1.6TD wastegate serviceability

[oblique]

'89 Canadian MF motor, new Giles pump and injectors, 1.03mm.

I get lots of black smoke at WOT and a constant whistle.

I know that the wastegate is press-fitted onto the turbo body but is it rebuildable? Does VW have parts?

[RabbitJockey]

t3?

[oblique]

not sure. pics of motor before any work, same turbo; (with CV boot grease strewn abotu for good measure)

[RabbitJockey]

wow a factory mk1 td

it looks like a k24, id need a picture of the intake side, or of the back side to tell for sure.  if the wastegate looks like a honey comb its a k24, if it looks like a tin can its a t3.  also the compressor side of the turbo will say airesearch or garrett if its a t3, or will say kkk if its a k24

the metal line attached to the compressor makes me think its a k24, which is adjustable.  they also have really sticky wastegates that you may have to work on freeing.

[oblique]

yea the cars an 84 jetta...w the Turbo Diesel emblem on the trunk   motor's been swapped though...has a hydro MF from an '89.

assuming its a k24...whats the procedure for cleaning and adjusting the wastegate?

[libbydiesel]

Getting the wastegate off is a PITA.  The wastegate is held to the turbo with three 5mm allen head bolts.  I spray with penetrating oil, use heat and shock, and loosen with an allen bit in a 6-point box wrench.  I have one 5mm allen bit that I ground down shorter for added clearance. 

Once off, I spray penetrating oil into the boost fitting and press push the valve in by holding the can and pushing down with the valve straight against a workbench or the like.  If the valve gets stuck in, you can free it with low pressure compressed air.  Keep working it until it moves freely. 

When it moves freely, you should be able to push the valve it and with it in put your thumb over the boost connection.  Then remove pressure on the valve part but keep your thumb on the boost fitting for a few seconds.  When you then pull your thumb off, you should hear the release of vacuum and the valve should pop out a little further.  That check tells you if the inner diaphragm is intact.

After the valve is moving freely and I've confirmed that the diaphragm is intact, I like to hand lap the valve seat before reassembling.  Use course valve grinding paste between the valve with care and you can get the seat cleaned up very nicely.  Use fine paste after the course to finish.  Reassemble with permatex ultra-copper to seal it.  Take care to seal the threads of at least one of the bolts that is a through-bolt into the exhaust area.     

[oblique]

just confirmed its a kkk.

ill have to get the wastegate removed and cleaned for sure...hopefully it will come off with the turbo on the car.

also am i correct in assuming this would be a logical reason why i make so much black smoke and whistle?

[libbydiesel]

There's no way I would pull the wastegate with the turbo on the car.  It's a bit of a pain to remove, but MUCH easier than trying to do the necessary work with the turbo still on the car. 

Black smoke and turbo whistle can both happen with the wastegate working fine.  Best thing to do would be to install a boost gauge to see how much boost you're getting and at what rpm. 

Excessive black smoke could be as simple as an old air filter.   

[kljaja]

With turbo in a car it's damn near impossible if it hasn't been done in recent years. Bolts are seized for sure. I tried for whole day to do it on k14 out the car and couldnt make it !

[burn_your_money]

'89 Canadian MF motor, new Giles pump and injectors, 1.03mm.

If 1.03mm is referencing the static timing, that's probably way too much. You should back it off to around 0.95mm

[fatmobile]

Kinda depends on what the injectors are set to.

[burn_your_money]

True. I read the original post as meaning both pump and injectors are new from Giles, which means factory specs for the injectors.

[oblique]

Correct, pump and injectors are Giles fresh, 160bar.

Replaced air filter with no effect.

Still working on getting a boost gauge - will report back.

So timing - is it not better to be advanced a little? For what its worth I timed the pump with the cold start on and ran the car for a while like that (turned out to be at approx 0.84mm) and she still smoked and the turbo  still whistled.

[RabbitJockey]

with a giles pump there is plenty of dynamic advance so theres no need to have it set so advanced initially