How to Relocate K03 DV to K04 Position Tutorial

[vRSAlex]

With the wiring on mine and the ones I do at work, you just need to pull with wiring back to the start of the coilpack wirings plastic housing.  That gives the perfect length to route the wiring round the right side of the engine and onto the DV.

Using a wiring extension is faster and easier, but costs more and imo doesnt look as neat/oem.

Depends how neat & OCD you are 

Very, but you have to be when you do it for a living. 

[Sammy]

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:

Hi Alex, Is the parts in the picture all that is needed for the DV relocation? I dont like the complicity i am seeing with all the extra wires and things that other places are saying lol, Your one looks fairly simple and straightforward

[short]

Learned something today! Never knew about that wiring bit. Good, looks like I'd be saving some (wee bit of) cash on that wiring extension harness. 

I wonder why some DV relocation kits (and K04 kits like APR etc) has that wiring extension though.

[RedRobin]

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.

....So with a Forge DV on a K03 car, there's no point in moving the DV location?

Do the latest OEM revision DV's suffer from the same potential heat problems?

[scopes]

Well at the front I find it easier to service as stated before,
With the forge DV being alloy metal type, when attached to the turbo it will get quite a lot of heat. 
Using the words heat soak, would that be the correct term… You could defiantly not touch it after a drive, even at the front it still gets hot, but I would imagine not as hot as being placed beside the turbo

When at the front it is constantly getting cold air passing over it thou, I personally think it makes sense...
 

[RedRobin]

^^^^
Thanks, scopes.

But does a hot DV (Forge) actually reduce its performance?

The heat problem with the early OEM DV's is the potential and relatively common diaphragm tear, not helped by the increase in boost pressure from a remap.

[scopes]

I would imagine its very much the same as a CAI, it would be very minimal, but its sounds like you have a task to do now Robin with some before & after logs & dyno runs
 

It’s not something I got round to do as I had other mods installed at the same time   

 

[RedRobin]

I would imagine its very much the same as a CAI, it would be very minimal, but its sounds like you have a task to do now Robin with some before & after logs & dyno runs
 

.... Logging and dyno-ing and moving my Forge DV is not something I need to consider. It's all currently working fine, so I won't mend it.

[Hedge]

The only problem I see is that the Forge DV is a serviceable item.

If you are going to the trouble of relocating it I would go for a rev G and if not a rev D.

[RedRobin]

The only problem I see is that the Forge DV is a serviceable item.

....And fortunately easily accessible when JKM service my car 

[Shabba168]

Does anyone have the part numbers for the large plastic hose and the alloy union the DV attachs to. Also the bracket

[doaburnout]

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:

Hey man what's that intake bung thing? You got a link for it? The thing you have plugged into your intake for the air to return through!