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Forum Volkswagen Golf IV R32 OEM+ Flapper Mod - this is a BRAND NEW way to do it!

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Thread: OEM+ Flapper Mod - this is a BRAND NEW way to do it!

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1. graeme86

Member Join Date Jun 27th, 2003 Location Brisbane Qld Posts 4,036 Vehicles 2004 DBP R32; 1971 Superbug OEM+ Flapper Mod - this is a BRAND NEW way to do it! 02-04-2010 12:08 PM #1

Here is the closest thing to an OEM+ Flapper Mod Installation I could come up with. As you all know, I am the OEM+ whore. Yes...a $2 switch from Radioshack would do the same job....that's not the point. Ghetto modders please stop reading now. Flapper can only have either Stock or Loud mode with this modification. Usual disclaimers about modding your car blah blah blah... Not for the fainthearted or light of wallet.

Here is what you need: 1 x 1T0 927 124 9B9 = Touran/Passat 3C "FS" switch (out of Taxi) 1 x 4D0 971 636 = 6 pin terminal housing for switch 2 x 443 937 527 = 9 Pin Clip in Relay mount

1 x 191 927 841 = Relay "79" 1 x 1C0 941 597 = Relay "434" 2 x 1K0 937 530 = Clip on Fuseholder (or you can use vacant positions in fusebox, need at least one large fuse space for the Resistor) 2 x 1K0 937 555 = Clear plastic cover for fuse holder 1 x 10 Amp fuse 1 x 2000 Ohm 1/4 W resistor 1 x Old fuse with open housing on top (see picture). BMW sell these type of fuses if you can't fined one. Various repair wires for relay terminals (see notes below) Butt connectors or solder and shrinkwrap Here is how it works. Locate and cut existing ECU to solenoid 1.0mm gray/blue wire as per all previous flapper mods. Relay 79 switches input to either stock mode or loud mode (with resistor load to prevent CELs etc). Dash switch is only a momentary action, so you also require the "434" relay to "latch" the switch signal. Whenever car is started it is always in Stock Mode. If you want it Loud you simply press the "FS" button. The small yellow LED telltale in the switch face will also then light up as well. At night, the "FS"symbol is red like all the other dashlights, so you can even find it in the dark. You can switch between Stock and Loud at your whim. Once ignition is switched off, the flapper always reverts to stock mode when you restart (same as stock ESP functions etc). If you wish, you can reverse the connections from the original flapper wire to -87- and -87a- pins on "79" relay so it will always be in Loud mode unless you press the switch. Wiring I have quoted metric VW wire sizes. Here are the approximate US equivalent sizes. 0.5mm ~ 20 gauge

1.0mm ~ 18 gauge 2.5mm ~ 14 gauge Terminal Pins If you look at the new relay plate mounts, you will note there are three different size terminal pins that they use. The relay plate only requires medium and large pins to plug in the relays for this installation. The VW Repair wires for the different terminal sizes are: Small 1.0mm = 000 979 133 2.5mm = 000 979 225 Medium 1.0mm wire = 000 979 135 2.5mm wire = 000 979 227 Large 0.5mm wire = You can buy bare terminals from Porsche - Part Number 999 650 330 00 1.0mm wire = 000 979 114 (or you can buy Porsche bare terminals 999 650 103 12) 2.5mm wire = 000 979 212 Additional clip on Fuseholder uses Medium terminal repair wires. If you use a spare Large Fuse in the main fusebox then you need medium terminals as well. If you use a spare small size fuse (minifuse) in the main fusebox, then you will need to use the Small terminal repair wires instead. The FS Flapper switch itself uses repair wires 000 979 009 When you buy a VW repair wire you get a length of wire with a terminal precrimped on each end. Power Fuse Run new 2.5mm wire from screw terminal -87F- to your new fuse (unfused side). Run new 1.0mm wire from your new fuse (fused side) to a new junction point that you need to create. I have designated it the "-87F- Connection Point" in descriptions below. I just used a VW Butt connector. You need to run these wires from this point: 1.0mm to FS Flapper Switch Pin 1 1.0mm to Flapper Relay (434) Pin 2 and 5 (or jump feed wire at relay pins) 1.0mm to Pin 1 on 2000 Ohm Resistor mounted in Additional Fuse Holder on Additional Relay Plate Flapper Relay (79) Pin =Terminal=Connection

