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HowTo: Diverter Valve Install |
| Last updated: 4/09/2008 |
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This only took like 30 minutes. Mostly because I had to stop and take notes and pictures for the site,
and get the damn stock one use hose clamps off.
On to the DV... Forge has a good name in DV's and I liked the black look of this one. The stock
diverter valve is crap. The dealer will refer to this part as the bypass valve sometimes
by the way.... If you are going to chip in the future like me this is a good one to have
in the engine ready for the increased boost, because the OEM DV will fall apart pretty quickly
from what I hear. The Forge 006 that I bought is a bit big, you might want to think about
the 007 because it is smaller and fits under the engine cover. I can't vouch for the 007
but it is probably the same quality as the 006. The reason I recommend it is because I can't
really put the engine cover on all the way anymore. I'm going to have to cut a hole in it so
the top tube of the DV sicks out and the middle screw can be tightened. Without doing that
the cover does not vibrate or anything but it sorta sucks to have it half assed.
Some of you may be wondering about installing DV's "upside down". I think this makes it
louder sounding when you lay off the boost, but I'm not positive if it makes a difference
in performance. You're on your own if you decide to do this. ;)
Equipment:
Tools:
Flathead screwdriver.
Needle nose pliars.
Flashlight (helps...)
Installation:
The stock DV is on the right. The nice big metal Forge is on the left. Look
what a piece of crap the stock one is. Bad! Bad VW! This is something
even normal non enthusiasts should get rid of....
Here is the phone I was going to use to call Kev (guy who helped me with
other HowTo's on this site) if I screwed up this one for some reason. I
figured he would get a laugh if I called him sceaming about cutting a hose
or something... he he. Luckily it all went fine.
Ok, I shimmed my DV. What does that mean? Simple, you put
two 35mmX2.5mm washers in the bottom like so, and it helps
smooth out the boost and hold boost better. I don't know why.
I am not a physicist. If you really want to know about turbos
ask john on club18t and he will fill your head with knowledge.
Now for step one. Take the engine cover off.
Here is what it looks like:
Take the top clamp off first. Then the bottom. Then the left.
It isn't easy, stick a screwdriver in the little space where
the clamp wraps around and slowly pry it off. Just take your time,
they come off quick once you get it started. The left clamp isn't
a pry off though, use the pliars to clamp the two prongs together to pull
the DV out of the tube. Here are the clamps, the left one is the smaller
tube on top of the DV, the one on the right is the one you use the pliars
on.
So there you have a bunch of hoses sticking out.
Now put the new DV in. The easy way is to attach the left hose, then
the bottom hose, then the top hose. Fun, eh?
You can see how I situated the bottom clamp so it was easy to screw in.
I faced the screw out towards the right front corner of the car.
Then put the engine cover back on. With the 007 you can't really
fit the right side on. I have the three corner screws in but not the
middle one. *Sigh...* Doesn't look bad or anything though.
And thats it! Enjoy smoother more easily available boost. :)
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