A4Q/TDI Swap - need specific harness info

[IglooMan]

I am close to pulling the mechanical and have most of my ECU and harness figured out for swapping my 2.0 BHW TDI engine from a 2005 passat into my 99 A4Q 2.8V6 chasis. I am using an '00 ARL (EDC15P) ECU complete with the 40 pin engine harness and an adapted ALH harness fo rthe 80 pin side.
Link for the project is here:

http://forums.tdiclub.com/showthread...32#post2129132

I am having trouble maching up a few existing chassis/ECU inputs with my new ECU. Specifically, on the AHA ECU there are the following inputs:

Pins 5, 19 & 45 have connections to the ABS
Pins 9, 29 & 41 are connected to the A/C system
Pin 18 is connected to the Auto check system.

I need to know specifically what each pin is for and figure out what I can do with it, or the consequences of not being able to tie them into my ECU.

Anybody have some direction on this or can lead me to a good source to resolve this? Much appreciated guys.

here is a link to my ECU spread sheet I made, if it helps:

http://forums.tdiclub.com/showthread...32#post2129132

[Bic-Ball]

awesome project

[IglooMan]

awesome project

thanks Bic-Ball. I now wish I would of imported the 6 speed 01E in stead of sticking with the 01A 5 speed. No I will have to wait until after I break this one. I love the torque on this particular engine. It's a PD, it will be around 320ft-lbs at 1900 RPM. Nice roll on. Mileage should be pretty sweet, which is much need since we are paying about 6.50/gallon up here now.

[Bic-Ball]

i've always thought swapping an engine from a passat or jetta into the a4 would be cool but i dont have the knowhow/tools/shop/money to do it :p the vws here pass emissions in new york, i doubt the 1.9tdi in europe would pass here. i book marked your thread in the other forum and ill be following it.

[IglooMan]

i've always thought swapping an engine from a passat or jetta into the a4 would be cool but i dont have the knowhow/tools/shop/money to do it :p the vws here pass emissions in new york, i doubt the 1.9tdi in europe would pass here. i book marked your thread in the other forum and ill be following it.

yes, I considered an AHU (A3 Jetta/Golf) and an ALH (A4 Jetta/Golf) for the swap, even bought an ALH for rebuilding. Then found the 2.0TDI from the passat (BHW) for a good price. So I sold the ALH. The ECU's for the North American PD's is to crazy with inputs and faults, that is why I went with a Euro ECU. The 2.0BHW is basically a PD130/150, as per Euro specs with a few differences, like the larger bore. The pistons, rods, crank and block are built heavier than the ALH. The excepted max boost on AHU/ALH is 30psi, then you have to replace rods and coat pistons etc. For my initial mild tune, I will be running around 26psi, with 35psi being reasonable with the stock internals. The BHW also has the right motor mounts and accessories config to drop right into the A4.

my main concern right now is messing up the autocheck system, abs and air bags operation. hopefully somebody on here will know a bit more about these links between the different modules. I do know that at least one of each of those wires has got to be related to the k-line communication, since you can access errors in the sub modules with VAG-com.

[djwimbo]

I'm jealous. As much as I want to do it, I also just want to import a 1.9TDI A4 straight from Germany.

I don't know much about the Diesel engine codes. What's the stock output of that engine? That's before they changed over to the newer 2.0 TDI that's rumored to be coming out in the MK2 TT, right?

[Burntaudi]

Sounds like a mess. Isn't your 98 DBC and the donor motor DBW? How are you gonna overcome this? I think you need to swap instrument clusters too.

[djwimbo]

Isn't your 98 DBC and the donor motor DBW?

It's a diesel, it doesn't have a throttle body. The controls for it come with the ECU/harness swap.

[IglooMan]

I'm jealous. As much as I want to do it, I also just want to import a 1.9TDI A4 straight from Germany.

I don't know much about the Diesel engine codes. What's the stock output of that engine? That's before they changed over to the newer 2.0 TDI that's rumored to be coming out in the MK2 TT, right?

There is a guy on the TDI forum that imports wrecks and half cuts for projects. That would make the project easier in the sense that everything is there and you can just transfer it over. Depending on what you want it can be less or more money, if that makes sense. I had a very specific build in mind..I like custom. I would not be happy with OEM set-ups.

The stock output is 134hp/250ft-lbs. I will carry a couple of flashes with me. 175hp/320ft-lbs and hopefully 220hp/400ft-lbs (after turbo swap). The HP levels arn't that big compared to a 1.8T, but the torque levels are monster. The pump-douse engine injects at 20,000 psi so it can pump out major fuel and controls timing of injection event very well. The pistons, rods and crank are also much heavier than the rotary pump style.

[IglooMan]

Sounds like a mess. Isn't your 98 DBC and the donor motor DBW? How are you gonna overcome this? I think you need to swap instrument clusters too.

That is a pretty easy step to deal with. TPS and pedal bolt right in. 6 wires through the fire wall for that particular componant. I only have questions related to 6 pins out of 80 on the current Audi set-up. All 121 pins on new ECU are a go. I will run engine on engine stand when I am done some mods, and prior to installing it. I can check the VAG-hex during that process to verify it's all good before starting to pull my current engine and tranny.
Yes, the existing cluster is not a perfect match and will have some issues. I am going to put a scope on the RPM feed from the ECU to the cluster and I might be able to make a circuit with the right output to run the cluster tach. I do not see any problems with Oil temp, engine temp, VSS. The autocheck system may get bitchy. I am going to experiment with that the next few weeks. Iether way I will be driving it with or without a happy autocheck.