2016 jetta 1.4T standalone swap into '74 Beetle

   #1  

davek181

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Give a monkey a crescent wrench, and what happens? I have swapped yet another VW engine into the wrong chassis, at least according to some people. I have adapted and installed a 2016 CZTA into a '74 Beetle and even have the original engine lid shutting to hide it. I am no stranger to VW swaps and adaptions but it is getting harder each year with electronics upgrades (?).

I bought a complete wrecked car so I would have all the parts I didn't know I would need. I have nearly everything figured out and mocked to fit. I separated the engine harness from the car harness and connected similarly to the original car. I used the instrument cluster and key reader coil and ECU from the car. I simplified the canbus system from the BCM/CAN unit into an older 20 pin canbus and connected only what I thought I would need to make it run, much like I have done in past swaps.

I have communication with all components through the can and I have the engine running in the car, but it is in limp mode. In my ignorance I bought a wrecked car with an auto trans and Kessey system, I was able to get around the Kessey and immobilizer function and get it to run. I was thinking I could just recode the ECU to manual trans and be done with that as I strongly believe that is the limp cause, no communication with transmission controller. I was unable to recode it and only received an out of range error when trying. I contacted Ross-tech and Dana replied that the ECU's are distinctive to the transmission and can not be recoded, so I suggested replacing the ECU, cluster and key from a similar manual trans car, which I am now trying to locate and purchase. I am hoping that will allow free revving. There was some question as to the need of wheel speed sensing even with a manual trans, and possible traction control intervention. Dana Had no answers as this is un-trodden ground and suggested I throw this out on the retrofit forum to see if anyone has experience or ideas.

I have tried contacting any tuners I could think of, originally just to do an Immo delete to make my install easier and so far all just have package tunes for the cars and no immo deletes at all. I am beyond the immo issue and will just hide the cluster under the back seat or somewhere along with the CAN gateway as I have done in the past swaps sometimes. So far though no interest in standalone tunes has been forthcoming. My last swap was a CBEA common rail diesel and Charley at Kermatdi helped immensely in eliminating the little bugs that popped up. He was interested in making a standalone file and I became a test bed for him and it has worked out well. He has since sold tunes to people wanting common rail swaps.

I was going to post an auto scan, but apparently I am not allowed that option, being a newb to this forum. I welcome any hints or suggestions, or just read the saga and shake your head.

Thanks for reading
Dave
 
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   #2  

Uwe

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Hi and welcome.

Why do you think you are "not allowed" to post a scan? Just copy & paste the text, and preferably put it between CODE tags, as explained here.

-Uwe-
 
   #3  

davek181

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It said at the bottom of the page I was not allowed to post attachments, and I found that true. It is all in knowing the proper procedure, thank you. There are many codes and problems shown, but bear in mind that I have only installed the ECU, cluster and can gateway. The cooling fans are not plugged in as the radiator is not fitted yet, and the intercooler water pump is dry, as it noted. (how do it know?)
I have located a car in a semi local wrecking yard that is a manual trans non kessey vehicle. They are rounding up the ECU, cluster and key for me and hopefully it will get me past the AT controller blockage and onto the next major hurdle.

Interesting side note: I have and use the Autel IM608 key programmer and before I harvested the engine from the wreck I purchased I was able to initialize a dealer key and encode an immobilizer chip for the car, though it did not return a SKC. I wanted to just tape the chip over the reader coil to run the car, and that part worked fine. Now that the car is missing from the equation Autel is incapable of connecting to the car at all, yet VCDS speaks freely. Unfortunately Autel does not have the MED17.1.21 in their database and I am unable to bench test the ecu and extract the pin code. I had hoped to be able to duplicate the immo chip and not have to buy the steering column from the wrecking yard just to get the key. I have contacted Autel support and requested that it be added to their database, but don't have a lot of hope of that happening soon enough for me.

Thank you in advance for any advice and help or even (Gulp) criticism.


