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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 July 3rd, 2017, 11:52   #16
Strider17
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TDI(s): MK4 and MK5
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Update on the wiring: - *This is from a CBEA TDI Body Harness (2009)*

2.5L ECU Body harness plug was different when comparing it to the CR TDI ECU body plug.

What i had to do is cut out both plugs from their wiring looms and manually wire in the TDI ECU 94pin plug into the body harness of the 2.5L.

A lot of the wires were the same color code. Almost all the wires i was able to trace from one and to another end, whether they went to a plug or into the cabin of the car.

The wires that went into the cabin of the car were either going to the relays above the VCM...or they were going into the VCM. I was able to test continuity with my multimeter and see where the wires went from the ECU plug.

I also had to change the 14pin plug that sits under the battery tray. TDI 14 pin plug is all wired in....but i still have some wires left on the 2.5L 14pin plug that i need to know where they are going - wiring diagrams needed for this.

Glow plug relay is all wired in as well...except one wire.

I was able to delete the following from the TDI ECU since it has it tuned out:

Exhaust Flapper Motor - Pin 7, Pin 29 , Pin76
Differential Pressure Sensor (DPF) - Pin 14, Pin 34, Pin 79
EGT Sensor #2 - Pin 31
EGT Sensor #3 - Pin 32
EGT Sensor #4 - Pin 75
O2 Sensor #2 - Pin 51, Pin 58, Pin 59, Pin 80, Pin 81


All those wires were taken out of the TDI ECU body Harness Plug

The only sensor i need is the #1 O2 Sensor and the EGT Sensor #1



Back to the wiring. I have pretty much wired in EVERYTHING manually except a few wires. For this I need help from the community and from people that have bentley wiring diagrams. I pretty much need to know where each wire goes, what it controls and if it can be wired up to the TDI plugs or if i have to run wires/relays/fuses manually.

Wires that need to be looked up on the 2.5L ECU body plug:

Pin 17 - Yellow
Pin 25 - Brown/Black
Pin 46 - Brown/Purple
Pin 50 - Brown
Pin 64 - Blue/Violet
Pin 80 - Violet

Wires that need to be looked up on the 2.5L 14-Pin Plug under battery tray:

Pin 13 - Blue/Violet
Pin 14 - Black/Yellow




now onto the TDI harness/plugs:


Wires that need to be looked up on the TDI ECU body plug:

Pin 27 - Violet/Brown
Pin 45 - Red/Black
Pin 70 - Blue
Pin 71 - Violet/Red

Wires that need to be looked up for the CTS Plug with the 3 wires (pic shown above):

Pin 1 - Black/Brown


Lastly the glow plug relay has a black/yellow wire on it that goes into the cabin but splits into multiple places:

One wire goes to Relay 370 under steering column - 2.5L doesnt have this relay

Another wire goes another Relay 370 thats directly beside the first relay 370 - the 2.5L doesnt have this relay either

Another wire goes Relay 449 under the steering column

and another wire goes to another Relay 449 that sits beside the first relay 449.

Lastly another wire goes to PIN 26 on the engine fuse box that is located in the engine bay.

So pretty much this one black/yellow wire gets split up 5 ways and it goes to all these places. My problem is that the 2.5L has wires going to the 449 relays but i dont know where they end up. Also the 2.5L doesnt have the Relay 370, 2 of them.


All these relays are located under the steering column.

Once i get this wiring sorted out the car will be 100% complete.

If anyone can help out with detailed instructions that would be great.

thanks
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Old July 3rd, 2017, 22:02   #17
Strider17
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Pin 64 - Blue/Violet on the 2.5L ECU Connector went to Pin 13 - Blue/Violet on the 2.5L 14-Pin Connector ....so i just took that out since i have a TDI 14-pin connector wired in already (except 1 wire)

Pin 17 - yellow on the 2.5L ECU connector went to the 2pin gray connector (picture above) that sits below the battery tray. I think this 2 pin gray connector was a coolant sensor on the 2.5L radiator flange. Since i am using a tdi front end i dont have that connector there. ...so i got rid of that as well. The other wire on the gray connector is brown...but not sure where that goes - wiring diagram needed for that. maybe its just a ground?


more updates to come..
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Old July 4th, 2017, 21:00   #18
Strider17
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more updates on wiring:

so i decided to run the black/yellow wire to see where it ends up

here is a pic of the relays under the steering wheel:

https://www.flickr.com/photos/joeyv79/5793925987/

that one black/yellow wire gets split into 4 of the relays.
numbers 1,2,3,4

then i traced relays 1 and 2 to see where they end up.
they ended up at the auxilary heater the TDI wagon had.
the 2.5L doesnt have an auxiliary heater so my conclusion is that the last wire im needing to wire up on the 14-Pin TDI connector is the yellow/black wire which controls the auxillary heater.

