forge泄压阀说明书.doc

Forge Motorsport 2.0T FSI Replacement Bypass Valve Kit

Please thoroughly read through and familiarize yourself with these instructions prior to beginning the installation process of any component. Please also ensure that the vehicle and engine have cooled down sufficiently to avoid risking skin burns or other injury.
Tools Required:
- Vehicle jack and jack stands or access to a vehicle lift
- 5mm Allen wrench or Allen socket with extension
- 3mm Allen wrench
- 1/8 Inch Allen Wrench
- Razor blade or Xacto knife to cut vacuum line
- Blue colored medium strength semi-permanent Loc-Tite thread locker

Begin by safely lifting the vehicle and then locating the turbo and the OEM electronically controlled bypass valve/solenoid, which will be bolted to the compressor cover of the turbo.
- On the MK5 VW GTI and Jetta GLI, the B6 Passat, and the 8P Audi A3, the OEM valve will be bolted to the turbo located on the lower passenger side of the rear of the motor.
- On the Golf ED30 and R, Leon Cupra, Scirocco R and Audi S3 the valve is located at the top of the engine bay at the front directly behind the radiator
- On the B7 Audi A4, the OEM valve will be bolted to the turbo located on the passenger side of the motor towards the front underside of the car

Once located, disconnect the electrical connector/plug for the valve and you can now use your 5mm Allen wrench or socket to remove the three 5mm Allen bolts which secure the valve to the turbo. You must be sure to save the OEM valve bolts as they will be reused later.
With the OEM valve removed from the turbo, you can now temporarily install the Forge replacement valve reusing the OEM bolts with them only hand-tightened. This initial installation is only temporary so as to find an appropriate mounting location for the solenoid and to find the appropriate lengths for the vacuum lines you will use on your car.
First, attach the solenoid to your choice of the supplied brackets using the two supplied 5mm Allen bolts. The solenoid can be mounted anywhere in the engine bay within reach of the solenoid wiring.
For the purpose of generating these instructions, we will mount the solenoid bracket using one of the bolt holes for the new Forge valve as shown below. You do not have to install the solenoid bracket in this manner on your application if you would prefer a different location.

With the new Forge valve loosely mounted to the turbo, and a location selected for the solenoid and it loosely mounted as well, measure to find appropriate lengths for the vacuum hose connections between the valve and the solenoid.
Please use the plumbing diagram below for the appropriate locations to connect the vacuum lines. As stipulated in the plumbing diagram, the plumbing MUST be as shown or the valve may fail to operate properly or possibly at all.

Once you have determined the length of vacuum line you will need between each connection of the valve and the respective connection on the solenoid, you can cut the appropriate lengths of line from the included spool. The lengths you cut and use will be based on where in the engine bay you have chosen to mount the solenoid.
You can now remove everything from the car to secure the lines between the valve and solenoid as shown above.
With the valve and solenoid plumbed together and the lines secured with the included zip ties, you can now permanently mount the valve and solenoid bracket.

Use your 5mm Allen wrench to bolt the new Forge valve to the turbo from where the OEM valve was removed, again, reusing the OEM valve bolts.
Securely clip the supplied wiring harness to the solenoid (it is a tight fit) before you mount the solenoid in the engine bay

With the valve securely mounted to the turbo and the solenoid bracket also secured at your desired location within the engine bay, you can reconnect the OEM wiring harness plug to the connection on the end of the Forge wiring harness.
We will now move on to the vacuum tap piece which will need to be connected to the intake manifold. The vacuum tap has 3 tap provisions and is supplied with multiple vacuum nipples and blanking plugs for you to select the number of provisions you will need on your application.
- One nipple must be used at a minimum for valve operation. (largest port nipple only)
- A second nipple can be used for a boost gauge tap. (smallest port nipple only)
- A third provision is available and can be used for whatever it may be needed for on your application.
- All unused port provisions must be plugged with the supplied port plugs. (3mm Allen)

It is highly recommended that all vacuum nipples and port plugs are secured with blue colored, medium strength, semi-permanent Loc-Tite thread locker. If not used, the vacuum nipples and port plugs may back out, becoming lost and/or causing a vacuum/boost leak.

To install the vacuum tap, you will need to unclip the PCV hose connection on the intake manifold. This can be found up and to the right of the throttle body while looking at the manifold. Pinch down on the two ribbed sections releasing the clips and pull the hose out of the manifold barb.
Next, you will slide the manifold tap over the barb until the edge of the lip can no longer be seen through the grooves in the tap. Once the lip is no longer visible, insert the black plastic C-clip to secure the tap in place. The o-ring seals are very tight and secure, so this may take a small bit of effort.
Once the manifold tap is held securely in place with the plastic C-clip, reattach the PCV hose to the barb at the end of the tap.
If you are using some sort of PCV “fix” or “bypass”, however, you will need to reconnect whatever components are supplied with that product. The barb on the end of our manifold tap is the same size and shape as the OEM manifold barb, so any hoses or caps that connect to the manifold barb will connect to the barb on our tap as well.
From the appropriate nipple on the manifold tap (largest port), run a length of vacuum tubing along the top of the motor, around the passenger side, following the fuel rail and fuel lines, down to the remaining linear port on the solenoid you mounted previously. (See plumbing diagram) Secure both ends of this line using two of the included zip ties. If any spare zip ties are available, use them to secure this vacuum line to the fuel rail and/or fuel lines.
Your valve installation is now complete, and you can now enjoy all of the benefits that a more reliable and performance orientated bypass valve has to offer. You should notice slightly quicker spool, less tapering, more responsive mid-range, and overall better valve and boost response.

