DIY: Adjusting a 12psi internal wastegate to open at 20psi and boost over 30+ psi

[CO AVANT]

http://www.youtube.com/watch?v=RhsGjSFUhTw

Disclaimer: I do not recommend doing this unless you have the correct hardware and software to run this kind of boost pressure safely. I also will only recommend this mod to people with vast knowledge of data logging and knowing if their car is running under safe parameters. Since I technically now have the wastgate set to open at 20psi my revo settings on boost 1 will be 20psi. This is the lowest boost I'll be able to run this turbo at.

[AudiA4_20T]

nice arms, I bet David is jealous he couldnt have his in there

[dougyfresh]

Thanks! 12psi FTL!

I might as well do this now since the front end is off my car and I've got dyno time for early Feb.

[Killerteve]

WTF Jordan ur video doesn't support iPhone!! Btw I'll have those parts soon so we can gt my shit out of your garage.

[Mark]

as a caveat . . . you'll eventually ruin your turbo doing this . . . it'll be overboosting way outside the specification map (and spinning WAY too fast).

[absolutegtr]

beer ftw.

informative vid too

[actlsub9]

I might as well do this now since the front end is off my car and I've got dyno time for early Feb.

Why would you do this?

[A4 Moda]

Thank you !!!!!

I've been looking for a DIY like this.

Time for the turbo to come off.

I hope I don't find FOD.

[A4 TSCHUSS]

nice arms, I bet David is jealous he couldnt have his in there

His arms are more diesel....... Thanks for thinking about me though

[dougyfresh]

Why would you do this?

I think my WG is opening in the upper RPM band which is causing my boost to drop dramatically while the RPMs climb. Wanted to tighten up the WG arm so the N75 doesn't have to cycle as much and see if it fixes the problem. If not, I'll put it back at 12psi. Doesn't take me long to pull the mani and turbo out (30min?). Just a pain in my lower back bending over the fender. However, since the core support is on Eric's garage floor I might as well do it now because the oil drain line is easy to get to, coolant is already drained and the engine is at chest level . Ergonomic work location FTW!


Martin. No more exhaust leaks. I fixed those. See above /\







Jordan.
How do you plan on logging boost if you can't get anything over 2540mbar through VAG-Com? That is, until you install the new MAP sensor.

[audi_a4_turbo]

so whats the point of a boost controller,if you can turn up the boost just on the wastegate, so say i got a turbo and i dont wana waste money on a boost controller or a chip to raise up the boost, so i just play with the wastegate to get more boost, im confused?

[Don Supreme]

Its much easier to turn a knob a couple clicks than adjusting your wastegate....

[vinny.dtw]

Right in time for me to do it. Thanks.

[CO AVANT]

Jordan.
How do you plan on logging boost if you can't get anything over 2540mbar through VAG-Com? That is, until you install the new MAP sensor.

MAP sensor is already in. I keep an eye on all other things first and foremost through vag before vag boost readings anyway. Good thing it's cold out cause this thing is gonna blow a lot of hot air boosting over 30psi. I'll most likely keep it at ~25psi for daily driving. Gonna have to keep my ebc connected as a boost gauge cause my AWE center vent gauge only goes up to 25psi. Need to replace that with one that goes up to 35 or 40.

and yes Mark, I should have put in my disclaimer that if you plan to run this turbo at 30+ psi all the time then the life span of the turbo will go down significantly...

[dougyfresh]

MAP sensor is already in. I keep an eye on all other things first and foremost through vag before vag boost readings anyway. Good thing it's cold out cause this thing is gonna blow a lot of hot air boosting over 30psi. I'll most likely keep it at ~25psi for daily driving. Gonna have to keep my ebc connected as a boost gauge cause my AWE center vent gauge only goes up to 25psi. Need to replace that with one that goes up to 35 or 40.

Right on. I forgot you received everything already.