2 / 30 =Medium=1.0mm -> Join to original 1.0mm gr/bl wire cut in A-pillar. Joins to ECU side of harness (going to engine bay) 3 / 30a = Not used in this application 4 / 86 = Large =0.5mm to Flapper Relay (434) Pin 8 and also splice to FS Flapper Switch Pin 5 in OBD harness 5 / 87a=Medium=1.0mm -> Join to original 1.0mm gr/bl wire cut in A-pillar Joins to Flapper Valve side of harness (going to rear harness) 6 / 85 = Large =0.5mm to Earthpoint (I used Steering Column Earthpoint). 8 / 87 =Medium=1.0mm to Pin 2 on 2000 Ohm Resistor on Relay Plate Flapper Relay (434) 1= Not used in this application 2 / 30=Medium=1.0mm jumper wire to Pin 5/56 AND 1.0mm to new -87F- connection point 4 / 31=Large=1.0mm to Earthpoint (I used Steering Column Earthpoint). 5 / 56 =Medium=1.0mm jumper wire to Pin 2 /30 6 / LU= Large=1.0mm -> FS Flapper switch Pin 2 8 / 56a = Medium = 0.5mm to Flapper Relay (79) Pin 4 / 86 and also splice to FS Flapper Switch Pin 5 FS Flapper Switch Pin 1 & 2 are the feeds for the on/off function Pin 3 & 4 are the feeds for the red illumination LED in switch Pin 5 & 6 are the feeds for the yellow telltale LED in switch

Pin Pin Pin Pin

1 2 3 4

= = = =

1.0mm to new -87F- connection point 1.0mm to Pin 6 on Flapper Relay (434) in Relay Plate dimmer positive - join to dimmer rheostat circuit dimmer earth - join to dimmer rheostat circuit

Pin 5 = 0.5mm to Pin 8 Flapper Switch Relay (434) and Pin 86 on Flapper Switch Relay (79) in Relay Plate Pin 6 = 0.5mm to earthpoint Sounds complicated when you read it,, but here is a schematic I drew up:

Switch

Plug for switch

Switch mounted in my chosen location in console (I also put in a switch for some footlights). Yes... it is on the right side...thats's where my steering wheel is.

Rear of switches

Old Fuse dismantled and resistor soldered to blades

Resistor mounted in fuseholder

Resistance ...close enough

Plugged in

With cover cap installed

Everything else is just adding wires and following correct protocols when working with electrics.

Thanks to VeeRSixx, the electrical guru, for doublechecking my schematic before I hacked into my own car. More pictures to come once I reinstall my interior....been doing some other mods as well.

Modified by graeme86 at 2:33 AM 2-5-2010 Modified by graeme86 at 2:43 AM 2-5-2010 PM if you are looking for: New Beetle RSI shift light; Euro Headlight switches; RHD folding Stubbies. Click below lnk for OEM FUNK Switches. OEM+ freaks click here: Graeme's Webspace - Latest Updates: Audi Brushed Alloy Mirror Switch; Camshaft Hall Sensors; W8 Light with Autodim Mirror Defeat Function
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2. 3. supline

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Member Join Date Jun 14th, 2007 Posts 326 Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (graeme86) 02-04-2010 12:34 PM #2

I just hid mine out of site, but kudos for the OEM style and integrating the lighting etc. I think we need pictures of the switch lighted in both on and off modes.

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4. Nemesis-Brad

Member Join Date Aug 16th, 2009 Posts 532 02-04-2010 12:57 PM PERFECT !!!!
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#3

5. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776

Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-04-2010 12:59 PM #4

Beautiful, Graeme! I used the Passat taxi knee-knocker panel, but that's no good for RHD cars. I like that a lot, particularly since you already have other similar buttons for your fuel door, etc. I want to redo the OEM+ flapper mod, but I sold the damn "alarm" button that I found on German eBay. If I had realized then that it was from a driving school car and absolutely IMPOSSIBLE to find, I never would have sold it.
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6. VeeRsixx

Member Join Date Jan 5th, 2004 Location Harrisburg PA Posts 2,761 Vehicles '04 R32 Black Magic Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (graeme86) 02-04-2010 01:09 PM #5

wOOt for the king of OEM++ !! I would venture to say this is the most involved flapper mod ever.. past dubs: (all black) - 1984 GTI - 1992 GTI 16v - 2001 GTI VR6 VAD mobile scans available
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7. schmuck

