Howdy y'all,
I've got a 1986 Transporter DoKa that I've swapped out the 1.6NA for a rebuilt AAZ with a K03 turbo from German Quality Autoparts in Southern California.
I've just gotten things far enough along to go for my first handful of test drives and went to go and confirm / adjust my boost levels this week.
I first wanted to see what amount of boost the wastegate actuator was set up for. I disconnected the hose that runs from the turbo to the wastegate actuator (A) and then used it to connect the waste gate actuator to a bike pump. The other hose (B) that would normally go to the N75 valve is plugged and everything else related to EGR had been deleted from my engine when I bought it.
When I started pumping the bike pump no pressure would build and I could hear and feel the air escaping from the wastegate actuator at the threaded rod (C).
The threaded rod for the actuator moves freely if I apply a modest amount of force.
Just as a quick gut check:
1. Under normal operation hose A would be under pressure and that pressure would cause the wastegate actuator to open/close the wastegate.
2. The B hose being plugged has no effect on the operation of the turbo. If I were to apply a vacuum to it, the actuator would start opening with less pressure required than if I had not applied vacuum.
3. The K03's wastegate is normally closed. If no pressure is able to build in the actuator, the wastegate will never open, and I'll be getting all of the boost all of the time.
4. The Bentley says that the actuator shouldn't be replaced on its own. Some folks seem mighty brave and have replaced it independently. Mine is likely toast and I should replace the turbo.
5. It's okay that my actuator is so dang close to my engine mount (yellow).
I spoke with German Quality Autoparts today and they're sending me out a new K03 to replace this one, but I want to make sure I'm not doing something stupid, and haven't accidentally given them bad information.
Thanks.