Auto to Manual conversion question - wiring..

[kester]

Hi All,

I'm just in the process of converting my 2.5TD 2WD from auto to manual and am a bit stuck with the wiring. When i first tried starting the engine it would not even turn over (as suspected as James at Premier, who supplied the kit, had already said that one of the connections would need to be grounded). I removed the Auto gear selector sensor from the old auto box and plugged that in, making sure it was in the PARK position. This time the engine turns over, but does not fire.The HOLD light continues to flash on the dash.

Does anyone have any ideas which connections need to be made to enable start, speedo and reverse. Although, I can get the car to "beep" and put its reverse lights on by turning the sensor to the next position manually, haha, but it's not ideal and fiddly!

Many thanks!

[teenmal]

Can you tell us what the kit from "James at Premier" consisted of and did it include any control unit modifier, if required. or is that the reference to ground .
Take care.

[kester]

Hi,

Got the box, pedal/master, reservoir, pipes and slave, prop, box hanger. Hopefully there's a way to fool the ECU that the auto is still attached?

Thanks
Kester

[g8dhe]

Surely you would need to change the ECU for one from a Manual vehicle ? There seems to be quite a few differences .....

[kester]

Thanks Geoff, was hoping it would be as extreme as that. Will try a few more things out before resorting to that. Ta.

[kester]

*wouldn't be as extreme" - stupid keyboard.. it can't keep up with my typing after I've had a few beers..

[teenmal]

It might be advisable to contact "James at Premier" if he sold you the kit (and makes a reference to Grounding a wire )it sounds like he may have done this modification before now.

Where did you plug in the inhibitor assy from the AT box to the MT box.

Take care.

Don't drink too much

[kester]

Thanks for the advice!

If by "inhibitor" you mean the position sensor off the auto box, I just removed it from the auto box and plugged it into the existing plug on the loom.

Ta
Kester

[Northern Bongolow]

i dont think there is a manual box ecu, and i cannot think why it would need one, im sure my manual bongo didnt have one.
you would have to fool the engine ecu into thinking its got a manual box, hence the ref to grounding. it sounds like if you do what you have done, already connecting the selector sensor to the loom then ground the body of the sensor to a good earth then it should run.

[g8dhe]

This is the Manual version of the ECU or PCM;


and this is the Auto version;

[TheLongRoad]

Sounds like quite an undertaking to convert to manual. Hope you get it operating ok soon.

[Merlot man]

This sounds like a very interesting project , what are the advantages of it , more speed, power and mpg I assume ?
Brian

[TheLongRoad]

I wonder if more modern 6 speed manual gear boxes would fit - increasing MPG

[teenmal]

i dont think there is a manual box ecu, and i cannot think why it would need one, im sure my manual bongo didnt have one.
you would have to fool the engine ecu into thinking its got a manual box, hence the ref to grounding. it sounds like if you do what you have done, already connecting the selector sensor to the loom then ground the body of the sensor to a good earth then it should run.

That sounds very interesting statement from prominent technical expert , I would ask you only as a matter of interest did the manual box that you have /had owned have a speedo cable or was it transmitted through the control unit/ ecu or whatever you call this device.

You take care ..

[kester]

Thanks for the diagrams and suggestions. I'll try properly grounding the gear selector properly to see if that helps first, although as I mentioned, it does notice when I move it one click into "reverse" as I get the revering beeps and lights, so maybe it already has it's own ground within the connector.

The reasons for attempting this are MPG, better use of the engine torque, but mainly because I just don't really like auto's. Still a bit of a boy racer at heart, so want to get this conversion completed and then start on building an engine with a little more "pep" Got a rather large T42 turbo sat in the garage doing nothing at the mo