OK so I'm all caught up on this whole thing. The only thing I think I may have missed is what tranny Is being used? Will a 6 speed manual work? And if it works for your TDI it should work the same for my 2.5 correct?
You should check if there is a 6 gear AWD gearbox that fits on the 2,5 engine. The AWD gearbox is also connected to the engine with a bracket where the right drive shaft is connected to the gearbox. See the black bracket on the picture below:
There are many brackets for different engines available, it has to be checked if on the 2,5 you have the mounting holes and if one of the existing brackets fits. Without this bracket you might have issues later.
I am doing a Jetta AWD conversion right now in Germany, you can take a look here:
It is in german, but the pictures help a lot.
You thread does help even though it's in german. At least I can go through the pics and get an idea of where to look for possible issues. I do have one question. I believe in this thread it was said that the shallower spare tire area of the jetta is what is needed, not the deeper spare tire of the golf. In your pictures it looks like the deeper one is what is needed. Any clarification on this?
There is no shallow and deep version for the Jetta. As the Jetta has the same floor pan as the Golf Variant (I Think is called Jetta Sportwagon in the US), I have compared the trunk floor between Jetta and Sportwagon FWD and the partnumber was the same. Than I purchased the trunk floor pan from the Sportwagon 4Motion, and found that only a small portion is different there. You can see in my pictures, my finger showes that region on the new trunk floor pan. This difference is only due to the exhaust pipe. The rear axle with Haldex fits without changing anything on the Jetta floor pan.
OK good that's what I thought. As far as electronics go, is there anything that has to be changed with the electronics I have already or is the 4motion pretty much it's own stand alone system? I have ESP on my vehicle. I'm not sure if that runs through my ECU at all. Would the 4motion hook up to that without issues?
With a 2008 version you might be lucky with the ESP; in my case (2007) I needed a new one. Check if you have an ESP MK60 as I had or MK60 EC1.
- replaced ESP unit (complete unit)
- replaced acceleration sensor unit for the ESP
- replaced the rear axle sensor for the Xenon (only with Xenon)
- new second fuel level sensor
- replaced 2x rear wheel speed sensors
- changed ESP wiring (same connector but different pin assignment + 1 new pin)
- new wiring for second fuel sensor
- new wiring for Haldex
- chenged the engine
- set up the AWD in the gateway
- changed headlight aim control (only with Xenon)