-
Forge Motorsport 2.0T FSI
Replacement Bypass Valve Kit
Please thoroughly read
through and familiarize yourself with these
instructions prior to
beginning the
installation process of any component. Please also
ensure that the vehicle and
engine have
cooled down sufficiently to avoid risking skin
burns or other injury.
Tools Required:
-
Vehicle jack and jack
stands or access to a vehicle lift
-
5mm Allen wrench or Allen
socket with extension
-
3mm Allen wrench
-
1/8 Inch Allen Wrench
-
Razor blade or
Xacto knife to cut vacuum line
-
Blue colored medium
strength semi-permanent Loc-Tite thread locker
Begin by safely
lifting the vehicle and then locating the turbo
and the OEM electronically
controlled
bypass valve/solenoid, which will be bolted to the
compressor cover of the turbo.
- On the MK5 VW GTI and Jetta GLI, the
B6 Passat, and the 8P Audi A3, the OEM valve will
be
bolted to the turbo located on the
lower passenger side of the rear of the motor.
- On the Golf ED30 and R,
Leon Cupra, Scirocco R and Audi S3 the valve is
located at the top of
the engine bay at
the front directly behind the radiator
- On the B7 Audi A4, the OEM valve will
be bolted to the turbo located on the passenger
side of the
motor towards the front
underside of the car
Once located,
disconnect the electrical connector/plug for the
valve and you can now use your
5mm
Allen wrench or socket to remove the three 5mm
Allen bolts which secure the valve to the
turbo.
You must be sure to
save the OEM valve bolts as they will be reused
later.
With the OEM valve
removed from the turbo, you can now temporarily
install the Forge
replacement valve
reusing the OEM bolts with them only hand-
tightened. This initial installation
is
only temporary so as to find an appropriate
mounting location for the solenoid and to find the
appropriate lengths for the vacuum
lines you will use on your car.
First, attach the solenoid to your
choice of the supplied brackets using the two
supplied 5mm
Allen bolts. The solenoid
can be mounted anywhere in the engine bay within
reach of the solenoid
wiring.
For the purpose of
generating these instructions, we will mount the
solenoid bracket using one of
the
bolt
holes
for
the
new
Forge
valve
as
shown
below.
You
do
not
have
to
install
the
solenoid
bracket in this
manner on your application if you would prefer a
different location.
With
the new Forge valve loosely mounted to the turbo,
and a location selected for the solenoid
and it loosely mounted as well, measure
to find appropriate lengths for the vacuum hose
connections between the valve and the
solenoid.
Please use the
plumbing diagram below for the appropriate
locations to connect the vacuum lines.
As
stipulated
in
the
plumbing
diagram,
the
plumbing
MUST
be
as
shown
or
the
valve
may
fail
to
operate
properly or possibly at all.
Once you have determined the length of
vacuum line you will need between each connection
of the valve and the
res
pective connection on the solenoid,
you can cut the appropriate lengths of
line from the included
s
pool. The lengths you cut and use will
be based on where in the engine
bay you
have chosen to mount the solenoid.
You can now remove everything from the
car to secure the lines between the valve and
solenoid
as shown above.
With the valve and solenoid plumbed
together and the lines secured with the included
zip ties, you
can now permanently mount
the valve and solenoid bracket.
Use your 5mm Allen wrench to bolt the
new Forge valve to the turbo from where the OEM
valve
was removed, again, reusing the
OEM valve bolts.
Securely
clip
the
supplied
wiring
harness
to
the
solenoid
(it
is
a
tight
fit)
before
you
mount
the
solenoid in the engine bay
With the valve securely mounted to the
turbo and the solenoid bracket also secured at
your
desired location within the engine
bay, you can reconnect the OEM wiring harness plug
to the
connection on the end of the
Forge wiring harness.
We
will now move on to the vacuum tap piece which
will need to be connected to the intake
manifold. The vacuum tap has 3 tap
provisions and is supplied with multiple vacuum
nipples and
blanking plugs for you to
select the number of provisions you will need on
your application.
-
One nipple must be used at a minimum
for valve operation. (largest port nipple only)
-
A second
nipple can be used for a boost gauge tap.
(s
mallest port nipple only)
-
A third provision is
available and can be used for whatever it may be
needed for on your
application.
-
All unused
port provisions must be plugged with the supplied
port plugs. (3mm Allen)
It
is
highly
recommended
that
all
vacuum
nipples
and
port
plugs
are
secured
with
blue
colored,
medium strength,
semi-permanent Loc-Tite thread locker. If not
used, the vacuum nipples and port
plugs
may back out, becoming lost and/or causing a
vacuum/boost leak.
To
install the vacuum tap, you will need to unclip
the PCV hose connection on the intake
manifold. This can be found up and to
the right of the throttle body while looking at
the manifold.
Pinch down on
the two ribbed sections releasing the clips and
pull the hose out of the
manifold
barb.
Next, you
will slide the manifold tap over the barb until
the edge of the lip can no longer be seen
through
the
grooves
in the tap.
Once
the
lip
is
no
longer
visible,
insert
the
black
plastic
C-clip
to
secure
the tap in place. The o-ring seals
are
very tight
and
secure, so
this may take a small bit of
effort.
Once the manifold tap is held securely
in place with the plastic C-clip, reattach the PCV
hose to the barb at the end of the tap.
If you
are using
some sort of PCV “fix” or “bypass”,
h
owever, you will need to
reconnect whatever
components are
supplied with that product.
The barb on
the end of our manifold tap is the same
size and
shape
as
the OEM manifold barb, so
any hoses or
caps that connect to the manifold
barb
will connect to the barb on our tap as
well.
From the appropriate nipple on
the manifold tap (largest port), run a length of
vacuum
tubing along the top of the
motor, around the passenger side, following the
fuel rail and fuel lines,
down to the
remaining linear port on the solenoid you mounted
previously. (See plumbing
diagram)
Secure both ends of this line using two of the
included zip ties. If any s
pare zip
ties are
available, use them to secure
this vacuum line to the fuel rail and/or fuel
lines.
Your
valve
installation
is
now
complete,
and
you
can
now
enjoy
all
of
the
benefits
that
a
more
reliable
and
performance
orientated
bypass
valve
has
to
offer.
You
should
notice
slightly
quicker
spool, less tapering, more responsive
mid-range, and overall better valve and boost
response.
打造赛车
2.0T FSI
置换旁路阀工具包
请彻底阅读并熟悉这些指令之前，在开始任何组件的安装过程。请确保汽车与发动机冷却
下来
了足以避免导致皮肤灼伤或其他伤害的风险。
所需的工具：
-
车辆杰克和杰克站或访问汽车电梯
-
5
毫米艾伦扳手或扩展名艾伦插座
-
3
毫米艾伦扳手
-
1/8
英寸艾伦扳手
-
刀片或
Xacto
把刀切真空线
-
蓝色彩色中强度半永久性
Loc
蒂特线程锁柜
安全地提升车辆并然后查找汽轮开始和电子控制的
OEM
旁路阀
/
电磁，将螺栓的涡轮压气机
盖。
-
关于
MK5
大众
GTI
和捷达
GLI
、
B6
帕萨特轿车和
8 P
奥迪
A3
，
OEM
阀将固定到位于
较低的乘客侧，后面的马达的涡轮。
-
高尔夫
ED30
和
R
、
Leon Cupra
、
非洲热风
R
和奥迪
S3
阀门的位置顶部的直接背后散
热器前面引擎湾
--
论
B7
奥迪
A4
，
OEM
阀将固定到位于前面的车底面朝电机的乘客侧的涡轮增压