MK5 Golf GTI
All Things Mk5 => How to Guides / Troubleshooting => Topic started by: vRS Carl on August 04, 2010, 06:34:28 pm
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Hi folks i have been meaning to do this for ages but just never got chance and then forgot about it. The process is done on a Octavia vRS but the engine is the same so will be the same for all 2.0 TFSi i would imagine.
Before i start the usual Disclaimer:
Neither i nor MK5GolfGTI will be held liable for anything that goes wrong. If you undertake this process you do so entirely at your own risk!
You will need
Decent set of Tools
T25,T30 Torx bits
Mole Grips or Vag Cable clamp removal tool
2 x OEM DV
DV Relocation Kit.
Bung for DV
This is where the Relocated DV will sit:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000790.jpg&hash=6345bb817b1a2a2c680148b8fcdd6ea6e9d565e3)
Ok firstly you need to remove your Engine Cover, Intake & Heat Shield.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000788.jpg&hash=2ce30fd4063c3688bb06b1a159e03c991a1c149e)
Remember to disconnect the MAF
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000792.jpg&hash=ca93fd2bca3a5ea0a79c207af812b816b9f51fcc)
Heat Shield
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000802.jpg&hash=d39632128cc0890b6e2d4b7aaffb41ec0023d01b)
I have not described how to remove the Intake as we all have different ones
Once you have removed the Intake, Heat Shield etc you then need to Jack the car up and put on Axle Stands. Once done remove the Undertray by undoing the 11 Screws (8 x T25 & 3 x T30 on a vRS so maybe slightly diff on a Golf)
You will now be left with the Top of the Turbo showing like this
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000806.jpg&hash=b3ffbd1e6e7f22df25963553f6ff68e4d9596fc6)
Next Unplug the connector from the DV and remove the DV (held in by either 5mm Hex Bolts or T30 Bolts 3 in total)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000811.jpg&hash=6a102e2036863b1007dbdcec5649d6f05c44e037)
Once you have removed the DV remove the MAF from the Housing
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000807.jpg&hash=b494dbd7c16c49e6eebcbfa20a67a0ef88846e16)
Place MAF into your new Intake Branch Pipe
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000815.jpg&hash=4470f4c05b49733763966bb396ee1481743bb860)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000816.jpg&hash=0ffafc91e104101b37ca2ce52adc12415aaa0843)
Now connect the Branch pipe to the top of the turbo (again not described in fine detail due to various kits available)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000814.jpg&hash=955d6ec0eedc1742540df5f81f3d3c4a83bc5e50)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000818.jpg&hash=3a2055ddc954f8de64aff606f4746eb49447ffdf)
Next take an OEM DV and place the Bung over the end
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000813.jpg&hash=00fd5e26f89947b8ae6a2ed9a7bc123ebbb1fc24)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000812.jpg&hash=81f749ce797d0e3bb912a0e3c2639322cd82e0dd)
Once done fit this onto the Turbo and tighten up the bolts. You will now need a wiring loom like this to extend the connection.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000821.jpg&hash=69eac93901751edef4656c53330dbaea4ae5450b)
Feed the wire down from the top of the Engine and plug into the connector that used to plug into the DV
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000817.jpg&hash=f93060a40f23dead316463ccfeb257ac9e709757)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000832.jpg&hash=e3805ddfd683a9774c5c1bfac7a28fc1b53d8e09)
You can see in that last pic i have cable tied it off just to keep it all neat.
