Wiring Details

ENGINE WIRING DETAILS

For a narrative with lots and lots of pics showing the info from these tables in action see my Wiring Harness and DTA Integration Page.

This is a detailed list of how I modified the wiring harness. It includes all of the AWP wiring harness components (engine harness only), as well as changes to stock wiring, additional components being added, power wiring components and gauges, relay board wiring, DTA wiring notes, and DTA wiring, . Anything highlighted in grey has been removed or is not being used in the case of the DTA and relay board wiring. In the notes section I have included the reason why it was removed or other relevant info. This is an all inclusive list in terms of the engine wiring, and should be a final draft for the entire engine swap. I have included the coloring of the wires below each component in the AWP harness section so that someone swapping in the AWP can benefit from not having to spend hours going through the wiring diagrams. It goes without saying that the colors are VW AWP specific (as opposed to Audi AWP). According to the Bentley, the colors of wire apply to the VW AWP engine used from 5/02 on.

When it came time to actually terminate all the wires at the DTA, I printed out this page and used it for reference purposes. Although this info is specific to my engine swap, I am hoping that others can use this as a rough guide for the wiring that will need to be done and then tailor it to their needs.

AWP WIRING HARNESS COMPONENTS

AWP WIRING COMPONENT (color of wires in AWP harness)	VW COMPONENT DESIGNATION	NOTES	PIN NUMBER ON DTA	CONTACT FUNCTION	COMPONENT CONNECTED
Ignition Coil 1 with Power Output Stage brown/yellow, brown, black/lilac, lilac/black	N70	Coil outputs on DTA are numbered in firing order (1-3-4-2) not cylinder order	1	Coil 1	Cylinder 1
Ignition Coil 2 with Power Output Stage brown/yellow, brown, black/lilac, black/yellow	N127		2	Coil 4	Cylinder 2
Ignition Coil 3 with Power Output Stage brown/yellow, brown, black/lilac, black/brown	N291		20	Coil 2	Cylinder 3
Ignition Coil 4 with Power Output Stage brown/yellow, brown, black/lilac, black/lilac	N292		38	Coil 3	Cylinder 4
Charge Air Pressure Sensor lilac/green, lilac/grey, brown/blue	G31	Using separate MAP sensor instead
Camshaft Position (CMP) Sensor lilac/yellow, lilac/green, brown/blue	G40		27	Cam Sensor	Signal to Hall Sensor on Cam Wheel with one tooth
Wastegate Bypass Regulator Valve green/brown, yellow/black	N75		21	Turbo Pressure Valve	Manifold Pressure Valve
Valve -1- for camshaft adjustment green/white, yellow/black	N205	Variable intake valve timing	42	Cam Phase Valve/ Aux Out 4	Cam Phase Valve
Recirculating valve for turbocharger grey/green, yellow/black	N249	Have the bypass valve getting the vacuum signal directly from the intake manifold
Engine Coolant Temperature (ECT) Sensor brown/white, lilac	G2	Sensor for Coolant Temp Gauge
Engine Coolant Temperature (ECT) Sensor brown/blue, grey/yellow	G62	Sensor for DTA	26	Coolant Temp	Coolant Temp Sensor
Intake Air Temperature (IAT) Sensor brown/blue, blue/green	G42		45	Air Temp	Air Temp Sensor
Throttle drive (power accelerator actuation) lilac/black, white	G186	Part of drive by wire setup not being used Went with cable actuated throttle instead
Angle sensor -1- for throttle drive (power accelerator actuation) white/grey, blue/grey	G187	Part of drive by wire setup not being used
Angle sensor -2- for throttle drive (power accelerator actuation) lilac/white, blue/white	G188	Part of drive by wire setup not being used
Engine Speed (RPM) Sensor black, brown, white	G28		8	Crank Sensor	Signal to Magnetic Sensor on Crank Toothed wheel with missing teeth
Knock Sensor (KS) 1 grey, blue	G61	DTA doesn't have knock sensing capabilities
Knock Sensor (KS) 2 green (according to Bentley: grey), yellow	G66
Cylinder 1 Fuel Injector red/lilac, lilac	N30	Injector outputs on DTA are numbered in firing order not cylinder order	37	Injector 1	Injector 1
Cylinder 2 Fuel Injector red/lilac, lilac/green	N31		54	Injector 4	Injector 2
Cylinder 3 Fuel Injector red/lilac, lilac/red	N32		18	Injector 2	Injector 3
Cylinder 4 Fuel Injector red/lilac, lilac/blue	N33		36	Injector 3	Injector 4
Evaporative Emission (EVAP) Canister Purge Regulator Valve blue/yellow, lilac/red	N80	Using only '79 emissions system
Oil Pressure Switch green/blue	F1	Using '79 sensor and wiring for idiot light and wiring in a new sensor for a pressure gauge
Speedometer Vehicle Speed Sensor (VSS) black/white, white/blue, brown	G22	Using '79 setup

