Installing the Forge DV006

The install of the Forge, as youve probably guessed, is just the reverse of removing the Bosche DV.

Now at this point as the hoses are exposed, you may wish to replace the two factory installed hose clips with the Halfords 16-22mm clips. I personally found them easier to work with than the VW clips, but it's up to you.

Firslty get a small ammount of the high temp grease (Optional) and coat the end of the ports on the DV.  This will make it easier to slide the DV onto the hoses.

With your new clips in place (if you used them), slide the Forge into the lower hose and tighten the clip. Make sure its quite tight but not too tight as to cut into the rubber hose. You might also have to hold the clip as you tighten with your finger to stop from sliding round. Also make sure the clip is positioned centrally on the hose. 
Repeat the same process with the side hose.  This may take a bit of work to get this on as the hose is slightly smaller than the intak port on the Forge valve (may be different on other Forge DV's), but if you put the grease on, it shouldnt be too hard.

As you have removed the O ring (or opened it up) you may have to use the cable tie to attach the smaller hose to the top port of the DV.  This one's easy and once the cable tie is fitted and tightened, clip the end of the cable tie with your wire cutters.

You may want to double check that the hose clips are tight and that you may not have disturbed any other hoses in the general area.

And...Thats it!

Replace your engine cover and admire your handy work....

All thats left now is to test her out!  Dont forget to let your engine warm up correctly so the oil gets to working temp -  As your no doubt going to be giving you Turbo a good thrashing to check the responsiveness of the new vavle!

Again, if you need to tighten any of the clips again just make sure that the engine has cooled down.

More pictures from the install can be found here in the Install Guides Gallery

Happy modding,

Tabs