Member Join Date Jun 22nd, 2002 Location naptown Posts 2,359 Vehicles 04 dbp r32, 98 gti vr6 Re: FV-QR (Mike Solo) 02-04-2010 01:11 PM #6

way cool, I am happy with mine the way it is, but that is the neatest looking way I have seen yet. props for finding all that figuring it out and sharing for others

David 04 R32 fun documentation project


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8. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-04-2010 01:11 PM #7

Also, these two parts are not available in the US. Impex can source them for roughly $80, TMT has them for half of that but shipping isn't cheap. 1C0 941 597 1T0 927 124 9B9
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9. R32R1

Member Join Date Jul 1st, 2008 Location South County, RI Posts 13,086 Vehicles project roided wookie Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (VeeRsixx) 02-04-2010 01:24 PM #8

Very cool. What did this all run you? Pics of your OEM+ car? The Build Thread RIP Alexi
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CTS Turbo

SoCalStance Shop

10. Mike Solo

Member

Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-04-2010 01:56 PM #9

Quote, originally posted by R32R1 Very cool. What did this all run you? Looks to be around $125 USD.
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11. Bolan Vdub

Banned Join Date Apr 23rd, 2008 Posts 1,792 Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (VeeRsixx) 02-04-2010 03:39 PM #10

Quote, originally posted by VeeRsixx

wOOt for the king of OEM++ !! Hail to the OEM King


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12. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-04-2010 04:05 PM #11

Graeme, please post a picture of that colossal wiring loom you've been working on.
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13. E Coded

Member Join Date Aug 28th, 2000 Posts 1,470 Vehicles 04 R32, 91 GTI 16v Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (graeme86) 02-04-2010 04:07 PM #12

You sir get one of these:


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14. R Line

Member Join Date Sep 3rd, 2007 Location New York Posts 2,355 Vehicles Mk4 R32

Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (E Coded) 02-04-2010 05:21 PM #13

I LIKE
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15. Brake_Dust

Member Join Date

Sep 23rd, 2001 Location West Chester, PA Posts 7,722 Vehicles R32/GTI 12V FV-QR 02-04-2010 05:21 PM #14

wow! OEM x eleventybillion -InvisibleReply With Quote

16. lil_kano

Member Join Date Apr 10th, 2007 Location Coral Springs, Fl Posts 2,299 Vehicles '04 RS .:R32 (Cloth), '02 Jetta TDI - R.I.P, '85 Scirocco - gone

FV-QR 02-04-2010 06:08 PM Wow! Very impressive! to you my friend... I drive a Chewbaka noise maker. What 'bout you?? WiTW'12 South East WiTW'12 Caravan!
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#15

17. .:Rcoholic

Member Join Date Jan 18th, 2006 Posts 1,961 Re: FV-QR (lil_kano) 02-04-2010 07:33 PM #16

Quote, originally posted by lil_kano Wow! Very impressive!

to you my friend... X2
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18. newcreation

Member Join Date Nov 23rd, 2003 Location HBG, PA Posts 10,693 Vehicles 04 R32 FV-QR 02-04-2010 07:41 PM #17

Haha nice nice awesome mod.Good job Rob for checking over his wiring schematics -JAMESDaily Drive /Beaten/Built /UM Turbo R - VR NATION
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19. Al Walker

Member Join Date Mar 14th, 2003 Posts 2,863 FV-QR 02-04-2010 08:00 PM #18

I've been watching Graeme do these mods first hand as we live across the street from each other and he has basically created his own wiring loom for the car, it is amazing to see his attention to detail, everything he has done looks 100% factory, even more so that I had to identify some of the wire colours for him as he is colour blind Wait till you see the other goodies he has been working on, simply amazing stuff. Cheers Al My Garage Walker Motorsport Facebook Fan Page People are mushy - Paul Hawkins on the merits of where to crash on the Targa Florio
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20. graeme86

Member Join Date Jun 27th, 2003 Location Brisbane Qld Posts 4,036 Vehicles 2004 DBP R32; 1971 Superbug Re: FV-QR (Al Walker) 02-04-2010 10:36 PM #19

Al, I only stuggle with reds greens and browns.

