03 Golf TDI into 99.5 Jetta 2.0

[ensanity]

Hello all! I know it has been done before, but this is my 99.5 jetta that was a 2.0. The motor mount broke on the 2.0 causing the timing belt to break. Even though it did not destroy the internals on the 2.slow I decided I needed a TDI, I missed my old one terribly!
<a href="http://s625.photobucket.com/albums/tt336/diesel_jr/Project%20TDI/?action=view&current=DSC02417.jpg" target="_blank"><img src="http://i625.photobucket.com/albums/tt336/diesel_jr/Project%20TDI/DSC02417.jpg" border="0" alt="Photobucket"></a>
Before at the GROOVE cars show in Springfield, mo...won 2nd in the stock water pumper division.
A few turns of the wrench later....
http://i625.photobucket.com/albums/tt336/diesel_jr/Project TDI/IMG00007.jpg
Then in comes what I call "The Ark of the Dub-enant" A TDI out of a '03 Golf TDI with the five speed transmission, complete wiring harness, vn17 turbo, upgraded injectors, and Rocket chip stage 1.
http://i625.photobucket.com/albums/tt336/diesel_jr/Project TDI/IMG00004.jpg
I completely gutted the car
http://i625.photobucket.com/albums/tt336/diesel_jr/Project TDI/IMG00059.jpg
got out the trusty toolbox
http://i625.photobucket.com/albums/tt336/diesel_jr/Project TDI/IMG00060.jpg
and began reassembly
http://i625.photobucket.com/albums/tt336/diesel_jr/Project TDI/IMG00072.jpg
So far it has been fun, but I only get to work on it on saturdays, so it's taking a lot longer than I wanted....But on the bright side I just bought an '05 Jeep Liberty CRD diesel for the wife!!

 

[ensanity]

I have a problem....I thought I was going to get to hear it run today, but it would not start. It turns over and the diesel lines are purged, but it won't start. Do you think it's my spark plugs?? (just kidding) But seriously...I think it might be the immobilizer because when I turn the key it beeps at me and flashes the brake light and a light that has a picture of the car and a key. The ecu, throttle pedal, and gauge cluster are from the tdi, but the ignition switch and key are from the 2.0, would this make a difference? My last TDI was a 99.5, so no immobilizer, I am beginning to wish it were one of those...

 

[G60ING]

yes it sounds like you are having immobilizer issues. Swap the ignition switch and key over from the 2003 donor.

 

[SeththeRuthless]

Yeah, the immobilizer system is seeing that the key does not match the ecu and cluster. You can either swap back to the TDI key which is already coded to match the immobilizer in the car now, your you could also recode the key that you have for the car now. Recoding Immo keys can be a PIA, though, especially with the newer Immo systems.

 

[G60ING]

You can't recode the key on the 99.5 because it doesn't have an immobilzer. My first TDI donor was a 1999.5 and I was able to by a valet key for $40 from the dealer and never get it programmed to the car. Hell I could run the engine without the key or instrument cluster.

The only way around swapping the key assembly is to get the ECU reprogrammed to bypass the immobizer.

 

[ensanity]

Sweet info! Can the immo be disabled in the ECU using VAG-COM or how can that be done. I got the key that matches the cluster, but not the ignition and I really do not want to re-key my car.

 

[vwmikel]

The immobilizer cannot be disabled via vag-com. You have to send the ECU out....there is another option but you already have RC so you don't want to hear it.

 

[ensanity]

Well
l got the carpet, padding, and front seats installed this weekend. I also got all the wheel speed sensors installed and got the wiper motor wiring straightened out (the connectors were different). I also managed to bend the brake lines so that they would work with the new ABS thing. I switched the shifter forks out of the 2.0 so that I would not have to change my shifter out. Now I just need to figure out what I am going to do about the immobilizer, finish wiring the heated seats and the air bags (brain and wiring from the 99.5) put in the headliner and trim, and the back seat.

 

[ensanity]

I forget to mention I wired in the dash lighting and the interior lighting because of the difference between the golf and the jetta.

 

[ensanity]

Okay...I got the ECU back from Jeff at Rocket Chip, he did an IMMO, EGR, and MAF delete and upgraded to RC 3+ BUT I installed the computer and it still will not start. It cranks and cranks, but does not start. I am getting fuel to the injectors. I jumped 12v to the fuel cut off solenoid and it still did not start. I checked the 109 relay since the glow plug light is not coming on, but it was the new gray one not the old black one. I am officially stumped and would appreciate any help!

 

[ensanity]

anyone?!?

 

[G60ING]

What codes is the ECU giving?

 

[ensanity]

well, I do not have a code reader, but the check engine light is not on.

 

[G60ING]

Sorry but Vag-Com is one of the most important tools these days when working on a modern VW. You might want to consider making it your next purchase even if you don't have a laptop. You could just put the computer near the car and then get a USB cable extension cord or something.

The another thing I would check is the timing. Do you have the cam locking Plate? http://www.metalnerd.com/cat02.htm

 

[ensanity]

It was a stinking fuse!!! I can't believe I missed that! I checked the fuses, but did not check for missing fuses! It started and sounded great! Now just to put the driver side CV on and the bumper. As far ad the vag-com, I would own one, but I am a Mac guy... No support for apples :-( hopefully sat I will be able to finish it and to take it for a test drive!