this also eminates Pin 27 and 71 which run to relays 1 and 2

the 2 relays consist of 4 connections

Relay 1

wire going to aux heater
wire going to ECU
wire going to 14-pin plug
wire going to fuse box - 8mm that gets screwed on

relay 2

wire going to aux heater
wire going to ECU
wire going to 14-pin plug
wire going to fuse box - 8mm that gets screwed on


can anyone confirm this?


also, i traced back the wiring for the secondary fuel pump that sits on top of the timing belt cover

its a 2 pin connector

one pin is ground
another pin runs to the relays under the steering column, i believe its relay 3 shown in the link above.
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Old July 12th, 2017, 16:20   #19
Strider17
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plugged everything in...and im getting these codes.
my headlights dont work at all.

Wednesday,12,July,2017,16:44:20:38813
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x86
VCDS Version: 17.1.3.0
Data version: 20170320 DS267.7
www.Ross-Tech.com


VIN: 3VWTM71K19M252602 License Plate:


Chassis Type: 1K (1K0)
Scan: 01 03 08 09 15 16 17 19 1C 25 42 44 46 4F 52 56 62 72

VIN: 3VWTM71K19M252602 Mileage: 40000km-24854miles

01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: Malfunction 1010
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: Malfunction 0010
1C-Position Sensing -- Status: Malfunction 0010
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: Malfunction 0010
4F-Centr. Electr. II -- Status: OK 0000
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine (CBE) Labels: 03L-906-022-CBE.clb
Part No SW: 03L 997 016 N HW: 03L 906 022 J
Component: R4 2,0L EDC G000SG 8680
Revision: 12H01--- Serial number: VWX7Z0H424U0DP
Coding: 0350072
Shop #: WSC 18761 167 591464
VCID: 3D7B258364E633A9C2-8068

No fault code found.
Readiness: 0 0 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl
Part No SW: 1K0 907 379 AC HW: 1K0 907 379 AC
Component: ESP FRONT MK60 0101
Revision: 00H11001
Coding: 0021122
Shop #: WSC 00066 000 00000
VCID: 73EFC3BB1222B5D9E4-8026

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 1K0-820-047.lbl
Part No SW: 1K0 820 047 HC HW: 1K0 820 047 HC
Component: Climatic PQ35 141 1010
Revision: 00141028 Serial number: 00000000000000
Shop #: WSC 00000 000 00000
VCID: 6CDDD8C74F1C6A2125-8038

2 Faults Found:
00229 - Refrigerant Pressure
002 - Lower Limit Exceeded
00898 - Control Circuit A/C compressor
010 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels: 3C0-937-049-30-H.lbl
Part No SW: 3C0 937 049 AJ HW: 3C0 937 049 AJ
Component: Bordnetz-SG H54 2202
Revision: 00H54000 Serial number: 00000000957117
Coding: 248D8F2340041500070000001C000000000973076400010000 0000000000
Shop #: WSC 00066 123 12345
VCID: 71E3C9B3683E87C916-8024

Subsystem 1 - Component: Fehler Lin-Slave 01

10 Faults Found:
01493 - Bulb for Blinkers; Front Left (M5)
012 - Electrical Fault in Circuit
Freeze Frame:
Fault Status: 01101100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 5.00 V
ON
ON
OFF
OFF
OFF

02071 - Local Databus
004 - No Signal/Communication
Freeze Frame:
Fault Status: 01101100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

01495 - Bulb for High-Beams; Left (M30)
010 - Open or Short to Plus
Freeze Frame:
Fault Status: 01101010
Fault Priority: 3
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 5.00 V
ON
ON
OFF
OFF
OFF

01499 - Bulb for High-Beams; Right (M32)
010 - Open or Short to Plus
Freeze Frame:
Fault Status: 01101010
Fault Priority: 3
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

00978 - Lamp for Low Beam; Left (M29)
010 - Open or Short to Plus
Freeze Frame:
Fault Status: 01101010
Fault Priority: 1
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 5.00 V
ON
ON
OFF
OFF
OFF

00979 - Lamp for Low Beam; Right (M31)
010 - Open or Short to Plus
Freeze Frame:
Fault Status: 01101010
Fault Priority: 1
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

00153 - Windshield Wiper Motor; Driver Side (V216)
004 - No Signal/Communication
Freeze Frame:
Fault Status: 01100100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 5.00 V
ON
ON
OFF
OFF
OFF

00926 - Terminal 30
011 - Open Circuit
Freeze Frame:
Fault Status: 01100100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

00927 - Terminal 30 (Right)
011 - Open Circuit
Freeze Frame:
Fault Status: 01101011
Fault Priority: 1
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 5.00 V
ON
ON
OFF
OFF
OFF

