Mellow Yellow 3.2ltr 24v Conversion
Posted
Old Timer
bigw2069 said
Do you remember what clutch/flywheel combo you used? I note the usual g60/vr6 option doesn't have enough holes in the flywheel for the mk5 24v.
You don't need anything from a G60.
It depends which gearbox route you go. If 02a / 02j 5speed 6 cyl bell housing then VR6 flywheel and vr6 clutch. My engine is a mk5 generation 24v.
Posted
Settled In
Was yours a DSG? I've heard some things about the needle bearing on the end of the crankshaft, unsure whether to just remove now going manual.
Posted
Old Timer
bigw2069 said
Thanks, I've got an 02A CCM going on to a BUB, I stumbled on the Darkside Developments 8kg SMF which looks to tick the boxes.
Was yours a DSG? I've heard some things about the needle bearing on the end of the crankshaft, unsure whether to just remove now going manual.
I started with a CCM and now have a V5 gearbox and added a diesel 5th gear for the shorter ratios 1-4 and a long 5th.
You don't need to spend a fortune on the clutch and flywheel. I bought my VR6 flywheel and Sachs VR6 clutch from Darkside and only came to £300 all in.
The needle bearing doesn't need to be removed. I still have mine in. If you can remove it then it wouldn't hurt.
No part of the 02a or 02j input shaft will engage with it .
Any questions give me a shout
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Settled In
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Settled In
Was it 066260087A you used for your accessory bracket and did you trim it?
Half thinking of getting the eurowise mini alternator and bracket setup as I'm working in the states in October.
Posted
Old Timer
bigw2069 said
Was it 066260087A you used for your accessory bracket and did you trim it?
Half thinking of getting the eurowise mini alternator and bracket setup as I'm working in the states in October.
I thought about the Eurowise route but if the alternator failed it's an expensive item to source from the states again. The stock R32 alternator fits well even with the massive Eurowise radiator. Check back through my build as there are clearance pictures.
I can't remember what the part number was but this was mine and I chopped the aircon compressor section off the bottom.
Posted
Old Timer
I replaced the filter with a new one and dead on 4bar. I'm wondering if my Bosch 040 pump is over working the regulator as I believe the filters have quite a restrictive return. At least I can monitor it now and will probably add an aftermarket FPR in the future.
Last edit: by Rich.
Posted
Old Timer
Posted
Old Timer
Posted
Old Timer
Maximised Mid bass with my 5 1/4 inch components by sealing the door, sound proofing inside and out. Made an aluminium panel to seal the large opening, bead rolled the outer edge so the panel sits in the door allowing clearance for the door cards.
Also added clearance for the tweeters like the cabriolets by cutting holes in the door skin to accommodate them.
Last edit: by Rich.
Posted
Old Timer
Epic and well engineered job as usual!
Posted
Old Timer
paceman said
It's no wonder you need all the extra horses to haul that lot around!
Epic and well engineered job as usual!
Ha thank you. Doesn't really add that much weight.
I think of it as ballast to counter the heavy nose
You wouldn't notice it with how quick the thing is .
Last edit: by Rich.
Posted
Old Timer
Posted
Newbie
I currently have just the stock 2 pin for brake lights.
I can see on pin 55 on ecu is for brake light switch. I have that wire not connected.
Is that the only wire I need to connect with a 3 pin switch or is there a total of 4 wires needed.
Many thanks.
Ps car looks and sounds bloody awesome👌
Posted
Old Timer
77mk1_R32 said
Hey Rich, please could you explain how you wired in the brake light switch if you don't mind.
I currently have just the stock 2 pin for brake lights.
I can see on pin 55 on ecu is for brake light switch. I have that wire not connected.
Is that the only wire I need to connect with a 3 pin switch or is there a total of 4 wires needed.
Many thanks.
Ps car looks and sounds bloody awesome👌
I must admit I cheated. I used a 2 pin brake switch and used CE1 connections for brake lights.
I have a clutch switch and 4 pin brake switch but haven't got round to fitting them yet. Spoke to rubjonny and he suggested:
12v to pin 55 on ECU so it's permanently showing brake disengaged.
Earth pin 56 brake light off
I've not detected any negative effects doing this.
rubjonny said to do it properly:
Clutch switch:
blue/black - ignition live
red/white - ECU pin 39
MK4 Brake switch pins:
1 - red/brown - original brake switch red/yellow (permanent live)
2 - blue/black - ignition live
3 - yellow/white - ECU pin 55 (cruise brake switch)
4 - black/red - ECU pin 56 & original brake switch red/black (brake lights on)
You can then check functionality in VCDS.
To be honest you have me motivated now to wire the switches. Might be a job for later 👍🏼.
Posted
Newbie
Tho I can't see any issue with the way you have wired it.
At the end of the day all we need to do is make the ecu happy with the correct inputs and outputs as we were not running ABS etc, but not sure what effect it will have with the ECU not seing a brake input regard to engine braking etc if that's even a thing on these motors.
Posted
Old Timer
Works a treat .
Posted
Old Timer
So to keep things simple I will use a mk5 generation fuel pump / sender which has an integral swirl pot. This will then supply the FPR full filter and job done . The one I've used is from a 2ltr TFSI.
I purchased a new tank a while ago before prices went crazy. It's a carb tank.
DISCLAIMER!!! -If you want to replicate what I've done do not use a fuel tank which previously had fuel in, this is super dangerous and will no doubt explode. Start with a new one like I did.
Started making the opening the pump unit would fit in. I've sunk it a bit to ensure nothing fouls the rear bench floor so I can attach the fuel lines and electrical connection easily. The fuel reading will stay full a bit longer as it doesn't reach the top of the tank. I will pressure test the tank before filling it with fuel to ensure there are no leaks.
Excuse the slippers… Health and Safety essentials .
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Old Timer
Posted
Old Timer
Then welded it in .
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