2stroke

My 1.8T engine suffered from error code for too low boost pressure,
which made me remove the downpipe + catalytic converter + turbo + manifold.
...discovered that I had a partially clogged catalyst and that I also have a wastegate actuator that is not working optimally.
Tried searching around Internet for help how to set up and adjust the wastegate actuator but can't find anything good.

So thought I'd ask here in the AudiWorld Forum if anyone knows how to set up and adjust the wastegate actuator ?


1. What should the actuator arm cracking pressure be/set to on these 4 different Turbos ?

2. What is the unloaded spring rate on the spring inside the actuator bell ?
( I have found information for some models that have a transversely mounted 1.8T engine, but nothing for longitudinally mounted 1.8T engines. )

K03-005
K03-029
K03-073
K04-015

I'm using Stage-1 software update in my car since 5 years back.

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INFO for Transversely mounted 1.8T engines:


All the following KKK / BorgWarner K03- turbos have the same installation dimensions and thermodynamical performance.

The differences are only in the actuator that opens the turbine bypass valve:
K03-011 ----> 65 N actuator
K03-026 ----> 85 N actuator
K03-035 ----> 85 N actuator
K03-044 ----> 65 N actuator
K03-045 ----> 85 N actuator
K03-049 ----> 65 N actuator
K03-052 ----> 85 N actuator
K03-053 ----> 85 N actuator
K03-058 ----> 85 N actuator

The 1.8T ( 20 v. ) versions with higher output have an actuator with a higher opening force due to the higher exhaust gas pressure
( which is a consequence of the higher boost pressure ).
Otherwise the valve would be pushed open by the exhaust gas pressure.

Additionally, with re-mapping of the ECU you can achieve about 215 hp with the newer K03's without danger of overspeeding the turbo.
With the older K03's turbos, 195 hp is the limit.

Best regards // BorgWarner Turbo Systems AG Germany.

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This is the Stage-1 Software that my car have: