Bit of a lengthy one.....R32 conversion running issue

So, ive put a BDB engine in my mk2 Jetta. Its in and running, pretty much ready to go. The engine was bought from a Corrado being broken and came ready converted for CE2 using the OE Audi ECU, the conversion was done by South West In Car Tech.

When driving however I experience a soft cut rev limit around 5-5.2k.

Using a cheapy VAGCOM ive scanned the following codes. Some are to be expected, others id like advice on please perhaps in relation to the above issue.

Control Module Part Number: 022 906 032 DP
Component and/or Version: MOTRONIC ME7.1.1 0006
Software Coding: 0000002
Work Shop Code: WSC 66565
17 Faults Found:
18044 - Powertrain Data Bus: Missing Message from Airbag Controller
P1636 - 004 - No Signal/Communication
18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
P1650 - 008 - Implausible Signal
18034 - Powertrain Data Bus: Missing Message from TCU
P1626 - 004 - No Signal/Communication
18036 - Powertrain Data Bus: Missing Message from Steering Angle Sensor
P1628 - 008 - Implausible Signal
17834 - EVAP Purge Valve (N80): Open Circuit
P1426 - 004 - No Signal/Communication
19475 - Valve for Exhaust Flap 1 (N321): Open Circuit
P3019 - 004 - No Signal/Communication
17841 - Secondary Air Pump Relay (J299): Open Circuit
P1433 - 004 - No Signal/Communication
17840 - Secondary Air Injection Solenoid Valve (N112): Open Circuit
P1432 - 004 - No Signal/Communication
16885 - Vehicle Speed Sensor: Implausible Signal
P0501 - 004 - No Signal/Communication
17837 - Circuit for Brake Vacuum Pump: Open Circuit
P1429 - 004 - No Signal/Communication


Everything upto here I would expect, would any of them cause an issue?


16440 - Oxygen (Lambda) Sensor B2 S2: Heating Circuit: Malfunction (Open Circuit?)
P0056 - 004 - No Signal/Communication
16420 - Oxygen (Lambda) Sensor B1 S2: Heating Circuit: Malfunction (Open Circuit?)
P0036 - 004 - No Signal/Communication
16414 - Oxygen (Lambda) Sensor B1 S1: Heating Circuit: Malfunction (Open Circuit?)
P0030 - 004 - No Signal/Communication
16434 - Oxygen (Lambda) Sensor B2 S1: Heating Circuit: Malfunction (Open Circuit?)
P0050 - 004 - No Signal/Communication
17522 - Oxygen (Lambda) Sensor: B1 S2: Internal Resistance too High
P1114 - 004 - No Signal/Communication
17548 - Oxygen (Lambda) Sensor: B2 S2: Internal Resistance too High
P1140 - 004 - No Signal/Communication

These lambda issues.....I assume therefore as its pinging a fault, the secondary lamdbas havent been coded out. Will that effect running, as I thought it was an OBD requirement to monitor for a faulty cat.

17755 - Camshaft Position Sensor 2 (G163) / Engine Speed Sensor (G28): Incor. Correl.
P1347 - 001 - Upper Limit Exceeded

This im guessing could be the problem. Suspect stretched timing chain, which isnt an issue to change (if a bit annoying), but I cant find the measuring blocks on VAGCOM to assess how bad it could be. I dont get an KW reading on 208/209 or 90/91, its CF?

So any suggestions would be appreciated. Equally if the various missing equipment needs coding out, recommendations on who/how I can get this done would be appreciated.

 

the speed limiter is because off vss not being connected code 16885

you should have a blue white wire coming from the ecu that needs connecting to w1 on your fuse box

 

As simple as that!

Do you know the pin out of the ecu?

 

Yep, exactly that.

Even the old VR6 12v (M3.8.1) needs that signal else an every rev-limit occurs.

When the blue/white is connected to W1 on the CE2 fusebox you can see vehicle speed (in km/h) on one of the measuring blocks.

This wire has nothing to do with the speedo,btw.

 

Im reassured it'll be a simple fix. The engine feels much more drivable than previous 12v's, so im looking forward to unleashing the top end. It had supposedly been mapped, combined with the decat and exhaust should make for some decent power.

 

I'm wondering if it will ever give full power with so many missing comms with the various modules, might be worth dropping a line to Toyotec on here.

I don't know which pin the VSS wire is on an ME7, it was 'just hanging there' on the old VR6!

 

t121/54 i believe

but as gvk says you need to get the ecu worked on to release its full potential

 

Well I'll start with making that connection and see where it takes me. Regardless of the result, I'm thinking it would be sensible to get the coding cleared up.

 

That thought had crossed my mind, but I should be seeing a gear selector error and I think the DSG ecu ends DP HW.

 

Justin, no I'm aware you can see the variance in the sensors to see if a stretched chain but not looked at them myself.
I did get a call recently from a guy who has had an engine in bits on a V5 and keeps getting a cam/crank out of correlation code.
Pretty sure a free/shareware version of vag-com/vcds won't let you view anything over block no 25.

Some info here

http://wiki.ross-tech.com/wiki/index.php/17755/P1347/004935

http://forums.vwvortex.com/showthread.php?5817156-R32-Timing-chains

http://www.clubgti.com/showthread.php?239642-R32-chains-and-tensioners

kevhayward and oburT6RV are the same person.

 

I've borrowed a dongle & net book from a friend, I only wanted it to read the codes but following on from what I found I decided it best to look further. I can read blocks 208/209 and if the CF value shown are what I need, I'll look tomorrow to see if the chain is an issue. I tried swapping the sensors round and still got the same code so assume it is. Should really sort that before I start spinning it into the upper regions of the speed range.

I should just just buy a pukka cable, as I'm sure it'll get enough use.

 

Well I thought I'd have a go at the rev limit issue......opened up the T121 connector but there's no connection on 54. In fact there's no blue/white wire on that connector.

I'm also missing a W connector on CE2 side either, but that's something I can resolve I'm sure.

Reviewed the BDB wiring diagram on Rubjonnys GDoc site, and I cant see reference to any blue/white wire other than one to the DBW pedal.

 

Bugger, as I posted earlier in the thread, my experience with this was on an old 12v VR6.

benthejettaman has a 2.8 24v mk2 Jetta, so I would've expected his contribution to be all good.

Unless his is an earlier loom that has similarites to the old VR6 stuff?

 

So a it more googling, turns out there's a number of Rado boys with a similar issue. BDB doesn't have a VSS input, but I need to add a pin to 121/54. Guessing the Audis use an ABS signal to indicate the vehicle is moving.

So it'll be a trip to the stealer tomorrow for some ecu pins.

Then it's cam timing......followed by ECU coding.

 

To work on a manual gearbox?

Do you know if the ECU displayed this symptom in the Corrado?

DSG ECU from a TT. Typical faults due to no CAN connections to Cluster connected ABS, Haldex SAS and so on. These can be coded out in the Bin file.
EVAP and SLS all emission controlled devices.They are not present and the ECU output driver 'sees' no load or current draw. So makes sense.
In an older car, these can also be switched off as features in the bin file.

The rear lambda sensors would not affect engine performance but as they are part of emissions control will cause the MIL. The faults above relate the the lack of feedback signal and low load on the ECU heater drivers due to an open circuit. These can be switched of in the ECU bin file.

Cam chain stretch a possibility of dodgy installation.

 

It was installed with the usual VR6 gearbox, dont know if the vehicle had this issue previously, it was bought as part of an abandoned project.

Luckily the sparkys had a roll of connections required to add a wire into 54, so i'll be having a go tonight.