potato head Posted February 12, 2011 Share Posted February 12, 2011 Can anyone let me know the distance from the centre of the Wastegate rod hole to the bracket face (as a standard setting before modification for turbo boost)? I have needed to replace my wastegate because it was leaking and the one that was originally on it is different to the one that I have to change (original has a lot of the thread showing and about 28mm from bracket face to nut and new one has a very small amount of thread showing, 30mm from bracket face to nut and no chance of screwing in the shaft to the rod end). I'm trying to get the turbo set up as standard before mods but now im little confused (200tdi disco engine) Quote Link to comment Share on other sites More sharing options...
reb78 Posted February 12, 2011 Share Posted February 12, 2011 AFAIK, there is no standard dimension/length - it will need to be adjusted with a boost gauge connected as the distance it is set to will differ with fuelling settings. I'd rig up a boost gauge and adjust the rod so it is at 0.8bar as a standard. Quote Link to comment Share on other sites More sharing options...
potato head Posted February 12, 2011 Author Share Posted February 12, 2011 Thanks Reb, I will get the gauge out and set it that way. Quote Link to comment Share on other sites More sharing options...
potato head Posted February 14, 2011 Author Share Posted February 14, 2011 Ok so I seam to have hit an issue here. Set the wastegate arm up so that it was on the pin with enough pressure to close the flap, put the gauge on and got 0.8 bar. Wound the wastegate rod in by about 9mm (all that it would go before to bottomed out) and its still at 0.8. Turned the star wheel by 3/4 turn and its still 0.8. Wound the 'smoke' screw I'm by a turn and its still at 0.8 bar. Am I missing a trick here? Quote Link to comment Share on other sites More sharing options...
simonb Posted February 14, 2011 Share Posted February 14, 2011 Did you do your measurements "on the road" with the engine under load? You won't get full boost by opening the throttle with the vehicle stationary. Quote Link to comment Share on other sites More sharing options...
potato head Posted February 14, 2011 Author Share Posted February 14, 2011 Yes, all trials with different settings were on the road. For ref the distance from the wastegate bracket to the lock nut on the wastegate arm is 29mm. Not sure if it should be less than this to achieve a higher boost pressure or not. The eye piece has not been modified in any way. Quote Link to comment Share on other sites More sharing options...
reb78 Posted February 14, 2011 Share Posted February 14, 2011 You shorten the rod to increase the boost, but may need to do this in combination with an increase the fuel. The two fuelling modifications you mention you have done wont do much to the boost pressure as they affect fuelling off boost (smoke screw) and the rate at which the boost affects the fuelling set by the cone under the diaphragm stay wheel adjustment). Alter the fuelling under boost by changing the position of the cone as described in the attached pdf (its more detailed than i can describe!) tdi pump tuning.pdf Quote Link to comment Share on other sites More sharing options...
potato head Posted February 15, 2011 Author Share Posted February 15, 2011 Thanks Reb, having read this doc a number of times I am now in this position.... Wastegate wound in by 9mm (max it will go) Stroke limiting pin checked - nice and loose Star wheel rotated by 3/4 cw Diaphram rotated to give max fuel Smoke screw wound in be 1 1/2 turns Still 0.8 bar :-( Quote Link to comment Share on other sites More sharing options...
reb78 Posted February 15, 2011 Share Posted February 15, 2011 hmmmmmm. I'm a little bit stumped. Perhaps the threaded rod from the actuator needs cutting to shorten it further? Wouldnt do this until others have commented though. Can you put some pics up of the old and new setup? I presume it is the correct part? Quote Link to comment Share on other sites More sharing options...
potato head Posted February 15, 2011 Author Share Posted February 15, 2011 The only difference between the old and new wastegates is the amount of thread on the shaft, more on the one that was replaced but the nut to bracket position is the same. Quote Link to comment Share on other sites More sharing options...
western Posted February 15, 2011 Share Posted February 15, 2011 old shaft might have been cut down previously. Quote Link to comment Share on other sites More sharing options...
potato head Posted February 15, 2011 Author Share Posted February 15, 2011 Just as a matter of interest when the turbo is in its rest position, what measurement do you have from the centre of the pin on the exhaust manifold (where the wastegate rod eye attaches) to the face of the wastegate bracket? Quote Link to comment Share on other sites More sharing options...
potato head Posted February 15, 2011 Author Share Posted February 15, 2011 Forget that, just realised yours and mine will be the same in that respect. Quote Link to comment Share on other sites More sharing options...
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