Golf 5 (1K): 4Motion

[maloosheck]

This is my quest for holy grail .

I am trying to retrofit 4Motion in my '06 Jetta TDI. The biggest concern is if Haldex controller needs different ECU (and other control modules). I was able to get the full scans from Tiguan FWD and AWD. Here are the differences I noted:

ECU:

Quote, originally posted by Tiguan AWD »

Address 01: Engine (CCT) Labels: None Part No SW: 06J 906 026 H HW: 06J 906 026 AF Component: MED17.5 TFSI 2,0 3322 Revision: AAH03--- Serial number: VWX7Z0H23NK1EN Coding: 0423010A190F0160 Shop #: WSC 06403 444 82690

Quote, originally posted by Tiguan FWD »

Address 01: Engine (CCT) Labels: 06J-906-026-CCT.clb Part No SW: 06J 906 026 G HW: 06J 906 026 AF Component: MED17.5 TFSI 2,0 3151 Revision: AAH03--- Serial number: VWX7Z0H13NR1ER Coding: 0423010A19070160 Shop #: WSC 09451 444 92448

I noted 2 differences:
1. Software revision
2. Coding

This is my major concern. Does it mean Haldex requires ECU that sends EXTRA signals over CAN-BUS? Is there any way I can check it or have it checked?

Transmission:

Quote, originally posted by Tiguan AWD »

Address 02: Auto Trans Labels: 09G-927-750.lbl Part No SW: 09G 927 750 GG HW: 09G 927 750 GG Component: AQ 250 6F 1174 Revision: 00H76000 Serial number: Coding: 0000840 Shop #: WSC 01324 785 00200

Quote, originally posted by Tiguan FWD »

Address 02: Auto Trans Labels: 09G-927-750.lbl Part No SW: 09G 927 750 GG HW: 09G 927 750 GG Component: AQ 250 6F 1174 Revision: 00H76000 Serial number: Coding: 0000840 Shop #: WSC 01324 785 00200

Differences: NONE!

ABS:

Quote, originally posted by Tiguan AWD »

Address 03: ABS Brakes Labels: None Part No SW: 5N0 614 517 L HW: 5N0 614 517 L Component: J104 C2 450 V2 0006 Revision: --H11--- Serial number: 00000001029003 Coding: 0002332 Shop #: WSC 01324 785 00200

Quote, originally posted by Tiguan FWD »

Address 03: ABS Brakes Labels: 5N0-614-517.lbl Part No SW: 5N0 614 517 L HW: 5N0 614 517 L Component: J104 C2 450 V2 0006 Revision: --H11--- Serial number: 00000000949435 Coding: 0002329 Shop #: WSC 01324 785 00200

Difference: Just coding. In my case (Jetta) I am quite sure I need to replace the ABS controller.

Steering Wheel:

Quote, originally posted by Tiguan AWD »

Address 16: Steering wheel Labels: 1K0-953-549.lbl Part No SW: 1K0 953 549 BG HW: 1K0 953 549 BG Component: J0527 752 0100 Coding: 0012022 Shop #: WSC 01324 785 00200 Part No: XXXXXXXXXXX Component: E0221 002 0010

Quote, originally posted by Tiguan FWD »

Address 16: Steering wheel Labels: 1K0-953-549.lbl Part No SW: 1K0 953 549 BF HW: 1K0 953 549 BF Component: J0527 752 0100 Coding: 0010022 Shop #: WSC 01324 785 00200

I believe the difference is related solely to the multifunction in AWD. I have read that Haldex controllers in VW do not use the wheel angle signal to calculate the car direction.

Steering Assist:

Quote, originally posted by Tiguan AWD »

Address 44: Steering Assist Labels: Redir Fail! Part No SW: 5N1 909 144 F HW: 5N1 909 148 D Component: J500__APA-BS KL.051 0401 Revision: 1AH03249 Serial number: 00073460078201 Coding: 0000258 Shop #: WSC 01324 785 00200

Quote, originally posted by Tiguan FWD »

Address 44: Steering Assist Labels: 5Nx-909-144.lbl Part No SW: 5N1 909 144 G HW: 5N1 909 148 E Component: J500__APA-BS KL.050 0401 Revision: 1AH01247 Serial number: 00080300121001 Coding: 0000258 Shop #: WSC 01324 785 00200

That slightly bothers me. I have no idea if this is just another revision of the controller or Haldex needs different steering assist module.

[vw leben]

Great post! This is the car vw should but won't make! there is a guy in the world speed challenge with a bi-turbo PD setup. Add that to this and thank you mama! Wish I could help, but sounds like you are on the rite track.

[EL_3grab]

Bump

[maloosheck]

Here is few more findings:

The engines BKC (1.9 TDI PD) and BKD (2.0 TDI PD) were both used in the FWD/AWD setups. Here is an extract from label files:

Quote, originally posted by 03G-906-016-BKC.LBL »

C00,Engine Control Unit (J248/J623) Coding C01,00?0xxx: Configuration I C02,0 = Standard (Flexible Service Intervals / 2 Coolant Fans) C03,3 = 1 Coolant Fan C04,5 = Flexible Service Intervals inactive C05,00x0?xx: Powertrain C06,0 = Front-Wheel-Drive (FWD) C07,1 = All-Wheel-Drive (AWD) C08,00x0x?x: CAN-Databus C09,+1 = Anti-Lock Braking System (ABS) C10,+2 = Airbags C11,+4 = Climate Control (Climatronic) C12,00x0xx?: Transmission C13,1 = 5-Speed Manual Transmission C14,2 = 6-Speed Manual Transmission C15,8 = Direct-Shift-Gearbox (DSG/02E)