Put the OE vent back in. Send me your rear view mirror and I'll put a digital gauge in it.

so whats the point of a boost controller,if you can turn up the boost just on the wastegate, so say i got a turbo and i dont wana waste money on a boost controller or a chip to raise up the boost, so i just play with the wastegate to get more boost, im confused?

You still need a 'boost controller' albeit EBC, MBC or N75. This 'mod' just increases where the wastegate opens thus allowing one to run higher levels of boost with more control through some form of boost controller. The one thing not specifically mentioned in the original post is that Jordan will be running the EuroCode fueling kit that Greg (400hpa4) helped work the kinks out with on his car. This 'kit' allows one to run higher levels of boost off the N75 and still keep ME7.5 within the load-controlled fuel/boost/timing/etc maps at 30+psi. I, on the other hand, have had all my maps reworked via a separate tuner to run higher levels of boost (which I already have been doing with the N75).

One is treading thin ice if this is attempted with a stock block (internal-wise). Jordan, the OP, has a fully built (forged internals) motor as do I.

One should also log the car religiously if doing this (as stated in the disclaimer) for this is not something the average-Joe should be attempting. Serious damage can result if attention is not closely paid.

[CO AVANT]

Put the OE vent back in. Send me your rear view mirror and I'll put a digital gauge in it.

Will I be able to hide the wires going to it though? I do not have a compass mirror in my 03...

I cannot find a 45mm gauge that goes over 30psi. Guess I'll need to scrap the AWE center vent gauge...

[actlsub9]

I think my WG is opening in the upper RPM band which is causing my boost to drop dramatically while the RPMs climb. Wanted to tighten up the WG arm so the N75 doesn't have to cycle as much and see if it fixes the problem. If not, I'll put it back at 12psi. Doesn't take me long to pull the mani and turbo out (30min?). Just a pain in my lower back bending over the fender. However, since the core support is on Eric's garage floor I might as well do it now because the oil drain line is easy to get to, coolant is already drained and the engine is at chest level . Ergonomic work location FTW!

What do your n75 duty cycles look like?

The downside I see here is that you now loose basically all part throttle boost modulation.

[dougyfresh]

Will I be able to hide the wires going to it though? I do not have a compass mirror in my 03...

I cannot find a 45mm gauge that goes over 30psi. Guess I'll need to scrap the AWE center vent gauge...

Email me some pictures of what it looks like. I haven't sat in a B6 without a compass mirror so I'm not sure if we can hide the wires. Could find a compass mirror for you. I've seen them for a good price.

What do your n75 duty cycles look like?

The downside I see here is that you now loose basically all part throttle boost modulation. (This is only for you Doug, since Jordan already uses an ebc)

I'm still waiting for the logs from ASP. Haven't had an opportunity to log it myself. I don't think I need much since I'm already spiking around 28-30psi. WG set to 15-18 maybe in order to hold better in the upper RPMs.

Jordan is/will be using the N75 soon.

[CO AVANT]

maybe Greg can chime in and say if the boost is very on/off or not...
If you can find a compass mirror let me know, I'll keep an eye out too. I'd rather have you do the boost gauge in the mirror over anything else.

[dougyfresh]

maybe Greg can chime in and say if the boost is very on/off or not...
If you can find a compass mirror let me know, I'll keep an eye out too. I'd rather have you do the boost gauge in the mirror over anything else.

I'll start looking. I'll also look at the wiring diagram and ETKA to figure out how we can wire the mirror into your car. Then you can decide if you want to do it or not.

[Audi Skate Snow]

I'll start looking. I'll also look at the wiring diagram and ETKA to figure out how we can wire the mirror into your car. Then you can decide if you want to do it or not.

PM'd ya back.

[dougyfresh]

PM'd ya back.

And again. Back to you.



EDIT: Clean out your mailbox please!

[dirtybrd]

From what Greg has told me, you will have throttle modulated boost.

[dr. brian]

OK, so most of us have K03's with Stage 1+ setups. What can we do with the actuator, wastegate, or whatever else to max that damn K03? Are you running the stock N75 or you using the Race N75 -"H"?

[CO AVANT]

I would not recommend pushing a small turbo like the k03 to 30+ psi. It cannot hold that boost for any length of time. It will just spike and fall on its face. It's even well out of the efficiency range for me to push my T25 2871R to 30+psi. I'm just doing this to max out my setup. I will only run 25-28psi on the street during daily driving (note that I run 104oct all the time). Run the stock N75 valve.

I only recommend doing this if you plan on buying the eurocode tuning BT fueling kit provided by David Sarabi. He is putting pricing together as we speak and will release this kit to the public VERY soon.

[dr. brian]

Mucho thanks! My Audi Tech has told me about getting a different actuator that gives 2psi more or something. Trying to research it but no real luck. Your video is way cool and very educational, dig that sh@t! The more I learn about this stuff the more I realize how much more there is to learn. Thanks for the info.

[actlsub9]

From what Greg has told me, you will have throttle modulated boost.

Yea he has told me that as well. Not until now did I think twice about it. But if you need to hit 20psi to overcome the WG spring to open the WG, then how do you have throttle modulated boost?

[martini]

i was going to write thsi up.. haha

[A4 Moda]

Yea he has told me that as well. Not until now did I think twice about it. But if you need to hit 20psi to overcome the WG spring to open the WG, then how do you have throttle modulated boost?

I dont remember what turbo Jordan is running, but the sucker is pretty stinkin big.

So, by all accounts, it probably takes time to Build boost.
Yeah your pedal may be down to the pavement, and your wastegate welded shut, but that doesn't mean you'll spike 30psi when you hit 2000 rpms.

It takes time. That's likely where the modulation is coming into play.

Like I said, I don't know, it's just a conjecture.

[A4 Moda]

i was going to write thsi up.. haha

You should still do it.

I like your write-ups.
Keep up the good work.

[A4 TSCHUSS]

His turbo is not big. He only has a 2871

[F16HTON]

What do your n75 duty cycles look like?

The downside I see here is that you now loose basically all part throttle boost modulation.

Wrong, I have 100% pefect part throttle boosy modualtion can drive aroung town at 3, 6, 9, 12, 15 psi etc...

Boost is dependent on how much the pedal is depressed. If the pedal is WOT, the lowest I will se is 19PSI though.

[dougyfresh]

My WG opens at 20psi now

Thanks Jordan.

I was able to accomplish this with the turbo and manifold in the car. My turbo is clocked so that the wastegate actuator arm is ontop of the engine mount but below the exhaust manifold. I unbolted the HFC from the turbo and wedged a 2x4 between the HFC and the firewall. The flex bellows in the downpipe allowed me to do this. This provided enough clearance for me to get my fingers in there and verify when the WG flapper opens.




I wound up doing adjusting the WG actuator rod from underneath the car (car was on a lift). Reach in with one arm from the front and the other from the back underneath the downpipe.

Here's what helped.. Instead of pulling on that WG actuator rod to overcome the new spring pressure... Open up your air compressor regulator (slowly) until it starts moving the actuator rod. Then put the rod onto the WG flapper arm and attach the c-clip. Good to go with little effort expended. (Some of us aren't as strong [in the arms] as Jordan and David so we must improvise.)






I did a partial pull (~5000rpm) and the car is overboosting. I'm seeing 34-35ish instead of 28. I might have tightened the actuator rod too much. Boost does come on a lot quicker at part throttle and the car feels very lively.

[F16HTON]

This thread is so last year

[dr. brian]

I know not recommended on K03 but can one still adjust rod for WG for even a slight improvment? Mentality is anything that improves is worth doing...imo

[dougyfresh]

This thread is so last year

aren't you special

[F16HTON]

I know not recommended on K03 but can one still adjust rod for WG for even a slight improvment? Mentality is anything that improves is worth doing...imo

No

[dirtybrd]

Short bus special.