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HELP! 1.6l to 1.8T conversion wiring issues....

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  • HELP! 1.6l to 1.8T conversion wiring issues....

    Hi guys, i need the help of a wiring guru.

    I have a 2000 1.6 Golf AKL engine and am mid conversion in putting a 1999 Audi 1.8T AGU.

    Yes there is a pending build thread....

    I have the entire Audi subframe and changed the lot over, including ECU and its looms - a big enough job

    However the plugs that go into the rain tray are slightly different - original being orange , brown and white, and new being orange , green and white. all but a few wies match, but I think that is where the trouble lies...

    The engine cranks, but doesnt fire (should at least run for a few seconds even if the immobiliser is locking me out...).
    Fuel pump doesnt run - but a hotwire to the pump and it does - fuel pump ok. Interestingly with a multimeter it shows only about 5 volts at the pump with the key on and cranking.

    ah ha, you say - the fuel relay. Well it clicks with the key on and off - so not totally stuffed (and worked fine before the change...) - I will replace it anyway.

    Any other ideas? Specific wiring diagrams for the 1.6 and 1.8 would be nice - but they need to cover the exact years and models as there were some wiring changes at about year 2000...

    i have the Bently pdf for Golf mk4 - but it doesnt cover the 1.6 and it's 1.8 section wiring is inaccurate for the 1999 Audi A3.

    I have access to vagcom if required, but havent used it before.

    This car is so close, but now I'm going f#$king nuts and am dreaming about wiring, relays and cars that wont go.

    What was changed into the Golf was the entire front subframe, ecu and the two main looms from the ecu.

    Any help greatly appreciated
    My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

  • #2
    any auto elecs want to help me out, it's 90% there.

    it's my daily driver as well, started this on leave and now it's over, wifey is not impressed
    My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

    Comment


    • #3
      Have you verified that all the basics are working?

      Are the plugs getting spark? Is the ecu getting power? Injectors operating?

      I realise these are basic things, but diagnosing this issue may be impossible over the net.

      Nice project btw!
      MKV Golf 2.0 TDI DSG Sportline. Just nice.

      Comment


      • #4
        If you have vag com erase faults then see what faults are still there this may be able to pinpoint which direction to take,
        If you can upload log of faults to thread..

        Comment


        • #5
          1,8l Motronic (AGU)1.pdf

          1,8l Motronic (AGU).pdf

          One of these diagrams might be of use.

          Gavin
          optimumcode@gmail.com | https://www.vwwatercooled.com.au/for...i-;-79012.html | https://www.facebook.com/TTY-Euro-107982291992533

          Comment


          • #6
            thanks guys, I'll run some tests, log faults and see what happens next.

            Thanks for the pdfs Gav!
            My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

            Comment


            • #7
              I presume you are talking about the wires that run into the white box in the rain tray on the driver side?
              As far as I am aware these are just communication wires. However they are the only plugs that run into the cabin so they must have something to do with the fuel pump issue.

              I've just done the 1.8t conversion myself if you have any questions please feel free to PM me.

              Comment


              • #8
                pm sent mate
                Alba European
                Service, Diagnostics and repairs. Mobile Diag available on request
                Audi/VW/Porsche Factory trained tech 25+ yrs exp
                For people who value experience call 0423965341

                Comment


                • #9
                  @ James D : yes the white box in the rain tray and the asociated plugs. Thanks for the offer mate, I probably will send a PM
                  My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

                  Comment


                  • #10
                    Thanks Jmac
                    My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

                    Comment


                    • #11
                      check faults, cleared them and checked again:

                      VCDS Version: Release 10.6.4
                      Data version: 20110418

                      Thursday,22,September,2011,13:01:07:48399

                      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

                      Mileage: 229400km/142542miles
                      -------------------------------------------------------------------------------
                      Address 01: Engine Labels: 06A-906-018-AGU.lbl
                      Part No: 06A 906 018 AQ
                      Component: 1.8L R4/5VT MOTR HS D06
                      Coding: 04000
                      Shop #: WSC 06313
                      VCID: 71E2F7D51139

