Dump Valve Fitting
Difficulty
Credit
Evilution
Cost
£50 - £200
For
Old Style 600cc For2
Old Style 700cc For2
Roadster
Old Style 700cc For2
Roadster
Dump Valve Fitting
Fitting a DV is a relatively easy process, depending on the type, it will replace 1 of 2 parts. Thanks to Shadow for the extra photos.
Fitting a DV is a relatively easy process, depending on the type, it will replace 1 of 2 parts. Thanks to Shadow for the extra photos.
First Things First.
It is a good idea to leave the dump valve submersed in clean engine oil over night before fitting,
it frees up the internals and makes it more effective straight away.
Allow the oil to drain fully from both ends of the DV before fitting.
DV With A Metal Pipe
Open up the boot, lift the carpet and hold it in place with either a wooden dowel
or a rod from the boot cover, remove the engine cover and put to one side.
Look at the engine and locate the pipe that you are going to replace. It is the pipe
between the intercooler and the engine inlet (between the red circles below).
First thing to do is to remove the 2 clips marked by the red circles in the above picture.
they will either be standard jubilee clips that can be undone with a screwdriver/socket or they will be clips that can be levered open with a screwdriver.
With the clips removed the pipe can be wiggled free from both ends.
With the pipe removed you will see a rubber joining hose connected to the intercooler.
Rubber hose circled red below.
Attach your DV to the pipe before fitting to the engine, space is limited and could be tricky.
The new metal pipe attaches in the same place as the old one and it will be quite obvious which way around the pipe should go. Push the lower part of the metal pipe into the rubber hose but don't tighten the jubilee clip yet as we need to be able to adjust the position.
With the bottom pipe connected it can be very hard to get the top part of the pipe in position and initially took 20 minutes of swearing to get it on, after taking it off and refitting again I found a simple way to do it. Push the supplied rubber hose all of the way onto the metal DV pipe, this gives you clearance to line it up with the engine inlet before you slide the rubber pipe off of the DV pipe and onto the engine inlet.
With both ends of the metal pipe attached correctly, tighten the
3 jubilee clips and ensure everything is held in place correctly.
With that done it is time to connect the vacuum tube.
The narrow tube supplied with the DV will be 3mm rubber or silicone, one end connects to the dump valve and the other is connected to the fuel pressure regulator.
Cut a 10cm section off the narrow tube and put it to one side for the moment.
Take the remaining part and fit one end to the DV and the other to the small plastic T piece.
Hold both ends in place with a zip tie just to stop it coming off.
Look at thefuel pressure regulator in the picture below.
Pull off the tube attached to it and attach it to the small T piece, take the left over 10cm length of tube and attach to the last leg of the small T piece. Fit the end of this short bit back onto the fuel pressure regulator where the old braided pipe was taken from.
Fit zip ties to all of the connections on the rubber hose to stop them coming off.
That is it, job done, check everything is tight and go for a drive to test it out.
DV With A Silicone T Piece
The fitting of this type of dump valve is slightly harder due to restricted space.
The silicone T-piece replaces the straight rubber hose between the intercooler and the
plastic pipe that runs up to the engine. Follow the pipe highlighted below down until
you reach a straight rubber hose That is the hose that we will be replacing.
Working from what angle is best (above or below the car) remove the 2 clips on
the rubber tube, slide the top pipe out and slide the hose off of the car. You will
now have the intercooler (air radiator with a fan connected to the back),
a gap and then a plastic pipe running up to the top of the engine.
Fit the DV securely to the narrow neck of the silicone T piece and then fit the entire unit into the space left when you removed the original rubber pipe. This can be very fiddly but make sure you have the jubilee clips over the pipes before you continue.
Once the intercooler and the plastic pipe are connected securely to either end of the silicone T piece, tighten the jubilee clips up and check for movement.
With that done it is time to connect the vacuum tube.
The narrow tube supplied with the DV will be 3mm rubber or silicone, one end connects to the dump valve and the other is connected to the fuel pressure regulator.
Cut a 10cm section off the narrow tube and put it to one side for the moment.
Take the remaining part and fit one end to the DV and the other to the small plastic T piece.
Hold both ends in place with a zip tie just to stop it coming off.
Look at the fuel pressure regulator in the picture below.
Pull off the tube attached to it and attach it to the small T piece, take the left over 10cm length of tube and attach to the last leg of the small T piece. Fit the end of this short bit back onto the inlet manifold where the old braided pipe was taken from.
Fit zip ties to all of the connections on the rubber hose to stop them coming off.
That is it, job done, check everything is tight and go for a drive to test it out.
Print page
Translate
Back to top
© Copyright 2012 Vone Internet Services. All rights reserved