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Haldex wiring loom OEM installation

haldex wiring loom oem complete incl fuel sender

 

Wiring installation

2 PIN Sensor From  To            
LI/BR T2/2 T36/16 Plug in Signal   Blue/White Sensor Signal plug it into cluster connector T36 pin 16
BR/BL T2/1 T36/33 Solder Sensor ground Brown/White Ground signal solder to wire from cluster connector T36 pin 33
                 
3 PIIN Sensor                
BR/BL T3/1 T32/20 Solder Sensor ground   Brown/White   Ground signal solder to wire from cluster connector T32 pin 20
BL T3/2 T32/3 Plug in Signal   Blue   Sensor Signal plug it into cluster connector T32 pin 3
LI/WI T3/3 T32/4 Plug in Signal       Sensor Signal plug it into cluster connector T32 pin 4
                 
 Haldex Connector                
SW/LI T8/1   Solder 12v   Red   Connect to switched 12volt you can find one behind fusebox driver side
BR T8/2     Ground   Brown   Connect to ground
OR/BR T8/5   Solder CAN Low   Orange/Brown Connect to canbus wires near the gateway located above footwell the pedal right side 
OR/BL T8/6   Solder CAN High   Orange/Black Connect to canbus wires near the gateway located above footwell the pedal right side 
SW/RO T8/3 E/2 Solder Brake   Black/Red Connect to black/red wire on connect E pin 2 from the electronic module under steeringwheel
                 
T2 Fuel sender connector 2 Pin          
T3 Fuel sender connector 3 Pin            
T8 Haldex Connector 8 Pin            
T32 Cluster connector Blue 2008+            
T36 Cluster connector Black before 2008    
E Connector E on Central module above footwell driver side    

haldex wiring loom oemhaldex wiring loom oem connect side

Haldex Controller Compatibility

Audi TT Quattro (8N)   1998-2006 Gen1
Audi A3 Quattro (8L)   1998-2003 Gen1
Audi S3 (8L)     1998-2003 Gen1
VW Bora 2.8 V6 4motion   1998-2004 Gen1
VW Golf Mk4    1998-2004 Gen1
VW Golf Mk4 R32    1998-2004 Gen1
Skoda Octavia Mk1 4x4   1998-2004 Gen1
Seat Leon 4    1998- 2005 Gen1
Seat Alhambra   1998-2008 Gen1
VW Sharan    1998-2008 Gen1
VW New Beetle   Gen1
    
Audi A3 8P Quattro   2004-2008 Gen2
Audi S3 8P Quattro (Pre-Facelift)  2004-2008 Gen2
Audi TT Mk2 3.2 Quattro   2007-2010 Gen2
Audi TT Mk2 2.0TDI Quattro  2007-2010 Gen2
VW Golf Mk5 R32 4motion  2007-2009 Gen2
VW Golf Mk5 2.0TDI 4motion  2004-2009 Gen2
Skoda Octavia Mk2 4x4   2004-2008 Gen2
SEAT ALTEA 2007-2010   Gen2 0AV
VW RABBIT 2007-2009   Gen2 0AV
    
Audi Q3 Quattro   Gen4 0AY
VW Tiguan 4motion   Gen4 0AY
Skoda Yeti 4x4   Gen4 0AY
VW Passat and CC 4-Motion  2009 Gen4
VW Sharan    Gen4 0AY
Seat Alhambra   Gen4 0AY
    
Audi TT    2009 Gen4 0BR
Audi TTS (8J)    2009 Gen4 0BR
Audi A3 Quattro (8P) Facelift Models 2009 Gen4 0BR
Audi S3 (8P) Facelift Models  2009 Gen4 0BR
VW Golf Mk6 'R'   2009 Gen4 0BR
Skoda Yeti    Gen4 0BR
Skoda Superb    2009 Gen4 0BR
    
Audi TT RS 8J    Gen4 0BY
Audi RS3 8P    Gen4 0BY
    
Seat Altea 4    2009 Gen4
    
Audi A1 / S1 8X    2015+ Gen5 0AY
Audi RSQ3 8U    Gen5 0AY
Seat Alhambra 7N   Gen5 0AY
Skoda Yeti 5L    Gen5 0AY
VW Tiguan 5N    Gen5 0AY
VW Caddy    Gen5 0AY
VW Sharan 7N   Gen5 0AY
       
VW Golf 7R 2013+ Gen5 0CQ
VW Passat 2015+ Gen5 0CQ
Audi TT TTS TTRS 2014+ Gen5 0CQ
Audi A3 S3 RS3 2013+ Gen5 0CQ
Seat Octavia 2013+ Gen5 0CQ


Not all cars are listed.

If you car is not listed feel free to ask if its compatible.

