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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.Connection Point" in descriptions below. I just used a VW Butt connector.5mm ~ 14 gauge Terminal Pins If you look at the new relay plate mounts.0mm wire = 000 979 135 2.5mm wire from screw terminal -87F.5mm = 000 979 225 Medium 1.5mm wire = 000 979 212 Additional clip on Fuseholder uses Medium terminal repair wires. If you use a spare small size fuse (minifuse) in the main fusebox. If you use a spare Large Fuse in the main fusebox then you need medium terminals as well.5mm wire = You can buy bare terminals from Porsche .0mm wire from your new fuse (fused side) to a new junction point that you need to create. Run new 1.0mm wire = 000 979 114 (or you can buy Porsche bare terminals 999 650 103 12) 2. The relay plate only requires medium and large pins to plug in the relays for this installation. Power Fuse Run new 2. You need to run these wires from this point: 1.0mm to Pin 1 on 2000 Ohm Resistor mounted in Additional Fuse Holder on Additional Relay Plate Flapper Relay (79) Pin =Terminal=Connection .Part Number 999 650 330 00 1.to your new fuse (unfused side).0mm to Flapper Relay (434) Pin 2 and 5 (or jump feed wire at relay pins) 1. then you will need to use the Small terminal repair wires instead.0mm to FS Flapper Switch Pin 1 1.0mm ~ 18 gauge 2. 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.0mm = 000 979 133 2.5mm wire = 000 979 227 Large 0. you will note there are three different size terminal pins that they use. I have designated it the "-87F. The VW Repair wires for the different terminal sizes are: Small 1.

0mm jumper wire to Pin 5/56 AND 1.join to dimmer rheostat circuit dimmer earth .5mm to Flapper Relay (434) Pin 8 and also splice to FS Flapper Switch Pin 5 in OBD harness 5 / 87a=Medium=1.connection point 4 / 31=Large=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.connection point 1.5mm 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 -> Join to original 1.0mm -> FS Flapper switch Pin 2 8 / 56a = Medium = 0. 8 / 87 =Medium=1.0mm gr/bl wire cut in A-pillar Joins to Flapper Valve side of harness (going to rear harness) 6 / 85 = Large =0.0mm jumper wire to Pin 2 /30 6 / LU= Large=1.0mm to new -87F.0mm to Earthpoint (I used Steering Column Earthpoint).0mm to Pin 6 on Flapper Relay (434) in Relay Plate dimmer positive . Joins to ECU side of harness (going to engine bay) 3 / 30a = Not used in this application 4 / 86 = Large =0.0mm -> Join to original 1.0mm to new -87F.5mm to Earthpoint (I used Steering Column Earthpoint).0mm gr/bl wire cut in A-pillar. 5 / 56 =Medium=1.join to dimmer rheostat circuit .2 / 30 =Medium=1.

but here is a schematic I drew up: .5mm to Pin 8 Flapper Switch Relay (434) and Pin 86 on Flapper Switch Relay (79) in Relay Plate Pin 6 = 0.Pin 5 = 0.5mm to earthpoint Sounds complicated when you read it..

Switch .

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

Rear of switches .

Old Fuse dismantled and resistor soldered to blades .

Resistor mounted in fuseholder .

.close enough ..Resistance .

Plugged in .

. More pictures to come once I reinstall my interior.With cover cap installed Everything else is just adding wires and following correct protocols when working with electrics. for doublechecking my schematic before I hacked into my own car.been doing some other mods as well. the electrical guru. Thanks to VeeRSixx....

3. RHD folding Stubbies.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.com/advertpro/servlet/view/banner/image/zone? zid=188&pid=0&position=1" hspace="0" vspace="0" border="0" alt="Click Here!">< /A> Member Join Date Jun 14th. supline < A href="http://ads2.Latest Updates: Audi Brushed Alloy Mirror Switch.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. .com/advertpro/servlet/click/zone?zid=188&pid=0&lookup=true&position=1" target="_blank">< IMG src="http://ads2. Camshaft Hall Sensors. 2007 Posts 326 Re: OEM+ Flapper Mod . Euro Headlight switches.vortexmediagroup.vortexmediagroup. Click below lnk for OEM FUNK Switches. W8 Light with Autodim Mirror Defeat Function Reply With Quote 2. OEM+ freaks click here: Graeme's Webspace . I think we need pictures of the switch lighted in both on and off modes.

776 . 2005 Posts 15. Mike Solo Member Join Date Jan 25th. 2009 Posts 532 02-04-2010 12:57 PM PERFECT !!!! Reply With Quote #3 5. Nemesis-Brad Member Join Date Aug 16th.Reply With Quote 4.

If I had realized then that it was from a driving school car and absolutely IMPOSSIBLE to find. 2004 Location Harrisburg PA Posts 2.this is a BRAND NEW way to do it! (graeme86) 02-04-2010 01:09 PM #5 . but that's no good for RHD cars. particularly since you already have other similar buttons for your fuel door. Graeme! I used the Passat taxi knee-knocker panel. I like that a lot. VeeRsixx Member Join Date Jan 5th.Vehicles 2011 135i. Reply With Quote 6. but I sold the damn "alarm" button that I found on German eBay. etc. I want to redo the OEM+ flapper mod. 2007 Mini Cooper FV-QR 02-04-2010 12:59 PM #4 Beautiful.761 Vehicles '04 R32 Black Magic Re: OEM+ Flapper Mod . I never would have sold it.

props for finding all that figuring it out and sharing for others .. 98 gti vr6 Re: FV-QR (Mike Solo) 02-04-2010 01:11 PM #6 way cool.2001 GTI VR6 VAD mobile scans available Reply With Quote 7.1992 GTI 16v .1984 GTI . but that is the neatest looking way I have seen yet. I am happy with mine the way it is. 2002 Location naptown Posts 2. schmuck Member Join Date Jun 22nd.359 Vehicles 04 dbp r32. past dubs: (all black) .wOOt for the king of OEM++ !! I would venture to say this is the most involved flapper mod ever.

David 04 R32 fun documentation project Reply With Quote 8. 2005 Posts 15. 2007 Mini Cooper FV-QR 02-04-2010 01:11 PM #7 Also. these two parts are not available in the US. TMT has them for half of that but shipping isn't cheap.776 Vehicles 2011 135i. R32R1 . Mike Solo Member Join Date Jan 25th. 1C0 941 597 1T0 927 124 9B9 Reply With Quote 9. Impex can source them for roughly $80.

Member Join Date Jul 1st.this is a BRAND NEW way to do it! (VeeRsixx) 02-04-2010 01:24 PM #8 Very cool. 2008 Location South County. Mike Solo Member . What did this all run you? Pics of your OEM+ car? The Build Thread RIP Alexi Reply With Quote CTS Turbo SoCalStance Shop 10.086 Vehicles project roided wookie Re: OEM+ Flapper Mod . RI Posts 13.

Join Date Jan 25th. 2008 Posts 1.this is a BRAND NEW way to do it! (VeeRsixx) 02-04-2010 03:39 PM #10 Quote. Reply With Quote 11. Bolan Vdub Banned Join Date Apr 23rd. originally posted by R32R1 » Very cool. originally posted by VeeRsixx » .792 Re: OEM+ Flapper Mod . 2007 Mini Cooper FV-QR 02-04-2010 01:56 PM #9 Quote.776 Vehicles 2011 135i. What did this all run you? Looks to be around $125 USD. 2005 Posts 15.

2005 Posts 15. E Coded . Mike Solo Member Join Date Jan 25th.776 Vehicles 2011 135i. Reply With Quote 13. please post a picture of that colossal wiring loom you've been working on. 2007 Mini Cooper FV-QR 02-04-2010 04:05 PM #11 Graeme.wOOt for the king of OEM++ !! Hail to the OEM King Reply With Quote 12.

