EuroVan Manual Swap Check Engine Light Hack

[@shirk15]

This is huge for the Eurovan community. Making it that much easier to decide on a manual swap and not having a CEL or the ABS / ESP issues.

[@jaredshearer7989]

That's an impressive and elegant solution. Reverse engineering, hardware hacking, 3D design, and 3D printing. A hell of a project!

[@woodsmith_1]

I don't even have a Eurovan but really appreciated your efforts here. Great work and great result!

[@kf7tkj]

Fun little video, was cool to see the process after seeing the post on twitter! Merry Christmas Dean!

[@PartTimeYooper]

Guys like this are the true inventors of the world. I feel when these types are given the right opportunity, they can problem solve almost anything. Amazing work here!

[@luke27luis]

Oh yeah, some good old hardware hacking! Merry christmas Dean!

[@HackaweekTV]

Same to you

[@DoRC]

Nice hack! Maybe I missed something but if you're just using the coils in the relays as a resistor why not replace them with resistors? Wouldn't that save a lot of space?

[@HackaweekTV]

Because the TCU sends 12 volts to them. I think one is powered on all the time. Resistors, even large power resistors, get too hot. I tried some. Relays do the trick!

[@DoRC]

@@HackaweekTV hmm. 14v 80ohms is 2.45 watts draw. You can get 10w wire wound 80ohm power resistors for not much money that will handle that load with no issues. Would definitely make for a smaller package. Just something to consider.

[@HackaweekTV]

@@DoRC As I said, I tried that and they get too hot.

[@DoRC]

@@HackaweekTV ok

[@yamspaine]

Try inductors.

[@hassanfortney8181]

Looks great! I really like the custom enclosure. For the folks talking about relays v resistors. The really does a nice job of acting like a coil simular to a solenoid. If I come across the need for this hack. I probably would do the very same thing. You did a great job showing the pin outs and wire colors. Again if I found myself doing this, I think I'd just shorten the harness and wire directly. The PCB idea is good. And maybe a guy could just have the terminations labeled, and then there would not be a need to buy harnesses and alter them. From a production standpoint, this would simplify your build. Thank you for laying this out.

[@HackaweekTV]

Thanks for watching. Agree with the direct wiring. The reason for the box and connectors was so I could build these and offer them to people as a plug and play device.

[@tylerbrower1151]

I just installed one of these emulators on my Eurovan when I did a manual trans swap, and it worked beautifully. I probably could have figured out my own setup based off the amazing notes that have been posted, but I figured after all the work done to figure this out for community I would buy a kit. It was truly plug and play, everything just worked and I'm driving my beloved van with a manual transmission. Its a much more enjoyable vehicle now, and how these should have came from the factory. Highly recommend. Thanks!

[@HackaweekTV]

Thank you! Happy to hear from yet another satisfied customer! They really are a much better van with a manual transmission.

[@tomgreer5560]

Tyler, I did a manual trans swap on a 1995 EV Camper a few years ago and am thinking of doing the same on our 2002 EV Weekender using this hack. Can you share any tips or are there any specific links you can share that will help me in the process of doing the tranny swap itself. Any mechanical Suprises I need to look out for? I'm definitely going to buy one of Dean's CEL hacks! It's brilliant!

[@saintpetersburg5818]

You're not Smart.... You're a fcuking genius. The mental, technical and physical ability to do this is beyond me & 20 of my closest friends...and 3 are mechanics!

[@sarathai2876]

Merry Christmas, have you gotten any snow this year ? I enjoy watching your videos.

[@DeanSegovis]

Just a dusting here. Lasted an hour. :) Merry Christmas to you Sara.

[@patapouf75]

Happy to watch new stuff on your channel. Useful and awesome as usual. Tanks for sharing 🙏👌

[@HackaweekTV]

Thanks for watching!

[@RaulGarcia-gi7rh]

this is great!!! from the eurovan community!!! thank you much! especially me. living in cali about to do a 6 speed swap.

[@HackaweekTV]

Good luck!

[@migasaursus]

Cool stuff, i do it all the time at louetta automotive now sun automotive in houston texas. L1 and L2 master technician i make electronic repairs and parts and my own test leads, it’s always been my forte, it is basically like mechanical logic gates. Good job, i like hearing your solutions to issues similar to mine. Keep up the awesome work man.

[@Davidjb37721]

Merry Christmas

[@HackaweekTV]

Same to you!

[@brians6174]

Just here to say you are a very gifted and brilliant person.

[@HackaweekTV]

Thank you.

[@AppleTheCake]

Amazing video! Thank you for all the work you put into designing and implementation.

