How to Relocate K03 DV to K04 Position Tutorial

[vRS Carl]

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:



Ok firstly you need to remove your Engine Cover, Intake & Heat Shield.



Remember to disconnect the MAF



Heat Shield



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



Next Unplug the connector from the DV and remove the DV (held in by either 5mm Hex Bolts or T30 Bolts 3 in total)



Once you have removed the DV remove the MAF from the Housing



Place MAF into your new Intake Branch Pipe





Now connect the Branch pipe to the top of the turbo (again not described in fine detail due to various kits available)





Next take an OEM DV and place the Bung over the end





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.



Feed the wire down from the top of the Engine and plug into the connector that used to plug into the DV





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)





Then remove the old intercooler pipe and replace with this one



Now connect the DV pipe



You now need to run the Connecting take off pipe from the DV to the Intake branch pipe





Now using mole grips or VAG Pipe Clamp tool connect the Take off pipe



Once this is done run the Wiring loom to the DV and connect. Then cable tie to keep it neat



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



Engine will finally look like this



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

[S2 Ant]

Nice guide, just what i was wanting to see   

[vRStu]

I'm sure I've seen that stuff somewhere before 

[vRS Carl]

Dunno what your talking about 

[Garth]

Forgive my ignorance.... What's the point in moving the dv?

[vRStu]

One of the problems with the dv in the ko3 is it's proximity to the turbo, it suffers with the heat.

[vRS Carl]

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

[vRSAlex]

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:



Forge Blank:



Bung insert for the 25mm take off:



Finished:

[Jaywoo-GTI]

Can this method be used to install vacum operrated DV to the car?

[vRSAlex]

Yep.  Like this:

[Jaywoo-GTI]

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?

[KRL]

Excellent and informative write as always Carl 

[vRSAlex]

The forge blank is the blank for the Vauxhall turbos :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.

[RedRobin]

.
Excellent write-up, Carl 

Is there any point or advantage on a K03 car moving a Forge DV off the turbo and onto the upper front position?

[vRSAlex]

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.