How To and Parts needed for relocating the DV on a K03 car?

[S2 Ant]

Hi All,

Is there a list of bits or guide for whats needed to relocate the DV on the K03 to the front like on the K04 cars?
Just want to know what bits i need in order to achieve this.

As im going K04 anyway it needs doing but thought if this isnt a huge PITA then i could do this whilst i get the pennies sorted for the other bits i need and im gonna need to know whats needed at some point anyway!

Cheers!

[S2 Ant]

Interestingly, how have people got on with doing this with the BSH kit as well given the location of the Brake Fluid Resevoir as i was looking at this last night and its pretty much on top of where the take off is on the intake pipework

[Jaywoo-GTI]

Would be interested in this to any main benefits other than being able to get rid of the electric recirc valve?

[S2 Ant]

I havent seen what bits are on the car to understand fitting and all the talk on the BSH kit tends to be on US cars and models that are already K04.

My car has a Forge DV at the moment, the BSH kit says about a bung that replaces the opening where the DV goes, i presume this is on the part of the turbo and not dependent on which DV you have fitted?

It also talks alot about the noise pipe and some box in the area under the wipers - i dont recall ever seeing this on my car - is it K04 specific? US Specific?

The rest seems to make sense, but i find seeing things tends to make it a whole lot easier to understand and i dont want to buy something to go down this route to then find i need to spend a whole lot more on other stuff because of assumptions of it going on to a K04 car.

Benefits of relocating the DV tho are posted about here....

http://www.golfmkv.com/forums/showthread.php?t=57388&highlight=relocation

[Jaywoo-GTI]

Noise pipe is US specific, read about them before.

[S2 Ant]

The only other thing i want to understand is... If the K04 cars come with the DV at the front of the car, then is the BSH Kit simply an aftermarket copy of K04 OEM pipework?

What is the difference?

[bacillus]

Why not get the standard K04 dv take off as that way you won't have to source a noise pipe?  

The bsh version comes with a huge Forge sourced dv.

[S2 Ant]

Thats kinda what im getting at. Whats the difference between the BSH relocate kit and just using K04 OEM pipework?
Aside from the Forge DV - which i already have (so presume can be reused in this application)

Also seen that the BSH kit using a vacuum based system instead of the electronic one utilised from the factory.

Just cant see in my head how the OEM one plumbs in thats all and finding pictures online isnt so easy

[S2 Ant]

Think i might have my head around it now.
I just spotted something on the K04 parts diagram with part numbers someone posted....

I didnt see the port on the OEM accordion type pipe that connects to the turbo. Now i can see how that long wiggly pipe goes from the DV to the intake.

So really, all the BSH kit achieves is putting a vacuum DV on to the car in the relocated position instead of using the electronic one and provides you with a plug for the position on or by the turbo to block off the original DV location

[Jaywoo-GTI]

Have you got a link to the diagram so i can try to work it out?

I amt thinkin of getting rid or the OEM electronic valve completely and replacing it with a Forge 007 valve as used on the 20v turbo engines.

[danishmkvgti]

Noise pipe is US specific, read about them before.

Noise pipe is LHD specific not US  

There's 2 types of DV relocating, one for the GTI LHD, seen here (noise pipe goes around airfilterbox to the noise thingy and on the side the DV fitted)





And the one you are after, the S3 solution (the parts encircled   ):



On the left the tube going from the DV to the intake pipe with the flange for fitting the DV. On the top right extension wires for the DV, bottom right is the tube from IC to intake manifold with the noise tube bung that enables the fitting of the DV.
Why chose the Forge that requires maintanence instead of the revision D DV that doesn't fall to pieces as the other OEM DV and doesn'r require maintanence???????      

[Jaywoo-GTI]

Ah sorry, Read it on alot of US forums that delete the noise pipe.

[S2 Ant]

Does the K04 turbo have a blank or bung for the DV port on it or is it simply manufactured with no port there to put a DV like on the K03?

[vRStu]

All you need to source non OEM is a blank for the Turbo (although I used an old OEM DV with a bung from BSH) and a wiring loom to extend the two wires from the KO3 position to the front of the car for the KO4 position.

All of the rest of the parts are OEM so can be obtained from a dealer.

[S2 Ant]

Spot on, thanks for that

So should need the following OEM part numbers i believe....

1K0 145 770 P - Intake pipework from IC to IM (£35.38+VAT)
1K0 145 693 B - Pipe from DV back to Intake pipework (£35.38+VAT)
06F 145 751 - Port connecting the DV to the pipework (
1K0 145 845 A - Hose connecting port piece to the DV and return pipe

With standard intake you'll also need this...

06F 129 627 H - Accordion pipe from Turbo to Inlet pipework - includes return feed for pipe 1K0 145 693 B (£26.30+VAT)

With aftermarket intake you'll need to adapt that pipe to fit whatever port is on it - BSH intake pipe has a 35mm ID port for this feed.
And obviously a bung for the original DV location.