2.0TDI engine conversion into suzuki

[joelywil]

howdy all i have a good one for all of you to ponder,
(i had a look around for a post like this but couldnt find it)

i have bought a rolled 2009 vw jetta, engine runs beautiful and all gauges run etc..
now i am going to do an engine conversion of this beautiful 2.0l TDI (20,000ks) into my suzuki sierra that
had a clapped out 1.3l petrol carby motor (300,000ks).
right i have the conversion plates and mounts to physically get it to mount and sit in the chassis
but the engine has a filthy west-east auto strapped onto it and i got a north-south 5sp manual bolted onto it now.

the problem starts here:
- the engine will not give me the rev range if i jerry rig the electrics to think its runing in "P" or "N" (3000rpm max)
- if i make the engine run in "D" it runs in limp home mode koz it dosnt see the auto trans electrics moving,
- if im clever and forced to i can make the engine run with the auto solenoids and the manual 5sp so
it will still shift but not effect the manual. but i got a feeling that it wont work koz of the feedback system
- to run the engine at all i have to have all the security setup (ie key, cluster, body computer etc...)
im an autoelectrician so i can make it work if i desire but would like the engine to just run with just power and earth.

so the drama states that i reken i need someone that can remap the ECU and "turn off":
- the auto and make it run in a "manual state"
- the imbolisier setup (not too fussed bout it)

any help, phone numbers web links or infomation would be appricated,
am willing to pay to get it remapped. will post some pictures of my project sortly

cheers joel

[jazd]

You obviously know its going to a bit of a bitch to get it to run right, the ECU is gonna be looking for all the bits and pieces and signals from all the sensors. I'd say you will need an extensive custom remap or a new ECU.

Hopefully one of tuners who are on this forum can chime in and give you some advice, but I'd say most of the Australian based ones wouldn't be too experienced in this kind of project.

[joelywil]

yeah its going to filthy but doable all the same,
i can move all the ECU related electrics into the conversion easy enough but the auto will be the killer
i can move the auto module from the auto housing to the chassis somewhere but i reken
if someone could knock the rev and boost limiter off so that it will operate fine in "n" or "p"
then the rest will follow without to many hickups.

any fellors out there reken it can be mapped?

[Guy_H]

For a start, change the coding from an Auto to a manual, but then the manual needs a gear position indicator (and speed signal) or it wont free rev (you can't "free" rev in neutral).

You would be better off starting with an earlier engine (like Mk4 TDI) - essentially the same engine with the earlier electronics.

Otherwise HKS's F-Con stand alone ECU is pretty flexible & may do what you want.

I have transplanted a couple of TDI engines over the years (and 1.8T's) into different vehicles.

[joelywil]

thanks for the tip, up im getting onto a speed sensor setup atm, beggs to reason that it will gointo limp home
mode if it dosent see the speed signal,
right how do i change the code from an auto to a manual?
if i can get that changed i can get some other stuff on the move

joel

[Greg Roles]

Wow, should make for quite a weapon, given the low weight to torque ratio!

Interesting, if not quite ambitious, project!!

[jazd]

thanks for the tip, up im getting onto a speed sensor setup atm, beggs to reason that it will gointo limp home
mode if it dosent see the speed signal,
right how do i change the code from an auto to a manual?
if i can get that changed i can get some other stuff on the move

joel

You may be able to use a Ross Tech VCDS cable to change it from auto to manual but I think you need to know the login code.

Out of interest what engine is it? The 103kW or 125kW, is it common rail or PD?

[Guy_H]

Its a bit hard to work out the coding without a live car on the end of a scan tool - unless you can compare coding with an identical car (same ECU Box Code) with the different transmissions.

Volkswagens literature is only for ever repairing cars, not modifying!

[joelywil]

the engine is the 103kw common rail TDI 2.0L
should put out a fair amount more torque that the original 1.3 banga ha
not really getting anywhere with this conversion atm. hmmmmm
ah so we think that a HKS's F-Con stand alone ECU might be the ticket?
if so who will tune the sucker? that will cost the moon ay.
how much are one of those puppies going to set me back?

might be the only way i can get the old girl out of static mode,
not really quite sure how else it can done.
just working at getting the engine mounted in the donk atm

i appricate all the input guys, any thought and comments always welcome ay
joel

[jazd]

Have you read these?
TDI (common rail) transplant - TDIClub Forums
2011 CR into 1963 type 3 Notchback (somewhat long) - TDIClub Forums

Also it is probably worth grabbing a VCDS so you can run a scan and see what faults are coming up.