Forge 007 DV installation question..

[04A6SLine]

first off, i did run a search and i still have a few questions.

i got a pair of Forge 007p DV 2 weeks ago. after installing it. the car start running kind of weird, it's not as smooth as before. the power is somewhat lost. when i push pass 3500RPM and let go of the gas, it drops to about 2000RPM and stays there for a good amount of time. i don't know if i'm loosing boost. i reinstall it again and try to tighten the small tip of the DV. i read to use 4MM hose and use a zip lock to tighten it. but it still seems loose. Am i suppose to use 3mm vacuum hose? if so where the hell can i find those? all i need is about 8 inch. also, how can i test if the forge DV is bad??.. i'm running with the green springs..

[African2.7T]

are you chipped if so look into ur tbb

[04A6SLine]

nah bro. not chip yet.. no one put forge on their 2.7t ??

[Alpinevelo]

I know exactly what you mean... You need to check two things. 1 the Vacuum line because it falls appart quite easily. 2 if you used the stock hoses on the left side valve you will notice that it fits kind of tight and such hose might have a somewhat irregular bend that could be restricting the flow??? Also zip ties coud do the job for a while but that area gets very hot and they won't last. You need to find the OE hose clamps or fuel line type clamps to replace all of the ones you "opened" to install your new valves. ECS tuning carries the hose clamps, but I have not checked to see if they have the crimping tool or can't figure out how to find the exact size we need. The OEM hose clamps have a loop on top that can be crimped to fit tight as far as I know. I just cleaned and greased my valves and having the same problem btw... So if anyone has more or better info please chime in...

[04A6SLine]

Alpinevelo - Is it that Z shape hose you're talking about? i also have an assumtion that it's blocking air from going/coming into the valve cuz of the bigger size of the Forge compair to the Bosch, it's hitting aginst the metal pieace in the middle. How can we fix that??
I also agree with you we need to find the OE clamps, trus me i went to Pepboys, autozone and the smallest clamps they have are 1/4 inch, which NOT enought to close anything. i also went looking for all size of vacuum hose, the 4mm that every place carrys are just too big for it. WHY DIDN"T forge provide us with some hose???. i'm going to try some import shops to see if they have 3MM ID hose(which the smallest i can find on line)... i'm starting to believe these Forge aren't a good size for our C5 egines.. should of went with the Baily ones......

if all fails, does anyone know any body who works for Audi that can provide us with those OEM (one and done) clamps??

[A62TURBO]

The dealer has those small OEM hose crimp clamps, I bought like ten of them and keep them in my tool box just in case.

[04A6SLine]

O.k.. i just got off the phone with the Guys at Forge. below are questions i ask and answer he provided.

Q: What size clamps do i used?
A: a zip tie would basically be enought for hose on the tip of the Valve if boost is stock (7 or so PSI).

Q: How do i know if the Valve is leaking?
A: Use a pencil or finger and push the piston all the way up, then use another finger to seal the small hole on the tip of the valve, the piston should stay up while your finger is holding the compression.

Q: when i rev the RPM pass 3500, and let go completely, it will fall onto and stays at 2000 RPM for a good amount of time. is that normal?.
A: It could be very possible there's a leak somewhere... (gee, thanks)..


O.k.... sooo,, what i concluded is, i need to tighten that dam hose.. i'm going to try and find some 3MM silicone hose, then go to Audi and get the clamps for it..


i also found this installation on Hyperboost, it seems they are also using zip ties... can someone explain to me where the air pressure is coming from to push the piston open? http://www.stratmosphere.com/HyperBo...structions.pdf

[white fish]

ok not sure if this it true for the 2.7
but on my 1.8 you install the piston type in reverse (turbo pushing on side not bottom of piston)

[Daft]

The concern of the position of the valve was presented to me at WF but, this is my opinion on the matter.

The valve really will still do it's job if the piston's bottom is pointed into the pressure side of the path. The spring being used and the combo of boost pressure at the back of the piston is meant to hold the valve shut. As soon as you lift off a hair, boost will drop and the piston will be lifted by air pressure and the negative vacuum on the piston.

If too much pressure is presented, the valve will blow open and therefore indicate that you need a stronger spring. You would also see lower than normal boost accompanied by boost readings that modulate as the boost rises, falls and rises again as the valve opens/closes.