470 Vehicles 04 R32. 91 GTI 16v Re: OEM+ Flapper Mod .355 Vehicles Mk4 R32 .Member Join Date Aug 28th. 2000 Posts 1. R Line Member Join Date Sep 3rd. 2007 Location New York Posts 2.this is a BRAND NEW way to do it! (graeme86) 02-04-2010 04:07 PM #12 You sir get one of these: Reply With Quote 14.

Re: OEM+ Flapper Mod .this is a BRAND NEW way to do it! (E Coded) 02-04-2010 05:21 PM #13 I LIKE Reply With Quote 15. Brake_Dust Member Join Date .

'02 Jetta TDI .P. PA Posts 7. lil_kano Member Join Date Apr 10th.299 Vehicles '04 RS . '85 Scirocco . 2007 Location Coral Springs.gone .R.:R32 (Cloth).I. 2001 Location West Chester.Sep 23rd. Fl Posts 2.722 Vehicles R32/GTI 12V FV-QR 02-04-2010 05:21 PM #14 wow! OEM x eleventybillion -InvisibleReply With Quote 16.

.:Rcoholic Member Join Date Jan 18th. What 'bout you?? WiTW'12 South East WiTW'12 Caravan! Reply With Quote #15 17.961 Re: FV-QR (lil_kano) 02-04-2010 07:33 PM #16 Quote.. I drive a Chewbaka noise maker. 2006 Posts 1.FV-QR 02-04-2010 06:08 PM Wow! Very impressive! to you my friend. originally posted by lil_kano » Wow! Very impressive! . .

newcreation Member Join Date Nov 23rd.to you my friend..693 Vehicles 04 R32 FV-QR 02-04-2010 07:41 PM #17 Haha nice nice awesome mod. PA Posts 10..Good job Rob for checking over his wiring schematics -JAMESDaily Drive /Beaten/Built /UM Turbo R . X2 Reply With Quote 18. 2003 Location HBG.VR NATION Reply With Quote .

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. it is amazing to see his attention to detail. 2003 Posts 2.Paul Hawkins on the merits of where to crash on the Targa Florio Reply With Quote 20. graeme86 . Al Walker Member Join Date Mar 14th.19. everything he has done looks 100% factory.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. simply amazing stuff. Cheers Al My Garage Walker Motorsport Facebook Fan Page People are mushy .

2003 Location Brisbane Qld Posts 4. . I only stuggle with reds greens and browns.036 Vehicles 2004 DBP R32. 1971 Superbug Re: FV-QR (Al Walker) 02-04-2010 10:36 PM #19 Al.Member Join Date Jun 27th.

As you can see there are a few other mods being done at the same time.Here is a pic of relay plate mocked up on bench. . I figured it was easier just to run one big loom so everything is tidy.

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

Shot of loom going into dash. .

.

2007 Mini Cooper FV-QR 02-04-2010 10:37 PM #20 You put me to shame.Latest Updates: Audi Brushed Alloy Mirror Switch. 2005 Posts 15. Graeme. RHD folding Stubbies. Mike Solo Member Join Date Jan 25th. W8 Light with Autodim Mirror Defeat Function Reply With Quote 21. Camshaft Hall Sensors.PM if you are looking for: New Beetle RSI shift light. You are crazy! Reply With Quote 22.776 Vehicles 2011 135i. graeme86 . Click below lnk for OEM FUNK Switches. OEM+ freaks click here: Graeme's Webspace . Euro Headlight switches.

036 Vehicles 2004 DBP R32. 2003 Location Brisbane Qld Posts 4.Member Join Date Jun 27th. 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

761 Vehicles '04 R32 Black Magic Re: FV-QR (Al Walker) 02-05-2010 02:11 AM #26 Quote.125.wait till you see the other goodies he has been working on. originally posted by NuespeedGTi » you forgot the engineering degree. VeeRsixx Member Join Date Jan 5th. total cost $80.. . 2004 Location Harrisburg PA Posts 2.00 USD Reply With Quote 27. originally posted by Al Walker » ..FV-QR 02-05-2010 01:07 AM #25 Quote.

