1995 3000GT VR-4: GReddy Bypass Valve Installation

These instructions apply to a 1995 Mitsubishi 3000GT VR-4, but are easily transferable to any model/year of Turbo 3000GT or Dodge Stealth.



The Procedure

Make Sure You Have All Required Parts
 
  This is what you should receive with your 3/S-specific kit: The BPV, a flange adapter, a gasket, 2 bolts, 2 lock washers, 2 nuts, a hose "tee", a sticker for the top of the BPV, and a length of vacuum hose.

 

Remove Airbox or Air Filter
 
  Remove your factory airbox, or if you've already installed a K&N filter, then remove that. You'll need a 10mm socket and/or a 10mm wrench for the stock airbox, and my K&N filter clamp uses an 8mm bolt.

 

Remove the Mass Airflow Sensor (MAS)
 
  All you have to do is loosen the hose clamp that secures it to the "T" pipe.

 

Remove Y-Pipe (optional)
 
  You don't technically have to do this, but it makes picture-taking easier :-) The y-pipe is removed by loosening the clamps on the two intercooler hoses and the throttle body clamp. Ther BPV inlet hose also attaches to the underside of the y-pipe.

 

Remove OEM BPV
 
  After disconnecting the vacuum line and loosening the clamp on the BPV outlet, remove the OEM Bypass Valve.

 

Clean Up Engine Bay (optional)
 
  While you've got everything out of the way, now is a good time to clean up this area of the engine bay.

 

Assemble GReddy BPV
  Using the instructions that came with the BPV, bolt the flange adapter to the valve with the supplied hardware, remembering to install the gasket between the two parts. Attach the OEM hose to the flange adapter and secure it with a hose clamp.

 

Install GReddy BPV
 
  It attaches pretty much like the stock one does.

 

Closeup of Outlet Attachment
 
  Remember to connect the vacuum hose to the nipple on the BPV, just like the stock setup.

 

Eliminate Shifter Counter-weight Interference
 
  With some second-generation cars ('94 - '99), the counter-weight on the shifter mechanism will interfere with (contact) the head of the Greddy BPV. This can be eliminated by wrapping a zip-tie around the BPV and the hard clutch vacuum line as shown. Pull the BPV away from the shifter linkage and then tighten the zip tie until the BPV's resting position allows you to shift into all gears.

 

Adjust BPV Spring Tension
  The little screw sticking out of the top of the BPV is the adjuster for the spring that controls the valve tension. To adjust the valve, loosen the 10mm locking nut on the top of the valve and then use a 3mm Allen wrench to turn the screw (clockwise for tighter, counter-clockwise for looser). I found that the best setting for my car was to have 4-5 threads showing on the screw once the nut was tightened down.

 




Technical Discussion




The following CAD diagrams were created by Jon (9mmcgxs) on DSMTalk.com He has generously allowed me to use his diagrams on this site. The diagrams were originally on this thread, but seem to be gone now. Please don't swipe these diagrams without talking to Jon first.



GReddy Type S Bypass Valve (Closed/Open)
 
  Here is a comparrison of the valve in the open and closed positions. As you can see, when there is manifold pressure in the upper chamber, it pushes against the valve plate assembly, and if it (along with the force of the spring) generates enough force, the valve stays closed against the boost pressure at the very lowest chamber. If the manifold pressure drops (or becomes vacuum), then the force keeping the valve shut may not be sufficient to keep the valve from being forced open by the boost pressure in the lower chamber. This causes the valve to open, releasing the boost pressure through the vent tube back into the pre-turbo intake.

 

GReddy Type S Bypass Valve (Chamber Volumes)
 
  This pictures shows the four different chambers present in the BPV.

 





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Last Modified Sat Mar 18 2006 15:05:20 Pacific Standard Time