Code:
Monday,27,April,2020,14:39:06:41227
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x86
VCDS Version: 20.4.1.0
Data version: 20200331 DS317.0
www.Ross-Tech.com


VIN: 3VWD67AJ7GM337978   License Plate: 



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: AJ-VW36 (7N0)
Scan: 01 17 19 25

VIN: 3VWD67AJ7GM337978   Mileage: 132470km-82313miles

01-Engine -- Status: Malfunction 0010
17-Instruments -- Status: Not registered 0011
19-CAN Gateway -- Status: Malfunction 0010
25-Immobilizer -- Status: Not registered 0001
 
-------------------------------------------------------------------------------
Address 01: Engine (J623-CZTA)       Labels:. 04E-907-309-V1.clb
   Part No SW: 04E 906 023 AQ    HW: 04E 907 309 AP
   Component: R4 1.4l TFS   H22 2954  
   Revision: X5H22---    
   Coding: 011A0012232400000000
   Shop #: WSC 00066 790 00013
   ASAM Dataset: EV_ECM14TFS01104E906023AQ 003003
   ROD: EV_ECM14TFS01104E906023AQ.rod
   VCID: 6FEDBBA6B63C07FEE2-803A

   CAN Converter 01: 

15 Faults Found:
4527 - Coolant Fan Control Circuit 1 
          P0480 00 [039] - Electrical Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

14643 - Coolant Pump for Intercooler 
          P16BA 00 [039] - Running Dry
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 3
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:42

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

9504 - Door Control Module - Driver's Door 
          U0199 00 [039] - No Communications
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

4708 - No Communications with HVAC Control Module (J301) 
          U0164 00 [039] - -
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

4710 - No Communications with Airbag Control Module 
          U0151 00 [039] - -
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

4713 - No Communication with ABS Brake Control Module 
          U0121 00 [167] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          MIL ON - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

4714 - Steering Column Control Module 
          U0212 00 [039] - No Communications
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

16706 - Steering Column Control Module 
          U0212 00 [039] - No Communications
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 5
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:37

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

4718 - No Communication with Transmission Control Module 
          U0101 00 [167] - -
          MIL ON - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40

11943 - EVAP System Leak Detection Pump Heater Control Circuit 
          P240A 00 [039] - Open Circuit
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

11940 - Control Circuit for EVAP Vent Control 
          P0447 00 [039] - Open Circuit
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

11949 - EVAP Leak Detection Pump Control Circuit 
          P2400 00 [039] - Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:39

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

4649 - Brake Booster Pressure Sensor 
          P0555 00 [039] - Electrical Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

7786 - Sensor for Ambient Air Temperature (G17) 
          P0070 00 [039] - Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:38:07

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

4252 - Sensor for Ambient Air Temperature (G17) 
          P0071 00 [039] - Implausible Signal
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:38:07

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 970 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

Readiness: 1110 0101

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 5C6 920 955 A    HW: 5C6 920 955 A
   Component: KOMBI         H04 1007  
   Serial number: 00000000000000
   Coding: 2700000000
   Shop #: WSC 00066 790 00318
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A05730
   ROD: EV_Kombi_UDS_VDD_RM09_005_VW31.rod
   VCID: 2D5161AE7CB035EE90-8078

9 Faults Found:
9453074 - Fuel Level Sensor 1 
          B103E 1B [009] - Resistance Too High
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1

9453330 - Outside temperature sensor 
          B103F 1B [009] - Resistance Too High
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1

12605184 - Databus 
          U1200 00 [008] - Defective
          Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 40

12605440 - Databus 
          U1201 00 [008] - No Communications
          Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 40

12648704 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1

12656896 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1

12664832 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1

12669184 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1

13638912 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1


-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 7N0-907-530-V2.clb
   Part No SW: 7N0 907 530 AJ    HW: 7N0 907 530 AJ
   Component: J533  Gateway H51 1634  
   Revision:   H51       Serial number: 18011400F16012
   Coding: 350000
   Shop #: WSC 12345 123 12345
   VCID: 78FF80FACB72404633-802C

2 Faults Found:
01336 - Company Data Bus for Comfort System 
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 0
                    Mileage: 132475 km
                    Time Indication: 0
                    Date: 2020.04.27
                    Time: 00:00:01

01044 - Control Module Incorrectly Coded 
            000 - -
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 132475 km
                    Time Indication: 0
                    Date: 2020.04.27
                    Time: 00:00:00


-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 5K0 953 234     HW: 5K0 953 234 
   Component: IMMO          H04 1007  
   Serial number:               
   Coding: 000000
   Shop #: WSC 00066 790 00318
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03710
   ROD: EV_Immo_UDS_VDD_RM09_VW31.rod
   VCID: 6ADBAAB28DDEE2D6B5-803E

No fault code found.
 
