Forge DV Cleaning DIY

[mr shickadance]

Ive been searching for the past 20 minutes and i remember seeing a DIY that featured an Oil Change + DV cleaning since i just changed my oil and i have a couple of free hours i was going to do this....can anyone point me in the direction of the DIY tho? i can't seem to find it

[schizzy]

I would def like to see a diy for this too, I need to do this in the spring

[mr shickadance]

there's one out there, i kno i've seen ti before, but i titled the thread so that when we get the link for the DIY when you go to search for it, it doesn;t take as long

[mr shickadance]

bump for help?

[mr shickadance]

so i just completed the maintenance on my forge DV... and here is the best way i could explain it

tools and things needed

- 5mm allen socket
- 1/4 inch ratchet + 3 inch extension
- mobil 1 synthetic high temperature grease (hard to find in stores, easy to find online)
- flash light
- tooth picks
- degreaser (i used palmolive dish washing soap but i think next time i would rather use something a bit more powerful
- tooth brush
- bic pen


part 1 removing the dv from the turbo

step 1)

unhook the electrical connector to your DV solonoid

step 2)

unscrew the 3 5 mm allen bolts that holds your DV in place

step 3)

disconnect the vacumn hose leaving only the metal mechanical dv, the 2 hoses that stem from it, and the electrical solonoid that is connected by the 2 hose
http://img.photobucket.com/albums/v478/Victor_Carruyo/P1080132.jpg


you now have the two pieces free and ready for maintenance/cleaning



part 2 cleaning and lubing the DV

step 1)

removed the hoses from the actual DV and put aside the electrical solonoid

now we only have the metal piece to work with


step 2)

using a tooth brush and mild soap, scrub the DV and try your best to clean the outside of it as best as you can (although this is not a neccessary step, you will find your DV is covered in grime and frankly giving it a TLC is something your gonna want to do)


to make this easier since i don't have pictures (sorry) let me explain that metal DV is composed of 4 pieces i will refer to them as:

http://i1238.photobucket.com/albums/ff494/skrzypczakscj/dv-1.jpg

BASE = this is the part on the DV that bolts to the turbo and is the largest piece of the DV
TOP = this part screws onto the base and has the word FORGE on it (note: this part is actually 2 moving parts but you cannot separate them so to make it easier i just called it one part)
SLEEVE = this is an internal part and looks like an oversized thimble, this part slides up and down the BASE
SPRING = this internal is the part that pushes down on the sleeve from the TOP and looks like a spring


step 3)

unscrew the TOP from the BASE and remove the SPRING

step 4)

using the blunt side of your bic pen gently push the SLEEVE from the bottom of the BASE

step 5)

using a few paper towels or shop towels, wipe the SLEEVE and the SPRING and the inside of the BASE and the inside of the TOP, keep wiping until they are very clean

are they clean yet? if not continue to wipe, this shouldn't take you more then 4-5 minutes but it should be a thorough job


step 6)

using your mobil 1 synthetic high temperature grease, spread a generous amount around the outside of the SLEEVE and the inside of the BASE (these two part slide against each other )

step 7)

notice how the bottom of the SLEEVE has a raised platform about the size of a dime, also notice that the BASE's hole is about the size of the dime these two should match up when you slide the SLEEVE back into the BASE

step 8)

put the SPRING back on the SLEEVE and screw on the TOP

step 9)

to test to see if you used enough grease and the DV is working properly before you re-install it, perform a simple test

1) using the blunt side of your bic pen, push up on the sleeve keep applying a bit of pressure
2) place your finger over the hole of the TOP
3) take away the bic pen
4) release your finger, the SLEEVE should come down instantly, if it does not, apply more grease in-between the SLEEVE and the BASE

if you pass the test you are ready to reinstall

re-install as you normally would when you install the DV or follow this DIY http://www.audizine.com/forum/showthread.php/143751-B7-A4-2.0T-Forge-DV-DIY except you dont need to run the wires as they are all already there for you

BEFORE YOU RE-INSTALL

a few tips

- use some dish soap and tooth picks to clean out the 5mm allen bolts as i found a lot of grime in them and it makes for a much easier re-install when your allen key fits all the way in the bolt

- have a friend hold a flashlight from above

- make sure you reconnect the hoses according to this photo

http://img.photobucket.com/albums/v478/Victor_Carruyo/P1080132.jpg

[mr shickadance]

please PM if you have any questions