K03 DV to K04 location wiring loom

[Dan_FR]

My intake is home made - same style as the RamAir but I played around extensively with lengths and angles of the pipework and managed to fully eliminate it. I have videos on youtube somewhere of a few runs and there's never a hint of that horrid whine it used to make

I say no gain as in no gain in terms of response, performance or anything tangible. Reliability maybe.

Getting everything you need for less than £50 is a bargain, but my DV+ cost me less than £80 delivered brand new and the gains in throttle response and vac to boost transition mean that to me the gain was worth the extra outlay

[Shoduchi]

AWE has a rear position DV relocate kit that would allow you to use the wiring you have. It puts the DV where the intake meets the turbo. http://www.eurosporttuning.com/audi/engine/turbocharger/awe-tuning-diverter-valve-relocation-kit-2-0t-fsi.html

The shorter, but larger diameter, hose is the intake to turbo...and the longer, but smaller diameter, hose is the DV to sound pipe connection. I have this with my K04...so this kit comes with the block-off plate for the K03.

LHD BYD engine have the DV located near the noise generator and the intake of the turbo, so I've done this to my engine: http://www.mk5golfgti.co.uk/forum/index.php/topic,95592.240.html

This week I got the last bits I needed to relocate my DV from VW. Fortunately my friend who offered to help doing this mod was free today so I went to his house in the morning.

My LHD BYD is a bit of an hybrid between an AXX or BWA engine and the CDL engine. It has the noise generator with the DV connected to it, so the DV isn't really accessible for a check-up or replacement as all the TFSI engines with the DV at the front of the engine are.

The list of parts needed isn't that long for my engine:
-06F129627H (x1)
-1K0145693B (x1)
-06F145383L (x1)
-N90687101 (x1)
-1K0971866A (x1)
-1K0971865A (x1)


My stock engine was like this:


We started by removing all the bits that @RBS mentioned:


For that we had to remove the wipers arms and the plastic cover. Then we fitted the new firewall cover without the hole for the noise pipe:



After that we starting fitting the new pipes. This intake side of the air pipe:


And this is the side of the throttle pipe from CTS Turbo:


I assembled the GFB DV+ in my Rev G DV solenoid. It was really easy. The DV membrane was intact and looking good. Bought Loctite 242 to secure the DV bolts:



This is the new DV fitted in the front of the engine. The DV bracket is secured with an existing nut, so I only needed the bracket and one bolt to secure the DV to the bracket:


The angle that the DV made with the small connection pipe to the throttle pipe wasn't really good, even after we tried to change it. The DV was too in line so what was needed was a straight connection pipe, not a curved one. We made it by cutting 10 cm of the old connection pipe (1K0145845):


The wire plug for the DV was already in the correct place, we only had to disconnect the extension wire. Easiest bit to do, really.


Here's the other side of the DV:


The air pipe fixed to the engine cover:


End result:


Bits removed (all except the air intake duct):


My friend also relocated the 3 small RVC wires to prevent them from breaking with the movement of the camera over the time. One of the wires of the RVC of the GT Sport broke a month ago and my friend had to repair the broken wire, strengthen the other 2 and relocate the loom to prevent from happening again soon.

After all the work done and all the pictures taken we went for a short road test. I can tell you that the engine now sounds different without the noise generator. I mostly hear the exhaust now, which is the best sound the car makes when on boost.

I didn't notice any big difference from the Rev G DV, but I can see the boost level with PolarFIS reaching a bit higher sooner than before. The car is still great to push hard.

[dazza]

Some good work here!! The noise pipe is pointless.

[gazaai]

AWE has a rear position DV relocate kit that would allow you to use the wiring you have. It puts the DV where the intake meets the turbo. http://www.eurosporttuning.com/audi/engine/turbocharger/awe-tuning-diverter-valve-relocation-kit-2-0t-fsi.html

The shorter, but larger diameter, hose is the intake to turbo...and the longer, but smaller diameter, hose is the DV to sound pipe connection. I have this with my K04...so this kit comes with the block-off plate for the K03.

I like the look of this kit, does this fit the UK AXX engine tho?

[r5gtt]

Nice job Shoduchi but unnecessary when fitting a dv +  imho If you someone was to stick with the Rev b d c f g which ever then ideal but having the dv + makes it so pointless for all that work.