00918 - Terminal 31
011 - Open Circuit
Freeze Frame:
Fault Status: 01101011
Fault Priority: 1
Fault Frequency: 1
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63


-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1K0-909-605.lbl
Part No SW: 1K0 909 605 AB HW: 1K0 909 605 AB
Component: 7B AIRBAG VW8R 034 8000
Revision: 05034000 Serial number: 003B6M05GEYP
Coding: 0014146
Shop #: WSC 00066 000 00000
VCID: 6CDDD8C74F1C6A2125-8038

Subsystem 1 - Serial number: 6332MSME351155090

Subsystem 2 - Serial number: 6342MSME35136E7CN

Subsystem 3 - Serial number: 6351HSME154B036C9

Subsystem 4 - Serial number: 6361HSME155B71042

Subsystem 5 - Serial number: 63727SME145A1B1E7

Subsystem 6 - Serial number: 63827SME1459277B7

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 BP HW: 1K0 953 549 BP
Component: J0527 051 0101
Coding: 0002022
Shop #: WSC 00066 000 00000
VCID: 01039973589E9749E6-8054

Subsystem 1 - Part No: XXXXXXXXXXX
Component: E0221 002 0010

4 Faults Found:
00576 - Terminal 15
012 - Electrical Fault in Circuit
00883 - Ignition Switch (D) Terminal S
012 - Electrical Fault in Circuit
00884 - Ignition Switch (D) Terminal X
012 - Electrical Fault in Circuit
01744 - Ignition Switch Terminal P (D)
012 - Electrical Fault in Circuit

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
Part No SW: 1K0 920 874 D HW: 1K0 920 874 D
Component: KOMBIINSTRUMENT 3HL 2418
Revision: V0005000 Serial number: VWX7Z0H424U0DP
Coding: 0004303
Shop #: WSC 00066 000 00000
VCID: 2E5912CFB980D8314B-807A

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 1K0-907-530-V3.clb
Part No SW: 1K0 907 530 N HW: 1K0 907 951
Component: J533 Gateway H06 0052
Revision: H06 01 Serial number: 080308F2000478
Coding: E9807F060012032002
Shop #: WSC 00066 000 00000
VCID: 326106BFADB8FCD12F-8066

1 Fault Found:
00466 - Control Module for Steering Column Electronics (J527)
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00110100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 152
Mileage: 40001 km
Time Indication: 0
Date: 2000.00.00
Time: 00:25:32


-------------------------------------------------------------------------------
Address 1C: Position Sensing Labels: 1Kx-919-xxx-1C.lbl
Part No SW: 1K6 919 879 HW: 1K6 919 879
Component: Kompass 001 0003
Revision: 00001000 Serial number: 1225223T1XTG03
Shop #: WSC 00000 000 00000
VCID: 7DFBE5832466F3A982-8028

2 Faults Found:
00466 - Control Module for Steering Column Electronics (J527)
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 3
Fault Frequency: 1
Reset counter: 152
Mileage: 40001 km
Time Indication: 0
Date: 2000.00.00
Time: 00:25:30

01316 - ABS Control Module
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 3
Fault Frequency: 4
Reset counter: 152
Mileage: 40001 km
Time Indication: 0
Date: 2000.00.00
Time: 00:26:17


-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
Part No SW: 1K0 920 874 D HW: 1K0 920 874 D
Component: IMMO 3HL 2418
Revision: V0005000 Serial number: VWX7Z0H424U0DP
Shop #: WSC 00000 000 00000
VCID: 2E5912CFB980D8314B-807A

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels: 1K0-959-701-MIN3.clb
Part No SW: 1K0 959 701 AC HW: 1K0 959 793 N
Component: J386 TUER-SG FT 1519
Revision: 72009005 Serial number: 00000836088517
Coding: 0001205
Shop #: WSC 00066 000 00000
VCID: 6FE7CFCB7E0A913900-803A

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-144-G2V3.clb
Part No: 1K1 909 144 M
Component: EPS_ZFLS Kl.070 H08 1901
Shop #: WSC 02069 000 90108
VCID: 356B3DA35CD6EBE90A-8060

1 Fault Found:
00778 - Steering Angle Sensor (G85)
000 - -

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1K0-959-433-MAX.clb
Part No SW: 1K0 959 433 CA HW: 1K0 959 433 CA
Component: KSG PQ35 G2 020 0204
Revision: 00020000 Serial number: 00000000000000
Coding: 129007885283083F2D04058FB0880F0488FC00
Shop #: WSC 00066 123 12345
VCID: 71E3C9B3683E87C916-8024

Subsystem 1 - Component: Sounder n.mounted

Subsystem 2 - Component: NGS n.mounted

Subsystem 3 - Component: IRUE n.mounted

2 Faults Found:
00332 - Control Circuit for Tank Flap
007 - Short to Ground
Freeze Frame:
Fault Status: 01100111
Fault Priority: 4
Fault Frequency: 7
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2000.00.00
Time: 00:01:00

