Porting the wastegate - Revision history

Geoff at 14:42, 15 September 2013

2013-09-15T14:42:10Z

Kmckmc: /* Porting the wastegate */

2009-05-06T08:26:20Z

‎Porting the wastegate

Kmckmc: /* Porting the wastegate */

2009-05-06T08:13:13Z

‎Porting the wastegate

Geoff: /* Top heatshield removal */

2009-03-28T21:05:54Z

‎Top heatshield removal

Foo: Undo revision 1508 by Foo (Talk)

2008-05-17T23:57:25Z

Undo revision 1508 by Foo (Talk)

Foo: Undo revision 1511 by Foo (Talk)

2008-05-17T23:56:31Z

Undo revision 1511 by Foo (Talk)

Foo: Restructure, cleanup.

2008-05-14T13:13:22Z

Restructure, cleanup.

Foo: /* Reassembly */ - Numbered List

2008-05-14T12:54:09Z

‎Reassembly: - Numbered List

Foo: Stub

2008-05-10T23:48:15Z

Stub

Geoff: /* Reassembly */

2008-02-27T23:58:09Z

‎Reassembly

@@ Line 9: / Line 9: @@
 == Exhaust manifold heatshield removal ==
+See [[Removing_the_exhaust_manifold_heatshield|Removing the exhaust manifold heatshield]].
-GS: WIP
-−
 == GS Notes ==

@@ Line 52: / Line 52: @@
 BEFORE:
+[[Image:M100BEFOREportedwastegate.jpg‎]]
 AFTER:
 == CLEAN! ==

← Older revision		Revision as of 08:13, 6 May 2009
Line 47:		Line 47:

	Clean out the pivot hole on the capsule actuation arm.		Clean out the pivot hole on the capsule actuation arm.
		+
		+
		+	Before/After pictures:
		+
		+	BEFORE:
		+
		+
		+	AFTER:

	== CLEAN! ==		== CLEAN! ==

@@ Line 5: / Line 5: @@
 == Top heatshield removal ==
-On the majority of SE's, there is no [[Oxygen (Lambda) sensor]] and the top heatshield can be removed by removing the three retaining bolts (M6 x 10mm) using a 10mm spanner.
+See [[Removing_the_top_turbo_heatshield|Removing the top turbo heatshield]].
-−
-−
-On S2, Fed, some ROW Elans and a handful of SE's, there is a sensor, which can sometimes be difficult to remove even after frequent dousing in penetrating oil, heat and using the correct lambda socket. The top heatshield '''can''' be removed without removing the sensor however. First remove the three retaining bolts and raise the heatshield as high as it will go.
-−
-−
-[[image:Turbo_top_heatshield_removal_1.jpg|Raise heatshield]]
-−
-−
-Gently raise the RHS of the heatshield and the gap will widen (shown by the red arrows) as the heatshield bends on the PAS mounting bolt (shown by the blue arrow).
-−
-−
-[[image:Turbo_top_heatshield_removal_2+.jpg|Bend heatshield]]
-−
-−
-Eventually, it should be possible to pop the heatshield over the top of the sensor and the heatshield will spring back to its original shape.
-−
-−
-[[image:Turbo_top_heatshield_removal_3.jpg|Remove heatshield]]
-−
-−
-Now simply unplug the sensor connector and release it from the bodywork by sliding to the side. The heatshield can then be removed completely.
 == Exhaust manifold heatshield removal ==

@@ Line 73: / Line 73: @@
 Everything!
-==Re-Assembly==
+==Reassembly==
-# Attach oil drain pipe to bottom of turbo.
+* Attach oil drain pipe to bottom of turbo.
-# Attach water inlet/outlet pipes to turbo fitting new copper washers (12mm ID & 18mm OD x 1mm).
-# Attach the small heatshields (left and right) to the exhaust manifold.
-# Attach the wastegate manifold to the turbo.
-# Make sure all pipes are clear (and in particular the EGR pipe )
-# Fit the EGR gasket
-# Fit the exhaust manifold gasket on the bolts.
-# Lower the turbo assembly into position.
-# Angle the side by the PAS pump towards the engine and insert the slotted hole ever the stud.
-# When the manifold studs are aligned, gently push so the exhaust manifold engages with the bolts; screw on two manifold nuts to retain the manifold loosely in position.
-# Loosely fit the remaining 7 manifold nuts.
-# Attach the turbo oil return pipe.
-# Gently press the EGR pipe into the hole in the manifold.
-# Fix the water pipe bracket, taking care to bolt though the heatshield.
-# Attach the turbo water cooling pipes (top and bottom).
-# Loosely clamp the oil feed banjo to the block fitting new copper washers (10mm ID & 16mm OD x 1mm) then loosely clamp the bracket onto the coolant bracket.
-# '''Fill the turbo with clean oil.'''
-# Fit the top banjo loosely to the turbo fitting new copper washers (10mm ID & 16mm OD x 1mm)
-# Tighten the manifold nuts to the specified torque in the correct sequence. Unless you have a torque spanner, it is impossible to get a torque wrench into all nuts - pull the torque wrench at the same distance as the length of spanner you're going to use then use a pipe or rag around the spanner to make it a similar diameter to the torque wrench. You should be able to estimate the torque reasonably well - about three grunts in my case!
-# Tighten both turbo oil feed banjos and the intermediate clamp.
-# Fit wastegate manifold bracket to block and wastegate manifold.
-# Loosely fit dipstick bracket. Loosely fit the dipstick pipe to the bracket then connect to engine. Tighten bracket and pipe.
-# Fit the top (manifold ) heatshield.
-# Fit the turbo outlet pipe.
-# Fit the wastegate capsule - lubricate the pivot with Copaslip or similar, engage in wastegate arm, attach the pipe, fix the capsule to the turbo, clamp the pipe and attach the C clip to the wastegate arm.
-# Fix the EGR to the manifold then tighten up the EGR pipe clamp.
-# Attach the engine hoist bracket and fix the turbo water cooling pipe to the bracket.
-# Fix the two studs at the bottom of the wastegate manifold, fit the gasket with some exhaust paste then attach the pre-cat to the manifold with two nuts. Fix the four remaining bolts and attach the pre-cat bracket to the pre-cat and block.
-# Fit the lower pre-cat gasket with some exhaust paste, fit the three studs in the pre-cat (through the exhaust flange), then tighten up the nuts.
-# Fit the lower turbo heatshield - fit all four bolts but only tighten up the bottom two. Remove the top two (shared) bolts as these were in place solely to make sure the holes were aligned.
-# Fit the top turbo heatshield.
-# Fit the oxygen sensor.
-# Remove the lower (shared) bolt from the bottom turbo heatshield and fit the pre-cat heatshield.
 [[Category:HowTo]]
 [[Category:Wastegate]]
 [[Category:Turbo]]