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   #4  

Jetta 97

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I would say this is your biggest problem.



4713 - No Communication with ABS Brake Control Module
U0121 00 [167] - -
[New feature! Extended UDS fault detail is only supported by current gen. interfaces]
MIL ON - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 132475 km
Date: 2020.04.27
Time: 00:37:38
 
   #5  

Dana

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Thanks Marin. That was one of my concerns because the lack-of ABS communication can cause limp mode problems in an assembled vehicle. Another thing I was worried about is that 7N0 CAN GW (because this would have had a PQ25 BCM with integrated 19) ... but that may only be a concern if a MK60EC1 module needs to be added and there's a VIN/internal communication problem between the related modules.

In the meanwhile I do believe getting a manual trans 01-Engine controller involved is a good place to start.
 
   #6  

NEtech

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Have you tried remove Airbag, HVAC, ABS in Engine Coding ?
One at a time.
 
   #7  

davek181

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I have tried to remove them all ways I could imagine, including one by one. I even added them back into the can gateway install list and tried to remove them from the engine again, one by one. I exit completely out of 01 each time I try and retry just for good measure. All I get is a code rejected out of range error for my trouble. I think they are hard wired into the ecu like the AT controller. They are shown in the long coding helper in blue typeface, where others removable are in black.

To top it off, the manual ecus and clusters I find available in the wrecking yards nearby are all missing the keys. I have a cluster and ecu coming anyway in hopes I can encode a chip for it. The parts are even out of the same date range as the car the engine came from as a bonus.
 
   #8  

davek181

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Well it was a failure trying to add a key to the cluster I got without one. I kinda knew it would go that way, but a person has to try. I could not communicate with the ecu or cluster without the rest of the car and autel tech had no answers though they are trying very hard. They seem to like the challenge and the project.

Trying to find a ecu and cluster and key matched is harder than you think. Firstly the manual cars are rarer, and to my surprise the key seems to always be the missing part. I had one yard tell me right from the start they would not have one for the car, yet in the pictures of the interior it is plainly in the switch. When I mentioned that he said that it was there then but the chances of it being there now are nil. How hard is it to zip tye a key to the column, I wonder. How do they ever expect to sell it without? I called several yards and finally located a possible match. It is out of a 2017 manual car, I hope that is compatible, their interchange says so but they had no part numbers for me. There seemed to be some confusion on the other end of the line, but they probably thought I was the idiot as I must have repeated 10 times that all parts had to come from the same car. But hearing "oh, I found cluster, and there is a ecu." a couple times got me worried. She said she would put it in the notes on the pull order too, but I have met some of the yard goons in the past and wonder how they even find their way to work in the morning. Maybe they live there.

At any rate some parts are coming and I will report findings as they develop. I am still hoping I don't have to wire in the BCM and ABS and engineer a speed signal. Not that it is hard to do, but space is very limited in a Beetle to start with and I already have to hide the cluster somewhere and the BCM is huge, larger than the ECU. Not to mention the ABS unit. I was hoping to have room under the back seat for an improvised HVAC unit that would blow out of the factory vents with original controls, but that may not be possible at this rate

My momma told me I should have been a doctor instead. They have only one model with two trim levels and no yearly updates or redesigns to worry about.
 
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   #9  

Ewan MacNee

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i really hope you can make this work. The only thing i would change is that i would have started with a karmann ghia lol.
 
   #10  

Jetta 97

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Well
those 2 you have to install otherwise you may burn that engine.They also may cause limp mode.