Next take the new DV and attach to the Branch pipe that fits onto the OEM intercooler pipe (do not connect to the OEM pipe just yet the second pic is for illustration)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000826.jpg&hash=bb5ab30727fceab009b90e2c51ed6e7eba1203ba)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000822.jpg&hash=ebb304fc883b845785d88cc69826e1c8365d3b66)
Then remove the old intercooler pipe and replace with this one
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000823.jpg&hash=27365f41018d97d4dad7da2cb8106d73512604b1)
Now connect the DV pipe
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000827.jpg&hash=809c9e89fb1e3594fb8913189d4137e5f55d7bba)
You now need to run the Connecting take off pipe from the DV to the Intake branch pipe
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000828.jpg&hash=2f740753ddcbced39f1adfd50a38cf872728a1b5)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000829.jpg&hash=d700262b5a5a39dc2688dbc205ae2d5282752d9d)
Now using mole grips or VAG Pipe Clamp tool connect the Take off pipe
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000819.jpg&hash=f25df57436328103cac82d5d1fcf2be20b0a5a1d)
Once this is done run the Wiring loom to the DV and connect. Then cable tie to keep it neat
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000830.jpg&hash=aa67d87fab35bfa6db8e5931ef89b98d00c0ba6b)
Once this is done ensure you have everything connected and have tidied up all the cables etc.
Replace the heat shield and then the rest of the intake and finally the engine cover
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000801.jpg&hash=1e7df4ca312a95e357a3324f23526f18ecc9da0d)
Engine will finally look like this
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FTaufe%2FBrisky_Pics%2FP1000898.jpg&hash=0b79b76284022df0dad00528d51786591ba7f260)
Next thing to do is go for a short drive and make sure all is ok (& if you have access to VCDS no faults)
Once done test drive put undertray back on and Voila DV relocated
Any Questions feel free and Comments good or Bad welcome as always
Carl :happy2:
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Nice guide, just what i was wanting to see :congrats: :happy2:
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I'm sure I've seen that stuff somewhere before :signLOL:
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Dunno what your talking about :innocent:
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Forgive my ignorance.... What's the point in moving the dv?
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One of the problems with the dv in the ko3 is it's proximity to the turbo, it suffers with the heat.
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Until VAG changed the design of the DV they used to have a rubber diaphragm in them.
On the K03 cars the DV is bolted directly to the turbo which meant it would get extremely hot and in turn the rubber would split causing a loss of boost. So this was a solution as the DV at the front of the engine keeps cooler due to the air coming in.
Now that they have a different design with no rubber diaphragm it's not really needed unless you are going K04 conversion.
EDIT: or what Stu said in a not so long winded way :laugh:
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You beat me to it Carl with another good how to:)! Did this 2 nights ago on my vRS and was about to put a tutorial up. I used the Forge blank for the turbo. Saves having another DV. I didnt do the wiring extension (I was too impatient to order the plugs) so I just pulled the wiring back and moved it to the front. The reason I did this is I will be going K04 soon and the dump noise through the filter is much better!!!
Parts I used:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2122.jpg&hash=5c4df0b1a192fb06e059758c284bc6bd8027b4a2)
Forge Blank:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2124.jpg&hash=d5b6ac3ae3742a3672c0132bf187e3c1f4128328)
Bung insert for the 25mm take off:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2123.jpg&hash=80d36d9c0488b7ea622453a191334e5ec8a81c10)
Finished:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2128.jpg&hash=5f276b1ae59cacf013b682f431739a3d3961420d)
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Can this method be used to install vacum operrated DV to the car?
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Yep. Like this:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2FBackdraft%2FDV_Kit%2F_MG_1449.jpg&hash=2d4317378d999f9089ce2b2ca41c69df9f1c3ae5)
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So the wiring doesnt need to be extended, anybody know whats in the forge electronics box that you get with there uprated diverter valve
Also does anyone have the part number for the forge blank?
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Excellent and informative write as always Carl :happy2:
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The forge blank is the blank for the Vauxhall turbos :http://www.forgemotorsport.com/content.asp?inc=product&cat=&product=FMBPVXA (http://www.forgemotorsport.com/content.asp?inc=product&cat=&product=FMBPVXA)
The part number for the valve that needs to be plugged in to avoid lights is: 06F 906 283F. I have these in stock.
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Excellent write-up, Carl :drinking:
Is there any point or advantage on a K03 car moving a Forge DV off the turbo and onto the upper front position?
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After changing mine it feels like there is better valve response, and the boost seems to come back on slightly quicker. This could just be in my head. Its also good to circulate the colder air back into the intake rather than the hotter air.