Quote, originally posted by 03G-906-016-BKD.LBL »

C00,Engine Control Unit (J248/J623) Coding C01,00?0xxx: Configuration I C02,0 = Standard (Flexible Service Intervals / 2 Coolant Fans) C03,3 = 1 Coolant Fan C04,5 = Flexible Service Intervals inactive C05,00x0?xx: Powertrain C06,0 = Front-Wheel-Drive (FWD) C07,1 = All-Wheel-Drive (AWD) C08,00x0x?x: CAN-Databus C09,+1 = Anti-Lock Braking System (ABS) C10,+2 = Airbags C11,+4 = Climate Control (Climatronic) C12,00x0xx?: Transmission C13,1 = 5-Speed Manual Transmission C14,2 = 6-Speed Manual Transmission C15,8 = Direct-Shift-Gearbox (DSG/02E)

So it seems like AWD / FWD was just a matter of coding. But per ETKA each transmission/powertrain setup has a different ECU.

So the question would be: do I need a separate ECU for each setup or can I have one and just recode it with VAG-COM depending on the setup?

Second thing I did was trying to find out what are coding options for my engine (BRM). The difficulty was there is no separate label file and VCDS uses BEW label file instead. I guess they are similar or the same.

Quote, originally posted by 038-906-016-BEW.LBL »

C00,Engine (J248) Coding C01,0?x00xx: Heating/Air Conditioning C02,0 = Automatic Climate Control (Climatronic) C03,1 = Manual Climate Control (Climatic) C04,0x?00xx: Service Interval C05,0 = with flexible Service Interval C06,5 = without flexible Service Interval C07,0xx00?x: CAN-Databus C08,+1 = Brake Electronics (ABS) C09,+2 = Airbag C10,+4 = Climatronic C11,0xx00x?: Transmission C12,1 = 5-Speed Manual Transmission C13,4 = 5-Speed Automatic Transmission C14,8 = 6-Speed Direct Shift Gearbox

So all options I have is FWD 5MT or FWD 5AT or FWD 6DSG. I cannot even code 6MT... But let's see. My current (factory) coding is:

Quote, originally posted by VCDS »

Address 01: Engine Labels: 038-906-016-BEW.lbl Part No SW: 03G 906 016 AB HW: 028 101 223 8 Component: R4 1,9L EDC G000SG 7550 Revision: --H01--- Serial number: VWZ7Z0E2763060 Coding: 0050071 Shop #: WSC 00066 000 00000

Which is: Climatronic, No flex, all CAN data, 5MT. Wait a moment, I do not have Climatronic in my car. And it works just fine, no errors.

So the next question would be: What is the ECU coding for? Does it enable additional transmission outside of ECU or does it configure the ECU itself internally and does not have an impact on any other component in the car? Is my engine going to explode if I use 6MT instead of 5MT?

The BRM comes with two different ECUs: 03G 906 016 AB for 5MT and 03G 906 016 AC for 6DSG. I have not done that yet, but I got the AC ECU and my tuner was able to upload my factory maps to the AC ECU saying that I can adapt it in my car and use it with 5MT just like AB. Well, as soon as I find some time, I will try to adapt it.

I believe that the most similar engine to BRM in EU is BLS. It is 1.9TDI 8V Pumpe Duse 105HP. The only difference I recall was the lack of vane position sensor on the turbocharger (and what I found out later - DPF). Similar setup was BMM: 2.0L 8V Pumpe Duse 140HP.

I was trying to find the label files for BLS/BMM engines to check if the coding allows for 6MT 4WD setup, but I have not found it in VCDS. Per ETKA BLS was paired both with FWD and AWD powertrain.

When I was looking for a bolt-in turbocharger in EU, I found that the BMM turbocharger should work. The problem was that vane position sensor. I was thinking about using BMM ECU and remap it to BRM ECU. So I started to study diagrams and it seems the ECUs use the same pin configuration for each sensor/actuator. I dropped the whole idea because of DPF sensors...

Would it be possible to use, say, BKC ECU in BRM engine after remapping it?


Modified by maloosheck at 5:48 AM 10-3-2008

[FluxedSpec-V]

Subscribed!!

Nice to start the same project on the GLi

[mYGeL]

i finished my AWD Conversion about 4 weeks ago

Everything works fine. Just that i need to fins a new ABS Module as it cant be recoded to handle the AWD. tried several codes from R32, S3 A3 and Altea AWD.

Still doesnt work and vagcom says wrong module installed.. Evrything besides ABS ESP works

Waked upp yesterday and some snow on the ground...
Wanted to test little.. but taking it little easy as the car is painted a week ago and also rims newly powdercoated..

but heres a video

http://www.youtube.com/watch?v=AkOcP314huk

[mYGeL]

i finished my AWD Conversion about 4 weeks ago

Everything works fine. Just that i need to fins a new ABS Module as it cant be recoded to handle the AWD. tried several codes from R32, S3 A3, Tiguan and Altea AWD.

Would like to try code from Gold R and R20 also but havent found them codes..

Still doesnt work and vagcom says wrong module installed.. Evrything besides ABS ESP works

Waked upp yesterday and some snow on the ground...
Wanted to test little.. but taking it little easy as the car is painted a week ago and also rims newly powdercoated..

but heres a video

http://www.youtube.com/watch?v=AkOcP314huk