Forge Diverter Valve (Bypass Valve) HowToNow, I have bad luck. Even with that, this only took like 30 minutes. Mostly because I had to stop and take notes and pictures for the site.
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:Forge 006 Dump/Diverter Valve for 1.8T BLACK
Some tube clamps. The OEM ones that you remove are one time use only.
My kit from stratmosphere came with clamps. Otherwise get some nice adjustable ones at Home Depot or something.
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....
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.
Information provided by: IzVW of club18t.com
personal site
http://www.IzVW.com
