Stuck wastegate on KO3 turbo?

[ilikevwdiesel]

I have a 97 AAZ engine with a KO3. With no downpipe on the turbo, I tried to open and close the wastegate lever by hand and it wouldn't budge. This is with the actuator rod attached. I can move it with a pair of pliers but it's tough. Isn't it supposed to move quite easily? Someone clue me in please this is my first KO3.

thanks

[gldgti]

grasshopper, you have much to learn in the ways of turbo's.

better to attach an air line to the wastegate actuator and use a bicycle pump or similar to apply some air pressure into the actuator canister and watch it move - just think - if the diaphragm in the actuator is 1.5" diameter, then it has:

 pi*0.75^2 = 1.77 sq inches area. if its set to open at 12psi, then you will need to apply:

F=P*A = 12x1.77 = 21.24 lbs of force to move it.

see now why its hard to move?

[gldgti]

sorry mate, didnt mean to sound condesending at all - i only meant to be friendly. some people dont know.... i just try to help. sorry if i offended you man.

oh - and i guess to comment any further on your original post - does the wastegate return to closed quicly after you've moved it with the pliers? i think it if returns ok its probably not stuck as such.

[ilikevwdiesel]

Ok no worries, snarky rebuttal deleted. Yes the wastegate door shuts after the lever is released. I guess I need a Bentley for this engine so I can find the correct way to test the wastegate operation. I can see a rubber tube on the turbo housing that boost pressure obviously goes thru to actuate the wastegate, then there is another vacuum fitting on the end of the actuator that is disconnected and I don't know where that is supposed to go. These engines weren't sold in the US so that's why I am pretty much ignorant about them. What you're saying makes sense though, it probably is functioning properly. This motor is going into a mk1 caddy and I don't want to have to deal with the turbo once it's in there.

[GEE-BEE]

did the same with a mk1 caddy , let me know if you need some help ?

Gee-Bee

[burn_your_money]

then there is another vacuum fitting on the end of the actuator that is disconnected and I don't know where that is supposed to go.

You have what is known as VWs "part time turbo wastegate". Basically vacuum is applied to the one side to pull the wastegate open. This reduces back pressure and is better for emissions; possibly fuel economy too, I'm not sure.

Just make sure that you have the boost line going to the correct side. I think it looks backwards but it's been a while since I looked at one.

[gldgti]

quite right -

the other line normally runs to a vaccum solenoid that is activated via a microswitch on the throttle lever, and also a signal from the tach. it would normally cause the solenoid to apply vacuum (open solenoid) to the canister when the throttle position switch is open (low throttle lever settings) or otherwise removes vacuum (close solenoid) when the engine rpm goes past 3200.

i think the canister will function normally without plumbing that line in - but it does allow you some flexibility in boost control if you want to choose to open the wastegate at certain times. a good one to have anyway :-)

best of luck with you endeavours :-)