GLX Jetta Wagon ALH Swap

[agentmaddock]

Hey everybody. I'm John. Been on here for a year or two now. Never posted much.

Here is my last TDI.


Now onto the current stuff. I picked up mk4 #7 at the end of July this year. Finally got a wagon, and only paid $2500 for it!!! It is a 2002 GLX vr6 5speed. Unfortunately it is reflex silver. Had 158k miles on it, and had not seen a bit of maintenance...or even a good cleaning for that matter. The only thing the PO kept up with was oil changes. The vr had a bad misfire, exhaust leak, a handful of coolant leaks, and super noisy chains. But it drove great, and seemed to be a solid car!

I have always wanted a tdi wagon, but with the way the tdi market is you can't come by one cheap. A good friend of mine totaled his '03 tdi sedan back in March and I bought it with the intentions of using the drivetrain. So why not build a diesel wagon with options not originally with a tdi.

Parts list:
Interior and license plate leds
High Bolster Black Leather seats
Golf front end swap
TDI swap 95% complete

To do list/parts I already have but not installed:
Button up TDI swap
Black interior conversion
Air
Fix rust on rockers
Gli skirts
Refinish 4 spoke steering wheel
Rock the c5's for winter
.:R pedals

Plans for next year:
Tune
Nozzles
Real wheels
Redo headliner and pillars
Possible respray

The wagon.


And the donor.



The day I brought the wagon home.


I don't think it had been washed or vacuumed in years. I had to bug and tar the entire car. Here is after a good cleaning.



Swapped some led's over.



Did some trading with a friend. Golf front end (minus bumper) with Helix headlights and C5's. It sat like this for 3 weeks in my driveway. MOAR 4x4 status!


Picked up a set of high bolster black leathers.

 

[agentmaddock]

Found a reflex bumper and two more fenders that were in better shape than the others. Also got some beetle steelies for dirt cheap.


Picked up my "new to me" tdi trans and axles. The trans from the parts car has some internal issues.


Drove the car to Florida and back at the beginning of October. 1800 miles, 27.1 mpg average, and a vr that was running like crap. Didn't miss a beat!



Finally parked the car on October 28th and started getting to work!


Started yanking the vr out.




Cleaned the bay. 162k miles of dirt and grime

 

[agentmaddock]

Then I started tearing the tdi apart.


Had to use my cousin's John Deere to lift the tdi out because the car was in grass.




This place is turning into a volkswagen junk yard


Got all the other parts that I needed off the sedan.




Got the tdi prepped for the wagon. Had to take the old trans off, install a new clutch, and put the new trans on.

 

[agentmaddock]

Old tdi trans busted the cover and has an issue with 5th gear.


Got the tdi set in the wagon. And made it look like a car again.



Swapped fuel tanks.

 

[agentmaddock]

Rear beam is in and GLI rear brakes are done. Had to get a new drivers side rear caliper, but no one had the right rear. :banghead: I'll paint them eventually. TDI cluster is in. Got the fuel sender plug switched, and it works!!! Put fluids in and primed the fuel system. Air ride controller is mounted and ethernet cable ran.

Modified the original dust shields. Not pretty, but they can't be seen and I will get gli/20th correct shields later.




Plenty of clearance now.

 

[dieselherb1]

Why change tank? Why change sending unit?

 

[samuraitd]

Whoa...that's a ton of progress!!

 

[agentmaddock]

Why change tank? Why change sending unit?

I have a full donor car. Easier to just swap tanks and lines, than swap parts and pieces of each one.

Whoa...that's a ton of progress!!

Thank you sir. Hoping to get it on the road as soon as possible!

 

[mcneil]

Love it!

Did you do a timing belt or anything else on the motor while you had it out?

 

[agentmaddock]

Love it!

Did you do a timing belt or anything else on the motor while you had it out?

Thanks man. The TDI's owner was a really good friend of mine. It had a full timing belt kit along with a new injection pump 20k miles ago!

 

[BlankThis]

Just saw this build the other day on vortex, love it man!

Also love the sawblades on your old Jetta. I'm on the hunt.

 

[agentmaddock]

Just saw this build the other day on vortex, love it man!

Also love the sawblades on your old Jetta. I'm on the hunt.

Thank you sir!

Update!

Got the accelerator pedals swapped out today. But she still won't start. I've primed the pump twice with my mity-vac. Doesn't seem to even be hitting. No smoke, no nothing. The pump is sucking fuel though. I can watch the line when I crank it and can see fuel moving easily in the line.

I'm wondering if I need to crack the lines going to the injectors. Also, since I swapped the gas pedal out I'm not getting any CEL's anymore. Anyone have any suggestions to whether I'm not getting fuel or if I'm missing something elsewhere?

 

[Bzillins8806]

I have swapped a pump, and primed with vac and still killed a battery trying to get it to start back up.

My foolproof method now is a tow vehicle, key on in first gear, a gentle pull at 7mph will get it started in under a 1/4 mile every time without killing starters or batteries.

 

[dremd]

Oh, didn't realize you were also on the good forum.

Sweetness.

 

[dremd]

Thank you sir!

Update!

Got the accelerator pedals swapped out today. But she still won't start. I've primed the pump twice with my mity-vac. Doesn't seem to even be hitting. No smoke, no nothing. The pump is sucking fuel though. I can watch the line when I crank it and can see fuel moving easily in the line.

I'm wondering if I need to crack the lines going to the injectors. Also, since I swapped the gas pedal out I'm not getting any CEL's anymore. Anyone have any suggestions to whether I'm not getting fuel or if I'm missing something elsewhere?

Below is all for newer CAN cars, but probably identical.

1 any codes?
2 your relay 109 is wired up, right?
3 T-14a is connected inside the drivers front fender?
4) scroll through the Chanel's on the engine controller inVCDS to check that everything reads something reasonable.
5 you can start it with the gasoline pedal, it just idles high
6 DO NOT start it without the pedal plugged in, IT WILL bounce off the rev limiter.

 

[dremd]

As far as getting fuel, I once pulled an injector on a buddies car that wouldn't start, plumbed it to the stock line just pointing up and eventually realized that we had the pump hammer modded in the wrong direction.

Best of luck.

 

[agentmaddock]

Update!

Made a little bit of progress today. Got the rear brakes bled and ready to go. Hopefully going to have relay 109 out of the old harness and plugged into the wagon by this weekend.

I started working on this...


And ended with this... Creeper cat is creepin'!


I also picked up this beauty yesterday from a local guy. '86 1.6D. Needs a little love, but mostly rust free and has been daily'd for the past 4 years, and everything works!

 

[dremd]

Jesums.
I never pulled a dash on mine.
Keep it up, you will get there.

 

[agentmaddock]

I have been trying to figure out if the wagon was IMMO2 or 3. The key fob and old cluster both had correct part #'s for IMMO3. So I pulled the CCM down... and sure enough its 1C0. So I guess the wagon is IMMO3 even though it was built in '01.



And in other news, I messed with this ball of fun and extracted a few things.


All that is left for the 109 relay is a reply from Dremd, and then I can throw it in and cross my fingers that it starts.

 

[SuperAdellic]

Great work. What are doing with the rest of that harness that you extracted a few things from?

 

[dremd]

Text replied.
I'm outright shocked that it's an IMMO 3 car. Way awesome for you.

Sleep well and talk to you soon.

 

[agentmaddock]

Great work. What are doing with the rest of that harness that you extracted a few things from?

Probably going to use pins here and there for OEM+ wiring shenanigans, and part the rest out if anyone needs anything specific.

Text replied.
I'm outright shocked that it's an IMMO 3 car. Way awesome for you.

Sleep well and talk to you soon.

Thanks again for all your help! You are the only thing keeping me motivated right now!!

 

[mkIValh]

Man i'm jealous, its super tough to find a ALH wagon and your building one! Thats awesome i hope everything goes well and good work

Happy Holidays!

 

[burpod]

nice work! tdi swaps fmtfw!! very glad you swapped in a golf front end, it's the ONLY way to have a vw wagon so jealous of that nice mk2 you just picked up too! *sigh*

as you work through the wiring, inspect each connector. it's a REAL PAIN if you get everything together and then have to chase a weird gremlin somewhere that could be as easy as a terminal contact that has come loose in the connector...

if you haven't already, probably a good idea to take the old foam off the hvac blend doors and put something in that won't eventually disintegrate! if it were me, i would take it all out and clean out the ducts... those nasty cars that haven't been taken car of ends up with all kinds of **** in there

 

[agentmaddock]

Man i'm jealous, its super tough to find a ALH wagon and your building one! Thats awesome i hope everything goes well and good work

Happy Holidays!

Thanks man! It's currently all together, but not going good as it won't start.

nice work! tdi swaps fmtfw!! very glad you swapped in a golf front end, it's the ONLY way to have a vw wagon so jealous of that nice mk2 you just picked up too! *sigh*

as you work through the wiring, inspect each connector. it's a REAL PAIN if you get everything together and then have to chase a weird gremlin somewhere that could be as easy as a terminal contact that has come loose in the connector...

if you haven't already, probably a good idea to take the old foam off the hvac blend doors and put something in that won't eventually disintegrate! if it were me, i would take it all out and clean out the ducts... those nasty cars that haven't been taken car of ends up with all kinds of **** in there

Thanks! Yes, Golf Variant is the only way to go! I just wish it wasn't silver.... The mk2 has already been sold. It had more issues than I wanted to deal with in a daily.

Yeah I have been checking every connector. I hope I don't have to pull the dash on the wagon, but if I ever do I will replace the foam on the blend doors.

 

[agentmaddock]

Update!

I am not happy...

Got the 109 relay wired up, got a vagcom, it still won't start, and I have no idea where to start troubleshooting!!!!

The pump has been primed multiple times, injector lines have been cracked at the pump and injectors and I am getting fuel, and it will crank and crank and crank but it will not hit and there is absolutely nothing coming out of the exhaust! I don't know where to go from here.

Here is the vagcom scan. What else do I need to check now that I have a vagcom?
Saturday,28,December,2013,22:54:30:32264
VCDS Version: Release 11.11.3
Data version: 20120401


Chassis Type: 1J - VW Golf/Bora IV
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
76

VIN: 3VWSP69M63M019146 Mileage: 297070km/184590miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-012-AGR.lbl
Part No: 038 906 012 GN
Component: 1,9l R4 EDC G000SG 4308
Coding: 00002
Shop #: WSC 00066
VCID: 62C1B451EE54909
3VWSP69M63M019146 VWZ7Z0B5161054

No fault code found.
Readiness: 0 0 1 1 1

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ASR.lbl
Part No: 1C0 907 379 D
Component: ASR FRONT MK60 0103
Coding: 0018945
Shop #: WSC 01317 785 00200
VCID: 2B5F1975891E111

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 3Bx-907-044.lbl
Part No: 3B1 907 044 C
Component: CLIMATRONIC C 2.0.0
Coding: 11200
Shop #: WSC 01317
VCID: 2143FB5DABD2CB1

2 Faults Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent
01274 - Air Flow Flap Positioning Motor (V71)
37-10 - Faulty - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 6Q0 909 605 F
Component: 03 AIRBAG VW6 0202 0004
Coding: 12339
Shop #: WSC 01317
VCID: 3A712C312644B89

1 Fault Found:
00592 - Seat Belt Switch; Passenger (E25)
32-00 - Resistance too High

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1J0-907-487-A.lbl
Part No: 1J0 907 487 B
Component: Lenkradelektronik 0002
Coding: 00008
Shop #: WSC 01317
VCID: 30650E19F038729

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 906 L
Component: KOMBI+WEGFAHRSP VDO V62
Coding: 07232
Shop #: WSC 09254
VCID: 31630B1DFB327B1
3VWSP69M63M019146 VWZ7Z0B5161054

1 Fault Found:
01304 - Radio
49-00 - No Communications

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00066
VCID: F0E54E19B0B8B29

1 Fault Found:
01304 - Radio
49-00 - No Communications

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 1G Komfortgerát HLO 0003
Coding: 00258
Shop #: WSC 01317
VCID: 377735051556A51

Subsystem 1 - Part No: 1C1959801A
Component: 1G Tõrsteuer.FS KLO 0003

Subsystem 2 - Part No: 1C1959802A
Component: 1G Tõrsteuer.BF KLO 0002

Subsystem 3 - Part No: 1C0959811A
Component: 1G Tõrsteuer.HL KLO 0002

Subsystem 4 - Part No: 1C0959812A
Component: 1G Tõrsteuer.HR KLO 0002

3 Faults Found:
01330 - Central Control Module for Central Convenience (J393)
53-10 - Supply Voltage Too Low - Intermittent
01331 - Door Control Module; Driver Side (J386)
49-10 - No Communications - Intermittent
01359 - Internal Central Locking Switch; Passenger Side (E198)
27-10 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1J0-035-18x-56.lbl
Part No: 1J0 035 180 B
Component: Radio DE2 0005
Coding: 02041
Shop #: WSC 01317
VCID: 1E39C0A19AACF49

No fault code found.

End ---------------------------------------------------------------------

 

[audiphile]

did you check if the fuel shutoff valve is getting power? (it's the little 8mm nut on the injection pump).. you should get 12v on it with ignition on. Next step is to get the appropriate wiring diagram out for the donor TDI car and make sure the wiring matches the way you put it together into your wagon..

 

[agentmaddock]

did you check if the fuel shutoff valve is getting power? (it's the little 8mm nut on the injection pump).. you should get 12v on it with ignition on. Next step is to get the appropriate wiring diagram out for the donor TDI car and make sure the wiring matches the way you put it together into your wagon..

Yes the fuel shutoff valve is getting power. I'm afraid that is my next step... I hate wiring diagrams!

 

[mkIValh]

did you try advancing the injection pump? happen to me also cranked and cranked but no sign of starting, left it alone for a day came back the next day advanced the pump a bit and she started. From what you discribe your getting fuel and power, you"ve cracked both the injection pump and the fuel lines but it's its not squrting fuel at the proper timing. I don't know if this will help but i thought i would share what happen to me. good luck!

 

[agentmaddock]

did you try advancing the injection pump? happen to me also cranked and cranked but no sign of starting, left it alone for a day came back the next day advanced the pump a bit and she started. From what you discribe your getting fuel and power, you"ve cracked both the injection pump and the fuel lines but it's its not squrting fuel at the proper timing. I don't know if this will help but i thought i would share what happen to me. good luck!

How do I go about advancing the pump?

Thanks for your help!