[@tomgreer5560]

Dino - AWESOME HACK!! After successfully converting a 1995 EV Camper to Manual a few years ago on my own, I'm contemplating doing the same thing with our 2002 EV Weekender which has a fried 4spd AT, so I'll contact you later to buy the kit. But first we need to fix and sell our (another) 1995 EV Camper with an Automatic. It's only got 130K and shifts perfectly into Reverse and forward through 1-3rd gear perfectly, then tries to slam into 4th gear and instantly goes into limp mode until I reset DTC 00596 (no other codes so I think it's wiring related, not trans related). I've replaced the Valve Body ribbon cable, and all the Solenoids and I'm inclined to think it's either the Trans. Control Module or the wire harness from the TCM to the Valve Body. The TCM looks very clean inside and nothing appears burnt or water-stained so I'm leaning towards Wire Harness or connector. I can't locate the Schematic anywhere and am wondering if you have one (098 Phase 1 Automatic which is an early 1995. The later 95's where a phase 2 if that makes a difference). If you can offer any other advice other than sell it, that would be great. I'd like to get it running in all 4 gears before we sell it since it's an awesome Camper in good condition. Thanks in advance! Tom

[@HackaweekTV]

Pretty sure it's a mechanical issue, not electronic.

[@tomgreer5560]

@@HackaweekTV Got it, thanks!

[@IgoRthethrasher]

How did you manage to start up The engine if there is a D position jumper wires fixed? If i leave it as on N position it would work as well?

[@4STEVEJOY34]

One of your best videos yet. I have seen them all. We have all the same tools... Hahaha

[@carlhansen-le1cn]

The 01P/01M Solenoids have coils inhume. The relays you are using to simulate are not duplicating a 'resistance', they duplicate a Coil. Analyze the transmission Solenoids for coil inductance, substitute a coil with same inductance and you should be good to go... without the bulky relays....

[@HackaweekTV]

The relays are cheap. I tried other relays with a higher resistance and they didn't work. That's why I measured the resistance of the solenoids and duplicated that.

[@davidtappe5337]

Hi Dino, Been a fan for years. Wear my HAck a week shirt all the time

[@niryado]

Simply mesmerizing to watch you work, the precision and attention to details is amazing. Thank you. Thumbs up:)

[@HackaweekTV]

Thank you very much!

[@davidsmith1546]

Where do you live with such awesome wildlife sounds chirping and howling in the background?

[@HackaweekTV]

Next door to a farm in NC.

[@sorin.n]

What a massive hack! Cool! 👍

[@richmadrid9563]

Wait! When using a MT, you always have to shift. So, does that mean that whenever he shifts to D, R, 1,2,3, there's a corresponding switch that tricks the ECM that the transmission is in that gear?

[@HackaweekTV]

The plug with a jumper that takes the place of the gear position switch or "multi-function switch" as it's called by VW, makes the control unit think it's in D. It doesn't care about what actual gear the manual is in.

[@richmadrid9563]

@@HackaweekTV Thanks for the quick reply. Got it! But what about the R, D, 1,2,3 lights on the dashboard? Does it just stay on D? Also, does it mean that this magic box that you've created, would work on other AT cars that were converted to MT?

[@IgoRthethrasher]

@@richmadrid9563 The R, D, 1,2,3 lights on the dashboard can be disabled via the OBD plugged diagnostic computer.

[@mcyclonegt]

You can't turn this all off with a VCDS? Amazing solution by the way, very creative.

[@HackaweekTV]

Nope.

[@yamspaine]

Could probably just buy some inductors instead of relays, and could use a wiring enclosure from home depot that will be weather resistant. can drill holes in them and use strain relief from electrical department

[@HackaweekTV]

Chose the relays because they're cheap when you buy 24 at a time.

[@yamspaine]

@@HackaweekTV , with all those housings and harnesses, inductors are going to be just the coils. they are probably gonna be cheaper and smaller.

[@Zehnuss]

I am nearing completion of an 02G swap into a 2002 weekender and am interested in your emulator. I have a couple other questions if there is any way for me to contact you.

[@HackaweekTV]

[e-mail] Emulator: hackaweek.com/hacks/donate/

[@blueberrychronic]

When old dogs try to learn new tricks...

[@itsreallytom4310]

Where can I find the wiring diagrams so I can print them out? Or a service manual on line for my t4

[@HackaweekTV]

Check on The Samba forum.

[@G3N3S1D3GAMING]

Do they not make a manual trans for that van why use the automatic trans? And why didn't you just find or make your own manual swapped chassis harness and use a manual ecu for the correct programming?

