05 Ranger TDI conversion

[Evguy1]

For a few years I have used this forum to find info but now have something to contribute!!
I started the conversion of an 05 Ranger Edge with a 3L and automatic to a 1.9L TDI and have been posting to the TDI club website http://forums.tdiclub.com/showthread.php?t=438039 but thought I would start a thread here as well.
This started as a hobby but as many hobbies go I had so much interest that I started a website with some of the parts. http://gastodiesel.tdconversions.com/
For the last 25 years my main business has been converting gas vehicles to electric so I have a good background in conversions. http://www.canev.com/
Most of my build will still be documented on the TDI site but I will update this one from time to time.

 

[Die.Fledermaus]

What pattern is that bell housing and manual trans support?
This does peak my interest depending on the neighbor's derelict 1.9tdi beetle and my desire to make a better driver based on a 2.9l Cologne (same as 2.8, 4.0 and less famous engines) B2.

 

[Evguy1]

At the moment we just have the 3L bolt pattern but will expand as demand increases.
We have been building EV adapters for 25 years so we have all the patterns already.

 

[RonD]

What did you use for the transmission computer and shifting?
I would assume the TDI has a much different power curve than the 3.0l, i.e. TDI max torque around 2,000rpm, max HP above 3,500rpm, 3.0l max torque 3,500, max HP 4,500

Very clean looking conversion, kudos

 

[Evguy1]

The truck is not running yet so I have not done anything with the trans.
Once I get it running then I will play with the trans. I do have a 5 speed standard sitting here as a backup. ;>)

 

[Evguy1]

Shipment of intake manifolds arrived today so I could start intercooler piping.
Need to build a race pipe adapter for the manifold but otherwise it all fits.




Intercooler just fits behind the grill.

https://flic.kr/p/utoRwF

 

[Evguy1]

Almost ready to fire up.
A bit of wiring and a couple more rad hoses.

 

[RonD]

Rad hose??
It's a VW isn't it air cooled?

Hey, where is the coil pack and spark plug wires............?

Joking


Looking good, outside of the turbo pipes, is alot of the stuff off-the shelf

 

[Evguy1]

You just need to know what shelves to look on. ;>)
I bought a universal turbo tubing kit off Ebay that had lots of different tubes and silicone couplers.

 

[Evguy1]

Got the TDI ECU mounted just below the battery tray.
The ECU has a Malone stage2 tune and most of the sensor inputs deleted




The finished remote oil filter adapter came in today.

 

[Evguy1]

Got it running today but still have quite a bit more wiring to get it out for a first test drive.
Really hoping the trans will shift with most of the engine sensors gone.

 

[RonD]

Great work getting the engine up and running

It won't work well, the transmission, it should shift, but never tried a full electronic one without computer.
Stand alone electronic transmission controllers are expensive, $650-$1,300, assuming someone makes one for the 5R44E


EDIT:
Found this stand alone trans controller: http://www.black-ridge.com/transmission-controller.htm
Says it has been used on Ford 5R55 so assume 5R55E, looks to be about $850 with wiring harness.
This should also allow you to set up trans shift points for TDI ranges as well

 

[Evguy1]

I'm hoping the stock ECU will run the transmission as it did with the gas engine.
Spent a good part of the day tracing wires and removing stuff like injector and coil wires.
I don't see why it wont work, may need a crank sensor signal but I can fake that.

 

[RonD]

Wow, that looks like more than a day

Yes, tach and EEC would need RPM, although you may want to fake higher rpm for EEC for better shift points
EEC would need speed as well and probably throttle position for trans operation.

 

[Evguy1]

Just had it out for a test drive. Nice performance, would be nicer if it shifted.
I suppose the ECU is looking for a crank signal to get RPM from?
From what I can find online the TPS would be putting out 1-5V so I should be able to pull that from the TDI throttle pedal through an Opto?
Any ideas as to how many pulses the 3L Crank sensor puts out?