 

[Diesel Nut 247]

It was a stinking fuse!!! I can't believe I missed that! I checked the fuses, but did not check for missing fuses! It started and sounded great! Now just to put the driver side CV on and the bumper. As far ad the vag-com, I would own one, but I am a Mac guy... No support for apples :-( hopefully sat I will be able to finish it and to take it for a test drive!

You can run bootcamp on the MAC to use the VAG-COM.

 

[roundout]

I don't want to thread-jack, but I'd like to ask you a few questions about your swap, as I'm currently doing the same thing.

What did you do about side airbags? The 99 I'm using doesn't have them, which means it doesn't have the mounting rivnuts for them or the brackets which the curtain things mount on. I'm considering plugging in the electronics so I don't get a code but leaving the bags themselves out.

Did you swap over the front springs from the TDI to the gas donor? My rears have the same paint codes on them but the fronts are different. If you left the 2.0 springs in it, how does it drive?

TIA

 

[ensanity]

I finally got to drive it! Granted I never got out of 1st gear, I used the shift forks, shifter, and linkages from the 2.0 cause I thought it would work, but I had no reverse! So if I can find a day when I do not work or have school I am going to switch all of that over from the TDI. As far as the airbags are concerned I unplugged the new comp and put the one from the 99.5 in its place and stripped the wiring from the old harness and grafted it into the new harness... I do not think I am going to have any problems because there is no light and the airbags did not go off, but like I said I have not had it out in the road yet. As far as the springs are concerned the previous owner had put in some kind of lowering spring, I just used those.

 

[G60ING]

you just need to adjust the shifter cable ends on the transmission to get reverse to work.

 

[ensanity]

I am making a zombie thread here bringing this back from the dead, but this project is dead. Things have been absolutely crazy in my world and I had put the project on the back burner. Last I had worked on it the car would start and drive, but it felt kind of weak, hard to tell just driving around a yard though. Anyway, when I started working on it again it will not start at all unless I give it a snort of ether. I know I am not supposed to do that, but when you get mad things happen! I can now get it to start on ether and have even got it to run by giving it a shot every few seconds until it would start running on its own. Then it will only run if the accelerator is mashed to the floor. Then it will run five minutes tops and then die and it will not get over 2,000 RPM unless it gets too much ether. I am completely stumped...I have no idea why it ran and I drove it around and now it will not even run! I need some wisdom! It acts like the potentiometer is not telling the computer to give it enough fuel or something. Any ideas?!?

 

[G60ING]

Did you swap over all of the TDI sensors including the go pedal? The go pedals are gasser and diesel specific. Have you checked the timing? Any engine codes? Fuel good? Filter good?

 

[slavik19]

sorry for the grave dig.
but do you have to swap out the body harness to swap a tdi into a wagon.
or just swap the engine harness thts it?

 

[ensanity]

I swapped all of the wiring over from the diesel except for the air bag harness and dash lighting. It is kinda funny because I have the plug for rear wipers, lol. I also did not swap out the door harnesses and apparently i need to do so because my windows do not work (I heard this was because of the difference between the no immo 99.5 and the immo2 03). I got a VAG Com and a bently manual!! The project had been dead in my garage for a very long time when I got motivated again. It turns out it was badly out of time AND the injection pump was all screwed up. I got a reman 11mm pump from bleachedbora and timed and primed it and it fired right up!!!! I adjusted prime and now she runs beautiful. I have to do a few things before I get it on the road, but hopefully I can take it for a drive on Saturday!

 

[steadFAST]

I don't want to thread-jack, but I'd like to ask you a few questions about your swap, as I'm currently doing the same thing.

What did you do about side airbags? The 99 I'm using doesn't have them, which means it doesn't have the mounting rivnuts for them or the brackets which the curtain things mount on. I'm considering plugging in the electronics so I don't get a code but leaving the bags themselves out.

Did you swap over the front springs from the TDI to the gas donor? My rears have the same paint codes on them but the fronts are different. If you left the 2.0 springs in it, how does it drive?

TIA

I don't want to thread jack, either, especially a decade (+) later...but I'm doing the same thing and wondering if either have further pictures/videos of their projects. Mine is a 02 Golf ALH with 159K miles that was rolled but still runs and drives into a 02 Jetta Wagon 2.0L with 268K miles on it. I was going to drive the wagon til it died, but had to put an engine position sensor in before driving it from Portland, OR to Kansas City at Christmas and I don't want to put any more money into the 2.slow and start with quite a commute in May, so needing to get swapped soon. Thanks for any responses!

 

[Mytdijetta]

I don't want to thread jack, either, especially a decade (+) later...but I'm doing the same thing and wondering if either have further pictures/videos of their projects. Mine is a 02 Golf ALH with 159K miles that was rolled but still runs and drives into a 02 Jetta Wagon 2.0L with 268K miles on it. I was going to drive the wagon til it died, but had to put an engine position sensor in before driving it from Portland, OR to Kansas City at Christmas and I don't want to put any more money into the 2.slow and start with quite a commute in May, so needing to get swapped soon. Thanks for any responses!

I am currently working on the same thing, 2003 ALH Manuel Wagon that was rolled into a 2003 2.0 Auto Wagon, Did you get it finished? what did you all have to swap electrical wise? Thanks for any response!