[@HackaweekTV]

The later 2.5 liter VR6 never came with a manual and there is no manual control unit.

[@JayLo413]

Ya l, the manuals don't need them more do they come with one (TCU that is) you could have used an ECM from a manual and possibly the BCM also of any Volkswagen the same year and engine size pretty much? manufacturers swap all their parts between makes and models. Of the same engine and trans size that's why it's always good to check the RPO codes and match them up most of the time they're on a sticker on the trunk.

[@JayLo413]

But the way you went about it is cool also and a very good learning and teaching experience on how those certain things work sensors and whatnot and how to fake them out you taught me something. LOL so I thank you. Amazing job

[@IgoRthethrasher]

@@HackaweekTV it's a 2,8L actually.

[@wenzenuf221]

Couldn't you just remove the tcu and use vagcom to recode to manual mode?

[@HackaweekTV]

Tried that, no can do. I even called Ross-Tech. They confirmed.

[@WallaceRoseVincent]

Have you ever thought about medical school and brain surgery as a future career?

[@soodzy]

Exceptional work mate

[@HackaweekTV]

Thank you! Cheers!

[@malcolmnunes8331]

This is brilliant. Thanks for sharing

[@HackaweekTV]

Thanks for watching.

[@migasaursus]

I haven’t got into the 3d printing process which i will like to soon

[@MrtalentedReid]

Good job where do you learn to do this very cool

[@HackaweekTV]

I've been a hardware hacker since I was six years old. Learn by doing and being fearless of trying.

[@MrtalentedReid]

@HackaweekTV lol ok 👍 thanks for getting back awesome keep up the good work. Please can u test drive it show us?

[@MrtalentedReid]

@@HackaweekTV I sub and hit the notifications bell so I can get your videos anytime

[@rhinomechanics8423]

How did you do this ? " I thought of someone smarter then me and I thought, how would he do it " Gene Hackman~

[@shortz1994]

Will this work for a jetta ? 2004

[@HackaweekTV]

Probably not.

[@IgoRthethrasher]

Can you share the 3D printing project file with us?

[@cdv130]

Ingenious, but I wonder if the beaurocrats in charge of vehicle inspections would pass it. I think in the US some jurisdictions might consider this hack a "cheat device" which is stupid

[@HackaweekTV]

It has nothing to do with emissions so it should pass.

[@rustyrobinson8027]

Thanks that's awesome

[@ceylonmooney]

how o i message you? lookin for a schematic.

[@HackaweekTV]

Which one?

[@ceylonmooney]

​@@HackaweekTV ive looked far and wide for a schematic for a baldwin orgasonic model 40 amplifier, a 6v6 pp mono amp. i probably dont know good places to. having seen your console restoration videos, thought yound know how to find something like that. what would u do? thanks buddy.

[@jmackinjersey1]

Why not just flash/program the computer to a manual? Much easier than all this wiring.

[@HackaweekTV]

Can't be done. I did my research. I even spoke to a facility that specializes in doing tunes and flashes. They said it was pointless to even try.

[@jmackinjersey1]

@@HackaweekTV Sorry to hear that. However, I know a few guys that have done just that. I'll try to find out what they did, so the next time, all you have to do is plug n play.

[@IgoRthethrasher]

The engine's code is AMV and they never has been paired with a MT so there is no flash for that.

[@eurowan]

@@IgoRthethrasherExactly that’s the issue.

[@JayLo413]

Why not just do a TCU delete, (manual trans cars don't even come with them) hit the junkyard or eBay find a Volkswagen with a 5-speed grab the ECU and BCM and a Tech 2 am do a little programing. . I'm pretty sure the hardest part was cutting all the holes for the clutch and the shifter. LOL

[@HackaweekTV]

Nothing got cut. It all just bolted in because earlier vans with the same chassis had manuals. Tech 2 is GM. You can't just delete the TCU on these.

[@UncopyrightableMuzik]

Black is brown, brown is black...

[@HackaweekTV]

Yeah as it turns out it doesn't matter. They are just jumpered with a wire.

[@howardfarley2434]

Wouldn't be easier to just put in the manual TCM

[@tristan6509]

Easier, but not cheap.

[@HackaweekTV]

There was never a manual TCM.

[@eurowan]

@@tristan6509Not easier but impossible since there is no such thing.

[@tristan6509]

@@eurowan I was thinking of the ECU when he said TCM, yes obviously a manual transmission doesn't have a TCM... but you can replace the ECU with one from a manual transmission which doesn't care about a TCM.

[@StarforceChannel]

Thanks brother

[@HackaweekTV]

You're welcome. Thanks for watching.