Here is a pic of relay plate mocked up on bench.

As you can see there are a few other mods being done at the same time. I figured it was easier just to run one big loom so everything is tidy.

The flapper relays are the two on the right on the top row. The resistor holder is at the top with the yellow and black wires coming out of it.

Shot of loom going into dash.

PM if you are looking for: New Beetle RSI shift light; Euro Headlight switches; RHD folding Stubbies. Click below lnk for OEM FUNK Switches. OEM+ freaks click here: Graeme's Webspace - Latest Updates: Audi Brushed Alloy Mirror Switch; Camshaft Hall Sensors; W8 Light with Autodim Mirror Defeat Function
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21. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-04-2010 10:37 PM #20

You put me to shame, Graeme. You are crazy!


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22. graeme86

Member Join Date Jun 27th, 2003 Location Brisbane Qld Posts 4,036 Vehicles 2004 DBP R32; 1971 Superbug Re: FV-QR (Mike Solo) 02-04-2010 10:49 PM #21

Here is a shot of the relay plate and dash loom properly mounted.

The flapper relay is on top left with 434 next to it. The other 79 and 434 (hidden under bound loom in pic) control the footlights. I added 10 relays altogether. A couple are still not plugged in until the circuits are complete.

Modified by graeme86 at 1:06 PM 2-5-2010 Modified by graeme86 at 1:19 PM 2-5-2010 PM if you are looking for: New Beetle RSI shift light; Euro Headlight switches; RHD folding Stubbies. Click below lnk for OEM FUNK Switches. OEM+ freaks click here: Graeme's Webspace - Latest Updates: Audi Brushed Alloy Mirror Switch; Camshaft Hall Sensors; W8 Light with Autodim Mirror Defeat Function
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23. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-04-2010 10:57 PM #22

Seriously people, this is the defining moment of the R32 OEM+ king. That looks completely factory. Bravo sir.
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24. Alive By time

Member Join Date Feb 2nd, 2006 Location North San Diego Posts 3,798 Vehicles CW 4DR Golf [R] 02-04-2010 11:38 PM my head just exploded Golf [R]-APR TUNED Golf R Build thread index
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#23

25. NuespeedGTi

Member Join Date

Oct 18th, 2002 Location Rehoboth, MA Posts 1,946 Vehicles 2011 E90 M3

Re: FV-QR (Mike Solo) 02-05-2010 12:02 AM #24

Quote, originally posted by Mike Solo Looks to be around $125 USD. you forgot the engineering degree. total cost $80,125.00 USD
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26. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper

FV-QR 02-05-2010 01:07 AM #25

Quote, originally posted by NuespeedGTi you forgot the engineering degree. total cost $80,125.00 USD

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27. VeeRsixx

Member Join Date Jan 5th, 2004 Location Harrisburg PA Posts 2,761 Vehicles '04 R32 Black Magic Re: FV-QR (Al Walker) 02-05-2010 02:11 AM #26

Quote, originally posted by Al Walker ...wait till you see the other goodies he has been working on.

Ok, Al said it, not me.. past dubs: (all black) - 1984 GTI - 1992 GTI 16v - 2001 GTI VR6 VAD mobile scans available
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28. Al Walker

Member Join Date Mar 14th, 2003 Posts 2,863 FV-QR 02-05-2010 06:32 AM #27

It's been an amazing process to watch all this take place, I knew he was planning some OEM+ upgrades but when he came over to borrow the table you see in the pics saying he needed it to layout the new wiring loom I got really really curious. I would drop over every couple of days and see the progress and it was amazing to see the attention to detail and craftsmanship in his work, the loom looks as OEM as you can get, seriously I reckon Graeme could teach the engineers at VW about the car. Cheers Al My Garage Walker Motorsport

Facebook Fan Page People are mushy - Paul Hawkins on the merits of where to crash on the Targa Florio
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29. xphiledan

Member Join Date Aug 11th, 2003 Location East Hanover, NJ Posts 2,786 Vehicles 2004 VW R32

FV-QR 02-05-2010 07:47 PM graeme = the man! what was the FS switch originally intended for?
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#28

30. g60racer

Member Join Date Nov 18th, 2000 Location San Diego Posts 10,603 Vehicles 93 VR6 Corrado, 04 R32

