Modifying an Audi Wastegate. PICS FIXED!!! 17 pics
 

Well many people are wanting to run these but at 14.5psi and non-adjustable it is not very feasble on a Honda. Well I redid this writeup so the pics are up to date. I'm not sure if it was the same method as Shorty's but this is what I came up with. I do not know the range of PSI it is now but from the lowest setting the is next to no pre-load on the spring and you can open the wastegate with your pinky finger. It can probably be adjusted to have a higher then 14.5PSI rating as the bolt you replace is longer then the Stock one.

First Pull the top of the wastegate off. there is 6 8mm nuts. Once apart it should look like this.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBElAPbXR2

Secure the Hat in a Vice for ease and Grab an Allen Wrench
http://us.a1.yahoofs.com/users/41e13...Y_ENEBSxZX7GS2

Next using an Allen Wrench remove the Little Spring Seat be turning the bolt. Mine was tight and had to use some leverage, but it should come.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBqK1M4TH.

Next go back to the hat and using a drill bit just smaller then the thread, drill through the hat. Be careful not to hit the threads, you need those!
http://us.a1.yahoofs.com/users/41e13...Y_ENEBLJ5X7UFM

Turn the hat over and using a larger bit drill out the little brown peice of metal you see here. If you use a large enough bit eventually the metal will break free and come out. Mine Did.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBNF4He6Iw

Now return to the spring seat, Cut off the extra boss on the bottom to shorten it. I use an 4.5" grinder. I tried my band saw, but it is Harden metal, so if all you have is a hack saw, you'l be there for a while.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBcqzM9t_P

Return to the hat and using a Large Drill bit, Drill off the Thread Boss to make it shorter, By the time I stopped, I have about 5-6 Threads left.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBLXEeAVbO
http://us.a1.yahoofs.com/users/41e13...Y_ENEB9Ocr1p7a

I did't have a large enough drill bit so I used a die grinder to flaten the boss and clean it up a little.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBNKcLI9VS

Next Get a longer bolt. Try to find the longer one that you can that still has full depth of threads. You also need a Nut and Washer. Bolt size is a M12x1.25
http://us.a1.yahoofs.com/users/41e13...Y_ENEB8va_OfL4

Side the bolt through the spring seat and place the washer on like so.
http://us.a1.yahoofs.com/users/41e13...Y_ENEByMf_Pm7U

I tack welder the washer to the bolt. This way the sping seat can still float and spin during adjustments.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBXLvO87WU

Thread the spring seat through the bottom of the hat.
http://us.a1.yahoofs.com/users/41e13...Y_ENEB8cUUhit.

Thread the nut that is going to serve as your lock nut from the top.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBVqYVu9G9

Reassemble the hat to the wastegat and reinstall the 6 8mm nuts.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBdMO53zYf

Next using a cut-off wheel I put a small notch in the bolt.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBN4i4pbLY

The notch is for using a flat head to adjust the spring preload, and thus boost.
http://us.a1.yahoofs.com/users/41e13...Y_ENEBRGiST_Mn

There you have it. Again I have not tested this theory,and wont be till next seaon probably, but I see no reason why this would not work, It acts the same way as most name brand waste gates.
Good luck and I hope this helps some people out.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Just mounted a audi gate onto my HF manifold and have it dumping externally.
It seems to only want to go upto 4psi stock (strange when i expected 14.5psi or so :p ). I ran it off the side port with that huge banjo bolt.
With boost controller inline it goes higher without issue.

Runs like this..... compressor housing..... purge cut solenoid..... audi WG
-------......stock WG.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Ya, You must have something off. They are 14.psi from factory.

UPDATE ON PSI RANGE:
I don't know the max, but again I know I can take it higher then the 14.5psi be preloading the spring.
As for the Min, Using a Digital Pressure, air press regualtor and a compressor, I was able to pull the Compressor down to a lowest setting of 4.0psi and the wastegate would open fully no problem. I probably could go lower yet, But Why?

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Why would anyone ever want to run less than 14psi boost?

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

That's badass....

No having to mess with boost controllers or wastegate springs, just turn a screw and done.

Think I could mod my Tial? Hmmm... I bet it could be done.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Thats what i was thinking ;) But mine ran 4psi :p

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

nice diy :)

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

nice job ;)

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

sweet writeup man

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Hehe, just to confirm it wasn't my vac line layout, i ran the compressor housing right to the banjo fitting on the WG. Still 4psi :p Maybe mine was modified... anyways, boost controller on it and its all happy.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

I was thinking that too, but without a buildup 14.5psi is a little high. But still, it can be adjusted for more psi so there!

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

http://www.elektro.com/~audi/springs/

according to that site, the stock spring is set for 1.3 bar wich is about 4 psi. I emailed him to confirm this was absoulte pressure, and wrather or not the audi's were set up like the 1g dsms where they have an ecu controlled sylenoid that allows the boost pressure to be higher under normal circumstances.




Sean

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

^^^ Correction

1.3 bar is not 4psi. You must have typoed and not hit the "1"

PSI Bar Kpa Atm
20 1.379 137.90 1.361

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

well notice i asked him if its absoulte, wich means includeing the atmospheric pressure. i know for a fact that the audi oem boost gauges show absoulte barametric pressure.

http://www.intendedacceleration.com/tip_1.html

"The BAR gauge in the Audi is an absolute pressure gauge and it takes into account the atmospheric pressure. It is an international unit of pressure that is used in most countries. It is equal to 14.5 PSIA or approximately 1 atmosphere. This is why our gauge read about 1 BAR when the engine is off at sea level. Those of you at a higher altitude like in Colorado will notice your gauge is lower than that."

http://www.elektro.com/~audi/springs/

"These will increase the boost from 1.3 bar on the dash guage to
1.6 - 1.7 bar. You can further shim this with a 1/8" washer to
get another 0.1 bar boost - giving 1.7 to 1.8 Bar."


