxjGp_T81KQXkc
https://drive.google.com/open?id=1A-2A9_VMQ7PGW6P2Vqa0fZtGFU4myNbN
About a 1000 miles in to the swap so far, and no issues with coolant leaks arising from running setup, though.
There's only a handful of wiring connections to make on the motor itself, most of the work with wiring came in routing it through the firewall, and finding homes for everything around the fuse panel (the connections TO the fuse panel itself were fairly intuitive). I will address the wiring mistakes I made perhaps in a later post.
After a couple runs around the block with the motor, I was having a no start issue -
https://drive.google.com/open?id=1bc_UaeNsRlA_01yeu7_IbsJX_v_nc94c
So I found that ALL of the bolts mounting the starter to the trans had backed out slightly, which ended up causing one of the flanges on the starter itself to crack, so off to the interwebs I went to buy a new starter. Luckily no damage to the flywheel, and upon installation she started right up.
This just speaks to the importance again of double and triple checking all your bolts!!! I loctited and torqued to spec every bolt I removed, and despite that, these still loosened only after a few miles of driving.