Giving a 405 Sport Wagon another chance

8 minute(s) of a 111 minute read

I've got this Wagon running today. Started right up too,idle is perfect and no check engine light at all :-)

I had it running only for 10 minutes as I haven't wired engine fans do to lack of informations. Also I need to determine if resistance is the same on coolant,oil temperature and oil level senders. I haven't found any useful information on this and key board mechanics are not very helpful.

Another thing that I need to do is add fuse for fuel pump and once again no information on keep alive memory which will need to be fused as well.

I'm hoping to drive it by Saturday.

11-19-2015

I figured out A/C wiring in that 8 pin connector my self. I'm surprised that various forums have no information on this and very little on OBD II socket.
I've made quick drawing but I don't have time to create Windows based file to make it look pretty. Hopefully next person may find this useful.
I did add 15A fuse for fuel pump as Motronic set up have fuel pump fuse in little fuse box by strut tower which is part of engine harness.

Another electrical issue that I came across on this swap is lack of information on KAM or constant 12+ at ECU as it's needed to retain memory after every key off cycle. From what have I seen is that ECU gets powered up with ignition switch live and goes dead after every ignition swich cycle.

I made a quick how to just in case if someone may need it in a future. I apologize for hand written diagram as at the moment I have no free time to make this on computer.

Pin #3 in small connector is White wire and it goes to ECU pin #50 (A/C ON) this wire needs to be shared with pin #6 in small GTI6 connector brown wire.This Brown wire goes to A/C compressor connector and it powers A/C compressor clutch (12V+)
Pin #4 in small connector is Green wire and it goes to ECU pin #26 (A/C compressor ON)

Also diagram below explain how to connect your fan switch. With out it with ignition on or engine running your cooling fans will be in default mode and ON at full speed.

Both of these wires are located in same MC3A connector in pin #B1 and pin #B2.
Connect your GTI6 Brown A/C cooling fan sensor to US 405 MC3A connector.

Small 8 pin connector pin#1 yellow wire to MC3A connector pin B1 (red wire)
Small 8 pin connector pin#2 yellow wire to MC3A connector pin B2 (red wire)

^^^back view of MC3A connector.

^^^Front view of MC3A 13 pin connector.

^^^GTI6 body side 8 pin connector.

^^^ GTI6 ECU pin out.

Good info can be found here.

http://205gtishop.moonfruit.com/gti-6-conversion/4570113521

11-24-2015

I'm really surprised how the ride quality has improved after suspension work. This car was riding really bad and I new after all that work it wilk ride much better but honestly I haven't expected to be this nice. This car is actually enjoyable to drive now :-)

Tomorrow or Wednesday I'll take it to emission test.

11-25-2015

That's a pass :-) I would lied if I would tell you guys that I wasn't worried not so much that would not pass the sniffer but the question what's a 6 speed and big shiny engine doing here?

Also today I went to DMV to pay registration fees as it's registered till this Saturday. Speaking of taking it down to a wire lol

12-17-2015

Finally got a new windshield:-) totally worthed $300.

I also replaced long dash vent trim by windshield and I'm hoping it will last for few years as  I ran out of them. I stll have one that I'm keeping so it can be used to create mold.

12-17-2015

Few weeks ago I noticed oil leak so long story short driver side sway bar end rubbed trough 6th gear end cover. No forums or keyboard tuner have mentioned anything about this problem so I learned on hard way...as I usually do...

I end up cutting end of sway bar off and added 6mm spacer between frame and sway bar bracket on both sides. Now that gave me plenty of space and no rattle or noises are present.

1-12-2016

Euro headlights and HID's. I also got turn signal-marker light sockets and pigtails out of 2g DSM to make front turn signals like Euro cars.

1-21-2016

Installed these Euro headlights and I love them.

I also added marker light inside headlights as they did come with socket and I made side marker light to work as turn signal and marker light like in Europe. All of my exterior lights are LED and H4 HI-LO 8000K HID.

Tomorrow I'm getting LED fog lamp bulbs.

I got new keys and key chains as well :-)

Ten years later this car has sound again. Two years in my possession and finally I got sound. I still need to clean up wiring and take better pictures when it's all done.

These are door speakers and tweeters.

2-2-2016

Lately when I would fill up I noticed very next day heavy fuel fumes smell inside the car. I found puel pump housing gasket faulty so I ordered one from Jürgen. I end up getting lock ring as well,today I replaced seal and lock ring filled it up with gas and it's great so far.

DSM turn signal socket end up being too long so I end up getting one out of Dodge Mini Van. Minimal modifications required but it works great. I also insatlled SpooxMotorsport's roll stop mount but with some reason I can't upload picture.