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Wastegate Refresh

 
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11356
Location: PacNW

PostPosted: Fri May 20, 2011 2:51 am    Post subject: Wastegate Refresh Reply with quote

I recently pulled the wastegate from Shaggy to pull that pesky .8 bar spring, and took the opportunity to freshen it up a bit.

PARTS NEEDED:

Studs - (4) M8x25, (4) M8x32
Copper locknuts - (8) M8
Gaskets - (2) 930 123 194 01
J-pipe gasket OR seal - 931 111 191 10 OR 931 111 195 00
Crush washers - (2) 900 123 043 30
Diaphragm - 930 123 210 01
Valve guide - fabricated
Asbestos gasket - fabricated
Copper anti-seize
Copper gasket spray

*Note - wastegate dump pipe connection to the cat has an expensive metallic sealing ring and clamp that should be inspected. They did not need replacement on this project.
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  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11356
Location: PacNW

PostPosted: Fri May 20, 2011 3:08 am    Post subject: Reply with quote

Apply anti-seize to studs, and start them by hand. Run them in with a stud tool until they JUST bottom. DO NOT TIGHTEN.






Here's the guide that a guy on Pelican had made for his 930. I don't have the measurements (and frankly am unqualifed to take properly precise measurements) but once your old one is pressed out a good head shop shoudl be able to replicate it. It was clearanced to .003, and felt much better than the old one, which had a ton of lateral play in the valve.





Here's the factory gasket that goes between the iron valve body and alloy housing. I think I bought the last one in existance from Andial. You MUST have a plan to fab this, as the old one will be destroyed on disassembly, and the seal here operates against intake vaccuum and boost.




Hit your gasket on both sides with a little copper gasket maker to ensure a good seal.





A little more antiseize preps the top and bottom halves of the wastegate for assembly.




Note the orientation of the boost signal port relative to the dump pipe flange.



Next we assemble the wastegate "fez," upper housing, and valve.



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Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress


Last edited by Rasta Monsta on Fri May 20, 2011 3:30 am; edited 3 times in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11356
Location: PacNW

PostPosted: Fri May 20, 2011 3:09 am    Post subject: Reply with quote

More Fezzenwerk:





Ready for the final phase.



Factory US spring, compared to the .8 BAR 930 unit:



Don't forget to shim the spring, top and bottom.



Here's where that gym membership pays off. People complain about this part being difficult, but it ain't. Be sure to get the bracket attachment point oriented correctly.









Here's the seat, which I found a bit nerve wracking. It is NOT a press fit into the valve body, it actually moves around quite a bit, and is held on only by tightening the dump pipe. Pressure from the wastegate spring aligns it with the dump valve on reassembly.




Add some studs, again with anti-seize:




Install the bracket, but only finger tight. Final alignment and tightening will take place on the car.


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  • Shaggy (1980 931) - Got Boost?
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  • Weiße Scheiße (1987 924S) - In Progress
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Rasta Monsta  



Joined: 12 Jul 2006
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Location: PacNW

PostPosted: Fri May 20, 2011 3:38 am    Post subject: Reply with quote

DONE! Boost in confidence that you won't pop your motor due to wastegate fail!
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Nein37  



Joined: 29 Dec 2009
Posts: 513
Location: New London, CT

PostPosted: Fri May 20, 2011 9:19 am    Post subject: Reply with quote

Question... How the F&^% did you get the wastegate bracket attached to the bracket on the torque tube??? I couldn't figure out how this particular task was possible.
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1981 931 CGT replica, OEM CGT intercooler, .8 BAR WG spring, GTS Headlights, Innovative Wide band A/F, A/C delete, 16" Fuchs, Weltmeister 200lb lowering springs, Bilstein HDs front, Koni Sport rears.
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11356
Location: PacNW

PostPosted: Fri May 20, 2011 10:14 am    Post subject: Reply with quote

Ratcheting flex head wrenches. . .maybe the most important toofah tools in my box. Also, all the bolts were loose until I was satisfied that everything was aligned properly AFTER the wastegate was secured to the j-pipe.
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flosho  



Joined: 01 Jul 2004
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Location: Eau Claire, Wisconsin

PostPosted: Fri May 20, 2011 11:34 am    Post subject: Reply with quote

Nice crotch-hole rip.


Also nice write up.
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Joes924Racer  



Joined: 03 Nov 2002
Posts: 11966
Location: Oregon, Denver Colorado native!

PostPosted: Fri May 20, 2011 3:44 pm    Post subject: Reply with quote

Com-on Flosho thats for his wfe... Rasta nice write up ...thanks ah dude.
Ill copy it.
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11356
Location: PacNW

PostPosted: Fri May 20, 2011 4:26 pm    Post subject: Reply with quote

Dear god, another cocklooker.
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  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 1587
Location: Somerset, UK

PostPosted: Fri May 27, 2011 6:08 am    Post subject: Reply with quote

Rasta Monsta wrote:
DONE! Boost in confidence that you won't pop your motor due to wastegate fail!


If your overboost switch is working you shouldn't pop your motor if the wastegate fails!!

Where did you get the diaphragm and gaskets. My UK OPC are claiming they are NLA. If Andial what price did you pay?

Need to do the same on mine soon
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1980 931 - forged pistons, Piper cam, CGT turbo, 951 ducted FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife LSD
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11356
Location: PacNW

PostPosted: Fri May 27, 2011 8:52 am    Post subject: Reply with quote

Carrera RSR wrote:
If your overboost switch is working you shouldn't pop your motor if the wastegate fails!!


Ja, unless you suddenly go lean at high RPM while overboosting. . .

Gaskets are HERE.

The diaphragm might be getting rare. There is an aftermarket teflon one out there someplace (search for early 930). . .
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Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress
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