00466 - Control Module for Steering Column Electronics (J527)
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 01100111
Fault Priority: 4
Fault Frequency: 7
Reset counter: 112
Mileage: 40001 km
Time Indication: 0
Date: 2000.00.00
Time: 00:01:00


-------------------------------------------------------------------------------
Address 4F: Centr. Electr. II (J533) Labels: 1K0-907-532.clb
Part No SW: 1K0 907 532 HW: 1K0 907 951
Component: J533 Gateway H06 0052
Revision: H06 01 Serial number: 080308F2000478
Coding: 050B0500
Shop #: WSC 00066 000 00000
VCID: 66C9AAEF91F0507173-8032

Subsystem 1 - Part No SW: 8R0 959 591 HW: 8R0 959 591
Component: J245EE16SKB09 H01 0170
Serial number: 0123456789ABCDEFGHIJ

Subsystem 2 - Part No SW: 8R0 959 591 HW: 8R0 959 591
Component: J394EE16SKB09 H01 0170
Serial number: 0123456789ABCDEFGHIJ

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels: 1K0-959-702-MIN3.clb
Part No SW: 1K0 959 702 AC HW: 1K0 959 792 N
Component: J387 TUER-SG BT 1519
Revision: 72009005 Serial number: 00000542288526
Coding: 0001204
Shop #: WSC 00066 000 00000
VCID: 70E5CCB763348EC119-8024

1 Fault Found:
00110 - Right Mirror Turn Signal Lamp (L132)
012 - Electrical Fault in Circuit
Freeze Frame:
Fault Status: 01101100
Fault Priority: 5
Fault Frequency: 1
Reset counter: 112
Mileage: 0 km
Time Indication: 0


-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No SW: 1K0 035 180 M HW: 1K0 035 180 M
Component: Radio DE2 016 0020
Revision: 00016000 Serial number: VWZ4Z7J3168277
Coding: 0010401
Shop #: WSC 00000 000 00000
VCID: 2A511EDF8568B41197-807E

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left Labels: 1K0-959-703-GEN3.clb
Part No SW: 1K0 959 703 Q HW: 1K0 959 795 J
Component: J388 TUER-SG HL 1120
Revision: 12006001 Serial number: 00000003138133
Coding: 0001168
Shop #: WSC 00066 000 00000
VCID: 3E79228F69E028B1DB-806A

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right Labels: 1K0-959-704-GEN3.clb
Part No SW: 1K0 959 704 Q HW: 1K0 959 794 J
Component: J389 TUER-SG HR 1120
Revision: 12006001 Serial number: 00000003153057
Coding: 0001168
Shop #: WSC 00066 000 00000
VCID: 3F875F8B6EEA21B9D0-806A

No fault code found.

End-------------------------(Elapsed Time: 01:58)--------------------------
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Old July 14th, 2017, 04:53   #20
dieselherb1
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Is this after everything was connected?
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Old July 14th, 2017, 10:09   #21
Strider17
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TDI(s): MK4 and MK5
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I had a ground not hooked up. That caused a lot of the codes.

Now the only codes I'm getting is for the fuel pump relays and the steering wheel codes


Here is how I things wired up


Here is how I have things connected

Pcv valve:
Pin 1 - joined at the maf sensor pin 5 black/blue wire
Which leads to fuse box C fuse #2 (10amp)

Pin 2 - going to pin 93 on the TDI 94 pin connector ( my tdi connector had a blank on pin 93 so I had to wire that in manually)


N75 valve -

Pin 1 - yellow/black - going to pin 21 on the engine bay fuse box. There is no pin 26 labeled anywhere. Neither on the 2.5 or TDI engine fuse box. From what I could tell from the original tdi wiring Harness. Pin 1 on the n75 connector went to pin 21 on the engine fuse box. So that's how I wires it in.

Pin 2 - goes to pin 20 on the TDI 60pin connector


14 pin plug on 2.5L:

Pin 14 black/yellow - still don't have anything connector to it. The black and yellow wire is joined together and one goes to pin 9 on the engine fuse box and the other goes somewhere in the cabin.



I had everything wired/plugged in as I explained above. Minus the pcv valve.

I was getting codes for fuel pump relay from the Module under the steering wheel as well as steering wheel codes.
The fuel pump relay codes were for the 2 wires that I had cut but not sure where to wire them. And the steering wheel codes had something to do with ignition switch wiring. Everything for the ignition switch wiring was left alone. Unless it's something to do with the engine wiring. I haven't tried cranking it over. Want to clear all the codes first.