2003 Posts 2. Al said it. the loom looks as OEM as you can get. past dubs: (all black) . not me.1992 GTI 16v . Cheers Al My Garage Walker Motorsport .1984 GTI . seriously I reckon Graeme could teach the engineers at VW about the car..Ok. 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.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.2001 GTI VR6 VAD mobile scans available Reply With Quote 28. Al Walker Member Join Date Mar 14th.

786 Vehicles 2004 VW R32 FV-QR 02-05-2010 07:47 PM graeme = the man! what was the FS switch originally intended for? Reply With Quote #28 . 2003 Location East Hanover. xphiledan Member Join Date Aug 11th. NJ Posts 2.Paul Hawkins on the merits of where to crash on the Targa Florio Reply With Quote 29.Facebook Fan Page People are mushy .

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 . 2000 Location San Diego Posts 10. Brendan Prout 04 R32 112k miles 93 VR6 Corrado 182k miles 90 G60 Corrado 304k miles . but your choice of location is excellent.30. Mike Solo . g60racer Member Join Date Nov 18th.RIP 2/12/11 Reply With Quote #29 31.

. Turn up the exhaust. 2003 . originally posted by g60racer » Very nice! I think I would rather use the OEM "FUNK" button . 2007 Mini Cooper FV-QR 02-05-2010 10:27 PM #30 Quote. graeme86 Member Join Date Jun 27th. get FUNKy. I know it's German. but your choice of location is excellent. 2005 Posts 15.. Reply With Quote (Yes.) 32.Member Join Date Jan 25th. That's what I'm going with now that the fahrschule button is long gone.776 Vehicles 2011 135i.

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). W8 Light with Autodim Mirror Defeat Function Reply With Quote 33. Click below lnk for OEM FUNK Switches. 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. Euro Headlight switches. OEM+ freaks click here: Graeme's Webspace .Latest Updates: Audi Brushed Alloy Mirror Switch. The switch supersedes to this one. RHD folding Stubbies. vwgeorge2 .036 Vehicles 2004 DBP R32. This circuit can be operated by any momentary switch of your preference. PM if you are looking for: New Beetle RSI shift light. so if you just want a hidden button somewhere that would work too.Location Brisbane Qld Posts 4. The FS switch is used in the Taxi to turn on their handsfree system. Camshaft Hall Sensors.

vwvortex.Member Join Date Mar 23rd. Do you do car stereo? http://forums.. 2008 Location Cumberland Md (Ridgeley WV) Posts 1. S/C FTW Reply With Quote 34.com/showthrea. GT42R32deepblue . my hat is off to you.-final-fantasy...this is a BRAND NEW way to do it! (graeme86) 02-06-2010 09:53 AM #32 The most professional install ever. Re: OEM+ Flapper Mod ..326 Vehicles MK4 S/C R32. MK6 TDI Jetta....

Member Join Date Feb 28th. 2008 Location union. graeme86 Member Join Date Jun 27th....036 ..haha... home of the fastest vw's Posts 1.. modded '06 S4 02-06-2010 07:15 PM #33 u got way to much time on your hands dude. 2003 Location Brisbane Qld Posts 4. i dont think ive written essays that long yes i drive a vw turbo R32 12.003 Vehicles 04 r32 T.8 @98mph (~410hp@9lbs) Reply With Quote 35.

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 ...

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

. Phatbox. JCaps.. OZ Ultraleggera. Light BBK F&R. 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. 225/40/18 AD08s.8 V6 4motion (5 door) . very well executed. Neuspeed. PSS9s. DLI-Teknik. Reply With Quote . bHPP. GC links.HGP Turbo Re: (graeme86) 02-07-2010 09:15 AM #35 Thats really classy mod graeme. Unibrace.Reply With Quote 36.629 Vehicles Euro 2001 MKIV 2. Recaro Interior. jmh2002 Member Join Date Jun 28th. H2Sport Stage 3. 2007 Location France Posts 1. MFD Navi. . etc.:R extras.

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