@@ Line 1: / Line 1: @@
 {{stub}}
-[[Wastegate]] porting is an expansion of the wastegate orifice to accomodate greater release of boost pressure while the wastegate is open.
+One of the first jobs is to remove the heatshields from around the manifold and pre-cat housing.
-The purpose of porting is to reduce or eliminate:
+== Top heatshield removal ==
-* Overboost (too much boost, which can blow the engine
-* Boost Creep (a progressive increase in boost during a period of heavy boosting)
-= Procedure =
+On the majority of SE's, there is no [[Oxygen (Lambda) sensor]] and the top heatshield can be removed by removing the three retaining bolts (M6 x 10mm) using a 10mm spanner.
-One of the first jobs is to remove the heatshields from around the manifold and pre-cat housing.
+On S2, Fed, some ROW Elans and a handful of SE's, there is a sensor, which can sometimes be difficult to remove even after frequent dousing in penetrating oil, heat and using the correct lambda socket. The top heatshield '''can''' be removed without removing the sensor however. First remove the three retaining bolts and raise the heatshield as high as it will go.
-On the majority of SE's, there is no [[Oxygen (Lambda) sensor]] and the top heatshield can be removed by removing the three retaining bolts (M6 x 10mm) using a 10mm spanner.
+[[image:Turbo_top_heatshield_removal_1.jpg|Raise heatshield]]
 Gently raise the RHS of the heatshield and the gap will widen (shown by the red arrows) as the heatshield bends on the PAS mounting bolt (shown by the blue arrow).
-<gallery>
-Image:Turbo_top_heatshield_removal_1.jpg|Raise heatshield
-</gallery>
+[[image:Turbo_top_heatshield_removal_2+.jpg|Bend heatshield]]
 Eventually, it should be possible to pop the heatshield over the top of the sensor and the heatshield will spring back to its original shape.
-== Exhaust manifold Heat-Shield ==
+[[image:Turbo_top_heatshield_removal_3.jpg|Remove heatshield]]
 == GS Notes ==
 ''Remove the top turbo oil pipe completely - banjo on top of turbo, retaining clip on right of manifold and banjo on back of engine.
 ''Remove the three studs from the exhaust flange and remove the gasket.
 ''Remove the three wastegate capsule retaining bolts, C clip on bottom of wastegate actuator and all pipes then remove the wastegate capsule complete. This aid removal and helps avoid scratching the paintwork.
@@ Line 57: / Line 55: @@
 ''Remove ...........................
-== Step 2: Port the Wastegate ==
+== Porting the wastegate ==
-# Plug cavity to turbo.
+== CLEAN! ==
-# Tie back the wastegate actuator arm
-# Lubricate the stone and don't let it get too hot.
-# Periodically, clean out the debris with a toothbrush or similar.
-# When complete, thoroughly wash out to remove all debris - remember, it is abrasive and you don't want that in your turbo!
-# Clean out the pivot hole on the capsule actuation arm.
-{{warning|text=At this point ''Clean everything''.}}
+Everything!
-== Step 3: Re-Assembly ==
+==Re-Assembly==
 # Attach oil drain pipe to bottom of turbo.

← Older revision		Revision as of 23:48, 10 May 2008
Line 1:		Line 1:
−	{{~~warning\|text='''Still under development by Geoff'''~~}}	+	{{stub}}

	One of the first jobs is to remove the heatshields from around the manifold and pre-cat housing.		One of the first jobs is to remove the heatshields from around the manifold and pre-cat housing.

@@ Line 109: / Line 109: @@
 * Loosely fit dipstick bracket. Loosely fit the dipstick pipe to the bracket then connect to engine. Tighten bracket and pipe.
-* Fit the top heatshield.
+* Fit the top (manifold ) heatshield.
 * Fit the turbo outlet pipe.
@@ Line 119: / Line 119: @@
 * Attach the engine hoist bracket and fix the turbo water cooling pipe to the bracket.
-* Fix the two studs in the wastegate manifold, fit the gasket with some exhaust paste then attach the pre-cat to the manifold with two nuts. Fix the four remaining bolts and attach the pre-cat bracket to the pre-cat and block.
+* Fix the two studs at the bottom of the wastegate manifold, fit the gasket with some exhaust paste then attach the pre-cat to the manifold with two nuts. Fix the four remaining bolts and attach the pre-cat bracket to the pre-cat and block.
 * Fit the lower pre-cat gasket with some exhaust paste, fit the three studs in the pre-cat (through the exhaust flange), then tighten up the nuts.