The way I have the fuel pump relays wires up is:

2.5L relay holder:



Pin 1 and pin 6 (red/yellow) are joined together and lead to fuse #27. This was the same on the TDI. The original 2.5L relay wiring also had pin 8 (red/yellow) joining and going to fuse # 27. I cut pin 8 out of the circuit because pin 8 was used to go to pin 15 on tdi 60pin connector.


Pin 2 (blue/red)is running to is going to pin 1 on the intank lift pump. This was the same on the TDI.

Pin 3 (black/purple) wire was cut in half. The half going somewhere into the cabin is left open (I think it needs to be wired up and is throwing the code)
The other half of the wire that goes to the relay was joined to a wire leading to the engine bay. In the engine bay the wire splits and goes to pin 6 (black/yellow) on the glow plug relay.
The other wire at the split goes to pin 26 (blue/red) on the engine fuse box. This is how the TDI Harness was wired up so I just copied that.

Back at the relay- Pin 10 red/black was also cut in half. The half going somewhere in the cabin is left open and needs to be wired up and the other half that goes to the relay is joined with pin 3 which leads into the engine bay and is joined with the rest of the wires mentioned above.

Pin 5 (black/brown) goes to pin 46on the 60 pin TDI connector.

Pin 6. Wired up to pin 1 and going to fuse #27 as mentioned above.

Pin 7 - blue/red. Going to auxiliary pump pin 2

Pin 8 - red/yellow - this wire was cut because it was going to fuse #27. One end of the wire is going to fuse 27 and the other half of the wire is wired up to a wire leading to the engine bay to pin 15 on the TDI 60 pin connector


Pin 10 is explained above.


Difference for the relay base between the 2.5L and TDI pins are

2.5pins TDI pins

Pin 1 Pin 3
Pin 2 Pin 5
Pin 3 Pin 1
Pin 5 Pin 2
Pin 6 Pin 32
Pin 7 Pin 52
Pin 8 Pin 22
Pin 10 Pin 12
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Old July 14th, 2017, 13:03   #22
Strider17
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TDI(s): MK4 and MK5
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some pictures for refrence

this is how the 2.5L fuel pump relays were originally wired up



this is how they are wired up now






these 2 wires i opened...need to be wired up since they are throwing codes




picture of ignition switch for reference .... some wiring i did must be wrong for it it throw the codes

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Old July 14th, 2017, 13:08   #23
Strider17
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Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 BP HW: 1K0 953 549 BP
Component: J0527 051 0101
Coding: 0002022
Shop #: WSC 00066 000 00000
VCID: 01039973589E9749E6-8054

Subsystem 1 - Part No: XXXXXXXXXXX
Component: E0221 002 0010

4 Faults Found:
00576 - Terminal 15
012 - Electrical Fault in Circuit
00883 - Ignition Switch (D) Terminal S
012 - Electrical Fault in Circuit
00884 - Ignition Switch (D) Terminal X
012 - Electrical Fault in Circuit
01744 - Ignition Switch Terminal P (D)
012 - Electrical Fault in Circuit



this is my main concern. i noticed if i unplug the 100 relay closer to the fender on the fusebox in the engine bay..i can clear the codes and they dont come back..but that relay needs to be plugged in...just no idea what is throwing these codes. its not a bad ignition switch because the car has been sitting and it worked perfect before i did the swap.

cross reference between the TDI wiring and 2.5L wiring will be needed...to see if anything goes to the engine bay that i may have wired up wrong
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Old July 16th, 2017, 05:11   #24
dieselherb1
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I found that the Bentley wiring is had to work with. The Mitchell ProDemand diagrams were easy compared to Bentley. But I don't have the 2.5 diagrams
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Old August 15th, 2017, 18:39   #25
Strider17
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TDI(s): MK4 and MK5
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I was away on vacation.

I went and checked all the wiring i have done. Wrote down each pin, wire color, which plug and where its going.

Here is what I have right now....this is how i have everything connected. I need to know if all my wiring is done correctly according to the way i have everything wired:

Numbers Represent Pins on each Connector:


Engine Fuse Box for 2.5L – 40 pin

1. Red/Black – Glow Plug Module
2. Red – Into Cabin
3. Black/Red – Into Cabin
4. Red/Black – Into Cabin
5. Open
6. Black/Gray – TDI ECU Plug – 69/94
7. Open
8. Brown/Violet – Cut – Nothing going to it
9. Black/Yellow – Cut – Nothing going to it
10. Open
11. Blue/Red – Radiator Fan/Pin 13 on 14 Pin Plug
12. Red/White – Wiper Linkage Plug
13. Open
14. White/Red – Into Cabin
15. Red/Black – TDI ECU Plug 92/94
16. Blue/Red – 02 Sensor #1 – Pin 4 on Plug
17. Open
18. Red/Brown – to Cabin
19. Red/Green – Pin 10 on 14 Pin Plug
20. Open
21. Black/Yellow – Pin 1 on N75 Plug
22. Red/Green – TDI ECU Plug – Pin 3 and Pin 5
23. Red/Yellow – To Cabin
24. Red/White – To Cabin
25. Red/Yellow – To Cabin
26. Blue/Red – Glow Plug Module Pin 6/ Fuel Pump Relay Pin 3 and Pin 8
27. Red/White – To Cabin
28. Red/Black – TDI ECU Plug 92/94
29. Open
30. Open
31. Red/Yellow – To Cabin
32. Open
33. Open
34. Red/Yellow – To Cabin
35. Red – TO Cabin
36. Open
37. Open
38. Red/Violet – To Cabin
39. Red/Yellow – To Cabin
40. Open


