Sticking wastegate

[BOB1558]

Here is my quickfix for a sticking wastgate that dispenses with the grab it with a mole grip and tug method. Make up the tool as illustrated in the photo,s. The bar is approx 240mm long X 6mm diameter. The blank that the U shaped lever is made of is 50mm X 40mm X 5mm. The U shape itself is 28mm deep and in my case is 16.3mm wide, this makes it a snug fit on the wastegate lever. Now you can struggle for an hour or so to remove the three screws that retain the turbo shield, lift off the shield. Now so that you dont ever have to struggle to remove this shield again, do the following. Copper slip the three screws, replace the one that goes in the right hand end of the shield, you know, the one that is a pig to remove, dont screw it right in yet , leave it a few threads clear for now. Then take the shield and with a smallish file elongate the hole in the front by a couple of mm in the up and down direction. With a hacksaw make two cuts from the bottom edge of the difficult to get at hole, changing it from a hole into an open ended slot. Thats it, you never have to struggle with the shield again, it is now a five minute job to remove or replace.
While it is off, slip the newly made tool over the wastegate lever and with a spanner on the end of the bar start to waggle it side to side. take it a little bit at a time, until you are moving it all the way from shut to wide open, keep waggling for a while just to ensure that it is nice and free. There is no need to disconnect the actuator lever for this. OK job done, next time it sticks, you have the 15 minute quick fix at your fingertips.
I drilled and bolted my bar to my blank, but if you have a welding machine handy then just tack it . Hope you enjoy waggling it as much as I do.

[Sy V]

Thanks Bob, I hope your efforts catch on and some of the more mechanically adept members use your wiggling tool. I'm especially impressed by the adaption of the whole to a groove on the side of the heat shield, cause that particular bolt is a bitch to remove.

I know it's an engine ancillary, but I'm going to move this thread into the turbo area.

[techlectic]

Was there a picture with this post initially? If so, I'd really like to see it.

[Sy V]

Yep. There are three downloadable pictures there now - they work for me.

[mikeydude]

fantastic tool,
I was a bit more rough and ready with mine. mole grips would not budge it...just got a long bar and a hammer and tapped the wastegate lever back and forth gently from under the car while spraying easing oil on it. eventualy it worked loose. then I coverd the whole thing in copper grease.