ALH in 2004.5 GLI

[dieselvwgolf]

Good afternoon all, I have search a ton trying to figure out all I need to move from my 2001 Golf with an ALH and 5speed into a 2004.5 Jetta GLI, with 6speed. Not much to be found using search or at least not the correct words. Is it really as easy as ECU and waterfall harness? Does everything communicate with the newer GLI can bus system? Thanks in advance.

 

[oilhammer]

It is technically not legal, and I have no idea what a "2004.5" is.

A 2001 Golf and a 2004 Jetta are both the same platform cars, so if you've got enough time to remove just about everything, you could convert it over.

Both cars would use the same CAN, however there were some changes middle 2002 regarding the radio and some other items.

The 6sp would be of no use (it is geared LOWER).

Now if you are mistaken, and you meant 2005.5, then that is an entirely different car, and shares virtually nothing with the 2001. You may as well be trying to put the ALH in a Camry.

 

[dieselvwgolf]

It going to be “off road use only”, also I did confirm it is a 2004 Jetta GLI. I like the upgrades to the Jetta and everything has failed on my golf except the motor/trans that I have built over the years.
I know that thetrans will rev high so I plan to use my 5 speed.
That being said is the wiring I need from the ecu to the engine and engine wiring, or will I need anything from inside the golf. My golf didn’t appear to have anything funky with the stereo as when I pulled it for a touch screen I can still connect the vag com.

also I have a tune that has the Immo delete.
Thank you for the help.

 

[GlowBugTDI]

Had I seen this thread i would have put my other comment here.
You'll need shifter/linkage and diesel fuses for sure. You could also swap your gauge cluster so that you have your glowplug light and such.

 

[dieselvwgolf]

Oh thank you, I forgot to mention the gauges. I don’t really want to, cuz the new ones are so nice, but I don’t want it to say unleaded fuel only, lol. Is the shift linkage different? It has an actual short shifter in it, and I have the sigma short shifter ends for my 5 speed. I thought I would be able to just transfer the sigma over and use the shifter and linkage… is the fuse block different? Or do I just need to insert fuses and the wiring for the diesel stuff? I am just liking to make sure I have everything I need pulled out of the old car before I roll in the new car. This will be my first TDI swap into a gas VW mostly just swapped the Cummins into other vehicles which proves to be incredibly easy.

 

[oilhammer]

There are differences in the dash harnesses, and of course the fuel tanks are different. Most everything under the hood will be different although a few items will be the same. You didn't say if the GLI was a 4 or 6 cyl, but the VR6s have an additional radiator mounted where the turbo cars have their charge air cooler. Either way, that would need to be swapped over.

 

[Zak99b5]

2004.5 GLi is the 1.8T version of the car. Before that, the revived GLI trim (no MkIIIs) MkIV cars had the VR6, and were little more than a "normal" VR6 Jetta. With the 04.5, VW spec'd them out much closer to a 20th Anniversary GTi.

 

[oilhammer]

There were GLX cars, too. I have a customer that had (parted ways when the chains blew) a nice 2004 VR6 GLI 6sp, that had Onstar and no sunroof (strange one).

I didn't know there was a middle 2004 change in them. Not too common of a car for me here.

I've had some strange ones over the years, though. Had a 2001 Jetta VR6, GLS trim, automatic, with no sunroof and steel wheels and hubcaps. Only one like it I've ever seen.

 

[dieselvwgolf]

There are differences in the dash harnesses, and of course the fuel tanks are different. Most everything under the hood will be different although a few items will be the same. You didn't say if the GLI was a 4 or 6 cyl, but the VR6s have an additional radiator mounted where the turbo cars have their charge air cooler. Either way, that would need to be swapped over.

It’s the 1.8t. It appears that the SMIC is roughly the same as our TDI cars.
Do I need to swap the fuel lines and cooler as well? Or just the tank?
as for the dash harness, is it splicing the different years harnesses together or just moving the cluster over?

I’ll get some pic up when I get the car into the garage and taken apart, it’s a blue lagoon color, recarro seats, alum wheels car.

 

[oilhammer]

The entire fuel line assembly and everything attached is different. Would all need to be changed.

The ALH only got a fuel cooler if it was an automatic.

The gas cars have one of two types of filters mounted underneath, depending on if it is a returnless system or not. But it is all different than the diesels.

If you just spend a little time looking, you'll see what all is different. Diesels have no evaporative emissions system, so all that is not used.

 

[dieselvwgolf]

Thank you. My 01 Golf is a GLS and started its life with a slush. That made it to 250k, so instead of keep sinking money into the tranny I swapped in a new 5speed with a .622 5th. It’s now at 400k with a lot of goodies. As for Hardware I have a pretty good grasp on, you had hit on a few things I didn’t think of yet, but would have got there when I started moving things over. I was mostly curious of the wiring part and making sure that I could still get everything working via plug and play or pin swapping for mild differences in gas vs diesel. If it’s literally a full wire harness swap I am cool with that too. Was just hoping to not have to strip both cars. I really appreciate the assistance it’s not everyday you get oilhammer responding to your posts.

 

[RexNICO]

Take a look at this Thread

 

[dieselvwgolf]

Take a look at this Thread

Thank you. That has some good information.

 

[mittzlepick]

Im in the process of similar swap. Alh into 05 gti with proper 6 speed. It idles so far after doing waterfall harness and powering the 109 relay. Some wires to figure out yet. Cruise and reverse light not working yet. The plenum plugs are not so simple and reading the wiring schematics in bentley are tiring for my eyes. They dont seem to follow simplicity.
I swapped the fuel tank and added a pd fuel pump. It runs with key on without stopping so need to figure that out or go back to alh unit.
The 05 fuel tank has a metal sending unit ring alh bew have a plastic thread on style.

 

[mittzlepick]

I swapped the black and blue fuel lines from donor. I intend to put cooler unit from an auto i have in the field for fuel cooling. Used the 1.8 pancake pipe and found a hose that adapted well. The wires for the alt ac harness output in a different spot so they need relocation. Unless the 1.8 is better for that need to investigate that

 

[mittzlepick]

The tank is swappable without removing the beam but i have a 2 post lift. Still took two people like wrestling a swan

 

[Nuje]

Replacing the fuel tank was pretty much the last thing I did on my swap (even ran a tank of fuel through the gas tank....after it'd been thoroughly mopped dry, of course). I can't imagine how you get that out without removing the axle and exhaust; I did it on my own and oh my - the curse words....they flowed aplenty.

 

[dieselvwgolf]

The tank is swappable without removing the beam but i have a 2 post lift. Still took two people like wrestling a swan

perfect!

 

[mittzlepick]

Exhaust was out ebrake cables u hooked

 

[Nuje]

Yeah - at that point, removing four bolts (bottom shock mounts and the rear axle bushings) doesn't seem like a big deal to get out of the way; cut a slot in the guides that contain the hard brake lines so you don't have to open the hydraulic lines and that makes it more manageable (and possible working by oneself).