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  1. #1561
    regcheeseman's Avatar Privileged
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    Quote Originally Posted by Activ8 View Post
    What size is the valve Reg?

    Could you use a TIAL style V-band clamp to reseal the actuator housing? Changing the spring would be useful upping it to 1 bar would claim a lot of the N75 map back for rebuilding the housing for bigger boost builds.

    So what's the plan? Remove the top port and replace it with a welded nut?

    Paid 7 for a v band - it doesn't fit, the thickness of the joined section is not enough for the shape of the vee to seal effectively - yeah I could mess around for ages and get something 80% ok, but is there any point?

    Now we know what is inside you can perform the mod to all your actuators and make them adjustable.

    All you do is unscrew the air fitting and replace with an M5 x 40+mm fully threaded bolt, ideally a cap head not a hex but I didn't have one. The more you wind it in the greater the preload on the closing spring. Once set you just lock it off with the nut.

    There's no need to cut another actuator apart, one was sacrificed for the greater good.


    I managed to fit the bolt into mine earlier with everything in situ - tricky but I did it. I've got about 15mm of preload on the spring, you'll need a lot to open that wastegate!

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  3. #1562
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    Quote Originally Posted by regcheeseman View Post
    Paid 7 for a v band - it doesn't fit, the thickness of the joined section is not enough for the shape of the vee to seal effectively - yeah I could mess around for ages and get something 80% ok, but is there any point?

    Now we know what is inside you can perform the mod to all your actuators and make them adjustable.

    All you do is unscrew the air fitting and replace with an M5 x 40+mm fully threaded bolt, ideally a cap head not a hex but I didn't have one. The more you wind it in the greater the preload on the closing spring. Once set you just lock it off with the nut.

    There's no need to cut another actuator apart, one was sacrificed for the greater good.


    I managed to fit the bolt into mine earlier with everything in situ - tricky but I did it. I've got about 15mm of preload on the spring, you'll need a lot to open that wastegate!
    Don't go all "Barry" Reg, you know too much preload and you're loosing the mapped boost control, possibly more limping too. Too much boost and it's "less-car-can-go" and more cooking those passengers of yours!

    I'll get mine out tomorrow.

    Save the parts, they might come in handy.

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  5. #1563
    regcheeseman's Avatar Privileged
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    As the wastegate opens before boost target is met, could it be there is a mismatch between what the ECU believes is required to open the 'gate and how much the gate opens as a result of a given signal? - The extra preload just restores the balance but it will need some fine tuning to make sure the preload is adequate but not too much.

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    The 'ECU' believes....?
    There's a broad range of targets across the rpm range plus allowances for gear changes when the rpm falls away. Like you state have a play with the best preload and do a log run then I can tweak the boost map to suit.
    Last edited by Activ8; 19th August 2019 at 02:45 PM.

  7. #1565
    regcheeseman's Avatar Privileged
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    Quote Originally Posted by Activ8 View Post
    The 'ECU' believes....?
    There's a broad range of targets across the rpm range plus allowances for gear changes when the rpm falls away. Like you state have a play with the best preload and do a log run then I can tweak the boost map to suit.
    I'm trying to rationalise how the wastegate responds to the N75 signal sent by the ECU, i.e could it be that the ECU thinks that the wastegate will open 50% with a 50% PWM signal but because of a mechanical parts mismatch the wastegate opens 75%???

    Whatever, the -20% map has killed the smoke, lost the constant limp mode trip point (hopefully) and unfortunately killed the sub 2000rpm torque (OBVS) - however boost is now up 10psi and there's some decent power if you rev it.

    It's going very nicely at the moment. dunno if I'll get the chiller back on before action - cant see anything wrong with it, probably needs a pressure test.

  8. #1566
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    Quote Originally Posted by regcheeseman View Post
    I'm trying to rationalise how the wastegate responds to the N75 signal sent by the ECU, i.e could it be that the ECU thinks that the wastegate will open 50% with a 50% PWM signal but because of a mechanical parts mismatch the wastegate opens 75%???

    Whatever, the -20% map has killed the smoke, lost the constant limp mode trip point (hopefully) and unfortunately killed the sub 2000rpm torque (OBVS) - however boost is now up 10psi and there's some decent power if you rev it.

    It's going very nicely at the moment. dunno if I'll get the chiller back on before action - cant see anything wrong with it, probably needs a pressure test.
    You would have to look at the duty cycle on a run. Request vs Actual boost. Measuring Block 11.

    With the current preload what boost are you seeing on the gauge at 1500, 2000 & 2500 rpm?

    Standard spring was 9-10psi iirc, so the -20% map should max out at 15.2psi ish, with your preload the ECU is not really controlling a lot within that boost window.
    Last edited by Activ8; 20th August 2019 at 07:41 AM.

  9. #1567
    regcheeseman's Avatar Privileged
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    Brembo discs and pads fitted. 67 from Euro for the lot.

    Click image for larger version. 

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    While they were off, I cleaned and polished wheels front and back then coated them in poorboys.

    Click image for larger version. 

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    Was hoping to impress Activ with the bling at Action.

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  11. #1568
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    Dragged out of the 15 toolbox thread to save the 'normals'


    Quote Originally Posted by Activ8 View Post
    how was the long drive to Santa Pod with the actuator mod?
    Been meaning to PM or email you about this very issue....

    It was holding 25 psi on the gauge, the pipes stayed on and we were flying up and down the M5 at (ahem) mph, not much came past on the journey home

    Obviously the fuel wasn't there to make clutch killing power as I'm on the -20% map

    However the off-boost coast 2200 rpm limp is still there- something odd going on. I think the fault code is a red herring, it just throws up the nearest report to the actual problem, could be a blip in the matrix?

    But this EXCITING thread about tools should not be spoiled by such banter, JoT4 will only stop reading it - I'll post up on my build thread because only you or I only dares go there anymore as it's turned into a two man nerd-off.

  12. #1569
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    Quote Originally Posted by regcheeseman View Post
    Dragged out of the 15 toolbox thread to save the 'normals'
    You're considerably over boosting at 25psi , thats well outside of compressors map and over spooling the turbo. Cannot recall the compressor wheel sizes but I know we peaked that wheel at 22-23psi at 1800-2000rpm and then backed it off to 18 in the mid 4's. Back your actuator screw off.

    I set (iirc) the turbo maps to 1 bar (15psi) max IQ fuelling would not of been touched, but I'd change and raise the AFR.
    Last edited by Activ8; 6th September 2019 at 09:20 AM.

  13. #1570
    regcheeseman's Avatar Privileged
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    Quote Originally Posted by Activ8 View Post
    You're considerably over boosting at 25psi , thats well outside of compressors map and over spooling the turbo. Cannot recall the compressor wheel sizes but I know we peaked that wheel at 22-23psi at 1800-2000rpm and then backed it off to 18 in the mid 4's. Back your actuator screw off.

    I set (iirc) the turbo maps to 1 bar (15psi) max IQ fuelling would not of been touched, but I'd change and raise the AFR.
    None of that is causing the limp mode.

    I rarely go WOT on the van, the boost peak seen was a one-off experiment to see where it was at, I control boost with my right foot in normal driving, but I will back off the preload.



    I set (iirc) the turbo maps to 1 bar (15psi) max IQ fuelling would not of been touched, but I'd change and raise the AFR
    Does this comment relate to the -20% map???

    You dropped the boost map 20% ????

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