CAN Controller overview

CAN Convertor to analog RPM signal For ECU's without RPM output this will convert the CAN bus signal to a 12v RPM signal.

Also for ECU's that have a 5v RPM output that cannot be used on a 12v Tacho.

All VAG CAN cars

Can convertor rpm tacho golf 2 golf 3 r32 r36 tfsi

Can convertor rpm tacho golf 2 golf 3 r32 r36 tfsi

Can convertor rpm tacho golf 2 golf 3 r32 r36 tfsi

Haldex 4Motion system

Gen I
Ab 1998
Hydraulische Ringkolben Differential Pumpe (Drehzahldifferenz HA / VA)
Lamellen Ölkupplung
Elektrisch kontrolliertes Druckventil
Regelelektronik.
Vorladepumpe, elektrisch, um etwas Vordruck aufzubauen.
´Der Filterdeckel ist kuppelförmig, aus Nylon und mit einem Spezialschlüssel Gr. 48 / 12 Zahn zu entfernen.

Gen II
Ab 2002.
Hydraulische Ringkolben Differential Pumpe (Drehzahldifferenz HA / VA)
Lamellen Ölkupplung
*Regelkreis mit Drucksensor und elektrisch kontrolliertem Druckventil.
Regelelektronik.
Von außen gesehen:
Bei Gen I war das Differential noch völlig separat und einfach an die Haldexkupplung angeflanscht.
Der Filterdeckel ist flach, rund, aus Metall und mit einer normalen Nuss (Gr. 23/24 ?) zu entfernen.
Der Filter selbst unterscheidet sich etwas von Gen I.

Gen III
Ab 2004.
In VAG Fahrzeugen wurde keine Gen III im eigentlichen Sinn verbaut.
Das war den Volvo und Opel Fahrzeugen vorbehalten.
Für VAG Fahrzeuge erfolgten aber Änderungen in der Software der ECU und Bauteile der Gen II wurden minimal geändert.
Daher wird hier oft auch mal von Gen III gesprochen. (Ist es aber nicht)
Gehäuse, Lamellenpack, Filter, Filterdeckel und Öl ist ist also identisch mit Gen II.
Erstmals wurde hier auch ein optionales quer sperrendes Differential eingesetzt, das von der Haldex ECU angesteuert wird.
(Sportdifferential)


Gen IV
Ab 2008 (Modeljahr 2009!)
*Die Druckregelung wurde geändert. Dazu wurde das Regelventil geändert und es fielen interne Ventile weg.
*Keine Ringkolbenpumpen mehr. Die elektrische Pumpe sorgt für den gesamten Systemdruck.
*Das System wurde noch schneller und wird über den CAN Bus in die Fahrdynamik einbezogen.
Von außen gesehen:
Bei der Gen IV sieht das ganze aus wie ein großer Block.
Filterdeckel und Filter siehe oben im Bild.
Der neue Filter ist wesentlich größer.
(optionales Sportdiff. möglich)

Gen V
Ab 2012 (MQB Plattform)
Die Druckregelung wurde völlig geändert und hat nun einen Zentrifugal Druckregler.
Dabei wurde die Anfälligkeit mit dem Einsatz von weniger Teilen reduziert.
*Wegfall von Akkumulator und Regelventil.
*Druckgenerierung nur durch die Hydraulikpumpe.

 

Audi:
A3
S3
RS3
TT Coupé
TT Roadster

Bugatti:
Veyron

Buick:
LaCrosse
Regal GS

Cadillac:
SRX

Ford:
Five Hundred
Freestyle
Kuga

Land Rover:
Freelander

Mercury:
Montego

Opel:
Insignia
Insignia OPC

Saab:
9-3 Aero
9-3 Sport Combi
9-3 Turbo
9-3 X
9-5

Seat:
Alhambra
Altea Freetrack
Leon

Skoda:
Octavia Scout
Octavia
Octavia RS
Superb
Yeti

Volvo:

S40    
S60    
S60R 2005 - 2005 Gen2
S60R 2006 - 2007 Gen3
S80    
S80L    
V40    
V50    
V70    
V70R    
XC60   Gen4
XC70 2003 -2005 Gen2
XC70 2006+ Gen3
XC90 <2005 Gen2
XC90 2006+ Gen3
     
     


Volkswagen:

Beetle RSI     Gen1
Bora    
Caddy    
Golf R    Gen4
Golf R32 2005 -  Gen2
Golf Variant    
Golf    Gen1
Multivan    
Passat CC 2009 - Gen4
Passat    
Sharan    
Tiguan    
Transporter    
     
     














Haldex Controller Installation

How to install the Haldex Controller:

 

Standalone

 

 

Inline

The Haldex Controller for inline use is designed to be plug and play.
It will be placed between the original wiring to the haldex with original connectors.

