MK5 Golf GTI

All Things Mk5 => How to Guides / Troubleshooting => Topic started by: olethalb on January 20, 2016, 09:17:09 am

Title: AWD / Quattrro Conversion
Post by: olethalb on January 20, 2016, 09:17:09 am
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  :happy2:

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
(https://daz.co/media/ollethalb/touran_2/3D6A6686-B2A9-419C-B787-388929CD0C18_zps5expifxa.jpg)

Box without transfer box fitted
(https://daz.co/media/ollethalb/touran_2/89A41F89-055E-47A8-B0D0-2FAA53F1FE75_zpsgk7dmgio.jpg)

Tank with second sender fitted
(https://daz.co/media/ollethalb/touran_2/9F9A081D-1B51-4B37-9226-AF9CF1D5B2C2_zpsopcwycc3.jpg)

Quattro vs fwd rear arb
(https://daz.co/media/ollethalb/touran_2/37FBA581-DE8F-40B5-8B45-3AFF561C6864_zpsxreksajo.jpg)

Rear assembly
(https://daz.co/media/ollethalb/touran_2/3D16AF2D-2438-4BAC-B5D3-436E94F471DF_zpscjjkwwb3.jpg)

Ttrs pump
(https://daz.co/media/ollethalb/touran_2/C67992CD-7693-4DA9-9306-8DAD45BF6FDD_zpstf3zzbcs.jpg)

Rear frame comparison
(https://daz.co/media/ollethalb/touran_2/B32EF157-9B0A-4347-A9B6-0C8AF3639F0D_zpsshtxvonm.jpg)

Tanks
(https://daz.co/media/ollethalb/touran_2/59939B3E-0613-4E67-B0BE-7EFF0621E3C2_zpsdbem4ztu.jpg)

Wheel well trimming
(https://daz.co/media/ollethalb/touran_2/B8E77F32-9A68-4F5C-877C-996B710FF8A6_zps7wrl6r8p.jpg)

Closing up wheel well
(https://daz.co/media/ollethalb/touran_2/F34A8F81-1A7E-4441-97DE-953DB3F7F6D4_zps4fzehnxn.jpg)

Tank with heatshield / prop and rear assy fitted
(https://daz.co/media/ollethalb/touran_2/4142850F-5AC2-4161-9EF9-AC17486401BD_zps3z520qzn.jpg)
(https://daz.co/media/ollethalb/touran_2/5292406E-8197-4942-A063-5EBE7892A926_zpszubguqt0.jpg)

Exhaust route modified
(https://daz.co/media/ollethalb/touran_2/75E09A55-0139-4750-8A66-22D07171E1D9_zpsmg49hktx.jpg)

Fwd vs quattro right side shaft

(https://daz.co/media/ollethalb/touran_2/67638136-3004-4BF1-AD0C-14030CF6EDFA_zps2aqagij1.jpg)

Transfer box and bracket fitted
(https://daz.co/media/ollethalb/touran_2/3FCC1554-7096-4CAA-838A-1881B39D0FAA_zpsx36tgvb7.jpg)

Prop mounts welded in place
(https://daz.co/media/ollethalb/touran_2/E374CA24-8912-4A13-9FDE-4E2A99507125_zpshubgqhkp.jpg)

Prop fitted with heatshield and exhaust
(https://daz.co/media/ollethalb/touran_2/26802A45-EB89-44E0-B0D5-71C1A296AE48_zpscxjmscrh.jpg)

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

(https://daz.co/media/ollethalb/touran_2/8FDD0A66-B3BB-4F96-A125-6515BE57D4E7_zpsjeqceqbq.jpg)

(https://daz.co/media/ollethalb/touran_2/0E8AE829-880A-402B-BC7A-AEDC709026E0_zpswamn9rlv.jpg)

(https://daz.co/media/ollethalb/touran_2/F67EBD6C-A2AD-405A-81D4-09CFC9F4D3B4_zpswyxx8ysk.jpg)

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

Green and white jumper / loop wire added to abs plug
(https://daz.co/media/ollethalb/touran_2/A0E14F8C-18E6-4DE0-AC20-95177FA54D51_zpswf3krtol.jpg)

