Forge K04 Actuator - Info Required

[mpanza]

Hey guys,
I’m doing some research on the Forge K04 Actuator – Has anybody installed this product and seen any positive performance improvements over the OEM Actuator.

Also please recommend the workshop that performed the installation..



I found some helpful info’ from our friends in America, but I would prefer to source local info..

LINK - http://forums.vwvortex.com/showthread.php?4732598

[Tarmac]

People have installed it with the blue spring (18psi) and noticed the difference. Boost comes on strong and is much smoother as its more controlable and the boost controller isnt going nuts trying to keep it at the required pressure. The fluttering that you are probably hearing will be gone as the actuator and N75 valve arent going mental trying to hold more boost.

Installing is a prick. Oil and coolant needs to be drained (well most of the coolant) turbo off. Full days work. Its expensive for a $200 part but for some its worth it. Most who have done it have had the skills to do it themselves which always helps.

What state are you in. Add it to your profile to help the brothers out.

[Lucas_R]

He is in NSW Ben. I met Michael at the dyno day last month.

Hey Michael - i think that either KRA21E or zbeasty have one of these installed on their cars. Otherwise, possibly Parso. Not positive though, but might be worth PM'ing them to check.

If they do, then the fluttering is still there, because i saw all 3x off the above mentioned cars run on the dyno and they were all fluttering at around 3,000-4,500 rpm (including mine).

PS - i think KRA21E has changed his username to Gogi.

[Tim]

I wouldnt mess with the wastegate actuator without speaking to your tuner first. They may not be willing to support it

[Lucas_R]

Some good info here too, read the stuff posted by the Forge guys > http://forums.vwvortex.com/showthrea...e-actuator#top


And someone in the UK who fitted one here > http://www.mk5golfgti.co.uk/forum/in...c,11134.0.html

[mpanza]

Tarmac / Turbo off - i was not expecting this... i was hoping it would be easy like the Forge DV install

Some good points...

As long as you have a HPFP upgrade, and either REVO or APR pump-specific software, it can provide a healthy jump in boost and power. We've seen around 20 peak whp and tq with APR software and around 40 peak whp with REVO software due to the ability to adjust various settings.
GIAC software doesn't seem to like the upgrade very much.

The higher than stock base spring pressure within our replacement units allows for the wastegate flapper to be held closed tighter and for longer against the exhaust gas pressure flowing through the turbo.
Consider that by increasing the boost pressure entering the motor on the intake side of the system, you will see a similar and corresponding increase in exhaust gas pressure that is exiting the motor into the exhaust manifold to spool the turbo. It is a common practice to upgrade the bypass valve to a stronger unit that will better support the increased boost pressure on the intake side, however, you need to also increase the spring tension of the wastegate actuator on the exhaust side to better contain/sustain these higher exhaust gas pressures as well.

With the weaker spring of the stock unit, the exhaust gas pressure can sometimes force the wastegate flapper open prematurely. When this occurs, the exhaust gas that is supposed to be spooling the turbo is dumped, which will subsequently slow the speed of the compressor wheel and limit the potential to make boost in the most efficient manner.

Tightening the stock actuator and adding preload to the stock spring will have the same effect as our replacement, as many people are finding with wastegate tweak mods, but to a much lower degree. You're still working with an altogether weaker base spring pressure to begin with. the stock FSI actuator has a cracking pressure of 4 PSI.

We can assemble our units with any one of 3 different base spring pressure ranges stiffer than stock (10-15, 14-18, 19-24) so the possibility of the exhaust gas pressure prematurely opening the flapper against this higher spring pressure is minimized, if not completely eliminated. All of the exhaust gas is then kept within the exhaust housing of the turbo to continue spooling the wheel keeping boost at it's peak potential at all times.

A boost controller, mechanical or electronic, and including the stock boost control solenoid (N75 valve) will still allow you to adjust up from the base actuator spring pressure, and it will open the actuator when the target boost pressure is reached, but with the stock unit, there is still the potential for the exhaust gas pressure to prematurely force open the wastegate BEFORE the target boost is reached and the boost controller would send the signal to open the actuator.

With our unit, the N75 valve will still function in the same way, sending the pressure signal to the actuator to open it fully when the target boost level is reached, but there is far less chance of the exhaust gas pressure opening the flapper before that occurs.

Depending upon which base spring pressure is used and how the units are adjusted, you may see changes like quicker spool, less tapering, and an overall increase in the area under the boost curve.

[sam_online]

If u need one, I have a brand new with blue spring

[dyljoy]

why u don't need it anymore, Sam

[Tarmac]

because he bought it from me for his K04 and the dumb ass mechanics FORGOT to put it on.

[mpanza]

because he bought it from me for his K04 and the dumb ass mechanics FORGOT to put it on.

Hahaha i wish i was advised about purchasing/installing with my K04 - now that the car is running 100%

Its a big job for extra add on.

Blue or Yellow spring for a tuned K04 ? Blue might be too stiff...