AAN Engine transplant into VW T3 Transporter

[RS2]

Ground-hog day here...

I'm now half way through installing the same engine into my 4x4 VW T3 Camper and I'm at the same stage as before... but I can't remember what I did to get it to run again other than it was as simple as 2 x wires!!

Unfortunately the S6 Auto that I borrowed is now abroad in Europe.

MG

[martinws]

Was it the POS's round the wrong way perhaps? I did that and it would just make all manner of weird farting noises but not start. What was the performance like in the van?

[RS2]

Hi, no I think it was to do with coding wiring that was wrong but none of the wiring diagrams or ECU pin out lists say what they should be set up with. I'm thinking of pin 38 and 39.

I didn't finish fitting the engine to the Bluestar... The same engine is going into my other van... A 4x4 camper. The Bluestar is now getting a 40v 4.2 v8 from a 2001 S8.

MG

[RS2]

Ok I've spent two days trying to get it running without success.

I now know what just about all of the wires do going to the 7 six pin plugs (T6a etc) but nothing I do with the remaining wires will make it run.

Does anyone have an Audi S6 Auto and is happy to give me a call (I'll call you back to save your phone bill) so I can check on which wires have 12v or earth ppppppplllllllllleeeeeeeeeeaaaaaaaaasssssssseeeeee eeeee ?????

07989 333437

Thanks in advance.

Mike

[RS2]

Ok... so just running through it out loud in case I'm missing something really obvious...

I have the following wires connected up...

Thick red (30) permanent feed
Thick black (15) switchable ign feed
Thinner black (87f) switchable ign feed (I think that this is the feed for the aux water pump relay)
Brown/Yellow (fuel pump trigger)
Black/Green (K-Line) connected to the Immob ECU
White/Red (L-Line) connected to the OBD2 plug
***** (K-Line) connected from the Immob ECU to OBD2 plug
Black/Green (Engine ECU pin 30) connected to earth
Brown (31) connected to earth


I'll check up and update this in a moment.

While I'm doing that... can anyone think what would stop the output test working of triggering the injectors? The injectors are good, the wiring is good, the feed is there. They're just not being triggered by the ECU. I'm thinking that I'm missing an earth to the ECU somewhere?

MG

[RS2]

Sorted

I had missed 87a as it already seemed to have a feed.

Now I need to pull the power steering pump apart to remove the feed for the brake bomb... Then it'll stop spraying fluid everywhere!

MG

[RS2]

Well it's up and running but according to my VDO boost gauge, I'm only getting 8psi max, 6-7psi the rest of the time.

What should a stock AAN give?

MG

[UrS4boy]

Well it's up and running but according to my VDO boost gauge, I'm only getting 8psi max, 6-7psi the rest of the time. What should a stock AAN give? MG

That is just waste gate spring pressure. Your N75 WGFV isn't working, perhaps because off a connection or the fact that you don't have the boost signal hose connected to the MAP sensor in the ECU.

WGFV info:

http://forums.quattroworld.com/s4s6/msgs/20987.phtml

MAP sensor info:

http://forums.quattroworld.com/s4s6/msgs/20417.phtml

AAN ECU wiring info:

http://forums.quattroworld.com/s4s6/msgs/21009.phtml

General AAN related Engine Bay info (the long version):

http://forums.quattroworld.com/s4s6/msgs/22625.phtml

[RS2]

Thanks, having read through a post about boost related issues, I figured that might be the case.

The ECU boost pipe is connected - it's on the same pipe as the fuel regulator. My boost gauge is connected to the other pipe coming off at the same area of the inlet manifold.

I'll go for a drive today with vag-com plugged in and read off the boost levels that the ECU is seeing.

The rest of the plumbing and wiring is as per factory and I've had the N75 clicking when using the 'output' test within vag-com.

How much boost should the AAN get?

MG

[RS2]

Well, the ECU isn't registering the boost. I've checked that the pipe to the ECU is showing boost, checked that the internal boost pipe isn't split (suck and blow on a pipe!) and disconnected the wastegate briefly to check that I will get more boost and it shot right round to 20 odd psi so I'm guessing that my MAP sensor is dead?

MG

[RS2]

A quick photo of the engine bay pretty much finished.



MG

[UrS4boy]

Well, the ECU isn't registering the boost. I've checked that the pipe to the ECU is showing boost, checked that the internal boost pipe isn't split (suck and blow on a pipe!) and disconnected the wastegate briefly to check that I will get more boost and it shot right round to 20 odd psi so I'm guessing that my MAP sensor is dead? MG

A stock AAN with 2.5 Bar MAP and stock chips will max out at 2.2 Bar absolute (about 17.2 psi relative pressure). If you disconnect the WG control hose, then it will make more than that but in an uncontrollable and potentially damaging manner.

The MAP sensors rarely fail so before you start chasing a new one, try a pressure test of the green nylon hose from the back of the intake manifold down to the ECU. While I am sure you are a good "blower" , I am also pretty sure that you cannot generate more than 6 psi while blowing down that hose. I suggest that you disconnect the hose at both ends, clamping the rubber end at the ECU and using a small compressor with a pressure gauge, run the pressure up to 10 psi (maybe 15 psi). My guess is you will find a split somewhere.

If I am wrong, you will need to find a new ECU or a replacement MAP. (You can sell the non-functioning ECU on to someone who wants to go to higher boost levels and install a 3.0 Bar or higher MAP sensor). Aftermarket MAP sensors are available:

http://www.efiexpress.com/catalog/pr...products_id=82

[UrS4boy]

A quick photo of the engine bay pretty much finished.
MG

Looking good, like it was always meant to be there.

[RS2]

Thanks.
I've pulled the ECU apart to check the pipe, removed the pipe and put it in line to my boost gauge, disconnected the WG and test drove it again. Still boosting up to around 18psi without trouble although it did start to get annoyed with me running at that level... Is there an over boost sensor on the engine?
Anyway... The internal pipe is ok so it looks like I'm looking for a MAP sensor.
I'd be interested to plug in another ECU just to be sure but most people don't have these sitting around!

MG

[Drummer87]

If your needing to borrow or buy an ecu i have a non chipped aby ecu. But I'm guessing you need the aan unless someone can say otherwise