R32 conversions - fine tuning after install

[Gti182 10]

Hi All,

 

Just fitted a mk5 r32 conversion to my mk3 golf.

 

Specs: Alfa V6 throttle body, emerald remapped ECU, rebuilt vr6 gearbox with Quaife LSD and sachs clutch kit.

 

It's all running now and fully serviced just needs some fine tuning of certain things to get the feel right and hoping to get some input from people who have gone through the same conversion.

 

I've only briefly driven it home in London traffic so will take it out the weekend to get a better feel but already found a few things I'd like to alter to improve the drive-ability.

 

1) Clutch feels like its slipping so will probably look into getting a new clutch kit soon, any recommendations? Looking for as close to a stock feel as possible

2) Clutch takes extremely high and has a judder/vibration on pull away.

3) Clutch pedal comes back smoothly but then towards the biting point gets sticky and feels like it hooks on something then releases very quickly right towards the end

4) Have a B&M short shifter installed but its very notchy and difficult to change gear, have to hunt for reverse and first gears, others seem ok just not smooth

5) Throttle response on acceleration is a bit eager and has a very small band

6) Letting off the throttle pedal car jerks and holds back i.e. doesn't smooth out if that makes sense.

7) When driving and coming to standstill rev's tend to drop slightly slower than i'd like towards 1000 revs and sometime hovers slightly high, around +- 1150 revs

 

pic of said conversion

Edited August 9, 2013 by Gti182

[Kevin Bacon 5]

1) - 3) - New clutch and slave cylinder will sort those issues. Check also your pedal for anything it might be snagging on under the dash.

 

4) Bin it, they're rubbish. Daves16V on here does a decent short shift, or pop a standard one back on for now.

 

5) That's how they are mate. Torque peaks at 2800rpm, holds to 3.5k ish then falls. Who ever mapped it might be able to soften the response a little, or try a smaller throttle. The R32 doesn't need one that big tbh.

 

6) That could be engine mounts (gearbox one usually) or how it's been mapped.

 

7) As above, mapping. Does it have an idle valve fitted and mapped?

Edited August 8, 2013 by Kevin Bacon

[Gti182 10]

thanks for the great comments, have taken them on board.

 

I have noticed the throttle body diameter being quite wide, what are my other options for throttle bodies and if i fit a smaller one is it plug and play or does it need to be reprogrammed?

 

Point 5 above is probably not explained very clearly, the pedal is very sensitive and has a very small range of feel almost like a bad hot water tap hard to get the right setting, 2mm and it goes from ice cold to scorching hot :)

 

Will follow up and see if it has the idle valve

Edited August 9, 2013 by Gti182

[Gti182 10]

ok so mechanic and i had a talk last night.

 

Seems like theres a bad flatspot between 500-1000rpm and the throttle is very twitchy so decided we binning the Alfa throttle in favour of an obd2 vr6 throttle with adaptor plate, hopefully dont have to remap the car after this but should improve the throttle.

 

Also noticed the release bearing is humming possibly causing the slipping and taking late issue so bit the bullet and bought a new uprated clutch kit. Should have everything in by friday

[Kevin Bacon 5]

Yeah the Alfa TB is way too big. Even an R32 throttle is way too big for an R32, lol! The way VW map it is 10% pedal movement = 40-50% throttle opening, which is just mental for town driving. Revo do a "linear throttle" map where 10% pedal gives you 10% throttle, but as you're running a standalone, it's a moot point. Still worth mentioning though and it's throttle sizing that's giving you the weird power band.

 

I suspect also if Emerald mapped the engine themselves, I bet they whacked the intake VVT open full instead of progressively like VW do.

 

I ran my old Corrado R32 on a DTA ECU with their DBW controller, so it all behaved like a stock R32, so if you need any more tips, let me know!

[Gti182 10]

I ran my old Corrado R32 on a DTA ECU with their DBW controller, so it all behaved like a stock R32, so if you need any more tips, let me know!

 

Read good things about the DTA ECU. If i'm not happy with the new TB might go this route later on and go DBW. Looking for as close to stock feel as possible which i think is possible but many people telling me differently.