Firstly, I know there are other threads about K04 wastegate tuning. I've read many of them and picked up little snippets of info here and there. So, I'm not trying to start a huge wastegate tuning discussion thread. Only trying to get some suggestions from the gurus out there for my particular situation. Of course, as many others, it may hopefully assist others, too.
Details:
So, I have an early 2006 GTI, 158K on the clock, stock internals (head redone with new cams @ 130K), 170-180 compression on all four bangers. It has the APR Borg Warner K04, APR K04 tune, APR HPFP, S3 injectors, full APR turboback exhaust, Eurosport intake with ITG filter (I also have the APR Carbonio stage 1 and stock engine cover), stock intercooler, rev D DV, IE PCV blockoff, and New South boost gauge.
After 45K on K04, I found I was having oil burn and too much shaft play on the turbo. Got a new genuine Borg Warner K04-0064 CHRA and rebuilt the turbo. No leaks and all is well. Even threw in a new Pierburg Rev D DV while I had it out.
The Problem:
So as many others have found, I tried to set the wastegate with the turbo out but sure enough it was way off. First time driving the car hard in 93 program I hit 30+ psi spikes both on my gauge and maxing out in VCDS. Terrible turbo flutter/surge from 3-4K RPM. My boost graph looked like a roller coaster. So I backed off the wastegate 3 turns, after which I saw spikes of 28-29psi and holding 25-24ish. Still surging/fluttering and VCDS looking funky. I backed it off another 2 turns and I am now seeing spikes of 26-27 psi and holding 22ish psi. A little less fluttering/surging but still present.
My wastegate connector with the jam nuts is now about 3/5 to 2/3 of the way down the actuator rod (towards the end of the rod). Also, just to test, I put the car in the stock program and it was spiking 15-16psi and holding 12ish, a bit above what it should be, and indicating the the software is not the issue.
My question:
Am I on the right track working the wastegate down little by little? Any guess how many more turns I might possibly need?
Details:
So, I have an early 2006 GTI, 158K on the clock, stock internals (head redone with new cams @ 130K), 170-180 compression on all four bangers. It has the APR Borg Warner K04, APR K04 tune, APR HPFP, S3 injectors, full APR turboback exhaust, Eurosport intake with ITG filter (I also have the APR Carbonio stage 1 and stock engine cover), stock intercooler, rev D DV, IE PCV blockoff, and New South boost gauge.
After 45K on K04, I found I was having oil burn and too much shaft play on the turbo. Got a new genuine Borg Warner K04-0064 CHRA and rebuilt the turbo. No leaks and all is well. Even threw in a new Pierburg Rev D DV while I had it out.
The Problem:
So as many others have found, I tried to set the wastegate with the turbo out but sure enough it was way off. First time driving the car hard in 93 program I hit 30+ psi spikes both on my gauge and maxing out in VCDS. Terrible turbo flutter/surge from 3-4K RPM. My boost graph looked like a roller coaster. So I backed off the wastegate 3 turns, after which I saw spikes of 28-29psi and holding 25-24ish. Still surging/fluttering and VCDS looking funky. I backed it off another 2 turns and I am now seeing spikes of 26-27 psi and holding 22ish psi. A little less fluttering/surging but still present.
My wastegate connector with the jam nuts is now about 3/5 to 2/3 of the way down the actuator rod (towards the end of the rod). Also, just to test, I put the car in the stock program and it was spiking 15-16psi and holding 12ish, a bit above what it should be, and indicating the the software is not the issue.
My question:
Am I on the right track working the wastegate down little by little? Any guess how many more turns I might possibly need?