Aussie work Van

[MWMRacing]

Spent today on the EOS Stripping most of what I still need out- so got the DSG pigtail out, DSG selector pigtail and the fuel pump controller pigtail out as well.

As I wasn't sure whether I could use some of the fuel lines from the eos or whether I would need the pump from the tank, so I dropped the tank and lines from the eos.

Once I had the pigtails out I laid up the pigtails into the car to check the lengths of the wiring, which all looks to be good.

So going to spend a few more hours tomorrow trying to pin it all in if I can.

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[MWMRacing]

Today's effort was trying to pin back in some of the DSG gear.

I had my first moments that I was in over my head with the wiring, but after half hour of overthinking it I went back to basics and went one pin at a time, and instead of stressing over stripping the loom completely back, ill patch in what I can where I need to.

Power wise I decided to go a bit of a lazy option and created a few new circuits using the EOS as a donor for the fuse connectors and the fuses themselves, instead of disturbing things in the caddy that already worked, ive documented them to pop in the service booklet in case I ever have to diagnose it.

In the engine bay ill hopefully just patch into what's already there in the high fuse box.

So what I achieved patching today
Laid in the wiring Ito the areas ahead of patching.
Canbus high and low for DSG
Canbus High and low for selector
Switched 12v for the selector
Switched 12v for the dsg
Full time 12v for the selector
Switched 12v for the MAF
New fuses for most of the above

Removed the dash bar to get access to all of the above.

Pinned in the ecu connection for the fuel pump controller.

Still have the remainder of the fuel pump controller to patch in, there's some power wiring which will be easily sorted as it already patched into the same areas on the eos as what I did today.

I also need to look into the pin location on the BCM for the DSG version of my caddy as the pin location on the BCM isn't the same (stupid me hadnt checked that given I was coming from a manual)

Also investigated why my petrol fuel tank seemed to be missing a location for the charcoal cannister, seems like the wreckers damaged the on tank charcoal cannister, which is ok as I have a charcoal cannister up front, so ill remove the on tank one, and plumb into the filler neck portion instead.

I also need to add the additional cable from the SWCM to the ecu for the cruise control to function, just have to investigate that too.

Kinda wishing I went manual instead of DSG for my first conversion as I can see how I would of already been done and driving it if I had of


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[UrbanDriver]

Sounds like an epic project you got going on with the TFSI swapped Caddy, mate! Gotta respect the hustle and the research you're putting in for that extra grunt. It's crucial to take your time with the swap and make sure you have all your ducks in a row when it comes to the wiring. Double-checking and organizing those ECU pinouts will definitely pay off in the long run, so keep at it. And don't forget to enjoy the process - building something unique like that ain't just about the end result, it's about the journey too. Good luck with the build, and stay safe on the road, man!

[MWMRacing]

Sounds like an epic project you got going on with the TFSI swapped Caddy, mate! Gotta respect the hustle and the research you're putting in for that extra grunt. It's crucial to take your time with the swap and make sure you have all your ducks in a row when it comes to the wiring. Double-checking and organizing those ECU pinouts will definitely pay off in the long run, so keep at it. And don't forget to enjoy the process - building something unique like that ain't just about the end result, it's about the journey too. Good luck with the build, and stay safe on the road, man!

It should be very much worth it, once its done the world is my oyster power wise. This project will certainly have plenty of interesting stories about the journey that's for sure. Its getting closer by the day, so that's all positive, just counting down the days till i get it done haha!

[MWMRacing]

Spent a couple of hours tonight doing some extensions on the wiring for the fuel pump controller and spent some time pinning in and splicing in the various wires for the fuel pump controller.

Still have a few wires to chase, one still has a pin in it, so need to figure out where on the caddy bcm that needs to go, but need to find out some info on that particular BCM which seems tricky currently, but we shall see.

Also spent some time just tying some of the wiring I've installed together.

Also had to resolder some work that the previous owner had done off the radio loom which was average at best, instead of electrical tape I replaced it with heatshrink.

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[MWMRacing]

Only a little bit of progress today- pulled the fuel pump from the eos tank to get it out of the way, drained the old diesel tank so it can be disposed of as well.

Interestingly the fuel filter is the same between the TSI and TFSI, so for the initial starts ill run the TSI filter as its new as the car the tank came from got crashed with 40,000kms on the clock- then ill throw another filter in before it gets run permanently.

The low pressure fuel pumps looked identical so also left that alone for now as if I can run a lower km pump that's ideal.

Also got some cable wrap that I should be able to use in some areas of the loom which shrinks with heat whilst keeping the loom flexible. Other areas ill wrap with the proper loom tape to tidy them all up once done.

