Forge Recirc Valve Installation

[RS6-T28RPH]

So having had repeated issues with the OEM DV valves, fluttering boost levels, big thuds when coming off WOT quickly etc. I decided it was time to f**k the OEMs off and get a pair of Forge DVs fitted. Knowing that its part of the airbox assembly a bit if fecking about was required but now its complete the car is amazing, back to smooth part/full throttle runs and power feels nice and progressive, have even got a bit of a woosh when letting off throttle when under boost

Should be able to do this in the best part of a long afternoon;

New Parts List
2x FMDV008 Valves https://www.forgemotorsport.co.uk/Turbo ... --756.html
2x Gorilla Glue - https://www.toolstation.com/shop/Adhesi ... lue/p94548
1x 800 grit sandpaper

Process
1 - remove top silver pipe arms
2 - remove airboxes (carfeully disconnecting the vacline and boost line going to existing DV)
3 - slice off the existing DV off the bottom of the airbox with a hacksaw
4 - sand down the port of the hole you just revealed with 800 grit to give the gorilla glue something to key onto
5 - change the spring in the forge DV depending on the boost range you are running, i've gone for the yellow spring as running stage2 MRC setup. https://www.forgemotorsport.co.uk/Valve ... --826.html
6 - stuff the forge DV into the bottom of the airbox to test fit then remove
7 - get setup with the gorilla glue, covering the inside of the port (don't forget the glue expands to make a snug fit!)
8 - stuff the DV back in, getting the intake port of the DV the correct orientation so the boost pipe reconnects ok and let the glue cure
9 - plumb it all back together, make sure the vac pipe fits well onto the forge DV and go for a spin!

[c3nturi0n]

So having had repeated issues with the OEM DV valves, fluttering boost levels, big thuds when coming off WOT quickly etc. I decided it was time to f**k the OEMs off and get a pair of Forge DVs fitted. Knowing that its part of the airbox assembly a bit if fecking about was required but now its complete the car is amazing, back to smooth part/full throttle runs and power feels nice and progressive, have even got a bit of a woosh when letting off throttle when under boost

Should be able to do this in the best part of a long afternoon;

New Parts List
2x FMDV008 Valves https://www.forgemotorsport.co.uk/Turbo ... --756.html
2x Gorilla Glue - https://www.toolstation.com/shop/Adhesi ... lue/p94548
1x 800 grit sandpaper

Process
1 - remove top silver pipe arms
2 - remove airboxes (carfeully disconnecting the vacline and boost line going to existing DV)
3 - slice off the existing DV off the bottom of the airbox with a hacksaw
4 - sand down the port of the hole you just revealed with 800 grit to give the gorilla glue something to key onto
5 - change the spring in the forge DV depending on the boost range you are running, i've gone for the yellow spring as running stage2 MRC setup. https://www.forgemotorsport.co.uk/Valve ... --826.html
6 - stuff the forge DV into the bottom of the airbox to test fit then remove
7 - get setup with the gorilla glue, covering the inside of the port (don't forget the glue expands to make a snug fit!)
8 - stuff the DV back in, getting the intake port of the DV the correct orientation so the boost pipe reconnects ok and let the glue cure
9 - plumb it all back together, make sure the vac pipe fits well onto the forge DV and go for a spin!

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Great post and thx for sharing.

I’ve been having some intermittent challenges (as in errors) with boost pressure and i’m yet to tackle this job... noticed when i push the car harder that it may throw check engine and albeit it runs smoothly i sense that either a vac line or dV could be a culprit.

Q i have is can Forge dV’s slot into the airbox as is or it needs to be mod’ed (eg. Cut)?

[Toady1]

Hi,

I've been having similar issues to what you've described and think I may therefore have a dv fault. I didn't realise they were under the air boxes though, so I'm glad you've posted this.

I've got full boost after about 3k revs but below that it is very flat and jerky.But I've no fault codes. I thought it was the engine breather pipes so I've bought a new set of them from Audi for £128!! As the pipe that goes into the rhs rocker cover snapped, and I could hear a hissing noise. I'm still yet to replace the pipes, but don't think they are actually my issue.

I will test the oem DV units when I strip it down with a vacuum pump on the vac line and it should hold vacuum. If it doesn't then I'll be doing this. Especially as it's half the price of a new oem air box!

Thanks.