Focus ST Dump Valve Relocation Kit Fitting Instructions The GGR Dump Valve Relocation Kit is designed to fit with the minimum of fuss. Although fitting of this kit is not overly complicated, certain aspects of the fitting are relatively tricky, and you may need an additional pair of hands. Great care should be taken to follow these instructions to prevent damaging your new ST. If you have any doubts about your abilities to fit this item, we would strongly suggest that you have this done professionally! Please note amended information at the end of these instructions Familiarise yourself with the component parts and read through these instructions before starting anything. Please take care to ensure that no foreign bodies can enter the pipework etc. whilst you have hoses removed, as engine damage could occur. There are two distinct parts of this operation: A) Fitting the new dump valve and relocation hose. B) Disabling the existing dump valve. These two operations can be carried out in either order, but both procedures must be completed before the engine is started. Fitting the new dump valve and relocation hose. The new dump valve is sited at the front of the engine bay with the relocation hose being effectively a large T Piece that replaces an existing flexible joining hose. A few additional components need to be removed to allow access to fit these items.

1. Jack up the off-side-front of your car and place securely on axle stands. Remove the off-side-front wheel and move aside. This is to allow you access to the original dump valve.

2. Remove the retaining screw from the top of the off-side headlamp unit. Carefully slide the headlamp forward (it is only held by this one screw, and retained in position on pegs), and remove the wiring connector. Carefully put the headlamp unit to one side. With the headlamp unit removed, you now have better access to the pipework from the Intercooler.

3. The Intercooler outlet pipe has a small take-off, this feeds a hard

plastic pipe that comes up, over the engine, and terminates below the windscreen. At the base of this pipe is a valve that is secured to the engine and the upper pipe is a tight push fit onto this. Remove this pipe from the valve by carefully pulling it upwards.

4. Pull the air valve to one side, releasing it from the mounting on

the engine.

5. Remove the two spring type hose clips that retain this valve to

the flexible joining hose that connects it to the intercooler outlet pipe.

6. Fit the new silicone dump valve relocation hose in place of the

flexible joining hose, and re-fit the spring hose clips to each end.

7. Remove the two Torx headed screws and remove the upper cam

belt cover, to gain access to the original dump valve vacuum hose. Carefully cut the vacuum hose as shown, and fit the T piece and extension hose supplied for the new dump valve.

8. Re-fit the upper cam belt cover and fit the new dump valve into the top of the relocation hose, using the hose clip supplied, cut the vacuum hose to correct length, and fit this to the top of the new dump valve.

9. Secure the dump valve into position using the double spring clip

as shown.

Disabling the existing dump valve. The existing dump valve is built directly into the turbocharger on the rear of the engine, and access to this is not easy, especially without the use of a vehicle lift. It may also be an advantage to have some assistance with this, as certain operations require more that two hands! To disable the dump valve, the original return spring has to be removed, and replaced with the stronger item supplied in our kit, and this is done as follows:

1. Remove the small dump valve vacuum hose from the T- Piece below the upper cam belt cover. Remove the three cap head screws that hold the dump valve top to the compressor housing and remove the dump valve assembly completely from the turbocharger. Be careful when undoing these screws as the top also holds the return spring into position.

2. With these parts removed, you can see the components that make up the dump valve. The piston & diaphragm return spring and valve top with integral piston guide. You can clearly see in this picture that the standard return spring is made from thinner material than our version.

3. Place the new return spring over the piston as shown, and place this assembly back into the compressor housing, making sure that the diaphragm seats correctly around its outer edge. Carefully place the valve top over the piston and push down into place. (This is where an extra pair of hands is required!) Whilst the valve top is held in place, carefully re-fit the cap head screws, and tighten them evenly to avoid damaging the valve top or diaphragm. Re-fit the small vacuum hose to the T-Piece below the upper cam belt cover.

Amendments a. Please note that although we have produced this Dump

Valve Relocation kit for the Focus ST and did run this on our own car without problems, we are aware of situations where customers have experienced ‘ESP System Fault’ warnings as a result of fitting a dump valve. This is due to the highly complex engine management system used on the car, and re-calibration of the unit cannot stop this happening. (October 2008)

b. It has been brought to our notice that the face-lifted (2008 Model cars) require removal of the drive shaft to gain access to the original turbocharger dump valve! (October 2008)

Graham Goode Racing

Lutterworth Road Aylestone Leicester LE2 8PH

www.grahamgoode.com sales@grahamgoode.com

Tel: 0116 2440080 Fax: 0116 2440140