I have labeled the above mentioned items in the pic below:

CHANGES TO STOCK WIRING

I have the appropriate tool for removing the contacts with the locking tangs used for the fuse panel wiring, so instead of just cutting the wires at the components I actually removed them from the plastic housings which plug into the fuse panel. I also managed to acquire some new contacts (which are no longer available in US although there is a company in the UK which has them) to use for adding wires.

ADDED/ REMOVED	COMPONENT	WIRE LOCATION
Removed	Control pressure regulator	T - cable adapter
Removed	Auxiliary air regulator	T - cable adapter
Removed	Fuel pump relay and wires	A8, A3, A5
Removed	Ballast resistance wire	C15
Removed	Ignition coil / Ignition distributor	C19
Removed	Cold start valve	T1j connector
Removed	Thermo-time switch	T1j connector
Removed	EGR switch and light	C2, T1e connector
Added	12V switch to relay board	A12
Added	12V switch to O2	G3
Added	Ground for O2	Ground pod on steering column support
Added	Tach input to DTA	C19
Removed	Brake light switch (stock setup on brake MC)	A2, A14, A16
Added	Later style brake light switch mounted on pedal	A14, A16
Added	Ground wire for Lambda On/Off switch for DTA	Ground Connector (11) on steering column support

COMPONENTS BEING ADDED TO WIRING

ADDITIONAL WIRING COMPONENT	NOTES	PIN NUMBER ON DTA	CONTACT FUNCTION	COMPONENT CONNECTED
Manifold Absolute Pressure (MAP) Sensor	GM	30	MAP	Signal for MAP Sensor
Throttle Position Sensor (TPS)		48	Throttle Wiper	Signal for TPS
Idle Speed Valve	Doesn't exist yet	4	Idle Valve	Idle Speed Valve
Wide Band O2 Sensor		44	Analogue Input 3	Wide band O2 Sensor

POWER WIRING COMPONENTS AND GAUGES

OTHER WIRING COMPONENT	NOTES
Alternator	Using the AWP connector from alternator to starter. Excitor wire gets wired into '79 wiring
Starter	Quick connect terminal from AWP harness spliced into '79 wiring
Oil Pressure Sensor (idiot light)	'79 sensor and wiring
Oil Pressure Sensor (pressure gauge and sensor)	New sensor and wiring. T-Connector will be used to allow for all 3 sensors
Oil Temp Gauge	New sensor and wiring
Volt Meter	Current wiring setup
Boost Gauge	Vacuum line running from intake manifold

RELAY BOARD

The relay board is actually a MegaSquirt Power Distribution Board, designed to be used with the MegaSquirt EFI system. It happens to suit my needs fairly well however, so why reinvent the wheel, aye? The board itself has an ECU power relay, Fuel pump relay, and Fast Idle relay as well as four fuses. At the bottom of the board is a 20-position terminal for the sensor wiring with internal connections to the pins for the DB-37 connector.

There are three wires soldered onto the relay board (top right in pic below). The main ground wire goes from the relay board to the cam cover, the switched 12V goes from the relay board to the fuse panel (A12), and the main power wire goes from the relay board to the starter. The 4 terminals on the right are power wires for the fuel injectors (the injector power wire comes from the wiring harness and splices into two seperate wires which then go to the top two terminals), ISV (still not installed), and coil pack You will note a second ISV power wire in the table below this picture...um...it is always nice to have options....