打造赛车 2.0T FSI 置换旁路阀工具包
请彻底阅读并熟悉这些指令之前，在开始任何组件的安装过程。请确保汽车与发动机冷却下来了足以避免导致皮肤灼伤或其他伤害的风险。
所需的工具：
- 车辆杰克和杰克站或访问汽车电梯
- 5 毫米艾伦扳手或扩展名艾伦插座
- 3 毫米艾伦扳手
- 1/8 英寸艾伦扳手
- 刀片或 Xacto 把刀切真空线
- 蓝色彩色中强度半永久性 Loc 蒂特线程锁柜
安全地提升车辆并然后查找汽轮开始和电子控制的 OEM 旁路阀/电磁，将螺栓的涡轮压气机盖。
-关于 MK5 大众 GTI 和捷达 GLI、 B6 帕萨特轿车和 8 P 奥迪 A3，OEM 阀将固定到位于较低的乘客侧，后面的马达的涡轮。
-高尔夫 ED30 和 R、 Leon Cupra、 非洲热风 R 和奥迪 S3 阀门的位置顶部的直接背后散热器前面引擎湾
--论 B7 奥迪 A4，OEM 阀将固定到位于前面的车底面朝电机的乘客侧的涡轮增压

一旦找到，断开连接电气连接器/塞阀，现在可以使用您 5 毫米艾伦扳手或删除的安全阀门的涡轮艾伦螺栓的三个 5 毫米的套接字。您必须确保他们会稍后重新使用保存的 OEM 阀门螺栓。
OEM 阀门汽轮从中删除，您现在可以暂时安装更换阀门重用 OEM 与他们只手拧紧螺栓的锻造。此初始安装只是暂时找到适当的安装位置的电磁阀，找到适当的长度为真空线你将你的车使用的。
第一，将电磁附加到您所选择的提供的括号使用艾伦螺栓的两个提供 5 毫米。电磁可以到达电磁布线的发动机托架中任意位置安装。
目的是生成这些说明，我们将装入使用螺栓孔的一个新的锻造阀，如下所示的电磁线圈支架。您没有安装电磁阀支架以这种方式对您的应用程序，如果您希望使用一个不同的位置。
使用新的伪造松散地装载到涡轮增压，阀门和电磁为选定的位置和它松散以及装载、 阀门和电磁线圈之间的真空软管连接为寻找适当的长度测量。

请使用适当的位置下水管图真空电话线连接。水暖图中的规定，管道必须如下所示或阀门可能在所有运作正常，或可能会失败。
一旦您确定您需要每个阀门的连接和各自连接对电磁线圈之间的真空线的长度，可切割线从包括线轴的适当长度。剪切和使用的长度将基于凡引擎湾已选择装载电磁阀。
现在可以删除一切都从这辆车到安全阀门与上面所示的电磁线圈之间的界线。

阀门和电磁检测一起和担保包括的 zip 联系的行，您现在可以永久地装载阀、 电磁阀支架。
使用您 5 毫米艾伦扳手到涡轮增压的新锻造阀门螺栓从 OEM 阀移除了，再次，重用 OEM 阀门螺栓。
安全地剪辑到 （它是紧配合） 的电磁阀的提供的线束您装载发动机湾电磁之前
安全地装载到涡轮增压的阀门和也获得您所需的位置，在发动机槽内的电磁线圈支架，可以重新连接锻造线束的一端连接到 OEM 布线线束插头。

现在，我们将到将需要连接到进气歧管的真空水龙头块上。真空水龙头有 3 分路规定配备多个真空乳头和冲裁为您选择的规定数目的插头您将需要对您的应用程序。
- 一个乳头必须最少用于阀门操作。(最大端口乳头只）
- 第二个乳头可以用于提高计水龙头。（最小端口乳头只）
- 一第三项规定是可用，可以用于无论是对您的应用程序需要的。
- 未使用的端口的所有规定必须提供的端口插头都插入。（艾伦 3 毫米）
强烈建议所有真空的乳头和端口插头用蓝色的彩色、 中等强度、 半永久性 Loc 蒂特线程锁保护。如果不使用，可能退出的真空乳头和端口插头，丢失和/或导致真空/升压泄漏。

要安装真空水龙头，需要对进气歧管 unclip PCV 软管连接。这可以找到和右侧的节流阀体边看着流形。捏下释放剪辑的两肋条，并拉出流形锋芒毕露的软管。
下一步，将多锋芒毕露滑流形的水龙头，直到边缘的唇不再可以看到通过在水龙头槽。唇不再是可见的一旦插入黑色塑料 C 剪辑到安全的地方在水龙头。O 形圈密封件是努力的非常紧和安全的因此这可能需要一些小。

一旦流形的水龙头与 C 的塑料夹牢固地保持在一个地方，重新连接到水龙头年底锋芒毕露 PCV 软管。如果您使用的某种 PCV"修复"或"跳过"，不过，需要重新连接任何组件提供使用该产品。我们流形的一端锋芒毕露是水龙头的相同的大小和形状作为 OEM 流形锋芒毕露，因此任何的软管或连接到流形锋芒毕露的大写字母将连接到我们分路器上锋芒毕露。

从流形水龙头 （最大端口） 适当乳头，运行的真空油管顶部的马达，周围乘客侧，燃料铁路和燃料行，到其余的线性端口对您以前安装的电磁线圈后的长度。（请参见水暖图）安全使用包括的 zip 联系的两个这条线的两端。如果可用任何备用 zip 联系，以确保这种真空燃料铁路线和/或燃料线使用它们。
阀门安装已经完成，现在，你现在可以享受的所有好处，更可靠和所能提供的性能为导向旁路阀门。您应该注意稍有更快的线轴、 少逐渐、 响应更快的中端市场和整体更好的阀门，大大提高响应。