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Even the Forge DV is a servicable item Robin so for ease of access then yes.
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I had the forge DV before I relocated and had to get a service kit for it
This incorporated a new spring, seals and grease. So as Ian says the relocation is best for servicing needs.
As I said earlier now that the DV design has changed there is no real need until you go to K04.
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You beat me to it Carl with another good how to:)! Did this 2 nights ago on my vRS and was about to put a tutorial up. I used the Forge blank for the turbo. Saves having another DV. I didnt do the wiring extension (I was too impatient to order the plugs) so I just pulled the wiring back and moved it to the front. The reason I did this is I will be going K04 soon and the dump noise through the filter is much better!!!
Parts I used:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2122.jpg&hash=5c4df0b1a192fb06e059758c284bc6bd8027b4a2)
Forge Blank:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2124.jpg&hash=d5b6ac3ae3742a3672c0132bf187e3c1f4128328)
Bung insert for the 25mm take off:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2123.jpg&hash=80d36d9c0488b7ea622453a191334e5ec8a81c10)
Finished:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2128.jpg&hash=5f276b1ae59cacf013b682f431739a3d3961420d)
do you have the part nos for all the parts please?
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Great how to there :congrats: it's what this forum is all about!!!
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Carl, is this picture looking up, from under the car?
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fi936.photobucket.com%2Falbums%2Fad203%2Fpagey1255%2FP1000811.jpg&hash=14f89557cd6eae4abbaae000799f35172da42077)
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Yes mate.
From the drivers side. The big black bar at the bottom of the pic is part of the axle :happy2:
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Take it you didnt have to untape the loom to pull cables around you just rerouted them??
Brill Tutorial got all the bits just need to do it, wen it gets warmer.
Sie
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Yes mate I just re-routed the extension loom down to the original connector. :happy2:
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I did see a Thread with some part numbers for the extension loom, is this how you made it??
You dont have the numbers do you??
BDMAlex you send about rerouting the cables is it long enough just to reroute??
Thanks Guys
Sie
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I built the Loom that Carl uses from OEM parts. Not sure if I've still got the numbers, I'll look.
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1J0 973 822 A 2 Pin Brown Flat Contact Housing 1
1J0 973 722 A 2 Pin Black Flat Contact Housing 1
000 979 134 Single Wire 1.0mm 2
000 979 133 Single Wire 1.0mm 2
N 107 324 01 Corrugated Pipe 4.5mm (M) 2
N 906 819 01 Corrugated Pipe End Piece 4.5mm 2
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Brill thank you. Did it all cost much?
Sie
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Not an enormous amount, no.
You'll also need some decent cable to make the length.
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With the wiring on mine and the ones I do at work, you just need to pull with wiring back to the start of the coilpack wirings plastic housing. That gives the perfect length to route the wiring round the right side of the engine and onto the DV.
Using a wiring extension is faster and easier, but costs more and imo doesnt look as neat/oem.
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With the wiring on mine and the ones I do at work, you just need to pull with wiring back to the start of the coilpack wirings plastic housing. That gives the perfect length to route the wiring round the right side of the engine and onto the DV.
Using a wiring extension is faster and easier, but costs more and imo doesnt look as neat/oem.
Depends how neat & OCD you are :P
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With the wiring on mine and the ones I do at work, you just need to pull with wiring back to the start of the coilpack wirings plastic housing. That gives the perfect length to route the wiring round the right side of the engine and onto the DV.
Using a wiring extension is faster and easier, but costs more and imo doesnt look as neat/oem.
Depends how neat & OCD you are :P
Very, but you have to be when you do it for a living. :P
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You beat me to it Carl with another good how to:)! Did this 2 nights ago on my vRS and was about to put a tutorial up. I used the Forge blank for the turbo. Saves having another DV. I didnt do the wiring extension (I was too impatient to order the plugs) so I just pulled the wiring back and moved it to the front. The reason I did this is I will be going K04 soon and the dump noise through the filter is much better!!!