I have labeled the relevant items below:

WIRE	WIRE COLOR, WIRE GAUGE	CONNECTION LOCATION
Main Ground Wire	brown, 12	Connected to cam cover
Switched 12V	blue/white, 18	Connected to fuse panel, A12
Main Power Wire	red, 12	Connected to starter
Power Wire for Injectors	pink, 20	1 of 2 wires spliced into main injector power wire
Power Wire for Injectors	pink, 20	1 of 2 wires spliced into main injector power wire
Switched 12V for added components
Power Wire for Coil Pack	red, 18	Pin 3 on Coil Pack

20-POSITION TERMINAL

The 20-Position terminal at the bottom has the following components connected to it. The items in gray are not being used:

TERMINAL NUMBER	PASS THROUGH TO DB-37 PIN	TERMINAL FUNCTION	COMPONENT CONNECTED	WIRE COLOR, GAUGE	NOTES
1	34, 35	Injector	Vacant		Injector to DTA
2	Terminal Position 1	Injector	Vacant		Injector to DTA
3	32, 33	Injector	Vacant		Injector to DTA
4	Terminal Position 3	Injector	Vacant		Injector to DTA
5	Fuel Pump Relay (FPO)	Fuel Pump Relay	Fuel Pump	dusty blue, 16	Fuel pump to RB
6	Fast Idle Relay (FASTIDLE)	Fast Idle Relay	Idle Speed Valve N75 Valve	green/brown, 20	Fast Idle Relay provides power to the N75 and ISV
7	25	S1	Ground for Idle Speed Valve		Idle Speed Valve doesn't exist yet
8	27	S2	Ground for N75 Valve	yellow/black, 20
9	29	S3	Vacant
10	31	S4	Vacant
11	36	S5	Signal for MAP sensor	lilac, 20	B on MAP sensor (GM) connector body
12	26	Vref	Power for MAP Power for TPS	pink, 20 blue, 20	C on MAP sensor (GM) connector body
13	22	TPS	Signal for TPS	green, 20
14	19	TPS Return	Ground for MAP Ground for TPS	white, 20 black, 20	A on MAP sensor (GM) connector body
15	24	Tach/Ignition	Vacant		Fuse panel to DTA
16	20	Air Temp	Intake air temp sensor	blue/green, 20
17	Terminal Position 14	Air Temp Return	Ground for Intake air temp sensor	brown/blue, 20
18	21	Coolant	Coolant Temp Sensor	yellow/grey, 20
19	Terminal Position 14	Coolant Return	Ground for Coolant Temp Sensor G62 Ground for Coolant Temp Sensor G2	brown/blue, 20 brown/white, 20
20	23	O2	Vacant		Fuse panel to O2

The pic below shows the 20-Position terminal wires connected and the main wres on the right hand side connected.

DB-37 CONNECTOR

The DB-37 Connector houses the following wires. It plugs into the relay board on the lefthand side and the wires go straight to the DTA from there:

DB-37 PIN	COMPONENT CONNECTED	WIRE COLOR, WIRE GAUGE	DTA PIN
1	Ground	brown, 20	55
2	Ground	brown, 20	55
4	Ground	brown, 20	34
5	Ground	brown, 20	34
7	Ground	brown, 20	15
8	Ground	brown, 20	15
9	Ground	brown, 20	51
10	Ground	brown, 20	51
18	Ground	brown, 20	46
19	Ground	brown, 20	46
20	Intake Air Temp	blue, 20	45
21	Coolant Temp	yellow, 20	26
22	TPS	green, 20	48
25	Idle Speed Valve	grey, 20	4
26	5V	pink, 20	28
27	N75 Valve	purple, 20	21
28 (12 RAW)	12V	red/black, 20	19
30 (IDL)	12V for ISV and N75	red/green, 20	41
36	MAP Sensor	orange, 20	30
37 (FP1)	Fuel Pump	red/yellow, 20	41

The picture below shows the back of the DB-37 connector. You can see that only about a half of the available spaces are being used:

DTA WIRING NOTES

Some cautionary notes regarding wiring in the DTA:

1. Getting the contacts into the white plastic housing for the DTA can be difficult. There is a trick for getting them in there however. The housing actually consists of two separate pieces which interlock in the middle. When you are pushing the contact into the housing, move the two halves just a tad until the contact slides into place.

