wastegate service

this is the key to have a pleasant to drive 208 turbo with KKK turbocharger. Pictures are before and after the service of my wastegate valve: thanks to the KKK technician (the F-chatter Morcal) that developed that engine with Ferrari, or we never had learned it was a critical aspect to check. My mechanic thanks him too, as he never knew the importance of properly serivicing that valve: until now he just checked if it opened at the correct pressure and cleaned it outside.

With everything in factory standard and with this wastegate properly serviced (not easy to do at all) you will have a car smooth, very pleasant and relaxing to drive and very powerful too: in one word, excellent.

In picture there is my silver 208 GTB wastegate service: the change of look is like the change of performance at low and mid RPM.

Thank you very much again, Morcal: you explained us what to do to have it perfectly working.

ciao
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Very informative. Nice post, thanks for sharing.

 

Always impressed by people who do things like that. I can't. Great work.

/Peter


Waste gate?
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Critical to turbo systems!!

Great post!

That was indeed quite dirty!!

 

I like it!

At Indy, called a Pop Off Valve, as the spring pressure predetermines the amount of "total boost" the system will see.....

So, there, you hope for a "stronger spring" although they are "supposed to all be the same"

 

Thank you again, Alberto, for making the contact to ToniAuto at Maranello.

My rebuilt Wastegate will arrive next week to be installed at the twin of your car.
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Mind that wastegate comes from a 64000 km car (40 k miles) gently driven. You had to see what there was inside Markus (2281GT) wastegate and in my red 208 GTB turbo with Modena plate... They were a disaster: this one, before the service, looked like a mirror if compared to them...

unfortunately your one was a disaster. Toni even had to cut the screw. Of course it had a huge amount of bypass flow throug the seat. They are sorry, but they couldn't remove a small damage there is on the body, that won't affect the walve working but won't look as perfect as it should.
Your engine should improve a lot until 3500-4000 RPM with this wastegate service: My cars did.

ciao

 

that wastegate is set to open at 0,6 bar (official factory data). But I saw with a pressure gauge on a shop table that it opens between 0,7 and 0,8 bar. The safety pressure switch cuts the ignition at 0,9 bar.

That thing, if 100% serviced, gives 220 Hp, just 10 HP less than an Euro drysump and more than any carbed USA 308. And more than the Euro three liters 2 V injected engines too. Not bad for a 1982 just 2 liters engine.

ciao

 

That's what turbos do!

My technician maintained an F40 a long time, never made any money it was VERY har to access components..but, a FUN ride!!

 

Ciao Alberto,
thanks for the appreciation and your valuable support in Maranello. A proper working Waste-Gate valve is crucial for torque development in small displacement turbo engines; it has to stay tight closed until the set boost is reached. In case of exhaust gas leakage ( you noticed the heavy corrosion on the valve seat ) you have delayed engine response and poor car acceleration. Once the boost is reached the WG shall control through its spring rate / valve lift the exhaust gas flow by-passing the turbine. So enjoy now your turbo cars and do not forget to run smoothly a bit after a hot stint to permit cool down of the turbocharger!

PS. I see my blue GT4 in the picture background, now is back home.

 

A wastegate will control the boost pressure and is incorporated into the exhaust side and will open the valve and bypass exhaust gases from the turbo flow, it is controlled typically with a spring and also a supply of the boosted inlet air.
The pop off valve such as used at Indy was a valve bolted onto the intake plenum, it was calibrated to open at the 'legal' boost pressure and vented to atmosphere. When they opened it took a while to recover full legal boost. Many tried and did figure out ways to overide especially in qualifying. A famous Texan among them.

 

Ok, got it. But I was close, sort of.
/Peter

 

I have a 930 and I know that some owners (not myself) added a knob on the dash such that you could adjust the waste gate for more boost. I had heard that these knobs lead to the early demise of the 930 engines and the turbos. Thus the practice was discontinued and KKK came out with a more potent turbo for the 930 which seems to have been a better aftermarket alternative to the boost knob.