Changing the wastegate diaphragm?

**Doug_RS2** · 8 December 2003, 07:26

I've BTDT - a few times at GTI !!

Safest bet is to take the complete wastgate off the car - it's not too bad a job. That way you can get access with a big hex driver to the bottom of the shaft.

You can change it by sticking a screwdriver between the inner wall of the wastgate and the metal plate, an putting pressure, sideways, on the plate to the shaft - but be warned - my top shaft is slighly bent and the thread damaged. Some ape tried to do it previously on my car.

Take the complete wastgate off - stick the big allen key in a vice and sit the wastgate on top of that.

It would be interesting to find out what the thread is on that nut - I think it must be a M7 - which I could not find a replacement for!

**Crawford_S2** · 8 December 2003, 08:41

I changed my WG diaphram in May and i found the same the inner just turns

I looked at taking the whole thing off and decided to try an air gun on it before doing it, you never know I thought

Worked, whizzed it straight off, just held the inner cup with a rubber glove and hey presto

Not saying this is a brill idea but worth a try, saves a lot of dismantling. Needs to be an air gun not an air ratchet the gun has impact effect as it works (you know the one like you use for wheel nuts but I turned down the air) Try it at your own risk but it worked for me

**S2central.net** · 8 December 2003, 08:56

IS the diaphragm split then ?

Agree the impact wrench sounds like a neat trick, but it can be done with great care using the wedge technique as Doug suggests...

Paul

**Martynf** · 8 December 2003, 11:36

Thank you very much guys!

The thought of removing the WG right now is not appealing, rusted studs and all, just waiting on something to snap and kill the car :confused:

So me thinks due to I haven't got air in my toolkit, I'll try the wedge method first and give it a short sharp tap to 'break' the grip.

Paul, there were no obvious signs of a split, but as you said, sometimes you just cannot see them.. it'll rule it out as a cause.

I've had a lot of hoses off this weekend but still cannot see anything obvious that is the cause of my overboost protection. No spilt hoses that I could see

I thought (right or wrong...!!) that I'll change all the cheap vacuum, turbo and breather hoses that I can and do the Wg diaphragm at the same time as its pretty cheap. All those part ar still original and at 100K they are going to be tired, so why not...? sledgehammer approach I know, but a pretty definative solution to rule those parts out.

Ok, I'll go with the wedge approach when I get the parts in. Actually.... can anyone lend me their pressure test gear please? I am pretty sure my problem is an air leak as for some time now, I've been sayng I could 'hear' the turbo, so the logical thinking is I'm actually hearing the leak!

I should be able to make the RR session next Monday, so maybe we could try the pressure test there please??

Pretty please???

Martyn

**martinjs** · 8 December 2003, 11:58

Thats one of the things i havent checked also, will there be a mityvac 'in the house' next monday

**Martynf** · 8 December 2003, 12:20

Form a queue

We could all put our collective heads together on the day and all look at each others problems whilst the cars ar on the RR :-))

10 heads are better than 1 confused, frustrated head in the garage on a Sunday on your own

Martyn

**Doug_RS2** · 8 December 2003, 12:37

I'll bring a mityvac and my ragu pressure tester - need to block the breather pipe - I think I have some 19mm dia ali rod. If someone can bring a wee compressor that will help (unless I get one before thursday - I'm not lugging the mains one with me)

I've also got spare diverter, wgfv, wg diaphragm and selection of silicon hoses and t-pieces if it gets serious.

**s2driveruk** · 8 December 2003, 12:41

Martyn,

Not owning an aby i am not sure if everything is in the same location but there is an angled hose that runs from the TBV back to the maf to cold side turbo hose which can rub on one of the metal bars to the right (as you peer into the engine bay from front of car) of the left headlight. Might be a possibility as mine was well marked but hadn't split when i last checked over the weekend.

Also, check them jubilee clips, mine seem to work loose after a few thousand miles and some probably lose enough pressure to cause you problems...

top candidates are:

The narrow guage hose which goes into the cold side of the turbo below the ribbed maf one, those before the throttle body, the two short lengths on the inlet pipe from the exit of the intercooler and obviously the exit of the intercooler to the crossmember pipe (unless you've done the 'halligan mod')

Hope you find it!

David

**S2central.net** · 8 December 2003, 13:10

A few minutes with a MityVac can find (or rule out) all sorts of leak problems... Iwon't be at the sesh on the 15th as Jim and I are playing with Samco hoses on the 13th.

I also have a bunch of spare parts including a MAF (and two leak testers) which I can offer to the cause if you are getting desperate.

@Martyn - when you say you can hear the turbo - do you mean you can hear air inside the cabin ? This would point to a leak in the control hose into the ECU or a boost guage.

Without a MityVac, you can pressure test the little hoses if you lash up a footpump thru some silicon tubing and hose joiners. Bit faffy tho...

With an hour or two at my gaff - we could check it all over. If you are available on the 13th to join me and Jim in MK, then you are welcome to play with MityVac etc etc and swap parts with my spares etc. I also have plenty of 4mm and 8mm silicon tubing if you need it.

Cheers,

Paul

**Martynf** · 8 December 2003, 13:18

Thanks guys :-)) you're the best!

Doug, will a 'normal' tyre compressors be ok? it says 260psi on the tin!

David, the ABY is a bit different, that small bore hose to the turbo you mentioned was indeed one of the most tired, perished hoses, but still in tact, however it will be replaced. I've done the Mark H mod and it's still on tight. Just don't see the split, so hoping a pressure test will show it up under load, it should...

Funny you shold say about the clips, as about 3 hoses were about to split due the the clips digging into the rubber soo much! looks like all mine had been done up extremely tight!

See you on the day hopefully!
Martyn

**Martynf** · 8 December 2003, 13:31

Paul,

There isn't a smilie good enough for your help!

This sounds great for the 13th!! I can indeed make it to you then, I'll head up the M1 early Saturday and aim to be with you by 10-11am if that's ok.

A ga-zillion thanks! :-)))

Martyn

**s2avant** · 8 December 2003, 15:46

Welcome to the fold Martyn

I'm still chasing boost gremlins. If it's OK with Paul I might try and make it over on the 13th for some brainstorming.

Ben

**GreenDestiny** · 15 April 2004, 21:04

Originally posted by s2avant

Welcome to the fold Martyn

I'm still chasing boost gremlins. If it's OK with Paul I might try and make it over on the 13th for some brainstorming.

Ben

Hi Ben,

I joined the list recently. I was glad to see that I am not the only one with the problem you talk about here. It is driving me mad and sapping all the money I wanted to spend on fancy brakes etc!

I was wondering if you could recommend someone I could take it to who really knows what he is looking for. I have taken it to a few people some better than others but I am no closer to finding the source of the problem.

I have tried the following;

Change boost sensor
Change Lambda probe
Change MAF Meter
rewired in the MAF wiring block
Had the engine stripped and hoses checked with a compressor

Any advice would be gratefully received.

Thanks

Austin

**Doug_RS2** · 15 April 2004, 21:11

Austin - what is wrong with your car?

Where are you?

Changing the wastegate diaphragm?

Changing the wastegate diaphragm?

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