2. When you terminate the wires at the DTA, be sure that you have finalized your plan for what wires are needed...where they go....length...etc. It is very difficult to remove the contacts from the white plastic housing once they are in place with the locking tangs. Having the correct extraction tool not only is of little use, it also has the potential for damaging the housing. Replacement of this item doesn't come cheap either.....I am now onto housing #3.

3. Label each wire to make sure you are putting each wire into the correct place in the housing. For motivation to do this extra step, observe picture above.

In particular, you should note that there are two lilac/green wires going to the DTA. One is from the camshaft position sensor (G40) and the other is from injector 2 (N31). Both are the same gauge and come from the same area in the engine bay, so before you button up the wiring from each component you need to trace the wire from the component to the end and label them. If you have already bundled all the wires together as I had when I discovered this, you can Ohm out both wires to determine which is the one coming from G40 and which is the one coming from injector 2. The wire from G40 is used to supply 5V to the toothed wheels (pin 10 on DTA) and the wire coming from injector 2 goes to the injector 4 contact on the DTA (pin 54). You should also note that the wires coming from the coil packs (if you stick with the stock coil on plug setup) all have VERY similar coloring.

4. I can't over-emphasize the importance of getting it right the first time. To further ensure correct wire placement, mark each slot in the white plastic housing that will be used with a dark colored marker. You may want to make a quick schematic showing all 55 slots with the ones that will be used noted.

5. Finally, since the majority of wires going to the DTA are very small in gauge, you should either get additional contacts that are for smaller gauge wire or fold the end of the wire once it is stripped for added thickness. The DTA does come with contacts supplied, however they are all designed for larger gauge wire. You can order the contacts for smaller gauge wire from Impex (PN: N 906 844 05) as well as additional contacts for the larger gauge wire (PN: N 906 845 05).

DTA WIRING

The DTA Wiring table includes all 55 pins available on the DTA. Again, anything in grey is not being used. I have included details on power supply and grounds as well. If a pin number isn't given in the last column, that means it is coming from the AWP harness as opposed to the relay board.

There are six pins that the DTA has for various grounds. Three of the pins are for power grounds and three are for specific groups of components. The toothed wheels, sensors, and switches all have specific pins for the signal grounds. I have routed grounds from the relay board for all three power grounds and two of the signal grounds (toothed wheels, sensors), using two 20 gauge wires for each pin. The last signal ground (switches) is left for future use.

Because I was unable to make the DTA work with the stock coil on plug setup, I went to a wasted spark setup using a single coil pack. The following table shows the current wiring:

