27W-6-808-11 Bypass Valve for 11th Gen 1.5T

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You will proceed to remove the OEM Bypass Valve from the vehicle in the coming steps

Removal of the Turbo Inlet Pipe is recommended to access one of the fasteners attaching the OEM BPV (Bypass Valve) to the Turbo. Due to the style of fastener used (Torx bit), they are easy to strip. This style of fastener is not reused. New hardware is supplied for reinstallation of the 27WON BPV making any future removal or maintenance easier

Use a 5.5mm socket and 1/4" ratchet to remove the two (2) clamps (red markups) securing the accordion style intake air tube

Remove intake air tube from car and set aside

Remove two (2) screws from Turbo Inlet Pipe (TIP) EVAP valve with T30 Torx Bit

Pop both EVAP lines from clip

Tuck EVAP valve out of the way as shown (blue box)

Use 10mm socket and ratchet to remove bolt from TIP bracket near inlet

Pull up on reservoir to free from bracket and relocate as shown

Use 10mm socket and ratchet to remove two (2) bolts from vacuum bracket

Use 10mm socket and ratchet to remove two (2) bolts from wiring loom

Unplug waste gate actuator by pushing the very top of the clip in with one finger and pulling the plug out with the other hand

Set wiring loom out of the way

Use pliers to slide the two (2) hose clamps up the rubber hose

Twist each hose to break adhesion to metal tube then and pull both hoses off

Use hose pliers if you have them, it's easier

Use caution to avoid tearing rubber but it can take some force to free hoses

Set hoses out of the way

Use caution not to bend or damage A/C line while removing TIP

Be careful not to damage A/C line

Remove bolt with 12mm socket, 3" extension, and ratchet

Remove nut with 12mm socket, 3" extension, and ratchet

OE Turbo Inlet Pipe will wiggle freely now

Unfortunately Honda used a single use hose clamps for the turbo inlet pipe. These are difficult to remove

Use caution not to damage rubber lines. This is tricky

You can use a grinder, Dremel, or perhaps even shears to remove this single use clamp. We prefer Dremel

Remove Clamp Shown

Partially cut through band of clamp. The idea is to remove enough material that the clamp will break

Place flat head screwdriver under cut. If cut enough band will break pretty easily with a bit of pressure

Pop crank breather hose off as shown

Use caution as you proceed to minimize coolant leaks

Pinch off coolant line in a manner similar to what is shown

There are various other tools and ways to accomplish this, like pinch or hose pliers

Put towel under coolant line to catch leak

Use pliers to slide clamp out of the way as shown

Remove rubber upper coolant hose from the TIP hard line

Set entire line and assembly out of the way

Plug coolant line attached to TIP with finger while removing TIP so as to avoid further coolant spills

Remove OE TIP from car and set aside

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

Set metal vacuum assembly & line aside

Note the type of fastener used to secure BPV to your Turbocharger

For OE style fastener (not shown), use 3/8" ratchet, 3" extension and T30 Torx socket to remove the screws. Alternatively, you can use a T30 Torx T-Handle tool

If OE Torx fasteners are stripped, removal of the turbocharger is necessary. Torx bit fasteners can more easily be removed from the BPV if the turbocharger assembly is out of the vehicle

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

Top-side

Nipple

Bottom-side

O-rings & Mounting Hardware

Need to add spare lube & clamp

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 openings on the turbocharger flange. These must align with the 27WON BPV during installation

Optional: use a zip tie (not included) to secure coolant line out of the way as shown

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

Move counterclockwise and thread 2nd fastener until finger tight

The last mounting hole is underneath and not visible. Using your fingers, hand thread remaining fastener into the turbocharger. Leave finger tight

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

Optional: Remove zip tie holding coolant line in place

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

Place TIP back in car as shown. You'll secure it later

Reinstall crank breather hose using provided worm drive clamp as shown

Slide rubber coolant line onto hard line

Slide clamp in place to secure coolant line

Remove clamp preventing leak from upper coolant hose

Be careful not to damage A/C line

Wiggle OE TIP into position as shown

Reinstall both OE bolt and nut securing TIP to turbo with 12mm socket, 3" extension, and ratchet. Torque to 15-19 ft-lbs

Using 10mm socket and ratchet reconnect TIP to bracket near TIP inlet

Route rubber hoses as shown and insert them into the clips

Reinstall two (2) screws into Turbo Inlet Pipe (TIP) with T30 Torx Bit to secure EVAP valve

Slide both rubber vacuum lines over hard lines

Slice clamps over rubber lines to secure

Use 10mm socket and both OE bolts to reattach OE vacuum hard lines to TIP

Plug in WGA

Reinstall both OE bolts into wiring loom with 10mm socket and ratchet

Put OE coolant tank back into original position in bracket

Reinstall accordion intake tube and tighten clamps with 5.5mm socket

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 every three oil changes or so depending your driving conditions

If you are constantly driving in dusty environments we recommending bumping your maintenance up to two oil changes or so

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

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!