 

Haldex Controller Manual

Haldex Controller Main screen

Lock Mode

The Haldex power is set by a fixed value that the user sets with the App
Can be adjusted in steps of 10%
100 / 0
90 / 10
80 / 20
70 / 30
60 / 40
50 / 50

100 / 0 is 0% to the haldex unit but the pre charge pump is still active for Gen1 and Gen2

Throttle Mode

The Haldex power is set by the configured value at a certain throttle position.
Throttle position in steps of 10%
0 – 10% 50 / 50
10 – 20% 60 / 40
20 – 30% 50 / 40

Speed Mode

The Haldex power is set by the configured value at a certain velocity.
Speed in steps of 20 km/h
0 – 20 km/h 50 / 50
20 – 40 km/h 60 / 40
40 – 60 km/h 50 / 40

Boost Mode

The Haldex power is set by the configured value at a certain boost pressure.
Boost in steps of 100 mBar
0 – 100 mBar 50 / 50
20 – 40 mBar 60 / 40
40 – 60 mBar  50 / 40

Passthru Mode

All signals from the car are passed thru to the Haldex so it will function like original.
The display will shows the current Haldex power.

Off

The Haldex unit is completely off including the pre charge pump.
The car will drive like any normal 2WD car.

 

Haldex status -- / --
This will show the actual status of the haldex clutch, front wheels / rear wheels.
Since the front wheel are always connected max power to the rear wheel can be 50% 50/50.

Settings button to the corresponding Mode settings.
Brake ignore settings (only visible when activated in settings menu).

 

Error Icon
When active you can tap the icon to show the error.
No connection to Haldex - problem with communication to haldex

Brake Icon
The icon will light up when the brake is applied.

Parkingbrake Icon

 

Haldex Controller Settings

haldex controller settings

Afb

On the settings tab all the settings of the controller can be changed.
All settings are saved on the controller

CAN Input settings:

Throttle input
Turn ON to use the CAN-BUS throttle signal from the ECU.
Turn Off to use the 5v Analog input on the controller.

Speed input
Turn ON to use the CAN-BUS speed signal from the ABS module.
Turn Off to use the 12v VSS Analog input on the controller.

Brake input
Turn ON to use the CAN-BUS brake signal from the ABS module.
Turn Off to use the 12v Analog input on the controller.
Preffered to set it to analog input its faster and all cars have it connected.

Boost input
Turn ON to use the CAN-BUS boost signal from the ECU.
Turn Off to use the 5v Analog input on the controller.

Parkingbrake input
Turn ON to use the CAN-BUS boost signal from the Tacho.
Turn Off to use the Analog input on the controller.

Other Settings:

Speed km/h / mph
Currently not in use, will change all values viewed on the App to mph

Default mode
The controller will start in the selected mode, in last used mode the controller starts in de mode that was used the last time.

Manual switch
When the Haldex Controller is delivered with a manual switch this option must be activated to use the switch.
Only activate when a switch is connected or it could leed to unwanted behavior.

Return mode
When the manual switch is set to App mode it will go to the selected mode.

Brake Ignore
By default the Haldex is turned off when brake pedal is applied.
Turn this option on the Controller will ignore the brake signal and keep the Haldex on the selected value.

Button on main screen
As requested for use on track to easly switch the brake ignore option from the main screen.
Turn on will add a button on the main screen to toggle brake ignore option.

Brake image
By default the brake icon is gray and light gray.
Turn on will set the brake active icon on the main screen to red.

Main screen
Normal is the default layout
Race layout has been added to be used in landscape mode and will have big buttons.

Broadcast Haldex
Special option only used in special occasions, only needed in inline configurations with cars that do not accept the haldex on the CAN network.
Turn off will block haldex traffic to the car this will fix ABS coding problem where coding of 4motion is not possible.

Boost calibration:

This option allow calibration for the analog boost sensor input.
Check datasheet from used pressure sensor for correct values.
VAG Boost sensor will have 555 mBar per 1 volt

Throttle calibration:

Throttle calibration for the analog input, here you can set the low and high point off the throttle pedal.

Controller Reset:

Controller Reset
When the button is pressed all current settings will be restored to the default setting.

Controller Reboot
When the button is pressed the Controller will reboot.

 

Throttle Settings

Settings for Throttle mode

Speed Settings

Settings for Speed mode

Boost Settings

Settings for Boost mode

Controller Search

To connect to a different controller, press scan for devices and select the new Haldex Controller from the list.
It will ask for the pincode press 1234 and OK, the new controller is now connected and saved.

Controller Update

This option allow the App to Update the Haldex Controller with new firmware.
Controller firmware will show the current version that is installed.
New firmware is the version that is available to load in the controller.

The Controller needs to be set to the Update mode press the Bootloader button.
When it replies with Bootloader not available the controller needs to be updated with correct firmware by USB cable!