(https://daz.co/media/ollethalb/touran_2/48F44FD5-7BDC-4B8C-BA40-BA203876A1F1_zpssljua0py.jpg)

Can wires tapped into airbag plug loom
(https://daz.co/media/ollethalb/touran_2/45253B58-ADAC-425E-97EE-CF5989C97E94_zpsqpertuic.jpg)

Ignition live to haldex tapped into cecm plug
(https://daz.co/media/ollethalb/touran_2/E960650D-872A-4D3C-B1ED-426636242E6B_zps1kkw5axp.jpg)

Additional sender wire (yellow in pic) added into plug for clocks
(https://daz.co/media/ollethalb/touran_2/2B213E9D-62D6-4960-B4FB-083A31BA724E_zpsuamabfri.jpg)

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

Title: Re: AWD / Quattrro Conversion
Post by: xjay1337 on January 20, 2016, 09:59:06 am
Very useful thanks for doing this olly.  :happy2: :happy2:
Title: Re: AWD / Quattrro Conversion
Post by: r5gtt on January 20, 2016, 10:38:30 am
That's excellent mate, I'd love to have the balls to do that  :jumping: :happy2: :happy2:

Was it all just bolt on parts?.

Is it all working properly?.

Also how much for the complete conversion please?.
Title: Re: AWD / Quattrro Conversion
Post by: dazza on January 20, 2016, 11:12:20 am
Nice one olly. Have you started on your next project yet?

r5gtt have a read of this my favourite build on the forum.

http://www.mk5golfgti.co.uk/forum/index.php/topic,96044.0.html
Title: Re: AWD / Quattrro Conversion
Post by: r5gtt on January 20, 2016, 11:55:29 am
Nice one olly. Have you started on your next project yet?

r5gtt have a read of this my favourite build on the forum.

http://www.mk5golfgti.co.uk/forum/index.php/topic,96044.0.html
Thanks dazza  :happy2:

What a great read and an awesome conversion  :jumping:
Title: Re: AWD / Quattrro Conversion
Post by: swebster94 on January 21, 2016, 09:42:55 pm
Ace!  :happy2:
Was only thinking the other day I should have bought a 4motion!
If only the parts were cheaper....
Title: Re: AWD / Quattrro Conversion
Post by: bluo on January 26, 2016, 02:16:47 pm
What generation haldex you using?
Title: Re: AWD / Quattrro Conversion
Post by: omeydz on January 26, 2016, 08:45:17 pm
Interesting to know what went into the mod! Cheers for this :)
Title: Re: AWD / Quattrro Conversion
Post by: Edi30boi on June 03, 2018, 12:25:21 am
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???
Title: Re: AWD / Quattrro Conversion
Post by: kam760 on June 15, 2018, 11:18:40 pm
Impressive
Title: Re: AWD / Quattrro Conversion
Post by: Vag-shane on July 10, 2018, 09:13:43 am
Does any one know the guyntjatbdid the bulid I'm doing one my self.and I'm.stuck
Title: Re: AWD / Quattrro Conversion
Post by: scopes on August 16, 2018, 10:04:50 am
You make it look easy big man...  :happy2:  Great write up!  :evilgrin:
Title: Re: AWD / Quattrro Conversion
Post by: ProffB on February 22, 2019, 11:38:41 pm
Hi guys,

Can someone please tell me how to wire up the 3 wires from the additional (2nd) fuel sender (suction-jet pump) to the car. I have recently installed a AWD drive tank on my FWD Golf MK6 and need to wire up the 2nd pump to the car but have no idea where each wire is supposed to connect to. Please help me :confused:
Title: Re: AWD / Quattrro Conversion
Post by: FranticG on October 06, 2019, 08:38:28 pm
Just a long shot. Anyone got any wiring diagram please for this?
Title: Re: AWD / Quattrro Conversion
Post by: jason_rmh on October 15, 2019, 12:16:47 pm
There's a guy on Facebook, Shane Rahman, selling a complete conversion kit who also offers to help with wiring, having done a few already.

May be a member on here?

