Wastegate turbocharger

Types of Wastegate Turbocharger

A wastegate turbocharger is a component of a turbocharger that controls the flow of exhaust gases to the turbine in order to regulate its speed and prevent overspeeding. There are two main types of wastegate turbochargers, which include the internal and external wastegate turbocharger.

• Internal wastegate turbocharger:

  The internal wastegate turbocharger is the most common type of wastegate. It is integrated into the turbocharger assembly and utilizes a wastegate valve that is located inside the turbine housing. The wastegate valve is connected to a control actuator that is usually linked to the boost pressure. When the engine reaches the desired boost level, the actuator gets activated, and the valve moves to divert some exhaust flow away from the turbine. This action helps regulate the turbine speed and maintain consistent boost pressure. Internal wastegate turbochargers are simple, compact, and cost-effective. They are widely used in small and medium-sized turbocharged engines.

• External wastegate turbocharger:

  The external wastegate turbocharger is a separate unit mounted on the exhaust system, and it has a wastegate valve located outside the turbocharger. An external actuator controls the wastegate valve, which is connected to the boost control system via a vacuum or pressure hose. External wastegate turbochargers offer more precise control over the boost pressure and turbine speed. They are commonly used in high-performance applications where maintaining optimal boost levels is critical. Additionally, external wastegate turbochargers can handle larger exhaust flows, making them suitable for big turbo setups.

Specifications and Maintenance of Wastegate Turbocharger

The specification of wastegate turbochargers varies depending on the size and model. However, all have the same fundamental parts. Here are the general parts of a wastegate turbocharger:

• Compressor wheel: It pulls in air from the atmosphere and pushes it into the engine. It is connected to the turbine shaft using a common rotating axis (a shaft).
• Turbine wheel: It pulls in exhaust air and pushes it out of the turbo. This action makes the turbine wheel spin, which in turn spins the compressor wheel. Like the compressor wheel, it is connected to the compressor wheel via the shaft.
• Turbine housing: It encloses the turbine wheel and forces exhaust air to flow around it, making it spin. The housing is designed to control airflow and create resistance to ensure the turbine wheel spins at the right speed.
• Compressor housing: Like the turbine housing, the compressor housing is designed to control airflow. It encloses the compressor wheel and forces air to flow around it, pushing it into the engine.
• Bearing system: This is a critical component that enables the turbine and compressor wheels to spin at high speeds with minimal friction. The bearing system is located between the compressor and turbine housings. It allows airflow between the two sides and ensures the wheels spin smoothly.
• Actuator: This component controls the wastegate valve. It is connected to the wastegate valve and the boost control line.
• Wastegate valve: The wastegate valve controls exhaust flow. It is connected to the actuator and the wastegate port.

Like other car components, the wastegate turbocharger requires regular maintenance to ensure it functions properly. Here are some maintenance tips:

• Regular oil changes: Oil is vital for the proper functioning of the wastegate turbocharger. Ensure the oil levels are adequate and change the oil regularly, as recommended by the manufacturer. This reduces the risk of wear and tear and keeps the turbo in good condition.
• Let the car idle: After a long drive, many people switch off the car immediately. This is not good for the turbo. Always let the car idle for a minute or two, especially after a long drive or hard acceleration, to allow the turbo to cool down. This prevents the oil from coking and prolongs the lifespan of the turbo.
• Use quality fuel: Using low-quality fuel, especially one with low octane ratings, can damage the wastegate turbocharger. Always use high-quality fuel, as recommended by the manufacturer, to ensure the turbo runs smoothly and efficiently.

How to Choose Wastegate Turbocharger

Choosing a wastegate turbo for an aftermarket project can be a daunting task for many. With the many options available, it can be hard to know which one is suitable for a specific project. Here is a simple guide on how to choose a wastegate turbocharger:

• Understand the Engine: Firstly, it is important to understand the engine in question. Analyzing the engine will help to know the power it generates and its potential for upgrades. The analysis will help to choose a turbocharger that will complement the engine and maximize its performance.
• Determine Goals: It is also important to determine goals before choosing a turbocharger. What does the project aim to achieve at the end of the day? Is it more torque, more horsepower, or better fuel efficiency? Having clear goals will guide the choice of a turbocharger that aligns with the set objectives.
• Consider Size: When choosing a wastegate turbocharger, it is important to consider its size. A larger turbocharger will generate more power but will have a lag. On the flip side, a smaller turbocharger will have little or no lag but will produce lesser power. Strike a balance between power and lag by considering size.
• Look for Quality: Quality is a key factor to consider when choosing a wastegate turbocharger. With many options in the market, it can be hard to know which one's quality is superior. To be sure of quality, look for reputable brands that are known to produce quality components. Quality is also determined by the material used to make the turbocharger.
• Check Compatibility: Another important factor to consider when choosing a wastegate turbocharger is compatibility. Make sure that the components of the turbocharger are compatible with each other. For example, ensure that the wastegate is compatible with the turbocharger actuator.
• Budget: Finally, budget is an important factor to consider when choosing a wastegate turbocharger. There are many options in the market with varying prices. Set a budget and stick to it while searching for the wastegate turbocharger within the range.

How to DIY and replace wastegate turbocharger

It is possible to replace the wastegate actuator and wastegate valve of a turbocharger with basic mechanical knowledge and the right tools. Follow the steps below to get it done:

• Identify the problem:

  Use a diagnostic tool to check the wastegate turbocharger model. Connect the tool to the car's OBD-II port and turn on the ignition. Read the diagnostic codes and see if there is any code pointing to a wastegate issue. Codes like P0299 (Turbo/Supercharger Undercurrent) or P0046 (Exhaust Turbocharger/Supercharger Control Valve Range Performance) indicate a wastegate issue.

• Access the turbocharger:

  Set the car's engine and open the hood. Locate the turbocharger and wastegate valve. It may be necessary to remove some engine covers or components to access the wastegate.

• Disconnect the wastegate actuator:

  Locate the wastegate actuator connected to the wastegate valve with a rod. Disconnect the actuator from the wastegate valve.

• Test the wastegate actuator:

  Use a hand pump vacuum gauge to test the wastegate actuator. Connect the gauge to the actuator and apply vacuum pressure. The wastegate should close completely with no leaks. If it doesn't, the actuator is faulty and needs replacement.

• Remove the wastegate turbochargers:

  Unscrew the bolts holding the wastegate to the turbocharger and remove it. This step may require special tools or adapters to reach the bolts.

• Install the new wastegate actuator:

  Mount the new actuator and connect it to the wastegate valve with a rod. Be sure to adjust the rod length so the wastegate opens and closes properly.

• Reconnect the wastegate turbocharger:

  Reconnect any vacuum lines or electrical connectors to the wastegate actuator. Ensure everything is secure and there are no leaks.

• Reassemble and test:

  Reassemble any engine covers or components removed earlier. Start the engine and test drive the car to see if the wastegate issue is resolved. Check the diagnostic tool again to ensure no new codes are present.

Q and A

Q1: How does one know a wastegate is faulty?

A1: There are several signs of a faulty wastegate, the most common being turbo overboost or underboost. In case of overboost, the vehicle may experience excessive power, while underboost results in a lack of power when accelerating. A rattling noise when the vehicle is idling is also a sign of a damaged wastegate. Other symptoms include the Check Engine light being activated and poor fuel efficiency.

Q2: Can a wastegate turbocharger be repaired?

A2: Yes, it is possible to repair wastegate turbochargers. However, the success of the repair depends on the extent of the damage. If the components of the wastegate are worn out or damaged, it may be possible to replace them. However, if the wastegate actuator or valve is pitted, the technician may recommend replacing the entire wastegate.

Q3: Can users drive the vehicle with a damaged wastegate?

A3: A damaged wastegate can affect the performance of the vehicle. While users may drive the vehicle, it may lack power due to underboost from the turbocharger. In case of overboost, the vehicle may experience power jerks, which may be dangerous at high speeds. Additionally, overboost can cause long-term damage to the engine and other components, making driving with a faulty wastegate risky.

Q4: Can one upgrade to a wastegate with a larger turbo?

A4: Yes, it is possible to upgrade to a wastegate with a larger turbo. The wastegate works with the engine's exhaust system to control airflow. As such, a larger wastegate will reduce back pressure and increase exhaust flow, resulting in a more significant boost from the turbo. This will, however, require modifications to the vehicle's exhaust system for proper fitment and functionality.

Q5: Does the wastegate require regular maintenance?

A5: Yes, the wastegate requires minimal maintenance to ensure it functions effectively. This includes checking for signs of damage, especially in the valve and actuator, and addressing them promptly. Users should also ensure the wastegate is properly calibrated to prevent turbo overboost or underboost.