AWD / Quattrro Conversion

[Shane_gti_4motion]

Hi guys yes that's me
I was active on here many many years ago.
 

[Saeed_GT]

Hi there. Any chance of a wiring guide for this 4wd. Done everything. No communication from awd.  Vcds has registered the awd is in so. Any help pleeeaaassseeee???

Hi there mate
Have you figured out how to wire up the haldex and secondary fuel pump wire thanks

[Saeed_GT]

As prices are coming down and seems to be more popular i thought i'd share my experience with performing FWD to Haldex conversion - if anyonew has any part numbers or something i've forgotton feel free to chime in 

First, Parts;

Gearbox with transfer box
transfer box to block mount / bracket with bolts
heat / driveshaft shield that atattches to the above
Drivers (right) driveshaft (passenger shaft is same as fwd)
front quattro ARB
prop shaft complete
prop shaft mounts 1k0 804 332 and 1k0 804 331
prop centre joint heatshield + bolts
complete rear assy - subframe/ diff/ arms / hubs / shaft / haldex / arb + mounting bolts
fuel tank from quattro (saddle) inc tank straps / heatshield / sender unit / quattro pump (ttrs popular option)
abs and esp controller from quattro car
some sheet metal as cutting of the wheel well is required
rivnuts or similar as tank straps land in a different place
exhaust from quattro car or modify existing to snake around diff
there are also wiring mods / additions that need to be done to get it all up and running (don't forget a decent earth strap from haldex to chassis)

Some of the parts together


Box without transfer box fitted


Tank with second sender fitted


Quattro vs fwd rear arb


Rear assembly


Ttrs pump


Rear frame comparison


Tanks


Wheel well trimming


Closing up wheel well


Tank with heatshield / prop and rear assy fitted



Exhaust route modified


Fwd vs quattro right side shaft



Transfer box and bracket fitted


Prop mounts welded in place


Prop fitted with heatshield and exhaust


Esp and abs units used note esp mounts upside down (bracket made)







Now some pics of wiring if i can remember what was what....

Green and white jumper / loop wire added to abs plug




Can wires tapped into airbag plug loom


Ignition live to haldex tapped into cecm plug


Additional sender wire (yellow in pic) added into plug for clocks


I have more loom pics but cannot find them at the mo :(

Hi there mate I’ve done all the wiring for the haldex and the fuel sender to the clock but for some reason it’s still showing I got fuel but my tank gets empty having a hard time to figure out what’s wrong and if I manually lift it up to show there’s fuel the needle goes down instead not sure what’s going on

[Robmk95gti]

What mods did you have to do to the drive tunnel ??

[raj]

i know its an old thread but was there anymore wiring/coding that needed to be done for everything to work?

[Marcos]

i know its an old thread but was there anymore wiring/coding that needed to be done for everything to work?

Depends how far are you now.

I have done Haldex wiring - working.
Replaced ABS pump - ended up with errors.
ESP Multisensor placed instead of ESP Duosensor - G202 Implausible signal or ESP System Fault.
Engine coding - not able to code to AWD but 4 wheels spinning

Wiring diagram looks same for FWD/AWD - only one wire extra for awd.

In my 2005 there was 4 cables and I was able to get rid of faults at standstill. When driving and making turn ESP goes mad. Not sure now if its wiring fault or sensor position (AWD should be upside down and facing back - not sure about this)

I will try to sort it tomorrow 

[pudding]

I would just buy an R32 and swap out the engines, or just buy a MK6 R.

Retrofits are never quite the same as factory built.

[raj]

i know its an old thread but was there anymore wiring/coding that needed to be done for everything to work?

Depends how far are you now.

I have done Haldex wiring - working.
Replaced ABS pump - ended up with errors.
ESP Multisensor placed instead of ESP Duosensor - G202 Implausible signal or ESP System Fault.
Engine coding - not able to code to AWD but 4 wheels spinning

Wiring diagram looks same for FWD/AWD - only one wire extra for awd.

In my 2005 there was 4 cables and I was able to get rid of faults at standstill. When driving and making turn ESP goes mad. Not sure now if its wiring fault or sensor position (AWD should be upside down and facing back - not sure about this)

I will try to sort it tomorrow 

i haven't started yet lol but im planning to do it in the Easter bank holiday weekend. i feel the mechanical side of it wont be a issue for me just getting the wiring sorted, i have vcds can do some coding if needs be but wouldn't i be able to use the codes from donor car? when you turn the esp off do you get traction control lights or anything ?
thanks for your reply much appreciated

[raj]

i know its an old thread but was there anymore wiring/coding that needed to be done for everything to work?

Depends how far are you now.

I have done Haldex wiring - working.
Replaced ABS pump - ended up with errors.
ESP Multisensor placed instead of ESP Duosensor - G202 Implausible signal or ESP System Fault.
Engine coding - not able to code to AWD but 4 wheels spinning

Wiring diagram looks same for FWD/AWD - only one wire extra for awd.

In my 2005 there was 4 cables and I was able to get rid of faults at standstill. When driving and making turn ESP goes mad. Not sure now if its wiring fault or sensor position (AWD should be upside down and facing back - not sure about this)

I will try to sort it tomorrow 

i haven't started yet lol but im planning to do it in the Easter bank holiday weekend. i feel the mechanical side of it wont be a issue for me just getting the wiring sorted, i have vcds can do some coding if needs be but wouldn't i be able to use the codes from donor car? when you turn the esp off do you get traction control lights or anything ?
thanks for your reply much appreciated

[Stupots]

"i haven't started yet lol but i'm planning to do it in the Easter bank holiday weekend"

I normally estimate a job duration and multiply it by 4, but I don't think even 16 days would be enough time for this.

Good luck though

[Marcos]

Fitted my ESP sensor same way as old one - works fine.
ABS In it Coding - used from old ABS Unit - works fine.
Ecu still as manual (wont accept VCDS coding).

You will need to code CAN and Central electronics + connect 5 wires to get haldex working (Can, +,-, ignition)

Sounds simply but took me a while as I went with swapping engine, gearbox to DQ500 (car was DSG already) + some other things.

[Stupots]

I'm assuming anyone doing this will need to change to the AWD compatible ABS Unit? This is from mine if it helps at all:

Address 03: ABS Brakes        Labels: 1K0-907-379-MK60-A.lbl
   Part No SW: 1K0 907 379 AB    HW: 1K0 907 379 AB
   Component: ESP 4MOTION MK60    0102 
   Revision: 00H13001   
   Coding: 0006786
   Shop #: WSC 01279 785 00200
   VCID: 72EB3C436D5AFA8E927-8027

[Marcos]

Yes. There is a chance to do spins with old ABS unit but to get rid of faults it has to be changed to 4MOTION one.

[Marcos]

PS mine is A3 - but its same as Golf under the badges so.. 

[Octoparrot]