Title: Re: AWD / Quattrro Conversion
Post by: Shane_gti_4motion on December 05, 2019, 08:08:28 am
Hi guys yes that's me
I was active on here many many years ago.
 
Title: Re: AWD / Quattrro Conversion
Post by: Saeed_GT on February 05, 2020, 07:14:00 pm
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
Title: Re: AWD / Quattrro Conversion
Post by: Saeed_GT on May 21, 2020, 02:59:55 am
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  :happy2:

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
(https://daz.co/media/ollethalb/touran_2/3D6A6686-B2A9-419C-B787-388929CD0C18_zps5expifxa.jpg)

Box without transfer box fitted
(https://daz.co/media/ollethalb/touran_2/89A41F89-055E-47A8-B0D0-2FAA53F1FE75_zpsgk7dmgio.jpg)

Tank with second sender fitted
(https://daz.co/media/ollethalb/touran_2/9F9A081D-1B51-4B37-9226-AF9CF1D5B2C2_zpsopcwycc3.jpg)

Quattro vs fwd rear arb
(https://daz.co/media/ollethalb/touran_2/37FBA581-DE8F-40B5-8B45-3AFF561C6864_zpsxreksajo.jpg)

Rear assembly
(https://daz.co/media/ollethalb/touran_2/3D16AF2D-2438-4BAC-B5D3-436E94F471DF_zpscjjkwwb3.jpg)

Ttrs pump
(https://daz.co/media/ollethalb/touran_2/C67992CD-7693-4DA9-9306-8DAD45BF6FDD_zpstf3zzbcs.jpg)

Rear frame comparison
(https://daz.co/media/ollethalb/touran_2/B32EF157-9B0A-4347-A9B6-0C8AF3639F0D_zpsshtxvonm.jpg)

Tanks
(https://daz.co/media/ollethalb/touran_2/59939B3E-0613-4E67-B0BE-7EFF0621E3C2_zpsdbem4ztu.jpg)

Wheel well trimming
(https://daz.co/media/ollethalb/touran_2/B8E77F32-9A68-4F5C-877C-996B710FF8A6_zps7wrl6r8p.jpg)

Closing up wheel well
(https://daz.co/media/ollethalb/touran_2/F34A8F81-1A7E-4441-97DE-953DB3F7F6D4_zps4fzehnxn.jpg)

Tank with heatshield / prop and rear assy fitted
(https://daz.co/media/ollethalb/touran_2/4142850F-5AC2-4161-9EF9-AC17486401BD_zps3z520qzn.jpg)
(https://daz.co/media/ollethalb/touran_2/5292406E-8197-4942-A063-5EBE7892A926_zpszubguqt0.jpg)

Exhaust route modified
(https://daz.co/media/ollethalb/touran_2/75E09A55-0139-4750-8A66-22D07171E1D9_zpsmg49hktx.jpg)

Fwd vs quattro right side shaft

(https://daz.co/media/ollethalb/touran_2/67638136-3004-4BF1-AD0C-14030CF6EDFA_zps2aqagij1.jpg)

Transfer box and bracket fitted
(https://daz.co/media/ollethalb/touran_2/3FCC1554-7096-4CAA-838A-1881B39D0FAA_zpsx36tgvb7.jpg)

Prop mounts welded in place
(https://daz.co/media/ollethalb/touran_2/E374CA24-8912-4A13-9FDE-4E2A99507125_zpshubgqhkp.jpg)

Prop fitted with heatshield and exhaust
(https://daz.co/media/ollethalb/touran_2/26802A45-EB89-44E0-B0D5-71C1A296AE48_zpscxjmscrh.jpg)

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

(https://daz.co/media/ollethalb/touran_2/8FDD0A66-B3BB-4F96-A125-6515BE57D4E7_zpsjeqceqbq.jpg)

(https://daz.co/media/ollethalb/touran_2/0E8AE829-880A-402B-BC7A-AEDC709026E0_zpswamn9rlv.jpg)

(https://daz.co/media/ollethalb/touran_2/F67EBD6C-A2AD-405A-81D4-09CFC9F4D3B4_zpswyxx8ysk.jpg)

