boost bypass valve installation (the igor/avi way)

["Meron" <phwomp@cosmoslink.net>]

Lucky for me I found the old post, here it is.........


I recently put in a bypass valve and I agree with Dave, makes a big
 improvement, my Q has" only" 16PSI positive pressure and the addition of
 the valve made it much less "picky", it drives now like a "normal" car
not like a snowmobile.......
 Before I get into the procedure,  here is a small note, the 1.8 also has a
 boost bypass valve but it is located at "accordion" hose.
 
 here is a description:
 1. get the valve from a Bosch dealer (Audi is too spendy), P.N. is 280 142
102 - cut off valve, 
 2. if you don't have a third opening in your cooler (intercooler), the
 opening is located between the "IN" and ''OUT" of the cooler, here is how
 to add one.
 
 3. remove your cooler, very easy, 
 
 4. remove the plastic end of the cooler (where the "IN" and "OUT"
openings are) bend the tabs back,
 
 5. install a nipple with a flange, the nipple should match the the size
of the valve, the nipple's flange should be glued to the cooler and also
 bolted, I did not use a gasket, the glue was enough (must be bolted with
 bolts that go through with a nut)
 
 6. the above nipple should be installed where you will see a raised area
on the "IN" side of the cooler
 
 7. drill through the nipple, now you have a third opening, 
 
 8. clean all plastic shavings and reassemble cooler,
 
 9. connect the valve to the cooler via a short rubber hose (make sure you
 connect the "IN" side of the valve)
 
 10. determine of the best position for the valve, no interference, etc.
 find a hose that fit the angles between the valve and the boot metal pipe
 (there are many "funny" coolant hoses you can try, I used a short BMW
hose),
 
 11. when you decide where your connecting hose (the 'funny hose") between
 the valve "out" to the metal tube will be, braze a nipple to the metal
tube,
 
 12. attach the out of the valve to the metal tube via a "curvy" hose (I
used a BMW hose),
 
 13. now your car will run... add an intake vacuum line to valve and
that's it, simple isn't it?....
 
 14. you can make the set-up look very neat, just like factory (maybe
 better), you can put the nipple on the metal hose facing down so it looks
very OEM,
 
 The valve works great and thanks to Igor for the inspiration, if you have
 any questions (I am sure there will be plenty....) don't hesitate to ask,
I will do my best to explain,
 Avi Meron