                      No fault code found.
                      Readiness: N/A

                      -------------------------------------------------------------------------------
                      Address 03: ABS Brakes Labels: 1J0-907-37x-ABS.lbl
                      Part No: 1J0 907 379 P
                      Component: ABS 20 IE CAN 0001
                      Coding: 03504
                      Shop #: WSC 01317
                      VCID: 3E781CE910E7

                      1 Fault Found:
                      00285 - ABS Wheel Speed Sensor; Front Right (G45)
                      35-00 - -

                      -------------------------------------------------------------------------------
                      Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
                      Part No: 6Q0 909 601
                      Component: 0C AIRBAG VW5 0004
                      Coding: 12355
                      Shop #: WSC 01317
                      VCID: F0E472D19A33

                      No fault code found.

                      -------------------------------------------------------------------------------
                      Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
                      Part No: 1J0 920 805 B
                      Component: KOMBI+WEGFAHRS. BOO V01
                      Coding: 03703
                      Shop #: WSC 30071
                      VCID: 254AD3859571

                      Part No: Ident
                      Component: Nr. WEGFAHRS.:VWZ6Z0Y1997147
                      Ident.-Nr. WEGFAHRS.:VWZ6Z0Y1997147

                      1 Fault Found:
                      01177 - Engine Control Unit
                      65-10 - Unauthorized - Intermittent

                      -------------------------------------------------------------------------------
                      Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
                      Part No: 6N0 909 901
                      Component: Gateway K<->CAN 0001
                      Coding: 00006
                      Shop #: WSC 01317
                      VCID: F0E472D19A33

                      No fault code found.

                      -------------------------------------------------------------------------------
                      Address 46: Central Conv. Labels: 1J0-959-799.lbl
                      Part No: 1J0 959 799 Q
                      Component: 4C Zentral-SG Komf. 0001
                      Coding: 04097
                      Shop #: WSC 01317
                      VCID: 4C9C4621565B

                      Part No: 1J2959802C
                      Component: 4C Tõrsteuerger. FS0002r

                      Part No: 1J2959801D
                      Component: 4C Tõrsteuerger. BF0002r

                      Part No: 1J4959811C
                      Component: 4C Tõrsteuerger. HL0002r

                      Part No: 1J4959812C
                      Component: 4C Tõrsteuerger. HR0002H

                      No fault code found.

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


                      I expect the ABS faults as the sensors are unplugged whilst I am doing the suspension.
                      My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

                      Comment


                      • #12
                        Originally posted by Stan View Post
                        -------------------------------------------------------------------------------
                        Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
                        Part No: 1J0 920 805 B
                        Component: KOMBI+WEGFAHRS. BOO V01
                        Coding: 03703
                        Shop #: WSC 30071
                        VCID: 254AD3859571

                        Part No: Ident
                        Component: Nr. WEGFAHRS.:VWZ6Z0Y1997147
                        Ident.-Nr. WEGFAHRS.:VWZ6Z0Y1997147

                        1 Fault Found:
                        01177 - Engine Control Unit
                        65-10 - Unauthorized - Intermittent

                        -------------------------------------------------------------------------------
                        What ECU, cluster, key/ignition barrel are you using?

                        Comment


                        • #13
                          using the 1.6 key and ignition, original 1.6 cluster, and the 1.8t ecu...
                          My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

                          Comment


                          • #14
                            It wont work.
                            You need to have the Key, ignition, cluster and ECU all the sync.
                            The only was around it will be to get an IMMO delete or something coded from the stealership. (Pretty sure they can sync it all if you can prove ownership.)

                            Comment


                            • #15
                              i thought as much, but cant vagcom put them all together - the ecu is the only odd one out in the group - key, ignition and cluster are all original....
                              My build thread here: 1.6 sr into 1.8T http://www.vwwatercooled.org.au/foru...-8t-63249.html

                              Comment

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