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

Green and white jumper / loop wire added to abs plug
(https://daz.co/media/ollethalb/touran_2/A0E14F8C-18E6-4DE0-AC20-95177FA54D51_zpswf3krtol.jpg)

(https://daz.co/media/ollethalb/touran_2/48F44FD5-7BDC-4B8C-BA40-BA203876A1F1_zpssljua0py.jpg)

Can wires tapped into airbag plug loom
(https://daz.co/media/ollethalb/touran_2/45253B58-ADAC-425E-97EE-CF5989C97E94_zpsqpertuic.jpg)

Ignition live to haldex tapped into cecm plug
(https://daz.co/media/ollethalb/touran_2/E960650D-872A-4D3C-B1ED-426636242E6B_zps1kkw5axp.jpg)

Additional sender wire (yellow in pic) added into plug for clocks
(https://daz.co/media/ollethalb/touran_2/2B213E9D-62D6-4960-B4FB-083A31BA724E_zpsuamabfri.jpg)

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
Title: Re: AWD / Quattrro Conversion
Post by: Robmk95gti on January 16, 2021, 08:47:34 pm
What mods did you have to do to the drive tunnel ??
Title: Re: AWD / Quattrro Conversion
Post by: raj on February 17, 2021, 10:31:05 pm
i know its an old thread but was there anymore wiring/coding that needed to be done for everything to work?
Title: Re: AWD / Quattrro Conversion
Post by: Marcos on February 18, 2021, 09:27:57 pm
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  :indifferent:
Title: Re: AWD / Quattrro Conversion
Post by: pudding on February 19, 2021, 10:29:28 pm
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.
Title: Re: AWD / Quattrro Conversion
Post by: raj on February 21, 2021, 09:51:06 pm
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  :indifferent:



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
Title: Re: AWD / Quattrro Conversion
Post by: raj on February 21, 2021, 09:51:29 pm
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  :indifferent:



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
Title: Re: AWD / Quattrro Conversion
Post by: Stupots on February 22, 2021, 04:04:19 pm
"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 :drinking:
Title: Re: AWD / Quattrro Conversion
Post by: Marcos on February 26, 2021, 06:48:21 pm
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.
Title: Re: AWD / Quattrro Conversion
Post by: Stupots on February 27, 2021, 10:53:44 am
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
Title: Re: AWD / Quattrro Conversion
Post by: Marcos on February 27, 2021, 11:01:49 am
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.
Title: Re: AWD / Quattrro Conversion
Post by: Marcos on February 27, 2021, 10:12:34 pm
PS mine is A3 - but its same as Golf under the badges so..  :driver:
Title: Re: AWD / Quattrro Conversion
Post by: Octoparrot on March 01, 2021, 04:02:13 pm
Title: Re: AWD / Quattrro Conversion
Post by: Marcos on March 01, 2021, 07:14:28 pm


If absolutely not... Why did they swapped i?

Anyway - we are not in America. We can barely afford a good used AWD car (golf passat jetta or audis) so why not build our own AWD if money is not a problem.
Title: Re: AWD / Quattrro Conversion
Post by: raj on March 01, 2021, 09:23:16 pm
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.


did you get the wiring out of a donor car ?
where did you run the "(Can, +,-, ignition)" wires from and to?
Title: Re: AWD / Quattrro Conversion
Post by: Marcos on March 01, 2021, 09:41:30 pm
Yeah, but also other spares from other cars.
Ignition as factory from fuse box, cans taken from door wiring as it was on my way, earth point somewhere.

Actually I think it was earth, ign, can, can + one to cecm.
I will have to check diagrams :fighting2:
Title: Re: AWD / Quattrro Conversion
Post by: Deutsch Boy on March 23, 2022, 09:54:00 pm
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  :indifferent:
Looking for an assistance
I have mechanic who was doing AWD conversion on my Golf 5 GTI
All hardware had been installed
Golf 6R gearbox and Haldex
The only thing left was to do the wiring. Unfortunately he has moved away and I am left stuck.
Any assistance with wiring the Haldex and the ABS for AWD, would be very helpful.
Any any coding to do afterward. I got the VCDS with me