Thats according to those two sights, so it might not be on all modles.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Wow, I have one of those in the garage and I finally figured out what I'm going to do with it. Yippee, I get to ---- with it. ;D

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

mine came adjustable from the factory. remember to be careful with the diaphram. when its old it rips easy

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Good writeup. hAs anone tried cutting the spring?

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Cutting the spring would be possible, but if you ---- up, the is not turning back. If you cut too much and go down to 3psi, its never good to use a Boost Controller to more then double the spring rating. Thus you would be stuck at about 5-6psi with a 3psi cut spring.

Ya, I was going to completely disassembly my wastegate to sandblast it but I didn't want to risk screwing up the diapham. Mine is that delicate though. It looks brand new, fairly durable, and hardly yellowed from the heat. stillnoturbo got it for me and he made a good pick at the junkyard!!!!

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

I figure ill slice mine and if the boost is to low buy a spring with a rate i want. for 60 bucks i figure i can take chances.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

I wouldn't slice it. Looking at the above info... its a 4psi spring. And as said above... if you want to double boost... you start to have issues. I did my best last night at the strip to use the boost controller to up the boost... can't get it to hold anything remotely high boost.

Looking for replacement springs now, including the 11psi option from a link above.

I'm also curious as to why all the drilling etc was needed... http://www.sjmautotechnik.com/parts_...ts/wginst.html seems much simpler. Since when you remove the shcs you reveal threads... and if you remove the cap off the WG cap... those threads go all the way through. This is my next step to remedy the 4psi.... and also looking into the stiffer spring.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

this is kinda what i thought.

kinda figured it was only a 4psi gate.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

so are there two different audi wastegates?! i need to put this on my car next week and dont know if i have to modify it or not. i sure as hell dont want the 14.5 psi one.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

theres alot of different variations because those wastegates are used on alot of different cars. im not sure if there all 4 psi, but according to that site the late 80s modles are, the eirly modles are not electronically controlled so they may be higher. just find out the year it came off of, and if its 86 or newer it should be 4 psi.





Sean

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

since you seem to be full of answers.. do you know of a way to tell what year it came off of? becasuse i got it from e gay. i have NO clue.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

yeah id hate to slcie mine or anything else if i got a 4psi spring. I dont really plan to push mine Past double or more its stock rate on my unbuilt motor so 8 psi or less is just fine for me daily.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

http://www.sjmautotechnik.com/parts_...ts/wginst.html
From the link above that I gave.. the audi5000 gates were basically all about 4psi...

I also just ordered a 1.9bar (13psi) spring from the same place.


ALSO... if you remove the cap of your WG and find that you DON"T have a SHCS... that the top perch has no bolt/shcs.... you gate is Adjustable. Drill a hole in the top metal cap and use a sheet metal screw or something into the hole and then pop it off. Under that will be a hex keyable piece that you can adjust. (I just did this on my car... like 2 minutes ago. Didn't check the adjustment, but it moves and will move the upper spring perch in the WG cap.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Ha....I got a "over 120 days old warning". Suprised this isn't a sticky anyway. What models of Audi's did they come off of? Since they are older are they really that much better than an internal gate? Being older what about the diaphram being an issue? My BIGGEST question is how to mount it being the flange on the bottom is a stander external WG flange and all? Thanks and sorry to stir up old news, but I consider this a good thread/post.


JP

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

I have pictures here... https://www.homemadeturbo.com/forum/...9845#msg609845 that show how we used one on my HF manifold and "flanged" it.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Excellent writeup. I'm in the process of installing an audi wg on my 280zxt. Has anyone tried applying a small amount of boost to the top port to increase boost pressure rather than above mods? You wouldn't want too much pressure in there but I would think it would work. Or maybe not.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Nope, but my Electronic Boost Control will!

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

. Pics dont work now that im tryin to do this. found out theres adjustable upper waste gate spring perch and threaded allen screw from the earlier 84-85 5000 Turbo, our quattro, or the later 20V Turbo 3B or AAN engines and reduce the spring tension from the 1.8 bar spring

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

i think the 5000 (sc was it?) quatro turbo was at 14.5 psi. fix the pics man ;D

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

I will try to re-host the pics tonight or tomorrow.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Well lets see i took off my hat off of my audi wastegate and used a punch and popped the cap off.
then used a longer m12 bolt and threw away the 10 mm alen hex bolt
then i used the inner hat that the 10mm hex nut sat on and double nutted it, 4 psi stock to whatever i want now.
and the 4 psi springs came on the adui 5000 sc, these are vaccumed silinoid controled.
the gaskets i can get for 28.00, but the funny thing is if you cut the spring u just bought u a $800 wastegate (that is at my price through my vw dealer i work at)

good luck

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

LOL, I was always told Audo external gates were 7 psi. :-\

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

You should feel honor cause that is the last audi wg I pulled for anyone including myself. Those things are nighmares to get off. Good to see it's getting some good use out of it. Holy ---- Threshold 800 bones for that thing? I guess there's a reason I never buy things from the dealership and never will.

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

thanks for fixing the pics man

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

Easy Newb!!! Not everyone sits at the computer all day! I figured this ---- out on my own, go try it yourself!

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

damn right 800 the best thing is when you take it off at the junkyard and pay 30.00 to 40.00 and walk away
with a very collectible item it is worth it...

Re: Modifying an Audi Wastegate. New Write Up, 17 pics
 

i got mine off ebay for $15
http://cgi.ebay.com/ebaymotors/ws/eB...RK%3AMEWN%3AIT

i hope this is the right one