TDI Conversion ( Sharan / AFN ) - My Build Diary

[ewenmaclean]

Hello,

glad the vacuum to the actuator is now working. Air in the fuel line is a pain - check all your clips and hoses and replace with proper fuel line clips. It sounds like your pump is losing its prime, which is odd given it looks like you have a one-way valve and primer already fitted? Did you check the leak-off pipes? It is still just possible the injector pipes are losing their prime through the leak-off pipes and the fuel return line. I'd still check this in case.

With regards to your bad temperature reading, is it reading ok in vcds? If the ECU is reading ok and the gauge is out, then I would check you have your yellow/red wire from the gauge, going to pin 4 and pin 2 (brown/green) is earthed correctly. For the ECU you want pin 1 to be earthed and pin 3 to the ECU.

Hope you sort it out

Ewen

[16vmini]

when i say gauge .. i mean my scan gauge reading OBD2 ... i dont have any other temp gauge at the moment

will check leak off pipes in a bit etc...even do a video but i can defo see bubbles coming from fuel filter ....

[ewenmaclean]

Ah ok - is it possible you've just not bled the system properly? That's almost the highest point of the cooling system on a 50 degree install - it might have a bit of an airlock just there..... just a thought.

Can you confirm whether you do have a one-way priming valve bulb thingy coming from the fuel filter to the IP? If so then any leak before it shouldn't be making the pump lose its prime.

[16vmini]

will go do a silly video

and you could be right about air lock on temp sensor ...

Matt

[ewenmaclean]

nice one - I just hope it's as good as the mini videos

[16vmini]

ok video uploaded :

http://www.youtube.com/watch?v=EQfX4GFkIGI&feature=plcp" onclick="window.open(this.href);return false;

i also notice if i sit at traffic lights for a few seonds ticking over .. the pickup is not instant .. again maybe air related ?

[ewenmaclean]

Good video - the air coming in is a pain - probably from the old style filter or connection thereabouts, but you do definitely had a primer there, which also acts as a non-return valve so if you are losing prime, then it's not that that's causing it.

Given that you are having probs with temperature readings, I might hazard a guess that your hard-start is more to do with that. Next time you start it after standing for a bit, disconnect the temp sensor and try starting it up - this'll make the ECU think it's cold and it'll cycle the glow plugs and give you timing advance and inject a bit more fuel - if it starts up right away it's not an air ingress problem.

Not instant pick up sounds like you still aren't getting quite enough vacuum to the VNT actuator - pick up should be pretty much instant. If that's ok and the pipes are good and installed properly etc, and then once you've eliminated some of the air from the filter, then I would consider cleaning your vane mechanism - not that hard once you've got the turbo off.

[16vmini]

if i blip the throttle .. pickup is fine the 2nd time ,, its only if i leave it ...

also what no is the glow plug relay ? before i cut it out ! LOL

should i change the filter to a different style ? or just re-do fittings ?

Matt

[ewenmaclean]

dunno off the top of my head - I'd wire it up to your original glow-plug system in the black box - you can connect the ECU output to the glow-plug light there - you don't use the L or T sender - the ECU just activates the glow plug relay for as long as it thinks. Blue/green - pin 48 is glow plug light, yellow/blue pin 50 is glow plug actuation (I'm pretty sure that's right). That's what I did and now the ECU tells me when there's a fault by flashing the glow plug light. You can just use your existing glow plug connection from the glow plug relay for the glow plug harness. (bit of soldering or junior timer required).

Ok -from what you say it sounds very much like not a low boost problem, but an ECU confusion issue - I had this before when I had to blip the throttle before it would set off properly. In my case it was all to do with the pedal switches - I would seriously check they are not open - particularly the clutch one. If the ECU thinks you have the clutch down and the brake on for example it won't let you accelerate.I think I mentioned the wires to check before.

[16vmini]

i am also still not sure where to mount my ECU , i am very wary of space .. i keep looking at that unused space under the westy rear cuboard in the engine bay ... ( above air filter location )

but i see most people mount them under the rear seat ... have not check ..but i guess there is room to run my cables etc as i have the intercooler over gearbox ...

hmmm need to find a place in morning ... as i need my rear seats for the afternoon ! LOL

Matt

[ewenmaclean]

I've got a decrepid leisuredrive, but mine's in the equivalent rear cupboard.... good place imho.... as long as it can't get wet

[16vmini]

think the hardest part will be drilling a big hole through the boot floor ! LOL

[phil miller]

think the hardest part will be drilling a big hole through the boot floor ! LOL

Matt to do the hole large enough why not get a set of cone drills off ebay, i got some, drilled it with ease and got a set of 3 for £10 iirc

[16vmini]

i have a set , but just wondering if i can get the drill in there ... assume boot floor is single skin with some sound deadining stuck on ?

Matt

[donciuz]

I marked up the hole, then made about 20-ish small holes around. Connected them and then smoothed with a round file. Grommet from golf front door did the job. My ECU is under rear seat now fitted near the blower.