waste gate on 1990 jetta

[jpedro]

i want to add more boost to my situation i have a boost gauge that goes to 20 is that high enough and if i disconnect the line from the wastegate all together how much boost will i end up with and what would be safe on a motor with 235000kms? what can i do as far as more boost thats quick cheap and easy

[Dirtrag2]

if you disconect the line you will be bypassing the wastegate altogether.

first step is to identify the turbo, i know that some 90 1.6's had the t3 garett turbo and some had the k24. there may be others, i'm sure someone will chime in on this 

the cheapest way to regulate your boos is to go to a small engine repair shop and buy a tap type fuel valve which you will install inline on the wastegate line. this will allow you to adjust your boost safely by bleeding the valve to whatever psi you desire.  btw when you install the valve, get enough rubber hose to mount the valve in the car, it makes adjustments on the fly much easier than stopping and raising the hood 

[jpedro]

i know its not a garret turbo cause that would be cast right into the front where the inlet is, and i cannt read wats there.

[jpedro]

so today i disconnected the wastegate and installed my boost gauge in that line. max i saw was 10psi then it would somehow blow off down the 5 then back to 10 and repeat as long as i was climbing up hill how do i stop this and why is it doin this... what do i do

[745 turbogreasel]

You gotta disable the safety valve

[jpedro]

wheres that and how do i do that lol

[smoken u]

did the same on my car about a year ago. the 1.6 has 2 ways of limiting boost, the waste gate on the turbo, and the blow off valve (BOV). so it soulnds as if youve already disabled the wastegate on the turbo, mine was a KKK so it was a bit different that what you described though lol. ok so the blow off valve is on the left side of the intake manifold, its that plasic round looking thing that sticks out about a good 4" off the top of the intake manifold, it also had a small tube that leads to the airbox/turbo inlet pipe.. the easiest way to gain good access to it is to remove the airbox, and all the related plumbing there. you should a slotted brass plug in the top of the BOV, you have to remove that, it just threads out so its pretty easy. after removing that, you should see a small spring underneath, thats what regulates at which point the bov opens, you wont need it but keep it just in case you wanna return it to stock. nest find a small bolt the about the same height and diamater of the spring. all you do now is replace that small spring inside the BOV with that bolt, tighten the brass plug down ontop of it, and enjoy all the newfound boost. just be warned with both the wastegate disabled you sill see a huge increase in boost, when i did this to mine i could max out a 30psi guage no problem mind you i also had increased my fueling, but at 496,000km my headgasket didnt take too kindly to it. so my advice would be to use the adjustable controll like dirtrag2 suggested. lol hope this helps some

[rallydiesel]

When you disconnected the wastegate line, did you plug the turbo end? Also someone already mentioned the manifold boost limiter. I would highly recommend an EGT gauge if you are running with a disabled wastegate as the k24 especially will run high EGT's very quickly.

[jpedro]

i removed my air box and mad my own cold air intake. but as far as bov is it under the turbo cause i dont think i have anything on the left side of the manifold. the only thing thats plastic is on top of the valve cover and i belive its a crank case vent. but ill take a pic so can show what i mean. and also when you say left is it drivers left or when you are looking at the motor. sorry for the dumb question ive never worked on these cars or had anything to do with them, im just learning. if it was a ford well thats a different story lol thanks again for your help

[smoken u]

lol sorry aout that left right thing, passenger side is what i mean lol. that BOV will be on the intake, its pretty buried under everything, not exactly the easiest thing to see.

[jpedro]

heres a couple of pics for you guys i havent a clue where you mean the bov is maybe if possible save pic and edit showing where it is located lol

[jpedro]

and one other question thats not related to this thread, where can i hook up a tach to this car? does it have to be hooked somewhere special or will any old universal tach work as long as its a 4cyl one?

[smoken u]

your the Bov is there remove your entire intake setup, all the hoses and you will see it. im pretty sure that the small breather hose closest to the front of the engine shown in your picture ( it looks like it goes down in behind the valve cover right at the oil fill cap) is the breather for the BOV, to recirculate the excess air.


as for the tach it takes its signal off of the alternator W terminal, it is on the back of the alternator. the easiest way to get a tach is to find one out of a diesel VW in the junkyard and just to swap it into your cluster. you can use a gas tach but it takes some serious modification becasue the w terminal generates a w wave signal as compared to a square wave signal that a normal distributor would generate.

[jpedro]

awsome. so i did as you instructed and its all done i just went for a test drive and at 80km/hr i hit 15psi and thats where it stayed, sounds much cooler as well. thanks for your help.

pedro

[smoken u]

lol no problem, glad i could help out, now you just need a pyrometer, to monitor your egts, adn then you can throw some fuel at it