DTA WIRING - WASTED SPARK SETUP

PIN NUMBER ON DTA	CONTACT FUNCTION	COMPONENT CONNECTED	NOTES	AWP CODE	RELAY PIN / WIRE COLOR, GAUGE
1	Coil 1	Cylinder 1, Clyinder 4	Pin 1 on Coil Pack		yellow, 18
2	Coil 4
3	Coil 6
4	Idle Valve	Idle Speed Valve			25/grey, 20
5	Aux Out 2	Relay or LED
6	Shift Light	Shift Light LED
7	Analogue Input 2
8	Crank Sensor	Signal to Magnetic Sensor on Crank Toothed wheel with missing teeth		G28	white G28, 22
9	Right Driven Wheel	Signal to Hall Sensor on Toothed Wheel	Traction control, right driven wheel
10	5 VOLTS	Toothed Wheels			lilac/green G40, 22
11	Undriven Wheel (must)	Signal to Hall Sensor on Toothed Wheel	Traction control
12	Lambda Signal
13	ALS On/Off alt Lambda On/Off	Toggle Switch: Lambda On/Off	Switch wired in for turning the closed loop function on and off for the WBO2 controller. In passenger compartment.		tan, 20
14	Traction Wet/Dry	Toggle Switch
15	POWER GROUND		2 wires wired through relay board then big 'ol wire from board to engine		7/brown, 20 8/brown, 20
16	Injector 8
17	Injector 5
18	Injector 2	Cylinder 3 Injector, Cylinder 2 Injector		N32, N31	lilac/red, 22 lilac/green, 22
19	12 VOLTS	12 Volt Supply	Voltage for driving DTA CPU, internal voltage supplies for sensors		28/red/black, 20
20	Coil 2	Cylinder 3, Clyinder 2	Pin 2 on Coil Pack		blue, 18
21	Turbo Pressure Valve	Manifold Pressure Valve		N75	27/purple, 20
22	Coil 8 or Aux 5
23	Turbo A Lag	Turbo ALS Valve
24	Tach	Tachometer	'79 wiring		C19 on fuse panel/ blue, 20
25	Analogue Input 1
26	Coolant Temp	Coolant Temp Sensor		G62	21/yellow, 20
27	Cam Sensor	Signal to Hall Sensor on Cam Wheel with one tooth		G40	lilac/yellow G40, 22
28	5 VOLTS	MAP Sensor, TPS	Run through relay board		26/pink, 20
29	Left Driven Wheel	Signal to Hall Sensor on Toothed Wheel	Traction control, left driven wheel
30	MAP	Signal for MAP Sensor			36/orange, 20
31	Launch Button	Momentary Switch: Push Button	Turns on launch control allowing the ECU to have control of the engine power output during the race start phase - used for better traction
32	Traction On/Off	Toggle Switch	Turns on traction control to limit amount of driven wheel spin to any desired slip compared with the undriven wheels
33	Shift Cut	Micro Switch	Allows ignition to be turned off during a gear change with a sequential gear box
34	POWER GROUND				10/brown, 20 5/brown, 20
35	Injector 6
36	Injector 3
37	Injector 1	Cylinder 1 Injector, Cylinder 4 Injector		N30, N33	lilac, 22 lilac/blue, 22
38	Coil 3
39	Coil 5
40	Coil 7
41	Fuel Pump Relay	Fuel Pump Relay	Connecting fuel pump directly to DTA		37/(red/yellow), 20 30/(red/green), 20
42	Cam Phase Valve/ Aux Out 4	Cam Phase Valve	Variable intake valve timing	N205	green/white N205, 18
43	Aux Out 3
44	Analogue Input 3	Wide Band 02 Controller output	Wide Band O2 Controller to DTA		WBO2/ dark purple, 16
45	Air Temp	Air Temp Sensor		G42	20/blue, 20
46	Signal Ground	MAP Sensor, TPS, Air, Coolant			12/brown, 20 13/brown, 20
47	Signal Ground	Wheels			black G28, 22 brown G28, 22 brown/blue G40, 20
48	Throttle Wiper	Signal for TPS			22/green, 20
49	Lambda Earth
50	Undriven Wheel (optional)	Signal to Hall Sensor on Toothed Wheel	Traction control
51	Signal Ground	Switches			18/brown, 20 18/brown, 20
52	5 VOLTS	Hall Sensor for Undriven Wheel (50)	5V to Wheel Speed Sensors and Analog Input 2		black/blue, 20 red/blue, 20
53	Injector 7
54	Injector 4
55	POWER GROUND		2 wires wired through relay board then big 'ol wire from board to engine		1/brown, 20 2/brown, 20

CHANGES MADE FROM STOCK COIL ON PLUG SETUP

PIN NUMBER ON DTA	CONTACT FUNCTION	COMPONENT CONNECTED	NOTES	AWP CODE	RELAY PIN / WIRE COLOR, GAUGE
1	Coil 1	Cylinder 1, Clyinder 4	Pin 1 on Coil Pack		yellow, 18
2	Coil 4
18	Injector 2	Injector 3, Injector 2		N32, N31	lilac/red, 22 lilac/green, 22
20	Coil 2	Cylinder 3, Clyinder 2	Pin 2 on Coil Pack		blue, 18
36	Injector 3
37	Injector 1	Injector 1, Injector 4		N30, N33	lilac, 22 lilac/blue, 22
38	Coil 3
54	Injector 4