Having it the other way will create a more solid barrier against airflow but, you will not be able to overpower the spring since you are pushing against the opposite axxis of the piston's travel path. If anything, you'd pin it shut.

For me, I'd rather it have the piston push open by the boost than have it be pinned shut. If your vacuum line was broken, it would prevent the valve from opening with all that pressure was against the side of the piston inside the diverter valve.

That's my $.02...

[FrankA6]

hmm forge gave me 4 new clamps for the DV's, ask Brett he knows, isnt that right Brett? lol

[VJ's A6]

Frank-- Did you install the lip yet?? Post pics man.. I know you like like pics.. Did you get chipped at WF??

[FrankA6]

first off , where were you on sunday, lol, and no i didnt get it chipped, but i picked up forge 007 DV's and the cupra lip i havn't got it on yet, i just got home yesterday.

[Daft]

hmm forge gave me 4 new clamps for the DV's, ask Brett he knows, isnt that right Brett? lol

Yes, Forge usually includes 2 new clamps per valve and the other springs/shims for increasing the spring rate.

[VJ's A6]

Frank-- I thought I told you I wasn't going to make it Sunday.. I was on call both sat and Sunday.. Luckily I didn't get call on Sat. Next year I am going Sunday..

[FrankA6]

oh yes i forgot, yeah i cant wait for next year, and i will have a whole new look for my car i hope!

[East2.7Six]

Thanks again brett for the DV install! also on a side note i got alot of positive feedback frome the new grill! thank god the guys at Forge gave me some nice vacuum line to use!
ive noticed the car runs alot smoother but i know that the TBB is going for a fact! next on the list! Bi Pipe! Frank did you change to a stronger spring rate?

[04A6SLine]

Thanks again brett for the DV install! also on a side note i got alot of positive feedback frome the new grill! thank god the guys at Forge gave me some nice vacuum line to use!
ive noticed the car runs alot smoother but i know that the TBB is going for a fact! next on the list! Bi Pipe! Frank did you change to a stronger spring rate?

thanks for rubbing that on our face...

you should take some picture of the install and let us see if the left side Z hose, how it's position. and what type of hose did they provide or what you use to clamp it..

[FrankA6]

Thanks again brett for the DV install! also on a side note i got alot of positive feedback frome the new grill! thank god the guys at Forge gave me some nice vacuum line to use!
ive noticed the car runs alot smoother but i know that the TBB is going for a fact! next on the list! Bi Pipe! Frank did you change to a stronger spring rate?

nope i left the green stock one in, the yellow and blue are for chipped cars with more boost, so no need for them ..... YET!

[Daft]

Just for informational purposes, here are the boost values matched to the different spring colors:

Green - 5-15 PSI

Yellow - 15-23 PSI

Blue - 23-30 PSI

Red - 30 + PSI

From here: Forge Site.

[East2.7Six]

lol i didnt mean to rub it in your face!! and ill take pics of the setup and post them this evening
try this link theres a few options for getting some vacuum line http://www.boostcontroller.com/index.php?category=8

[04A6SLine]

lol i didnt mean to rub it in your face!! and ill take pics of the setup and post them this evening
try this link theres a few options for getting some vacuum line http://www.boostcontroller.com/index.php?category=8

haha thanks buddy,, as you know. its BS when you waste 300bucks on something that should improve your car but instead the other way around... should of add another 300 and went GIAC.... ... then ask the guys what to recommend in DV

[East2.7Six]

lol i know.. its a process id rather do the chipping last since i have to remove my ECU.. bi-pipe & intake.. which would be better the bi-pipe or the samco TBB? samcos alot cheaper but better? prolly not.. right?

[FrankA6]

lol i know.. its a process id rather do the chipping last since i have to remove my ECU.. bi-pipe & intake.. which would be better the bi-pipe or the samco TBB? samcos alot cheaper but better? prolly not.. right?

forget the bi-pipe you dont really need that unless you are Stg 3 and still then its not needed, get the TBB because its a must, and call it a day! , hey did you get that pump fixed yet?

[East2.7Six]

ordering both the TBB & the pump tomorrow... i just had to put more coolant in today! i also heard that our coolant tanks have a common issue of cracking so i got a list a parts to get....
im also considering to purchase the air intake kit from lltek.. you get that lip on yet frank!? i wanna see how it looks

[04A6SLine]

wow,, first time my thread got flamed...

anyways back to the topic.. can someone draw a diagram of the valve illustrating how pressure is coming and going.. so that we all have a good understanding of how it works , therefore making it easier to fix..

