27W-6-808-10 Bypass Valve for 10th Gen 1.5T

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Open the hood to access the OEM Bypass Valve

Installation shown with 27WON Turbo Inlet Pipe (TIP). OE TIP will be similar

Removal of the Cold Side Boost Tube from the Turbo Inlet Pipe will free up space for Bypass Valve removal & reinstallation. Installation can be completed without removing this Boost Tube, but space will be tight

Using an 10mm socket and ratchet, loosen the bolt securing clamp around Boost Tube. 27WON Boost Tube shown. OEM will be similar

Slide Boost Tube off the Turbo Inlet Pipe leaving clamp loosely attached to the end

Tuck the Boost Tube up and out of the way as shown

The 27WON Boost Tube is reinforced so it will take a bit of muscle to tuck out of the way. OEM Boost Tubes are easier to maneuver (if equipped)

Locate OEM Bypass Valve

Installation shown here with 27WON Turbo Inlet Pipe. OEM and other Aftermarket Turbo Inlet Pipes steps will be similar

Optional: Loosen upper bracket for factory A/C line using 10mm socket and ratchet

Optional: Loosen lower bracket for factory A/C line using 10mm socket, 10" extension and ratchet

Using pliers, remove spring clamp from vacuum line leading to the BPV by sliding it up. Then disconnect the line from the OEM BPV by pulling up on it

Note the orientation of the BPV nipple. The 27WON BPV will need the nipple facing the same way once installed

Use 1/4" ratchet, 3" extension and 8mm socket to remove the (3) bolts shown then remove OEM Bypass Valve

Note the proximity of the factory A/C line here. A 8mm ratcheting wrench may be used in place of the 8mm socket to reach these bolts

Top-side

Nipple

Bottom-side

O-rings & Mounting Hardware

Apply a small amount of supplied lubricant or engine oil to both O-rings prior to installation

Insert large O-ring into groove on bottom-side and press down firmly to secure

Insert small O-ring into groove on bottom-side and press down firmly to secure

Note the location of the Bypass Valve openings on the face of the Turbo Inlet. These must align with the 27WON BPV during installation

27WON Turbo Inlet Pipe shown

OEM Turbo Inlet Pipe shown

27WON Bypass Valve opening

Using a 5mm ball end hex socket and 3” extension, guide the first fastener through the BPV mounting hole and thread onto Turbo Inlet Pipe. Leave finger tight

Move counterclockwise and thread 2nd fastener until finger tight

The last mounting hole is underneath. Using your fingers, hand thread this remaining fastener. Leave finger tight

Torque all three mounting bolts to 7-9 ft-lbs with ratchet

Confirm BPV fitting is pointed in direction as shown. Adjust if needed

To adjust nipple position loosen the knurled ring 1-2 turns

Once loose, rotate the top portion "W" until proper alignment is achieved. Hold top "W" portion in place while rotating knurled ring in opposite direction to tighten

Re-attach vacuum line onto your new 27WON BPV

Using a set of pliers, slide down spring clamp to secure line to BPV

Re-attach Cold Side Boost Tube by first sliding it back onto the Turbo Inlet pipe opening, then tightening the 10mm nut

Now is the time to reinstall both the upper and lower A/C bracket bolts if you removed them earlier

The 27WON BPV is designed to provide OE like boost control and trouble free operation. Periodic service is necessary. If the valve is not serviced it may cease to perform correctly. This could shorten the life of your turbocharger. See instructions at the end of this guide for BPV service

BPV service should happen around every third oil change (12,000-15,000 miles). Spare lubrication is included for this

This chart shows good BPV operation for both the OE BPV and the 27WON BPV. Your boost control should look something like this

Notice there is not a spike in boost pressure as the turbocharger spools up

Notice there is not a spike in pressure when letting off throttle

Notice the time to go from purple arrow to green arrow. This is time to vent TC pressure. You see 27WON and OE are very similar

Improper BPV operation can trigger CEL

P2261: Turbocharger BPV Issue. This may trigger for reasons not related to BPV. Check boost control using the example on the previous step to make sure your BPV is working properly. OE BPV can throw this code when the rubber seal tears

A properly functioning BPV will make some noises when it vents. With an OE intake you might not hear these. With an open filter intake you'll hear all the noises. A "Psssst" or "whooshing" sound is normal

If your turbocharger is not able to vent quick enough (for various reasons) it can make an audible noise. This 'flutter' or 'choo choo' sound is from compressor surge. This can reduce the life of the turbocharger. If you hear this noise, check out your entire boost control system including BPV

Watch this video https://www.youtube.com/watch?v=2QaajARc... at around 15-17s there is an example of compressor surge from the throttle plate closing

This completes the installation of your 27WON BPV

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Continue to the next steps for cleaning and lubrication of BPV

The 27WON BPV will require maintenance three oil changes or so depending your driving conditions

If you are constantly driving in dusty environments we recommending bumping your maintenance up about every other oil change

To perform maintenance properly, you will need the following items

27WON BPV removed from your vehicle

Clean paper towels / shop towels

Provided vial of high temp grease

A couple of Q-tips, or another instrument for applying the grease

11th Gen BPV shown here. 10th Gen BPV is similar

Twist the knurled ring on the BPV counter clockwise to loosen the BPV cap as shown

Remove the cap and set it to the side

Flip the BPV over and press on the center of the internal piston as shown

It is important to press as close to the center as possible. If the piston is pressed off to one side it can become crooked and stuck inside of the BPV

With the BPV fully disassembled, wipe all of the parts clean with shop towels

You can use a cleaning solution here if your BPV is especially dirty, just make sure any solution is fully wiped out before you apply grease to the internal components

With the components all clean, generously apply the provided grease as shown:

Inside of BPV body

BPV upper o-ring

BPV piston

Properly lubed components should appear as shown

Insert the piston back into the BPV body in the orientation shown

Just as when it came out, the piston will need to pressed in as even as possible

Place the BPV cap back onto the body as shown

Ensure the BPV spring sits inside of the piston indent circled in green

Hand tighten the knurled ring onto the BPV body as shown

Use your finger to push the piston from the bottom a few times. The piston should return smoothly to the closed position

Reinstall your 27WON BPV!