Press Start Update to load new firmware to the Controller, this may take 5-10 minutes to complete the blue bar below will show the progress.
When the update is complete it will message Ready.
When a update fails the controller can be updated or reloaded with a USB cable.

Manual Switch

All positions of the manual switch can be programmed.
Press get settings to retrieve all the current settings from the controller.
For each position you can set the desired behaviour.

The switch can be calibrated when position are not cerrectly.
Switch position will show current position if this in not correct perfrom the calibration.

For each position you need to calibrate
Move the switch to the 1 position most left then hit the button set next to Pos 1.
Do this for each position.

haldex controller manual switch settings

Haldex Controller Overview

Haldex Controller

 

The Haldex Controller can be used for all 4 Motion vehicles, original or Standalone.
All connections are Plug and Play except for the standalone functions.
The controller works completely standalone so it does not need the App to function.
When the controller is powered up it starts running the program that was last used.
All settings made in the App are saved to the internal memory of the controller.
The App is used to display the status and change mode and settings.

The Controller can use the input signals from the CAN-BUS or Analog signals
Brake           CAN-BUS and Analog 12 volt signal
Speed          CAN-BUS and Analog VSS signal
Throttle        CAN-BUS and Analog 5 volt signal
Boost           CAN-BUS and Analog 5 volt signal
Handbrake   Analog Ground signal
RPM             from CAN-BUS only

The Controller has a RPM output for converting CAN-BUS RPM to Analog.

 

Hako1241 vi

Currently available for VAG:

Gen 1 1998 and up
Gen 2 2001 and up 02D 0AV
Gen 4 2007 and up 0BR 0BS 0BY

Working on supporting other is in progress.
VAG and Volvo

Gen 3 2006
Gen 5 2012

Dutchbuild Haldex controller gen1Dutchbuild Haldex controller gen4

 

 

Controller Modes:
OFF mode
The Haldex unit is completely off including the pre charge pump.
The car will drive like any normal 2WD car.

Locked mode
The Haldex power is set by a fixed value that the user sets with the App
Can be adjusted in steps of 10%
100 / 0
90 / 0
80 / 0
100 / 0 is 0% to the haldex unit but the pre charge pump is still active

Throttle mode
The Haldex power is set by the configured value at a certain throttle position.
Throttle position in steps of 10%
0 – 10% 50 / 50
10 – 20% 60 / 40
20 – 30% 50 / 40

Speed mode
The Haldex power is set by the configured value at a certain velocity.
Speed in steps of 20 km/h
0 – 20 km/h 50 / 50
20 – 40 km/h 60 / 40
40 – 60 km/h 50 / 40

Boost mode
In development

Passthru mode
All signals from the car are passed thru to the Haldex so it will function like original.
The display will shows the current Haldex power.

Brake Signal
When the brake signal is applied, the Haldex will be set to 100/0 so no torque is applied to the rear wheels.

Handbrake Signal
When the handbrake signal is applied the Haldex will be disabled including the pre charge pump.
Burnouts are possible since the Haldex is completely turned off.

 

Dutchbuild Haldex controller AppScreenshot 20160329 155249Screenshot 20160329 155238Screenshot 20160329 155355

 

 

Manual switch

its possible to install a rotary switch and program each position to a specific mode.

20161006 175250

Wiring:

The wiring is supplied with the controller.
One loom goes from the controller to the Haldex unit
One loom depends on the car. This one goes from the Controller to the car.
For original 4Motion cars connect to the connector.
For standalone run the wires to the front of the car and connect them according to the schematics

Haldex connector:
Power 12v
Ground
Brake signal
Handbrake signal
CAN-BUS signals
K-Line

Car Connector Standalone and original:
Power 12v
Ground
Brake signal
CAN-BUS signals
K-Line

Extra for Standalone:
Handbrake
Speed VSS
Throttle position 5v
Boost pressure 5v
Output 1 (can be used for RPM output for tacho)
Output 2 (Not used)

 

Dutchbuild Haldex controller connectorsDutchbuild Haldex controller haldex wiringloom

Dutchbuild Haldex controller wiring standaloneDutchbuild Haldex controller wiringloom standalone

 

Haldex Oil temperature
The oil temperature display only works on the latest Gen 1 models and on all Gen 2 and above
All the original oil temperature functions of the Haldex unit are always working if the oil gets to hot the Haldex unit will shut down 4x4.

Haldex Controller software.
The software will be updated with improvements, bug fixes and new features.
Any input and suggestions are welcome, please use our website to submit.
On the settings tab in the App you can see the Firmware version of the Haldex Controller.
The firmware in the controller can be updated thru the USB port.
Updates are available on our website.
The App will be updated thru the Google Play store

 

Dutchbuild Haldex controller

Haldex Controller Firmware

4-11-2017

v1.1.1