Re: FV-QR (xphiledan) 02-05-2010 09:48 PM Very nice! I think I would rather use the OEM "FUNK" button , but your choice of location is excellent. Brendan Prout 04 R32 112k miles 93 VR6 Corrado 182k miles 90 G60 Corrado 304k miles - RIP 2/12/11
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#29

31. Mike Solo

Member Join Date Jan 25th, 2005 Posts 15,776 Vehicles 2011 135i, 2007 Mini Cooper FV-QR 02-05-2010 10:27 PM #30

Quote, originally posted by g60racer Very nice! I think I would rather use the OEM "FUNK" button , but your choice of location is excellent. That's what I'm going with now that the fahrschule button is long gone. Turn up the exhaust, get FUNKy.
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(Yes, I know it's German...)

32. graeme86

Member Join Date Jun 27th, 2003

Location Brisbane Qld Posts 4,036 Vehicles 2004 DBP R32; 1971 Superbug Re: FV-QR (Mike Solo) 02-06-2010 04:55 AM #31

I tried to get the FUNK button that looked exactly the same as this FS switch but it was no longer available. The switch supersedes to this one. The FS switch is used in the Taxi to turn on their handsfree system. FS = Freisprechen The part number for the matching interior Light Switch is 1T0 927 235 by the way (no extra colour code on this part for some reason). This circuit can be operated by any momentary switch of your preference, so if you just want a hidden button somewhere that would work too. PM if you are looking for: New Beetle RSI shift light; Euro Headlight switches; RHD folding Stubbies. Click below lnk for OEM FUNK Switches. OEM+ freaks click here: Graeme's Webspace - Latest Updates: Audi Brushed Alloy Mirror Switch; Camshaft Hall Sensors; W8 Light with Autodim Mirror Defeat Function
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33. vwgeorge2

Member Join Date Mar 23rd, 2008 Location Cumberland Md (Ridgeley WV) Posts 1,326 Vehicles MK4 S/C R32, MK6 TDI Jetta... Re: OEM+ Flapper Mod - this is a BRAND NEW way to do it! (graeme86) 02-06-2010 09:53 AM #32

The most professional install ever, my hat is off to you. Do you do car stereo?

http://forums.vwvortex.com/showthrea...-final-fantasy.... S/C FTW


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34. GT42R32deepblue

Member Join Date Feb 28th, 2008 Location union.. home of the fastest vw's Posts 1,003 Vehicles 04 r32 T..... modded '06 S4 02-06-2010 07:15 PM #33

u got way to much time on your hands dude..haha.. i dont think ive written essays that long yes i drive a vw turbo R32 12.8 @98mph (~410hp@9lbs)
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35. graeme86

Member Join Date Jun 27th, 2003 Location Brisbane Qld Posts 4,036

Vehicles 2004 DBP R32; 1971 Superbug Re: (GT42R32deepblue) 02-07-2010 09:00 AM #34

Centre console with carbon look treatment is back in.

Here are a two shots of switches in proper position

Night shot of dash

Switches dashlit but off

Footlight switch on with yellow telltale to give you an idea what it looks like

...and my sat nav information displayed in FIS

PM if you are looking for: New Beetle RSI shift light; Euro Headlight switches; RHD folding Stubbies. Click below lnk for OEM FUNK Switches. OEM+ freaks click here: Graeme's Webspace - Latest Updates: Audi Brushed Alloy Mirror Switch; Camshaft Hall Sensors; W8 Light with Autodim Mirror Defeat Function

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36. jmh2002

Member Join Date Jun 28th, 2007 Location France Posts 1,629 Vehicles Euro 2001 MKIV 2.8 V6 4motion (5 door) - HGP Turbo Re: (graeme86) 02-07-2010 09:15 AM #35

Thats really classy mod graeme, very well executed, nothing like OEM+ I have medium terms plans myself to add dual flapper control (custom exhaust for the turbo) to a funk switch in a knee-knocker panel. This provides even more inspiration HGP-T 450PS, Unibrace, 225/40/18 AD08s, OZ Ultraleggera, Light BBK F&R, Recaro Interior, .:R extras, MFD Navi, Phatbox, JCaps, Neuspeed, PSS9s, H2Sport Stage 3, DLI-Teknik, GC links, bHPP, etc...
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