Code:
[COLOR="#FF0000"]4527 - Coolant Fan Control Circuit 1 [/COLOR]
          P0480 00 [039] - Electrical Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:38

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 98 kPa abs
                    Engine torque: 0.0 Nm
                    Fuel level: 327.67 l
                    E-machine torque actual value: 0.0 Nm

[COLOR="#FF0000"]14643 - Coolant Pump for Intercooler [/COLOR]
          P16BA 00 [039] - Running Dry
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 3
                    Mileage: 132475 km
                    Date: 2020.04.27
                    Time: 00:37:42

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 63 °C
                    Intake air temperature: 21 °C
                    Ambient air pressure: 980 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
 
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   #11  

davek181

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i really hope you can make this work. The only thing i would change is that i would have started with a karmann ghia lol.
I would love to do a Ghia, supply and demand issues there you know and I had a pretty clean Beetle that had been chopped up a little to do a crappy electric conversion. Type 3 Fastback is also in my radar, but even rarer around these parts. Once perfected, if that happens, there are lots of possibilities, and I am always on the lookout for cars to play with. This engine is so compact and light and plentiful to ignore. There is a DKW sitting across town with no engine, but alas no title either.

Marin:
As far as the radiator cooling fan issues, I have that all wired in but during the testing the radiator was already mounted in the body and the engine in the pan. I will get the two mated together as testing progresses. I ignored that code as I knew it was unplugged, but did not consider possible limp mode causation from it. Good point, and I will test that theory too before I am done I am sure. The intercooler pump running dry code is also true, it is running, it is attached to the engine and powered through that harness. I wonder how it determined it is dry though. Possibly from current draw?
If I need a key chip encoded to my cluster/ecu combo can you do that if I send them to you?

Another thing I have to consider now is the fuel pump. I have built a surge tank to house it and plan to gravity feed it from the original tank to keep it submerged at all times and eliminate cavitation on corners. I am thinking I will have to insulate the surge tank from body grounding, the adapter I use just grounds the pump to the body of itself and I feel from the wiring diagram that the fuel pump controller wants to handle that duty itself. The controller is grounded to the body, but the wires to the pump come from the controller only. I know controllers most often use ground control on duty cycled components, so better safe than sorry.
 
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   #12  

Ewan MacNee

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my dad had a type 3 variant when i was a kid. i never realise what they were worth until of late lol. i looked into building a ghia back in my 20s, there was a kit you could buy for a standard beetle floorpan but back then it was looking circa £20k and that was 30 years ago.
 
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davek181

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Just an update, been awhile since I posted. This is kind of a side job, fun project so it sometimes doesn't get to advance fast. I have been chatting with Marin quite a bit and he may be able to massage a ecu a little to make it forget about a couple things that i am not going to have like auto trans and ABS. I hope he can because it will make my life easier. It will be totally legal when done as it will not violate any emissions laws that I am aware of. I know on an engine swap to remain legal you have to meet the standards of the date of manufacture of the car. I will far exceed the requirements as I fully intend to run the original cat and both o2 sensors on the engine, and retain the charcoal canister on the body incorporating the later purge valve and plumbing.

Otherwise all is going well and just finishing up wiring harness and component placements, motor mounts, etc.. I am still leaving room for the cluster and canbus and ABS controller just in case, but hopefully those can be jettisoned. So far our best suspicions for limp mode are ABS missing, and auto trans controller missing. I did get a manual ecu and run it on that and it still limped. I have fleshed out plans to install the ABS controller and feed it a speed signal if needed, but would rather not if avoidable.

I will update more as I get new info to report.
 
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Zenerdiode

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Don’t be frightened to post as many photos of said conversion as you wish. :)
 
   #15  

davek181

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I didn't want to muddy up the posting with photos, I do have some interesting ones. Also not sure how to post pics here.
 
   #17  

davek181

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Still a work in progress, these are early shots but not a lot of visual changes since. Did put the hood back on and it shuts just fine over the engine as you can see in the one pic, ignore all the extra stuff hanging down. Also a pic of the engine mounted in the pan to show how that is, since then however we did a full disc brake conversion and dropped spindles to try to make up for a slight body lift that was needed to clear the rear engine lid. We have almost everything mocked up and fitted that we can think of so far. Lots of little things to deal with on a swap like this and I am sure we will stumble onto even more unseen obstacles as we proceed along. Luckily the car was pretty cherry so we had very little rust to erase and no paintwork to do.


