Before we begin. This is a giude to installing a Forge DV006, and although there are similar Forge DV's available, its not the 'defacto' way to install a DV. So if you experience any problems then I cannot be held responsible for any issues that may arise. Also, if you feel that your not upto the task of installing the valve yourself, please seek the advice of a professional. Although this install is based on an AGU non-drive-by-wire 1.8Turbo, the information and pictures are still relevant to the later drive-by-wire engines.
:: Important ::
Also, before starting any work, make sure your engine is cold! You will be working around the back of the engine, in particular by the turbo, and probably resting on the Cyliner head while you do some work. I dont have to tell you how hot it gets - especially the Turbo Compressor outlet.
I've split this guide into two parts to make it easier. You will find a link to Part Two at the end of this giude.
Before we begin I know my engine looks like its been to Afghanistan and back, But with all the bad weather we've been having lately its not worth getting my engine cleaned. UPDATE - I don't own this car anymore so odd's are it looks ten times worse now!!
OK on with the install allready..
Tools needed.
1 x Phillips head Screwdriver
1 x Flat Head Screwdriver
1 x Small Cable tie
1 x Stubby wire cutters
1 x Pack of two 16-22mm Hose clips (Halfors / Motor Factors sell these)
Some High Temperature Grease (again, Halfords or Motor Factors)
1 x Forge DV (duhhhh)
Removing the Bosch DV
First off, heres the engine:
Take a good look at it. Try to Familiarise yourself with the various comonents. Now as I stated where going to be working around the back of the engine, so your going to have to get the Engine cover off. This is an easy task. Unscrew the caps arrowed, using a quater turn with your Phillips Screwdriver. They should pop-up easily. If they don't pop up, I usually find rocking the cover gently helps the caps to come loose.
With the engine cover off we get our first good look at the Bosch OEM DV, its the component circled. Try and get a good look at it from different angles. You will note that it has three hoses attched. The Left side hose - where the 'diverted' pressure comes in. The small hose on the top (Vacuum hose), and the last down below - where the diverted boost pressure is released into your air intake. These are the three hoses that need to removed thus enabling you to remove the DV.
Here's some more pics of the DV and closeups of the connected hoses:
As you can see its quite a confined space, but with some good steady hand work you'll have it out no problem.
Removing the Hoses:
At this point your hose clips may look different to the ones pictured (as I have had my Forge in for some time and replaced the original hose clips some time ago). Update - I've been alerted by some forum members that the factory fitted clips are quite hard to remove, resulting in many a blue word swearing bout and skin removed from knuckles. You have two options with the stock clips - either try to prize them off - or cut them. As you'll no doubt be purchasing new clips I suggest you go with the latter of the two options. Remember be careful when cutting as you don't want to damage any of the boost pipes!
First unscrew (or unclip / cut) the clip on the side, then pull the hose off, holding the DV as you do this.
Now comes the fiddly one, you may have to use a long shafted screw driver to get to the lower hose clip. Once unscrewed pull the DV upwards and it should slowly slide out.
Now you need to remove the small hose at the top. I used the set of stubby wire cutters to prize this O ring open, but you can just clip it off as the metal is fairly soft.
Congratulations! You've now succesfully removed your OEM Bosch DV!
Click here for part two - Installing the Forge DV006