Parts I used:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2122.jpg&hash=5c4df0b1a192fb06e059758c284bc6bd8027b4a2)
Forge Blank:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2124.jpg&hash=d5b6ac3ae3742a3672c0132bf187e3c1f4128328)
Bung insert for the 25mm take off:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2123.jpg&hash=80d36d9c0488b7ea622453a191334e5ec8a81c10)
Finished:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2128.jpg&hash=5f276b1ae59cacf013b682f431739a3d3961420d)
Hi Alex, Is the parts in the picture all that is needed for the DV relocation? I dont like the complicity i am seeing with all the extra wires and things that other places are saying lol, Your one looks fairly simple and straightforward
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Learned something today! Never knew about that wiring bit. Good, looks like I'd be saving some (wee bit of) cash on that wiring extension harness. :signLOL:
I wonder why some DV relocation kits (and K04 kits like APR etc) has that wiring extension though.
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Until VAG changed the design of the DV they used to have a rubber diaphragm in them.
On the K03 cars the DV is bolted directly to the turbo which meant it would get extremely hot and in turn the rubber would split causing a loss of boost. So this was a solution as the DV at the front of the engine keeps cooler due to the air coming in.
Now that they have a different design with no rubber diaphragm it's not really needed unless you are going K04 conversion.
....So with a Forge DV on a K03 car, there's no point in moving the DV location?
Do the latest OEM revision DV's suffer from the same potential heat problems?
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Well at the front I find it easier to service as stated before,
With the forge DV being alloy metal type, when attached to the turbo it will get quite a lot of heat.
Using the words heat soak, would that be the correct term… You could defiantly not touch it after a drive, even at the front it still gets hot, but I would imagine not as hot as being placed beside the turbo
When at the front it is constantly getting cold air passing over it thou, I personally think it makes sense...
:happy2:
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^^^^
Thanks, scopes.
But does a hot DV (Forge) actually reduce its performance?
The heat problem with the early OEM DV's is the potential and relatively common diaphragm tear, not helped by the increase in boost pressure from a remap.
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I would imagine its very much the same as a CAI, it would be very minimal, but its sounds like you have a task to do now Robin with some before & after logs & dyno runs
:signLOL:
It’s not something I got round to do as I had other mods installed at the same time :grin:
:party:
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I would imagine its very much the same as a CAI, it would be very minimal, but its sounds like you have a task to do now Robin with some before & after logs & dyno runs
:signLOL:
.... :confused: Logging and dyno-ing and moving my Forge DV is not something I need to consider. It's all currently working fine, so I won't mend it.
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The only problem I see is that the Forge DV is a serviceable item.
If you are going to the trouble of relocating it I would go for a rev G and if not a rev D.
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The only problem I see is that the Forge DV is a serviceable item.
....And fortunately easily accessible when JKM service my car :happy2:
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Does anyone have the part numbers for the large plastic hose and the alloy union the DV attachs to. Also the bracket
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You beat me to it Carl with another good how to:)! Did this 2 nights ago on my vRS and was about to put a tutorial up. I used the Forge blank for the turbo. Saves having another DV. I didnt do the wiring extension (I was too impatient to order the plugs) so I just pulled the wiring back and moved it to the front. The reason I did this is I will be going K04 soon and the dump noise through the filter is much better!!!
Parts I used:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2122.jpg&hash=5c4df0b1a192fb06e059758c284bc6bd8027b4a2)
Forge Blank:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2124.jpg&hash=d5b6ac3ae3742a3672c0132bf187e3c1f4128328)
Bung insert for the 25mm take off:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2123.jpg&hash=80d36d9c0488b7ea622453a191334e5ec8a81c10)
Finished:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Ffordkaracing%2FOctavia_vRS%2F_MG_2128.jpg&hash=5f276b1ae59cacf013b682f431739a3d3961420d)
Hey man what's that intake bung thing? You got a link for it? The thing you have plugged into your intake for the air to return through!