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   #19  

davek181

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OK, update time again. Some progress but not as much as I hoped. I have been busily laying out and mocking up fuel system and lines, A/C system and lines, Heater system and wiring. wiring final placement and engine firewall and box planning, and a few more things.
Got a new ecu that has been surgically altered and there is much success there. I plugged it in and it ran the car with cluster and switch attached, still in limp mode though. I then proceeded to check codes and eliminate what I could. I originally had an install list of 01 engine, ABS brakes, 19 Can gateway, 25 immobilizer. by going into the can gateway I was able to remove ABS brakes from the installed list unlike before. Now all that shows installed is engine and can gateway.
Next i went into engine and was able to remove the ABS there too. I was not able to remove it from long coding though however, all I was able to change in long coding was the cruise control uninstall. As before some items were in blue print, and those could not be removed.
Now my install list shows only 01 engine and 19 can gateway.
The engine will start and run with no cluster or key attached but is still in limp mode.
I believe more ecu surgery is needed as I was forewarned that might be the case.
Here is a new autoscan from the new ecu.

And a couple more pics. I really have to refrain from jumping too far off the intent of the thread and turn this into a build post. I will enclose a couple of random pics, but if that violates the rules let me know and I will delete them. I had to make a surge tank to hold the pump under fuel at all times and it is insulated from the body of the car/tank. Had to hunt high and low to find a suitable size tank to fit under the main tank and be gravity fed. Wiring is much more compact now, there is now no cluster or switch on the left side of the pan at all now, like those seen in the picture, so there is room for my heater system. Firewall is the original I cut out, the hole will be patched, it got put in as the car was converted to an electric vehicle in it's past life. Good thing we can remove the body to do all the mock up and fitting separately. I decided to use a retro underdash air conditioner dating from the period of the car. It is labeled Wards Riverside and came out of a customers Ford years ago and he gave it to me to use.


Code:
Monday,11,May,2020,13:40:55:41227
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x86
VCDS Version: 20.4.1.0
Data version: 20200331 DS317.0
www.Ross-Tech.com


VIN: 3VW2B7AJ6HM404140   License Plate: 



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: AJ-VW36 (7N0)
Scan: 01 19

VIN: 3VW2B7AJ6HM404140   

01-Engine -- Status: Malfunction 0010
19-CAN Gateway -- Status: Malfunction 0010
 
-------------------------------------------------------------------------------
Address 01: Engine (J623-CZTA)       Labels:. 04E-907-309-V1.clb
   Part No SW: 04E 906 023 AL    HW: 04E 907 309 AP
   Component: R4 1.4l TFS   H22 3669  
   Revision: X5H22---    
   Coding: 011A0012230400000000
   Shop #: WSC 00066 790 00016
   ASAM Dataset: EV_ECM14TFS01104E906023AL 005004
   ROD: EV_ECM14TFS01104E906023AL.rod
   VCID: 6ADBAAB28DDEE2D6B5-803E

   CAN Converter 01: 

5 Faults Found:
14643 - Coolant Pump for Intercooler 
          P16BA 00 [039] - Running Dry
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 0 km
                    Date: 2000.00.00
                    Time: 00:00:00

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 39 °C
                    Intake air temperature: 27 °C
                    Ambient air pressure: 960 mbar
                    Voltage terminal 30: 11.897 V
                    Unlearning counter according OBD: 40

17143 - Oxygen (Lambda) Sensor B1 S2 
          P0137 00 [039] - Signal too Low
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 0 km
                    Date: 2000.00.00
                    Time: 00:00:00

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 39 °C
                    Intake air temperature: 27 °C
                    Ambient air pressure: 960 mbar
                    Voltage terminal 30: 11.897 V
                    Unlearning counter according OBD: 40
                    Exh mss flw bef main cat conv bank 1 filtered: 0.0 kg/h
                    Exhaust gas temperature before catalytic converter: 35.43 °C
                    Heated oxygen sensor bank 1: sensor 1: activation: 0.000 %
                    Heated oxygen sensor bank 1: sensor 1: resistance: 0.00 Ohm
                    Oxygen sensor 1 bank 1 ceramic temp: -273.15 °C
                    Intake camshaft bank1 active operating mode-Bits 0-7: 0
                    Intake camshaft bank1 active operating mode-Bits 0-7: 0

17141 - Oxygen (Lambda) Sensor B1 S2: Heating Circuit 
          P0036 00 [101] - Malfunction / Open Circuit
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 0 km
                    Date: 2000.00.00
                    Time: 00:00:00