[Shoduchi]

Nice job Shoduchi but unnecessary when fitting a dv +  imho If you someone was to stick with the Rev b d c f g which ever then ideal but having the dv + makes it so pointless for all that work.

I'm that kind of person who likes reliability and since I was messing around with the DV I preferred to make it as perfect as I could. I think the DV+ is better than the Rev G DV and preferably now I won't have to think about that engine part again. I think it was money well spent.

After a couple of weeks a friend asked me if I could sell my rev G membrane so I got a bit of money back from it.

[r5gtt]

Nice job Shoduchi but unnecessary when fitting a dv +  imho If you someone was to stick with the Rev b d c f g which ever then ideal but having the dv + makes it so pointless for all that work.

I'm that kind of person who likes reliability and since I was messing around with the DV I preferred to make it as perfect as I could. I think the DV+ is better than the Rev G DV and preferably now I won't have to think about that engine part again. I think it was money well spent.

After a couple of weeks a friend asked me if I could sell my rev G membrane so I got a bit of money back from it.

Hope you didn't mind me making a comment on this as it's not meant in vain mate 

[ROH ECHT]

After all the work done and all the pictures taken we went for a short road test. I can tell you that the engine now sounds different without the noise generator. I mostly hear the exhaust now, which is the best sound the car makes when on boost.

I didn't notice any big difference from the Rev G DV, but I can see the boost level with PolarFIS reaching a bit higher sooner than before. The car is still great to push hard.

That is a tidy kit for giving better DV access than my AWE kit. The AWE positions the DV back near where the noise pipe attaches to the firewall. That one looks to be made for the stock intake bits, yes? The AWE DV relocate kit does allow for no need of a wiring extension...and that can be helpful for some I suppose. 

[Shoduchi]

After all the work done and all the pictures taken we went for a short road test. I can tell you that the engine now sounds different without the noise generator. I mostly hear the exhaust now, which is the best sound the car makes when on boost.

I didn't notice any big difference from the Rev G DV, but I can see the boost level with PolarFIS reaching a bit higher sooner than before. The car is still great to push hard.

That is a tidy kit for giving better DV access than my AWE kit. The AWE positions the DV back near where the noise pipe attaches to the firewall. That one looks to be made for the stock intake bits, yes? The AWE DV relocate kit does allow for no need of a wiring extension...and that can be helpful for some I suppose. 

Since my LHD BYD engine has a K04 turbo I only had to get OEM parts to make it like the CDL and the RHD BYD engines that have the DV located in the front. My engine already had the loom placed correctly, VW just fitted a wiring extension to connect the DV near the noise generator and turbo air intake (looks like AWE copied the setup that my engine had from factory, apart from the wiring). Really didn't like to have a noise generator.

[ROH ECHT]

Wasn't the oem DV location on your Ed30 up front?

The AWE kit put the DV back by where the sound pipe goes into the firewall and released boost goes into the transfer hose from intake to turbo. I believe they did that so the original wiring could be used on US version mk5's. So when converting to a K04, with no built in DV like the K03, the wiring was already right there. I had to get a new solid up pipe(fmic to throttle body pipe) that had no port for the sound pipe thus eliminating it completely

This is the discharge pipe with the noise pipe port deleted from it:

[Shoduchi]

Wasn't the oem DV location on your Ed30 up front?

The AWE kit put the DV back by where the sound pipe goes into the firewall and released boost goes into the transfer hose from intake to turbo. I believe they did that so the original wiring could be used on US version mk5's. So when converting to a K04, with no built in DV like the K03, the wiring was already right there. I had to get a new solid up pipe(fmic to throttle body pipe) that had no port for the sound pipe thus eliminating it completely

This is the discharge pipe with the noise pipe port deleted from it:

You didn't read what I wrote, I think.

My left hand drive BYD is a bit of an hybrid between an AXX or BWA engine and the CDL engine. It has the noise generator with the DV connected to it, so the DV isn't really accessible for a check-up or replacement as all the TFSI engines with the DV at the front of the engine are.

All European Edition 30 (LHD) have the noise generator so the DV is located near the firewall and turbo intake, just the UK Edition 30 have the DV at the front of the engine.

[gazaai]

Does anyone know if the UK gti is compatible with the AWE relocation kit?

[Shoduchi]

Does anyone know if the UK gti is compatible with the AWE relocation kit?

Should be.