Glow Plug Module for CR TDI – 10 pin

1. Black/Red – Pin 8 on 14 Pin Plug
2. Black/Blue – Pin 7 on 14 Pin Plug
3. Black/Green – Pin 6 on 14 Pin Plug
4. Black/White – Pin 5 on 4 Pin Plug
5. Open
6. Black/Yellow – Engine Fuse Box 26/40 and Fuel Pump Relay Pin 3 and Pin 8
7. Brown – Ground
8. Open
9. Violet/Gray – TDI ECU Plug – Pin 20/94
10. Violet/Yellow – TDI ECU Plug – Pin 61/94


14 Pin Plug:

1. Green/Black – Into Cabin
2. Open
3. Open
4. Brown – Ground
5. Black/White – Glow Plug Module – Pin 4
6. Black/Green – Glow Plug Module – Pin 3
7. Black/Blue – Glow Plug Module – Pin 2
8. Black/Red – Glow Plug Module – Pin 1
9. Brown - Ground
10. Red/Green – Engine Bay Fuse Box – Pin 19/40
11. Black – TDI ECU Plug – Pin 14/94
12. White – TDI ECU Plug – Pin 11/94
13. Blue/Red – Radiator Fans Plug and Engine Bay Fuse Box – Pin 11/40
14. Brown/Yellow – Pin 2 on N75 Plug


2.5L ECU Plug – 81 Pin (some wires were taken out – marked as “open”)


1 – Ground
2 – Ground
3 – Engine Bay Fuse Box – Pin 22/40
4 – Open
5 – O2 Sensor #1
6 – Open
7 – Open
8 – Open
9 – Open
10 – Open
11 – Open
12 – Open
13 – Open
14 – Open
15 – Open
16 – Open
17 – Yellow – 2 pin Gray Plug
18 – Open
19 – Open
20 – Open
21 – Black/Violet – Power Feed
22 – Open
23 – Black/Gray – Power Supply Relay
24 – Open
25 – Brown/Red – Leak Detection Pump
26 – Violet – MAF
27 – White/Brown – MAF
28 – Blue/White – Alternator
29 – Green/Brown – MAF
30 – Open
31 – Open
32 – Open
33 – Gray/Blue – Accelerator Pedal – Pin 5
34 – Brown/Blue – Accelerator Pedal – Pin 6
35 – Gray/Red – Accelerator Pedal – Pin 3
36 – Open
37 – Black/White – Steering Column Module
38 – White/Red – Clutch Pedal Switch
39 – Open
40 – Open
42 – Open
43 – Gray/White – OBD Port
44 – Open
45 – Open
46 – Brown/Violet – Engine Bay Fuse Box – Pin 8/40
47 – Open
48 – Open
49 – Open
50 – Brown - ??
51 – Black – O2 Sensor #1
52 – Green – O2 Sensor #1
53 – Violet - ??
54 – Open
55 – White/Green – Clutch Master Cylinder
56 – Black/Red – Clutch Master Cylinder – Pin 3
57 – Open
58 – Orange – Can Bus
59 – Open
60 – Orange/Black – Can Bus
61 – Open
62 – Red/Black – Engine Bay Fuse Box – Pin 28/40
63 – Open
64 – Blue/Gray – Pin 13 on 14 Pin Plug
65 – Black/Brown – Fuel Pump Relay
66 – Yellow/Violet – Radiator Fans
67 – Open
68 – Open
69 – Open
70 – Gray/Red – O2 Sensor #1
71 – Gray/White – O2 Sensor #1
72 – Gray/Black – Accelerator Pedal – Pin 1
73 – Yellow/Green – Accelerator Pedal Pin 2
74 – Open
75 – Open
76 – Open
77 – Open
78 – Open
79 – Open
80 – Violet – Leak Detection Pump
81 - Open
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Old August 15th, 2017, 18:44   #26
Strider17
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I wrote this out because i am still getting codes for the terminal 15 and fuel pump relay

I was able to start the engine. It ran fine, no check engine lights But i didnt want it to run incase the fuel pumps arent working properly

Back when the 2.5L was in stock condition and i opened the drivers door i heard the fuel pump prime. Now that i have changed the wiring for the TDI fuel pump relay, and i open the door, the fuel pump doesnt prime anymore.