When fiddling with fuel pumps we did a bit of research into Nylon fuel line repairs so have ordered a kit so I can adjust the lengths of the line to suit the tank considering we couldn't get caddy lines for the petrol.

Also determined how I was going to route the charcoal cannister as well, removing the one on the tank in the rear and running the front charcoal cannister from the eos instead plumbing into the line off the filler as the charcoal cannister on tank had been damaged by the wreckers on removal.

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[MWMRacing]

Only a little bit of progress today- pulled the fuel pump from the eos tank to get it out of the way, drained the old diesel tank so it can be disposed of as well.

Interestingly the fuel filter is the same between the TSI and TFSI, so for the initial starts ill run the TSI filter as its new as the car the tank came from got crashed with 40,000kms on the clock- then ill throw another filter in before it gets run permanently.

The low pressure fuel pumps looked identical so also left that alone for now as if I can run a lower km pump that's ideal.

Also got some cable wrap that I should be able to use in some areas of the loom which shrinks with heat whilst keeping the loom flexible. Other areas ill wrap with the proper loom tape to tidy them all up once done.

When fiddling with fuel pumps we did a bit of research into Nylon fuel line repairs so have ordered a kit so I can adjust the lengths of the line to suit the tank considering we couldn't get caddy lines for the petrol.

Also determined how I was going to route the charcoal cannister as well, removing the one on the tank in the rear and running the front charcoal cannister from the eos instead plumbing into the line off the filler as the charcoal cannister on tank had been damaged by the wreckers on removal.

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No piccies today as tapatalk didn't want to play with the upload

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[MWMRacing]

Busy few weeks with work, so only a little more progress today- spent some time doing new Nylon fuel lines for the caddy petrol tank- they came up fantastically- they are now adjusted for length for the new fitting locations, and the fuel cooler removed- next job is tank installation.

Attached is the tool I used for the new ends and to be able to safely hold them.

Spent some time blowing clear the reused diesel lines as well, so they are cleaned ready for petrol instead of diesel.

The engine is officially plumbed up for fuel now on the engine bay side- the fuel pump wiring I only have 2 wires left, the common ground and the ordinary ground- then the pump wiring is complete too.

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[MWMRacing]

Getting towards the end of what most people would find the boring stuff!

Spent the last few days trying to get "the last" of the goodies I need out of the EOS Donor car- this included the 14 pin plug for the engine loom, the entire power steering harness leading back into the car, and also the 4 pin plug for the engine loom on the front of the gearbox.

I spent Saturday Patching them in and splcing where needed, I thought we were good to rock and roll- so plugged a battery in for the first time and we have life!
Currently the immobiliser is triggered- I think it's a key reader issue as it's saying the signal is out of tolerance- so ill whip that across from the EOS.

After checking with VAG Com it became apparent several things weren't powering up, including the ABS and ECU- after some analysing it was a simple case of me having wishful thinking regarding the high level fuse box- thankfully after inspecting the pinouts there's no potential damage to any components to due to the difference from the pinouts- so I spent today creating some additional diagrams between the two high level fuse boxes and creating a conversion diagram on what I need to move and where. I had a little bit of time for some I had already created- so patched in 8 of the required moves, leaving about 7 left before ill attempt to provide power to the car again.

There's still a few more things I need to install into T94 while I'm there- including the cruise control/steering wheel diagnostic cable line- starter line and a few relay control wires- then hopefully we might be good to try a test crank.

Exciting to see the doors open on the dash and seeing them close when I shut the caddys doors though, I really feel like I'm making progress now!

Some shots showing where I got to yesterday in neatening- vs where I'm back to again after determining there was more wiring to be done on the high level fuse box.

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[MWMRacing]

Well I said I was getting close to the end of wiring- this weekend I thought was going to be the day it started...

Unfortunately I was wrong

Currently investigating why I'm not getting any crank from the starter, all my engine electronics appear to be powering on as well as my fuel pump- so chasing that currently- I'm missing a couple of pins from the DSG to the BCM- so I'll pin those in and also an issue with the brake switch- so ill replace the brake switch from the EOS and pin it in to match as well.

Vagcom also believes that nothing can communicate between the ecu and other modules which seems odd as the Vagcom can talk to the ecu sucessfully and clear codes and see measuring blocks- so also investigating what's going on there. I had an issue earlier where the Terminal 15 relay was constantly cycling, so hopefully now I've resolved that it resolves rhe communication drama.

However because I thought it was nearly ready to fire I put the front end back on the van and topped it up with fluids and got the servicing done- so once it's fired up I can start the process of doing the ABS coding and chasing any other issues that crop up.

