Go Back  AudiForums.com > Audi Tech > DIY - Do It Yourself
 Installing and Servicing your Forge DV/BOV >

Installing and Servicing your Forge DV/BOV

DIY - Do It Yourself Within you will find how-to's on many aspects of modding and caring for your ride as told by your fellow members.

Installing and Servicing your Forge DV/BOV

  #1  
Old 12-07-2007, 08:31 PM
chaos92287's Avatar
5th Gear
Thread Starter
Join Date: Aug 2006
Location: Orlando, FL
Posts: 8,355
Default Installing and Servicing your Forge DV/BOV

Swapped my Forge 006 out for my Forge 004 so i thought i would do a quick write-up so we dont keep having to outsource links for DIY's

Tools Required [ul][*]Socket Wrench[*]T30 Hex Bit (unless you have really small hands)[*]Screwdriver[*]New Vacuum hose (if yours is old or cracking)[*]Clamps [/ul]
Servicing the Valve [ul][*]Remove the 6 screws using a 2mm hex key. As soon as you remove the screws it should want to pop open to release the springs tension.[/ul]BOV
Name:  S5000436.jpg
Views: 251
Size:  84.5 KB

Name:  S5000433.jpg
Views: 328
Size:  91.4 KB

DV


Name:  S5000458.jpg
Views: 232
Size:  100.2 KB

Name:  S5000456.jpg
Views: 556
Size:  123.2 KB [ul][*]Clean the entire DV/BOV[/ul]Name:  S5000457.jpg
Views: 250
Size:  99.7 KB [ul][*]Apply some grease to the piston and the o-rings. I recommend Mobil 1 high temp grease[/ul] [ul][*]Put everything back together and screw the 6 screws back in [/ul]

Installing the Valve

Side note: Many people do this from the bottom after jacking it up, but I find it easier doing it from the top. You can pop out the headlight to give you more room to work in. Either way the instructions are basically the same [ul][*]Remove the side marker if you have the 2 piece style headlights by unclipping the clip in the back and pushing it straight out[/ul]Name:  S5000442.jpg
Views: 200
Size:  60.6 KB [ul][*]Remove the 3 screws using a T30. My side screw wasn't a T30 bolt for some reason but yours should be[/ul]Name:  S5000438.jpg
Views: 210
Size:  81.5 KB

Name:  S5000439.jpg
Views: 203
Size:  84.9 KB [ul][*]Remove the headlight. I couldn't remove mine because of a wire I couldn't disconnect, have no idea why it is like this, but you should be able to remove yours by detaching a clip. If you can't just sliding it up forward will be sufficient enough[/ul]Location of DV
Name:  S5000465.jpg
Views: 216
Size:  81.2 KB [ul][*]Remove the clamp coming from the TIP by using a long extension (or pry off the 1 time clips if you have the stock dv) [/ul]Name:  S5000468.jpg
Views: 216
Size:  84.0 KB [ul][*]Pull the DV up to the top, the hose leading to the turbo outlet hose should be in some clips so take them out before pulling the DV up[/ul] [ul][*]Remove the other clamp and vacuum line[/ul] [ul][*]For a DV you just plug everything back in, reverse of how the stock dv was. The bottom goes to the turbo outlet hose, and the side goes to the TIP. Just do the side while you have it at the top and then plug the bottom back in and tighten it the same way you loosened it. Make sure to put the hose leading to the turbo outlet hose back in its clips, and zip tie the vacuum hose out of the way from the fan by tying it to the coolant hose[ul][*]If anyone installing an APR R1 is using this guide, you will actually put the bottom going towards the TIP, and the side going into the turbo outlet hose. This is because with diaphragms, the pressure needs to come in from the side so that there isn't constant pressure beeing put on both sides of the diaphragm, like if you were to put the bottom of the valve into the turbo outlet hose.[*]Also some people run their piston style DV's (like Forge) the way the stock valve is run, with the bottom going towards the TIP, and side to the turbo outlet hose. Normally piston type valves are installed with the pressure under the valve so that it helps open the valve when the pressure in the small vac line is released and becomes vacuum. If you install it so that the pressure is coming in thru the side it ends up forcing the piston inside toward one side of the valve causing it to have some drag while it is trying to open/close. For some the only difference is how loud the DV is, but for others they also notice an increase in psi, so it's worth trying both ways. [/ul][/ul] [ul][*]For a BOV like the Forge 004 you plug the TIP with a 1" billet plug, remove the hose which you used to run up to your DV, and plug the bottom of the 004 to the turbo outlet hose. [/ul] [ul][*]Apply alcohol and bandaids to cut up hands [8D][/ul]

To help illustrate where the DV connects to I made some modifications to a drawing created by Redgoat. Here's his original drawing which shows how you can mount a BOV on your intercooler piping.


Here's my modified drawing showing how to install a DV/BOV on an AEB engine


Later B5's have the DV placed lower than on AEB engine's so I modified it again to show how to install a DV (in this case a Forge Splitter). The connection's are the same, only the placement is different.

 
  #2  
Old 12-07-2007, 08:33 PM
chaos92287's Avatar
5th Gear
Thread Starter
Join Date: Aug 2006
Location: Orlando, FL
Posts: 8,355
Default RE: Installing and Servicing your Forge DV/BOV

i also have video comparisons, but its taking forever to upload...
 
  #3  
Old 12-07-2007, 09:34 PM
chaos92287's Avatar
5th Gear
Thread Starter
Join Date: Aug 2006
Location: Orlando, FL
Posts: 8,355
Default RE: Installing and Servicing your Forge DV/BOV

...
 
  #4  
Old 12-08-2007, 07:31 AM
chaos92287's Avatar
5th Gear
Thread Starter
Join Date: Aug 2006
Location: Orlando, FL
Posts: 8,355
Default RE: Installing and Servicing your Forge DV/BOV

bump
 
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
nova_ss672001
B5 Models
13
12-22-2008 10:43 PM
chaos92287
Audi A4
0
12-08-2007 07:31 AM
operator
Audi A4
6
11-06-2007 11:18 AM
my99audia6
Audi A6
0
09-06-2007 10:12 AM
vegastt
Audi TT
5
09-04-2007 12:18 AM


Thread Tools
Search this Thread
Quick Reply: Installing and Servicing your Forge DV/BOV


Advertising
Featured Sponsors

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.