id like for it to be wired so that when i open the door, the TDI pumps prime .
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Old August 21st, 2017, 17:34   #27
Strider17
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fixed the terminal 15 code:

im still getting codes for fuel pump relay:

01259 - Fuel Pump Relay (J17)
Open or Short to Ground - Intermitent

and

009779 - Relay for Fuel Pump 2 (J49)
P2633 Short to Ground - Intermitent


Everything else seems to be ok. Steering angle code will go away as soon as i start the car and drive a bit... here is a vcds full scan:




Monday,21,August,2017,20:06:48:38813
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x86
VCDS Version: 17.8.0.1
Data version: 20170721 DS276.2
www.Ross-Tech.com


VIN: 3VWTM71K19M252602 License Plate:


Chassis Type: 1K (1K0)
Scan: 01 03 08 09 15 16 17 19 1C 25 42 44 46 4F 52 56 62 72

VIN: 3VWTM71K19M252602 Mileage: 40000km-24854miles

01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
1C-Position Sensing -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: OK 0000
4F-Centr. Electr. II -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine (CBE) Labels: 03L-906-022-CBE.clb
Part No SW: 03L 997 016 N HW: 03L 906 022 J
Component: R4 2,0L EDC G000SG 8680
Revision: 12H01--- Serial number: VWX7Z0H424U0DP
Coding: 0350072
Shop #: WSC 18761 167 591464
VCID: 3D7B258364E633AEA1-8068

No fault code found.
Readiness: 0 0 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl
Part No SW: 1K0 907 379 AC HW: 1K0 907 379 AC
Component: ESP FRONT MK60 0101
Revision: 00H11001
Coding: 0021122
Shop #: WSC 00066 000 00000
VCID: 73EFC3BB1222B5DE87-8026

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 1K0-820-047.lbl
Part No SW: 1K0 820 047 HC HW: 1K0 820 047 HC
Component: Climatic PQ35 141 1010
Revision: 00141028 Serial number: 00000000000000
Shop #: WSC 00000 000 00000
VCID: 6CDDD8C74F1C6A2646-8038

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels:. 3C0-937-049-30-H.lbl
Part No SW: 3C0 937 049 AJ HW: 3C0 937 049 AJ
Component: Bordnetz-SG H54 2202
Revision: 00H54000 Serial number: 00000000957117
Coding: 248D8F2340041500070000001C000000000973076400010000 0000000000
Shop #: WSC 00066 123 12345
VCID: 71E3C9B3683E87CE75-8024

Subsystem 1 - Part No: 1K1 955 119 E Labels: 1KX-955-119.CLB
Component: Wischer 030608 021 0501
Coding: 00038805
Shop #: WSC 00066

1 Fault Found:
01259 - Fuel Pump Relay (J17)
009 - Open or Short to Ground - Intermittent
Freeze Frame:
Fault Status: 00101001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 152
Mileage: 40001 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
OFF
Voltage: 11.95 V
OFF
ON
OFF
OFF
OFF


-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1K0-909-605.lbl
Part No SW: 1K0 909 605 AB HW: 1K0 909 605 AB
Component: 7B AIRBAG VW8R 034 8000
Revision: 05034000 Serial number: 003B6M05GEYP
Coding: 0014146
Shop #: WSC 00066 000 00000
VCID: 6CDDD8C74F1C6A2646-8038

Subsystem 1 - Serial number: 6332MSME351155090

Subsystem 2 - Serial number: 6342MSME35136E7CN

Subsystem 3 - Serial number: 6351HSME154B036C9

Subsystem 4 - Serial number: 6361HSME155B71042

Subsystem 5 - Serial number: 63727SME145A1B1E7

Subsystem 6 - Serial number: 63827SME1459277B7

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 BP HW: 1K0 953 549 BP
Component: J0527 051 0101
Coding: 0002022
Shop #: WSC 00066 000 00000
VCID: 01039973589E974E85-8054

Subsystem 1 - Part No: XXXXXXXXXXX
Component: E0221 002 0010

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
Part No SW: 1K0 920 874 D HW: 1K0 920 874 D
Component: KOMBIINSTRUMENT 3HL 2418
Revision: V0005000 Serial number: VWX7Z0H424U0DP
Coding: 0004303
Shop #: WSC 00066 000 00000
VCID: 2E5912CFB980D83628-807A

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels:. 1K0-907-530-V3.clb
Part No SW: 1K0 907 530 N HW: 1K0 907 951
Component: J533 Gateway H06 0052
Revision: H06 01 Serial number: 080308F2000478
Coding: E9807F060012032002
Shop #: WSC 00066 000 00000
VCID: 326106BFADB8FCD64C-8066

No fault code found.

