Changing a Tial Diaphragm/Spring Cup Assembly

Has anyone ever changed one of these before? I have a V44 wastegate and it appears as though the diaphragm has been pierced when I test fitted the bolt in it :

I've looked around and you can get the diaphragms as a service part, but if they are that tricky to do/need specialist equipment then I'll look into sending it to a dealer over here.

Also on a side note, the dash 4 ended banjo's I'm now using are a little shorted in height than the ones that come suppplied. Am I ok to use two washers between the banjo and wastegate?

Edit: Quick how to guide in post #7.

I took a HKS one apart once (& I believe the diagphram can be purchased seperately for those) so there's no reason why you can't if you can get hold of a new diagpgram.

Becarefull taking it apart though, the tops come off with some force due to the spring inside, I undid the bolts & it was siezed on, so I tapped the top with a hammer, it shot across the garden

Has anyone ever changed one of these before? I have a V44 wastegate and it appears as though the diaphragm has been pierced when I test fitted the bolt in it :

 

http://i201.photobucket.com/albums/aa39/Casey-Kev/ResizeofTialWastegate004.jpg

 

I've looked around and you can get the diaphragms as a service part, but if they are that tricky to do/need specialist equipment then I'll look into sending it to a dealer over here.

 

Also on a side note, the dash 4 ended banjo's I'm now using are a little shorted in height than the ones that come suppplied. Am I ok to use two washers between the banjo and wastegate?

Ref. the washers Kev. I'm thinking a Dowty washer would be more appropriate. They are quite a bit thicker.

No idea on the wastegate question I'm afraid.

What are you doing working on the car on New Years Eve anyway. Go down the pub.

I took a HKS one apart once (& I believe the diagphram can be purchased seperately for those) so there's no reason why you can't if you can get hold of a new diagpgram.

 

Becarefull taking it apart though, the tops come off with some force due to the spring inside, I undid the bolts & it was siezed on, so I tapped the top with a hammer, it shot across the garden

I've already removed it, but thanks for the warning Jay.

If anyone ever does read this prior to removing the top, make sure you undo the bolts a little at a time, and opposite each other, a little like undoing a wheel

Ref. the washers Kev. I'm thinking a Dowty washer would be more appropriate. They are quite a bit thicker.

No idea on the wastegate question I'm afraid.

What are you doing working on the car on New Years Eve anyway. Go down the pub.

I'll look into a Dowty washer, thanks Andy. I'm on anti-biotics so can't drink until Saturday

I've already removed it, but thanks for the warning Jay.

If anyone ever does read this prior to removing the top, make sure you undo the bolts a little at a time, and opposite each other, a little like undoing a wheel

 

 

 

I'll look into a Dowty washer, thanks Andy. I'm on anti-biotics so can't drink until Saturday

bummer. Hope you're better soon.

Looking more closely at the connection and that washer seems quite thick anyway. As thick as a Dowty.

You can get different thickness coppers. I try never to use two washers. That's a personal thing though.

Wish you a happy new year and a hangover Sunday.

bummer. Hope you're better soon.

 

Looking more closely at the connection and that washer seems quite thick anyway. As thick as a Dowty.

You can get different thickness coppers. I try never to use two washers. That's a personal thing though.

 

Wish you a happy new year and a hangover Sunday.

It's nothing big, just tonsilitus over the Christmas holidays . I'll certainly be feeling rough on Sunday

The washers are thin, just think the camera has reflected the two washers that are already fitted.

Happy new year to you too

Just for future reference, a 4mm allen key is required to undo the 6 bolts inorder to open the top of the wastegate.

Once inside, you'll need a 2mm allen key to undo the 4 grub screws:

With all 4 removed, you'll need to 'wiggle' the spring cup assembly off. The diaphragm membrane is simply laid in the gap and comes off easily:

In this picture you can clearly see where the grub screws are located once fitted:

Simply reverse this process to fit the new diaphragm

Rather than copper I would use fibre washers or a dowty seal or two. You need to torque up banjos quite hard to seal on copper washers, especially if they are a bit hard, and the banjo is going into soft alloy....

Will fibre washers take the heat of the area the wastegate is in?

Yes, for sure, it doesn't get that hot in the diaphragm chamber.

Cool (literally)