                    Engine speed: 1626.50 /min
                    Normed load value: 15.7 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 39 °C
                    Intake air temperature: 27 °C
                    Ambient air pressure: 960 mbar
                    Voltage terminal 30: 11.638 V
                    Unlearning counter according OBD: 40
                    Exh mss flw bef main cat conv bank 1 filtered: 26.5 kg/h
                    Exhaust gas temperature before catalytic converter: 71.03 °C
                    Heated oxygen sensor bank 1: sensor 1: activation: 2.975 %
                    Heated oxygen sensor bank 1: sensor 1: resistance: 0.00 Ohm
                    Oxygen sensor 1 bank 1 ceramic temp: -273.15 °C
                    Intake camshaft bank1 active operating mode-Bits 0-7: 0
                    Intake camshaft bank1 active operating mode-Bits 0-7: 0

5582 - Oil Pressure Switch for reduced Oil Pressure 
          P164D 00 [100] - Malfunction
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 0 km
                    Date: 2000.00.00
                    Time: 00:00:00

                    Engine speed: 1856.00 /min
                    Normed load value: 22.7 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 39 °C
                    Intake air temperature: 26 °C
                    Ambient air pressure: 960 mbar
                    Voltage terminal 30: 11.638 V
                    Unlearning counter according OBD: 40
                    Outside air temperature: 215 °C
                    Absolute intake pressure: 51 kPa abs
                    Engine torque: 53.5 Nm
                    Fuel level: 0.00 l
                    E-machine torque actual value: 0.0 Nm

5523 - Engine Start Blocked by Immobilizer 
          P1570 00 [229] - -
          MIL ON - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 0 km
                    Date: 2000.00.00
                    Time: 00:00:00

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 255 km/h
                    Coolant temperature: 39 °C
                    Intake air temperature: 27 °C
                    Ambient air pressure: 960 mbar
                    Voltage terminal 30: 11.897 V
                    Unlearning counter according OBD: 40

Readiness: 1110 0101

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 7N0-907-530-V2.clb
   Part No SW: 7N0 907 530 AJ    HW: 7N0 907 530 AJ
   Component: J533  Gateway H51 1634  
   Revision:   H51       Serial number: 18011400F16012
   Coding: 350000
   Shop #: WSC 12345 123 12345
   VCID: 78FF80FACB72404633-802C

1 Fault Found:
01336 - Company Data Bus for Comfort System 
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 2
                    Time Indication: 0


End-------------------------(Elapsed Time: 00:44)--------------------------
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   #20  

davek181

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After feedback from Marin, the next job to do is to squash codes that are present if we can. I erased the codes from 01 and rechecked them to see what came back. I had the intercooler pump and start blocked by immobilizer. After starting, despite the immo blocked code, I picked back up the ignition switch, o2 and oil pressure codes. The ignition switch code was not present in the original ecu, and i am not running the 2016 switch, rather switching it on off like the original '74 if I can for simplicity and originality sake. The oil pressure code is new too. The o2 low signal is explained by literally no exhaust system yet, except the heater part on b1s2.

i will pin out all my connections again for the umpteenth time to be sure the wiring to the affected parts is intact, fabricate some sort of exhaust to stick o2s into, and wire in the coolant level sensor. I suspect that is how it derives the pump running dry code. As I was not going to use the cluster I ignored that connection, much like brake pad sensors, etc.

I will probably have to add the ABS to the can gateway and provide a speed signal. I could install ABS on the car as I do have all the parts from the original car and the pan now has all disc brakes, but did not want to add to the complexity of the project. I had hoped to keep the car true to it's roots, but ABS would be cool too. As would power brakes and windows, etc.

I have seen on some manual trans cars that they will not free rev in neutral unless you switch off the traction control, so I may experiment with that first. I know traction control turns itself back on in the car while driving so I have to defeat that. My guess is that it is triggered by wheel speed and reactivates. Maybe I can give it wheel speed sensors to look at but never have wheel speed and trick the controller into thinking it is in neutral and not moving forever to get my free revving.

I know this is all untrodden ground and there are no answers yet, but I do welcome any theories that I can get. The body is still off the car and easy to modify almost anything at this point so that is an advantage for sure.
 
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