-------------------------------------------------------------------------------
Address 1C: Position Sensing Labels: 1Kx-919-xxx-1C.lbl
Part No SW: 1K6 919 879 HW: 1K6 919 879
Component: Kompass 001 0003
Revision: 00001000 Serial number: 1225223T1XTG03
Shop #: WSC 00000 000 00000
VCID: 7DFBE5832466F3AEE1-8028

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
Part No SW: 1K0 920 874 D HW: 1K0 920 874 D
Component: IMMO 3HL 2418
Revision: V0005000 Serial number: VWX7Z0H424U0DP
Shop #: WSC 00000 000 00000
VCID: 2E5912CFB980D83628-807A

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels:. 1K0-959-701-MIN3.clb
Part No SW: 1K0 959 701 AC HW: 1K0 959 793 N
Component: J386 TUER-SG FT 1519
Revision: 72009005 Serial number: 00000836088517
Coding: 0001205
Shop #: WSC 00066 000 00000
VCID: 6FE7CFCB7E0A913E63-803A

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-144-G2V3.clb
Part No: 1K1 909 144 M
Component: EPS_ZFLS Kl.070 H08 1901
Shop #: WSC 02069 000 90108
VCID: 356B3DA35CD6EBEE69-8060

1 Fault Found:
00778 - Steering Angle Sensor (G85)
000 - -

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels:. 1K0-959-433-MAX.clb
Part No SW: 1K0 959 433 CA HW: 1K0 959 433 CA
Component: KSG PQ35 G2 020 0204
Revision: 00020000 Serial number: 00000000000000
Coding: 129007885283083F2D04058FB0880F0488FC00
Shop #: WSC 00066 123 12345
VCID: 71E3C9B3683E87CE75-8024

Subsystem 1 - Component: Sounder n.mounted

Subsystem 2 - Component: NGS n.mounted

Subsystem 3 - Component: IRUE n.mounted

No fault code found.

-------------------------------------------------------------------------------
Address 4F: Centr. Electr. II (J533) Labels:. 1K0-907-532.clb
Part No SW: 1K0 907 532 HW: 1K0 907 951
Component: J533 Gateway H06 0052
Revision: H06 01 Serial number: 080308F2000478
Coding: 050B0500
Shop #: WSC 00066 000 00000
VCID: 66C9AAEF91F0507610-8032

Subsystem 1 - Part No SW: 8R0 959 591 HW: 8R0 959 591
Component: J245EE16SKB09 H01 0170
Serial number: 0123456789ABCDEFGHIJ

Subsystem 2 - Part No SW: 8R0 959 591 HW: 8R0 959 591
Component: J394EE16SKB09 H01 0170
Serial number: 0123456789ABCDEFGHIJ

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels:. 1K0-959-702-MIN3.clb
Part No SW: 1K0 959 702 AC HW: 1K0 959 792 N
Component: J387 TUER-SG BT 1519
Revision: 72009005 Serial number: 00000542288526
Coding: 0001204
Shop #: WSC 00066 000 00000
VCID: 70E5CCB763348EC67A-8024

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No SW: 1K0 035 180 M HW: 1K0 035 180 M
Component: Radio DE2 016 0020
Revision: 00016000 Serial number: VWZ4Z7J3168277
Coding: 0010401
Shop #: WSC 00000 000 00000
VCID: 2A511EDF8568B416F4-807E

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left Labels:. 1K0-959-703-GEN3.clb
Part No SW: 1K0 959 703 Q HW: 1K0 959 795 J
Component: J388 TUER-SG HL 1120
Revision: 12006001 Serial number: 00000003138133
Coding: 0001168
Shop #: WSC 00066 000 00000
VCID: 3E79228F69E028B6B8-806A

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right Labels:. 1K0-959-704-GEN3.clb
Part No SW: 1K0 959 704 Q HW: 1K0 959 794 J
Component: J389 TUER-SG HR 1120
Revision: 12006001 Serial number: 00000003153057
Coding: 0001168
Shop #: WSC 00066 000 00000
VCID: 3F875F8B6EEA21BEB3-806A

No fault code found.

End-------------------------(Elapsed Time: 01:55)--------------------------
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Old August 22nd, 2017, 03:53   #28
dieselherb1
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I have moved all the wires that were needed in T94 connector. Won't start and can not link to ECM with Vagcom?
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Old August 22nd, 2017, 07:23   #29
Strider17
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There is a gray and white wire for the obd port and a black/violet or black/red wire for the power feed. Also make sure your wires from pin 1-6 are going to fuse box in engine bay and ground as well.
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Old August 22nd, 2017, 17:15   #30
dieselherb1
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I have red/blk is going to fusebox #15 I believe and to pin 92. The fuel pump in the tank is not get a signal( pump is good I jumped the relay) I don't think the injectors are getting the signal to fire either.
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