My AAZ swap, some turbo connection questions, and a few others....

[vwnut84]

Ok, So I got my wastegate unstuck from the other day, and it seems to be staying freed up.  (thank you pb-blaster haha).  So I've almost got the engine all back together from a good cleaning/reseal, and I have a question about a line.  On the wastegate actuator, there are two lines, one goes to the intake side of the turbo, and the other is a stock size vacuum line that is smaller.  Where does that line go to?

Thanks!

[vanbcguy]

Assuming you have a T3...

I believe one line is the wastegate actuator line, while the other provides airflow to the actuator to cool it down.

[vwnut84]

Ah stupid me, the turbo info might help.     haha

It's a K03 turbo.  I have been sifting through info on here, and I think I found out that the line I'm talking about goes to the vacuum pump?  Can anyone verify this?  If it does go to vacuum then why?

Also, just so I have a better understanding of how this works, does the hose that goes to the intake side of the turbo from the wastegate regulate the pressure?  As in, when it gets to a set PSI on the intake, the wastegate opens?  Sorry for such dumb questions, I'm new to these turbos. 

[GEE-BEE]

two lines on the turbo
one to the manifold /intake
other is a overboard vent

want a pic
email me at [email protected]

I have a KO4 hot/ KO3 cold side

[vanbcguy]

Ah stupid me, the turbo info might help.     haha

It's a K03 turbo.  I have been sifting through info on here, and I think I found out that the line I'm talking about goes to the vacuum pump?  Can anyone verify this?  If it does go to vacuum then why?

Also, just so I have a better understanding of how this works, does the hose that goes to the intake side of the turbo from the wastegate regulate the pressure?  As in, when it gets to a set PSI on the intake, the wastegate opens?  Sorry for such dumb questions, I'm new to these turbos. 

OK, PROBABLY your car has a part-time turbo.  Some AAZ models have a system that disables the turbo under certain circumstances.  It's an emissions thing, but not anything that will change whether you pass or fail an inspection.  I don't personally have the details but they are alluded to in the "Make your 1.9TD a faster car" thread on here.  Guessing your car might have EGR as well?

[burn_your_money]

Yes, sounds like a part time turbo to me. From what I have seen it's not a sure sign of an EGR

The wastegate on that turbo is tricky, as I recall you need to hook the boost sensor line up to what appears to be the wrong end of the wastegate. If you have some regulated compressed air play around with it and see which end goes where.

[vwnut84]

My engine does not have an EGR valve on it. 

I did actually get the swap up and running and took it for it's first drive, and I'm only getting 5-6psi of boost.  This is with the smaller of the lines hooked up to the vacuum pump for constant vacuum.  It also seems like the wastegate actuator is now being a bit floppy for some reason, I have to go back out and check that as well. (almost like in the 'neutral' position of the wastegate it's half open, which would explain the boost.)

[vwnut84]

Also, I am having a problem with the power steering pulley on the crankshaft hitting the frame rail.  This is in a MK2 jetta.  So I need a smaller diamater pulley (it would clear then at least)  If so where would I get one? 

[vwnut84]

Fixed the boost issue, this is one of the "part time" turbos.  After I read that I remembered that the small vac hose off of the turbo actually came off of a valve that was never hooked up to anything.  As long as that line is off, I get 10psi.  Awesome!      (and wow this thing rips!)

Still have the issue with the power steering pump pulley off of the crank hitting the frame.  I had read something about this before but I couldn't find the post again.  Don't really want to go notching my frame.     I did have an ABA lower pulley that I tried and it won't fit in the AAZ's balancer.