First port of call is to pin the last DSG wires in, then clear all codes and see where we end up.

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[Pineapple1984]

Just had a Quick Look through. Il have a good read later. looks like your making some good progress.
Nice to see another caddy conversion the other side of the pond


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[MWMRacing]

Well made some progress!

Pinned in the remainder of the DSG wires- massive thanks to @Pineapple1984 as you gave me the answer on the coding side which solved the DSG diagram showing up on the dash!
I then discovered when I went to select a gear it would error the gearbox strangely- quickly discovered I had forgotten to move the lock solenoid across- which is now done and it selects the gears sucessfully without issue- and without error.

Troubleshooting the no start further I discovered that the ecu communication issue I was encountering was a stupid mistake of mine as I had been testing different relays and left the wrong one in for the engine component circuit, once I changed that the error immediately went away and we were talking properly on VCDS.

Unfortunately that wasn't the issue with the no start- so I investigated the brake switch which was constantly on- turns out the switch was bad (never got to test drive the donor prior to commencing)- so a quick trip to the local wrecker got me out of strife, bench tested the switch, issue solved on the bench, put it in the car and fixed! Now we have functional brake switching in VCDS and brake light wise.

After fixing that, still no start, upon chasing it down further it appears like there's a dead short to ground or something going on with the starter relay, it's clicking in but it's dragging the current down to 2.4 volts, so currently doing the investigations into that to see if I've made a whoopsie or it's just a bad battery- so charging thr battery up over night and will give it another go tomorrow, and try chase it further.


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[MWMRacing]

Well after a couple of nights pottering through the various issues, I reached an exciting point last night!

It finally started!

It had numerous issues that cropped up immediately afterwards, which after further investigation appeared to be from a relay not powering up, so I chased that down this evening and thankfully was a nice simple fix!

Unfortunately there was an issue with the wiring from the throttle pedal with one of the wires being impossible to locate, so had to run a new replacement wire which solved the issue! Whilst down at the pedals I realised I hadn't bolted the pedals in properly, so that's now completed- and with the issues I've been having with the brake switches I think ill be switching to the on master cylinder based sensor instead.

Unfortunately I missed that I needed to replace the ABS module as it's an MK70, and I don't believe there's any way to code it to the EOS clocks etc. So now investigating the wiring to retrofit the MK60 from the eos into it which will be a tricky job but after what I've done with the engine and DSG it's just another wiring job

Whilst I had it running tonight I ran it up on the stands and the DSG is operating as expected, selecting every gear without issue, so extremely excited to see that

Will get the ABS done before I start wrapping the harness again, and reassembling the interior.


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[MWMRacing]

Well ended up swapping the ABS pump to the MK60 anyway, instead of reaching into the engine bay and trying to splice everything I figured I would just develop a patch loom.
Bit barbaric in a way, neat in another.
Once the MK70 was removed I ended up cutting it in half and getting the connector off the module, I then developed a conversion diagram and wired up the pigtail from the EOS ABS into the connector, soldering and heatshrinking as I went.
I then backfilled it with glue, and put the cap on it to make it look nice and neat.

Installing the MK60 in my caddy required one change in line, the secondary line from the master cylinder was the wrong size so I had to use the line from the EOS, this wasn't a straight fit with a bit of bending required to get it to fit neatly, just being careful not to kink it or damage it.

But the MK60 is now installed, I just need to plug my patch loom in and install the ESP/Yaw sensor in the cabin now, then ill fire it all up again and check for errors and commence the bleed process for the ABS module.

Hopefully once I've cleared all the errors and gotten the coding completed that I should be able to start the wrapping and reassembly process.

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[MWMRacing]

Been some slow progress the last couple of weeks as I've been busy with life, work and everything in between.
Now the MK60 is installed, the right brake lines to make it fit, and the patch loom mostly complete, spent a couple of hours doing the patch back through of the ESP sensor, whilst working realised I mixed up two pins on the ABS which both go to the brake switch, after confirming I got those two switched around on the patch loom.

Also added the tyre pressure monitoring switch, and patched all the wiring in to make it work as well.

Then spent a little of of time wrapping the ESP wiring ahead of popping it under the rubber floor carpet thingos, and tying the interior loom segments together making it easier to chase in the future if there's any issues. I have an issue with the ABS saying it can't communicate with the steering rack controller, but I believe it's to do with the steering angle sensor having not been calibrated yet, so next step is to reinstall everything to mount the steering column back in the car, re mount the dash and meter the fuel pump control wire to double check another error, which can be done whilst I run the esp wiring.

Unfortunately, when doing tests the coolant T piece failed, I was hoping to do another test start, but not till I get the T piece replaced with an aluminium replacement.

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