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It should just plug in. If the connector is different, just use the connector from the automatic transmission
It should work just fine, TDI people have been using 1.8T starters for the longest time if they need something in a pinch.
the key, cluster, and ecu are all interconnected, it's called an immobilizer. have you tried to change the fuel filter? you'll need to prime the system again, but inability to rev in a diesel is fuel limited, there may be other problems as well, but again it's not the swap that would have caused the issue. might try sending me a message instead of posting it on the discussion, since it's no longer a problem with the transmission swap.
It's not going to be a part of the swap why it's not revving past 1800 RPM, what codes are in the system? and did you check your vacuum lines? also have you tried to unplug your MAF?
what are your symptoms?
I'd check your vacuum lines, occasionally, by moving the engine around to getting the transmissions in and out it will pull on the vacuum lines. it's usually the line that goes to the anti-shutter valve behind the intake leading into the main lines behind the small coolant line
check out:http://dspauto.com/node/33this instructable is for an ALH version only. yours is a BEW.The reverse, and starter wiring is the same, just the cruise control and A23 bus is different.
the link goes to my web page, but it does have wiring instructions like on here. the web page has my phone number
Never had that problem... maybe you have the wiring going to the wrong pin in the ECU?What codes do you have?
You need to have a 1.8T, 2.0l, or TDI transmission to fit it. The 1.8T if you use something out of a 2.0 or a TDI will need to be tuned to let the cruise control work correctly, you'll also need the computer from a manual, and the immobilizer code for the ECU and your instrument cluster. The cruise control is different between the TDI and the 1.8T, and if yours was a 5 speed you'll need to wire up the speed sensor, and A23 bus as well.
The reverse lights, and starter section are the same, the cruise is (mostly) different. I'll need some time to write up a wiring instructable for a 1.8T jetta.You will also need an ecu and some way of programming the immobilizer on the manual ecu.
No it will mate up, you can keep the automatic axles as they are the 108mm the 1.8t manual uses. Wiring will be the same as listed on tdiclub forums or on dspauto.com... the beetle wiring is a little different than the jetta/golfYou likely will be pushing 3500 RPM at highway speeds... You might look into getting a .612 5th gear. you can have close ratio gears 1-4 and a tall 5th.
No, but there is no need to use the manual dash, I think you are thinking too hard on how to finish the project. if you follow the instructable it will be working correctly without having to pull everything apart, it's only a few small cuts on the existing harness, then splice in 3 connectors, install a wire in the ECU and you are basically done. The way you are doing it adds hours upon hours of labor.
the ECM will need to be programmed or it will not be able to start, you'll need to find someone who can do a VCDS readaptation of the instrument cluster to allow the ECU to start. This is much harder than just keeping the ECU that came with the automatic and converting it to a manual coding, however both require a VCDS (vag-com) cable. The instructable only covers converting the automatic harness to the manual harness, therefore I'll need to completely write up a new instructable for this, or append this instructable for the scenario you have listed... by swapping the harness and the ECU you have complicated the swap at least by a measure of 6-10 hours, possibly more. It will be easier if you just follow the instructable, convert it back to an automatic harness and go from there.
http://forums.tdiclub.com/showthread.php?t=258297this is the best writeup of the hammer mod
that's a lot of work! modifying the wiring harness from the automatic would have been easier... only takes me about 2 hours for everything. Swapping the entire harness takes days.The injection pump from the automatic is actually a better pump for performance reasons, it's called an 11mm pump, and you'll need to do the "hammer mod" to it if it idles rough or has a slowdown shutter.
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