[East2.7Six]

Oh yea! damn i forgot to take a pic! ill definately post one tomorrow

[white fish]

off topic again

is the spring kit for the forge and hyperboost (old one) interchangable?

[Alpinevelo]

thanks for rubbing that on our face...

you should take some picture of the install and let us see if the left side Z hose, how it's position. and what type of hose did they provide or what you use to clamp it..

Hey bud! Sorry I couldn't reply before above about the Z hose, life's a BEOCH for me right now and going back to tech stuff that's what I meant exactly, the bend must be making airflow more difficult... What is everyone else using for hoses and how are you possitioning your valves. It's atight fit for sure...

Peace!!!

[East2.7Six]

is this the pic of what you wanted? the guys at forge gave me the black vacuum line.

[ENDEE666]

I also recently installed my DVs I picked up @ WF. I used the blue spring since I run ~23psi. How much difference to the shims make? I didn't out those in...

[Daft]

I also recently installed my DVs I picked up @ WF. I used the blue spring since I run ~23psi. How much difference to the shims make? I didn't out those in...

Nick, I'd drop to the yellows if I were you. The Blue springs are for 23-30 PSi. Yellow is for 15-23PSi. The blue ones will open slower and not drop pressure fast enough between shifts. You have to crush the spring to divert the boost pressure.

Spring Specs.

The shims are to make small adjustments upward in spring rate. So, if you have a yellow spring and you wanted another 1-2PSi, you'd add a shim to it.

[ENDEE666]

Oh ok cool. Maybe I will run the yellows with a shim then...

However... I did start my Meth Injection install today :) So a few more psi might be in my future :)

[04A6SLine]

is this the pic of what you wanted? the guys at forge gave me the black vacuum line.

i have similar valve. the only thing different is the location of the tip of your valve is on the side, where mine's on the top...

don't the boost pressure come from the bottom of the valve and release the pressure to the side?? so making your installation wrong... please correct me if i'm wrong .. but i don't think that's the right set up...

[ENDEE666]

Forge says they can be installed either direction. Either way, when the diaphragm opens, it releases... Supposedly they make a different sound based on which direction they are installed..

[04A6SLine]

Forge says they can be installed either direction. Either way, when the diaphragm opens, it releases... Supposedly they make a different sound based on which direction they are installed..

if your statement is true. then tightening the valve tip on the top is very important as it's the only thing that pulls and holds the piston open to release the pressure.

[ENDEE666]

Look about half way down this page-

http://www.audizine.com/forum/showth...t=forge+spring

Pat@Forge says either way works..

[Daft]

I have mine installed that way too and it was mainly because the 007A has the vacuum barb on the side. After I installed them it made sense to me that you would want charge pressure to push against the bottom of the piston so that if you run over the spring's capabilities, it will blow open and limit boost. It should also open faster/easier upon lifting the throttle this way.

If you install them so that the charge pressure is hitting against the side of the piston, it will hold pressure easier but, it will be harder to blow the piston open if you go beyond the boost setting you are supposed to be at.

That's my $.02.

[blkrhyno]

I have a newbie question. I'll be purchasing my DV's & TBB within the next week or two. Do I just install the DV's right out of the box since my car is still stoock?
Do I need to purchase the spring kit in addition to the DV's?
Is the stock boost pressure set at a certain psi?
How do you guys know what your boost pressure is?

[Daft]

Ryan, stock boost is 8-9Psi. The Forge valves come new with the 3 most common springs that people use (green, yellow and blue).

If you are stock, the green spring is just fine. Yellow can be used when you are chipped and blue is for heavily modified cars that run 24-30PSi. Hell, I still use the yellow since my peak boost is 23PSi.

The Forge DVs are sold with the green springs inside and ready to go. Just swap them in and off you go. It definitely will be a good idea to do the TBB at the same time since you need to remove the DVs to get the TBB out. Just remember to take your time and don't force things if they get stuck.

You also might want to replace your vacuum hose with a new set of silicone hoses. Silicone hoses are very heat resistant and have a great deal of durability without cracking. The stock hoses are a mix of cloth wrapped rubber and straight rubber which will dry rot over a few years of use and cause vacuum leaks.

[blkrhyno]

Thanks alot Brett you always give clear and precise info. Can you also tell me where I can get the silicone vacuum hoses from?