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Discussion Starter · #1 ·
Hi, I just bught a Forge 007 Race DV from my friend who has an S4 and the ECS site says the 1.8 and 2.7 turbos use the same model DV and was wondering what I had to do to get it in. I got the stock one out and this one seems to have bigger ports on the inlet and outlet sides so I was wondering how to get the thing in.
TIA,
Mr. d
 

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try spraying a little WD40 on the thing, and try to work it in that way. i didnt have any trouble installiing my 007. since they are 25mm, they will fit. just dont break anything!
 

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Discussion Starter · #5 ·
Mine's a 99 and I think post-2k use 25 mm ports wile mine is 20 mm. shoot, now I gotta sell it to another friend. I tried the WD-40 but it won't fit the intake hole (tight spot).
 

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Discussion Starter · #6 ·
Ok, I spoke with a friend of mine and he said the Forges come with larger ports so you don't have to clamp the worm clamps so damn tightly as stock. It takes some lube and two people to get it on. Sucks but worth it.
 

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Didnt have a problem with my 98 1.8T when i fitted the forge, i used a bit of washing up liquid to lubricate the the ports so that they slipped on easily (don't use oil, it deteriorates rubber), had to use a bit of force to get the vacuum line on though.
 

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Sure the 007 Forge works on our cars, but I highly recommend you checking the spring inside the DV. The green spring is too weak to hold boost on a chipped 1.8t w/ the K03 sport. You will get choppy acceleration if you don't change the spring to the yellow spring. I use the yellow spring with 2 washers...works great now - almost forget i'm driving a 4 cylinder.
 

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Discussion Starter · #9 ·
I've got the red spring in, since my buddy had them in with his Garret chip. How did anyone connect a vacuum line to the top? My stock one didn't have vacuum lines to it.
 

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luvmyb5 said:
I've got the red spring in, since my buddy had them in with his Garret chip. How did anyone connect a vacuum line to the top? My stock one didn't have vacuum lines to it.
Um... are you sure? The DV really won't work correctly without a vac connection to pull the diaphragm open. :???:

Keep looking -- your vac line is probably dangling loose around there somewhere. On the other end it connects to a nipple on the front or a check valve on the underside of the intake manifold, depending on your engine code.

^^^^^^^^^^^^^^^^^^^^^^

BTW, yes, the 1.8T and 2.7T diverter valves are the same... you just need two DV's for the 2.7T. :D
 

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luvmyb5 said:
I've got the red spring in, since my buddy had them in with his Garret chip. How did anyone connect a vacuum line to the top? My stock one didn't have vacuum lines to it.
uhh, are you sure youre tryijng to put it in the right place???
 

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IDriveB5 said:
luvmyb5 said:
I've got the red spring in, since my buddy had them in with his Garret chip. How did anyone connect a vacuum line to the top? My stock one didn't have vacuum lines to it.
uhh, are you sure youre tryijng to put it in the right place???
Yeh i second that 'DriveB5'.

Does the old DV look the same as the forge, i.e. does it have 2 x 25mm ports at 90` degree angles to each other and a small nipple port on top for the vacuum line?

I have just re-read the whole thread again and you said something about a metal breather pipe??? i'm not sure what your on about, all my pipes are rubber, and you said it took 2 people to get it on, not sure how you fit 2 pairs of hands down there, as there is barely enough room for 1 pair.

You did jack the car up, take the bellypan off to get to it didnt you, as the DV on the passat is under the engine, where as the TT and Golfs are in easy reach on top of the engine???
 

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^^Uh oh. PSM20VT, I think you're onto something here... luvmyb5 you may be trying to replace the wrong part. The DV is at the bottom of the engine bay, almost directly behind the passenger-side taillight (driver's side if you're from the UK). You can not reach it from the top, you have to take off the belly pan and look from underneath to see it.
 

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http://1.8t.org/~quattroman/Audi%20B5%2097-2001/Engine%20Mechanical/1.8T%205V%20(%20AWM%20)/Turbocharge/21-1%20Charge%20air%20system%20with%20turbocharger%20checking.pdf

page 7 of 17 in the charge air system of the turbocharger section. #22 is that part you SHOULD be trying to change.
 

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IDriveB5 said:
http://1.8t.org/~quattroman/Audi%20B5%2097-2001/Engine%20Mechanical/1.8T%205V%20(%20AWM%20)/Turbocharge/21-1%20Charge%20air%20system%20with%20turbocharger%20checking.pdf

page 7 of 17 in the charge air system of the turbocharger section. #22 is that part you SHOULD be trying to change.
NO, It's Part #23. :poke: The N75 is not the DV. :)
...nevermind... the pictures are fk'd up. The picture on page 21-7 is the right one. It's part #23 on the pictures on pages 21-6 and 21-5.
 

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pete1 said:
IDriveB5 said:
http://1.8t.org/~quattroman/Audi%20B5%2097-2001/Engine%20Mechanical/1.8T%205V%20(%20AWM%20)/Turbocharge/21-1%20Charge%20air%20system%20with%20turbocharger%20checking.pdf

page 7 of 17 in the charge air system of the turbocharger section. #22 is that part you SHOULD be trying to change.
NO, It's Part #23. :poke: The N75 is not the DV. :)
...nevermind... the pictures are fk'd up. The picture on page 21-7 is the right one. It's part #23 on the pictures on pages 21-6 and 21-5.
yea, on page 21-7, the page i was quoting from, #22 on the diagram pointed to the DV, so i used that reference, but #23 on the list describes the DV.
 
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