DTA WIRING - COIL ON PLUG SETUP

PIN NUMBER ON DTA	CONTACT FUNCTION	COMPONENT CONNECTED	NOTES	AWP CODE	RELAY PIN / WIRE COLOR, GAUGE
1	Coil 1	Cylinder 1		N70	lilac/black, 22
2	Coil 4	Cylinder 2		N127	black/yellow, 22
3	Coil 6
4	Idle Valve	Idle Speed Valve			25/grey, 20
5	Aux Out 2	Relay or LED
6	Shift Light	Shift Light LED
7	Analogue Input 2
8	Crank Sensor	Signal to Magnetic Sensor on Crank Toothed wheel with missing teeth		G28	white G28, 22
9	Right Driven Wheel	Signal to Hall Sensor on Toothed Wheel	Traction control, right driven wheel
10	5 VOLTS	Toothed Wheels			lilac/green G40, 22
11	Undriven Wheel (must)	Signal to Hall Sensor on Toothed Wheel	Traction control
12	Lambda Signal
13	ALS On/Off alt Lambda On/Off	Toggle Switch: Lambda On/Off	Switch wired in for turning the closed loop function on and off for the WBO2 controller. In passenger compartment.		tan, 20
14	Traction Wet/Dry	Toggle Switch
15	POWER GROUND		2 wires wired through relay board then big 'ol wire from board to engine		7/brown, 20 8/brown, 20
16	Injector 8
17	Injector 5
18	Injector 2	Cylinder 3 Injector		N32	lilac/red, 22
19	12 VOLTS	12 Volt Supply	Voltage for driving DTA CPU, internal voltage supplies for sensors		28/red/black, 20
20	Coil 2	Cylinder 3		N291	black/brown, 22
21	Turbo Pressure Valve	Manifold Pressure Valve		N75	27/purple, 20
22	Coil 8 or Aux 5
23	Turbo A Lag	Turbo ALS Valve
24	Tach	Tachometer	'79 wiring		C19 on fuse panel/ blue, 20
25	Analogue Input 1
26	Coolant Temp	Coolant Temp Sensor		G62	21/yellow, 20
27	Cam Sensor	Signal to Hall Sensor on Cam Wheel with one tooth		G40	lilac/yellow G40, 22
28	5 VOLTS	MAP Sensor, TPS	Run through relay board		26/pink, 20
29	Left Driven Wheel	Signal to Hall Sensor on Toothed Wheel	Traction control, left driven wheel
30	MAP	Signal for MAP Sensor			36/orange, 20
31	Launch Button	Momentary Switch: Push Button	Turns on launch control allowing the ECU to have control of the engine power output during the race start phase - used for better traction
32	Traction On/Off	Toggle Switch	Turns on traction control to limit amount of driven wheel spin to any desired slip compared with the undriven wheels
33	Shift Cut	Micro Switch	Allows ignition to be turned off during a gear change with a sequential gear box
34	POWER GROUND				10/brown, 20 5/brown, 20
35	Injector 6
36	Injector 3	Cylinder 4 Injector		N33	lilac/blue, 22
37	Injector 1	Cylinder 1 Injector		N30	lilac, 22
38	Coil 3	Cylinder 4		N292	black/lilac, 22
39	Coil 5
40	Coil 7
41	Fuel Pump Relay	Fuel Pump Relay	Connecting fuel pump directly to DTA		37/(red/yellow), 20 30/(red/green), 20
42	Cam Phase Valve/ Aux Out 4	Cam Phase Valve	Variable intake valve timing	N205	green/white N205, 18
43	Aux Out 3
44	Analogue Input 3	Wide Band 02 Controller output	Wide Band O2 Controller to DTA		WBO2/dark purple, 16
45	Air Temp	Air Temp Sensor		G42	20/blue, 20
46	Signal Ground	MAP Sensor, TPS, Air, Coolant			12/brown, 20 13/brown, 20
47	Signal Ground	Wheels			black G28, 22 brown G28, 22 brown/blue G40, 20
48	Throttle Wiper	Signal for TPS			22/green, 20
49	Lambda Earth
50	Undriven Wheel (optional)	Signal to Hall Sensor on Toothed Wheel	Traction control
51	Signal Ground	Switches			18/brown, 20 18/brown, 20
52	5 VOLTS	Hall Sensor for Undriven Wheel (50)	5V to Wheel Speed Sensors and Analog Input 2		black/blue, 20 red/blue, 20
53	Injector 7
54	Injector 4	Cylinder 2 Injector		N31	lilac/green, 22
55	POWER GROUND		2 wires wired through relay board then big 'ol wire from board to engine		1/brown, 20 2/brown, 20

No navigation frame to your left? Click Here: