IT'S ALIVE!!!!! Updates to engine repl./install

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

Well, I have to provide some updates to my frantic revival of the car.

I am heading out of town on Sunday so I have until then (in my mind) to get this done and the car running so I don’t leave town for a week or two with it still disabled in the driveway.

I pulled off the front of the car to make the swap easier

Unhooking everything, the engine was ready to come out

Aah….the genius…er, um, I mean madman at work

Next thing you know, there’s a gaping hole where the engine used to be:

hmmmm….is there something missing from this photo?

I also took the opportunity to powerwash the engine bay really well…300K of gunk and buildup finally came off!!!!!!

There’s the old engine out…with the new one in the background

As of bedtime tonight (now) this is how it sits. The new engine (from the ’99 Manual NB with 19K on it) has the manual injectors, the auto pump, and a nice new TB and tensioner…almost ready to put back in

Tomorrow night it’s time to put the torque converter on this one, put the tranny back on, and put it in the car…at least get it hung.

Wish me luck.

I will try to keep updating.

Mike

 

[Herm TDI]

Re: 303K miles is all she\'s got!!!! Carnage insid

Wish me luck. I will try to keep updating. Mike

Certainly...you deserve a little more than just luck after taking such a set-back like losing an engine.
I hope the rest of the process goes smoothly for you.

 

[verbalnoncents]

Re: 303K miles is all she\'s got!!!! Carnage insid

I want to wish you all the best with your new lease on life...

I thought the mini VW beetle you have in your garage is really cute too. Nothing like getting the kids hooked on VW at a young age... is that mini a diesel?

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

I thought the mini VW beetle you have in your garage is really cute too. Nothing like getting the kids hooked on VW at a young age... is that mini a diesel?

No, it's not a diesel, but she is able to ID a diesel just by sound...good for a 3 year old!!! She wants to help me work on cars all the time.

Mikey

 

[Muggins]

Re: 303K miles is all she\'s got!!!! Carnage insid

My hat's off to you Mikey, for taking on such an ambitious project.

Thems that can, do. Thems that can't, talk.

You're a them that can, Mikey!

Keep us updated.

 

[clove911]

Re: 303K miles is all she\'s got!!!! Carnage insid

Way to be Mikey. I am almost done with my car. Should have the hood aligned maybe tomorrow. Will post some pics when its done. Hope to hear that you get it running soon.

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

I had a minor setback tonight by not having replacement stretch bolts for the flywheel/driveplate and for the harmonic dampner. I do not dare reuse these as I don't want anything else to fly loose on this engine.

Soon enough, this engine will be running and will be powering my lovely TDI down the highway.

Thanks for the words of encouragement. God knows I need them!!!!

Mikey

 

[runonbeer]

Re: 303K miles is all she\'s got!!!! Carnage insid

Relish these moments

good luck with the install

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

Well...major progress made today. I got the tranny on the engine (after much fighting and yelling at the engine and tranny as they would not mesh properly for over 8 hours!!!)

I also got the engine back in the car...

I didn't get to snap a pic of it all back together...you'll have to wait until tomorrow AM. The whole front is back on the car with nothing left to connect...less what what is described below.

It's about ready to start...but I am running into trouble now.

I'm not sure if the tranny selector isn't working right or what, but the car will try to start....but will only click and not even try to start.

Not sure why.

I do have one connector that I can't find any place for it to go.
It comes off the same wire loom as the coolant temp sensor...but I have no idea where it goes....HELP

I will likely cross post the help request just so I can get add'l help from those that don't check in here.

Mikey

 

[BlueKnight]

Re: 303K miles is all she\'s got!!!! Carnage insid

It sounds like you aren't getting fuel. Make sure you purge the air out of all the fuel lines if you haven't. Also make sure you are getting fuel at the injectors.

Gook luck!!

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

It sounds like you aren't getting fuel. Make sure you purge the air out of all the fuel lines if you haven't. Also make sure you are getting fuel at the injectors.

I should note that it's not even turning over, just a click and nothing...

Mikey

 

[strretch]

Re: 303K miles is all she\'s got!!!! Carnage insid

You getting any codes?

 

[tongsli]

Re: 303K miles is all she\'s got!!!! Carnage insid

It's for a speed sensor. Posting PDF soon...

 

[tongsli]

Re: 303K miles is all she\'s got!!!! Carnage insid

The Connector:

http://pics.tdiclub.com/data/500/13052001ecu_harness.pdf

The Sensor:
http://pics.tdiclub.com/data/500/1305speed_sensor.pdf

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

I'll have to see if I can find that in the morning...thanks.

I will also check codes.

I'll let you know what I find out. I want this thing running before I leave tomorrow evening!!!

Mikey

 

[tomo366]

Re: 303K miles is all she\'s got!!!! Carnage insid

Did you put the automatis wiring harness on it??

 

[tongsli]

Re: 303K miles is all she\'s got!!!! Carnage insid

The original car is an automatic. The tranny is an auto, the donor engine is from a manual.

L

 

[Dodoma]

Re: 303K miles is all she\'s got!!!! Carnage insid

As you may be aware, the TDI with automatic transmission and those with manual have slight different pump (pump plunger diameter is different). You have to choice, either replace the engine with the failed engine pump, of disammble the pump and swap the plunger.

Or: start the car by by passing ignition switch. All you want is to start the engine. Directly connecting wire from the battery to the stater and another wire to the pump fuel solonoid. Once it starts, you can tinker to identify what is causing the stater not to "fire" or crank.

I don't think you have a serious problem.

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

I did swap all of the critical components of the harness. I also swapped over the parts of the engine that are automatic specific so that it should have all of the automatic "doohickies" on it.

I did leave the manual injectors on it and put the automatic pump on it...

hopefull for a little bump.

Mikey

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

DELETED: see VAG-COM readout below

 

[DPM]

Re: 303K miles is all she\'s got!!!! Carnage insid

Did you have the ignition turned on whilst any components were disconnected? Any chance you've omitted to reconnect a ground wire somewhere?

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

Did you have the ignition turned on whilst any components were disconnected? Any chance you've omitted to reconnect a ground wire somewhere?

Had to in order to move the car around in the driveway...but I cleared all the codes and these came back.

I know the Bentley says so, but where are the grounds in the engine bay? I may have missed one.

Mikey

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

Updated VAG-COM....after clearing codes all the way through once:


Address 01: Engine
Controller: 038 906 012 BD
Component: 1,9l R4 EDC G500AG 2507
Coding: 00001
Shop #: WSC 00066
2 Faults Found:
17946 - Fuel Shutoff Solenoid (N109): Open or Short to Ground
P1538 - 35-00 - -
16764 - Glow Plug/Heater (Q6) Circuit Malfunction
P0380 - 35-00 - -
Readiness: N/A

-------------------------------------------------------------------------------
Address 02: Auto Trans
Controller: 01M 927 733 HK
Component: AG4 Getriebe 01M 4606
Coding: 00000
Shop #: WSC 00000
No fault code found.
------------------------------------------------------------------------------
Address 17: Instruments
Controller: 1J0 920 900 M
Component: A4-KOMBIINSTR. VDO V55
Coding: 07242
Shop #: WSC 00066
IMMO-IDENTNR: VWZ7Z0X1291828
1 Fault Found:
01314 - Engine Control Module
49-10 - No Communications - Intermittent
-------------------------------------------------------------------------------
Address 19: CAN Gateway
Controller: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00007
Shop #: WSC 00066
1 Fault Found:
01314 - Engine Control Module
49-10 - No Communications - Intermittent


Mikey

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

Long story short....It's alive

Story:
So after staring at the engine bay all morning trying to figure out what was wrong, I started tugging on wires to make sure they are all tight. Just now I found one tucked very neatly under the battery box....

The friggin' negative cable from the battery. It was grounding out against the chassis, but wasn't hooked.

I hooked it up...albiet probably to the wrong place (where is the right hookup for the negative battery cable)...and cranked and it started!!!!

I still don't have a hookup for that one connector (see above) but it's alive. I met my aim...to have it running before I leave town this evening!!!!!!!!!

Mikey

 

[asau]

Re: 303K miles is all she\'s got!!!! Carnage insid

Congrats :-D

 

[strretch]

Re: 303K miles is all she\'s got!!!! Carnage insid

That's awesome! I'm very glad you got it running before leaving town, and it sounds like it was a pretty simple fix. Sorry I wasn't there to help out.

 

[whitedog]

Re: 303K miles is all she\'s got!!!! Carnage insid

Turn on your sound and click me.

 

[clove911]

Re: 303K miles is all she\'s got!!!! Carnage insid

awesome mikey. congrats

 

[Muggins]

Re: 303K miles is all she\'s got!!!! Carnage insid

You have a lot of courage and fortitude for even attempting this daunting project.

WAY TO GO!!! YOU DA MAN, MIKEY!!

 

[mikeyworks]

Re: 303K miles is all she\'s got!!!! Carnage insid

Turn on your sound and click me.

Thanks, I needed that!!!!

It's the exact sound going through my head!!!

I have a little tinkering left when I get home:
Exhaust to hook up
Ground to hook up properly - where does the main ground hook to?
One last connector - one listed above, where does that go?

Thanks,
Mikey