[xlipower]

Hi

Big problems. I have lost more or less all turbo boost, and know the cause - the inlet on the actuator that controls the wastegate has rusted and broken off. Meaning the tube is of, and not controlling the wastegate at all.

Left it at mechanic yesterday in hope of the actuator being changed today - but he now tells me that the part is not possible to get, only along with complete turbo. That is insane - turbo is fine, it is only problem with small inlet on actuator...

My question - anyone know if it is possible to get this anywhere (ebay etc)? I'm thinking more people than me must have had this problem, the actuator is rusted because of Water has come in somewhere. Probably same thing with all 2008 i30 CW 1,6 CRDI.

[xlipower]

By the way - picture of the problem here

https://www.dropbox.com/s/86gnnfhai81zpru/IMG_2966.jpg

[Aussie Keith]

What happened under there that its so nasty rusty??

[Asterix]

The problem is it's mounted as you see it on the pic. It allows Water and dirt to stay for long time in that recess, thus the hose connection will rust over time.

I have filled the recess with Pava, a rust protective.

Isn't there a specialised garage somewhere near, Odense maybe, where they do Turbo's...

That actuator must be available without buying the complete turbo.

[bloodnut]

If the rusted actuator is not under massive pressure,  maybe vacuum only, could you clean the rust & epoxy the pipe back on, braise or tig weld it back on?
Cheers Bloodnut 

[Dazzler]

If the rusted actuator is not under massive pressure,  maybe vacuum only, could you clean the rust & epoxy the pipe back on, braise or tig weld it back on?
Cheers Bloodnut 

 

If it is easy to get off, maybe you could get it gently sandblasted then do as above ... 

[Keith]

Ooooh that'll is pretty grievous to me!

Have any other with the same model noticed this propensity to hold water and quickly rust away?

[Phil №❶]

 

I'd be manufacturing my own connection by cleaning the rust making a robust connection using a solid plate and epoxy the whole plate over the actuator, provided it is only subject to vacuum.

Looks like salt damage to me.

[Just Rick]

being 2008 and warranty no longer applies,surely there are many aftermarket actuators which would fit, 

[Asterix]

Hi

Don't know the exact type of turbo on the i30, but is this of any use...

http://www.ebay.com/bhp/wastegate-actuator

[rustynutz]

I think I've read elsewhere on the forum that it is a Garrett.... 

[Dazzler]

I think I've read elsewhere on the forum that it is a Garrett.... 

 

[xlipower]

Thanks for the replys. My mechanic tried a temp fix which partly fixed it, so tomorrow I will attempt to improve this fix, as I have found a small plate with a tube coming up the middle. I will attempt to epoxy this on, and then seal with rtv silicone.. Hope this does the trick, at least until I locate correct part..

[xlipower]

By the way, if anyone have the possibility to read anything on the top of their actuator, I would really like to know if there are any numbers that can be used to track down correct one.
 (I cant read anything on mine because of the rust)

I am right know waiting for my epoxy fix to cure, think it will actually fix it, but would still lile to have the actuator replaced ofcourse.

[potnodleman]

have you tried the scrapyard/breakers yard for a 2nd hand one?

[agentr31]

garret would sell them... (i think its a garret turbo)

if i can get different actuators for my normal turbo, im 100% positive you could get that new from a PROPER turbo repair shop.

[agentr31]

ohh and WHY is your engine bay so corroded... i would hate to see the rest of the car! do you store it in salt water when you are not using it?

[xlipower]

Think main problem is climate in Denmark. And then crappy design from Hyundai, which lets water in where it shouldnt. The thing is, when the roads starts freezing during winter, they use salt on the roads, and this ofcourse causes corosion...

Funny thing is, I have a second car, a 2005 Suzuki Swift, and this is in much better shape everywhere than the newer i30. So starting to be a bit disapointed by the quality of Hyundai:(


I have managed to make a air tight seal now, but the actuator is not working quite as it should. I hope this is caused by corosion inside the actuator, and not lack of vacuum, because thats where my talent stops.

I used epoxy glue and some metal tube to make a new connection, and it is completely airtight, but when i test it by making vacuum with just my mouth, it need quite a lot of vacuum to contract fully. But ofcourse, I dont know what normal condition is.

It seems turbo is not damaged, as, if I manually move the arm that the actuator controlls to fully opened/closed or whatever, and then blinds of the inlet tube so the arm stays, the turbo is generating normal boost when taking a short test drive.. Ofcourse I did not force it, but i could feel that turbo kicked in around 2k rpm, instead of 3-3500 as before..

But I need to figure out if sufficient vacuum is being generated. When i pull of the tube and engine is idle, and I put my finger on the end of the tube where vacuum should be, i can bearly feel vacuum. But that is of cause at idle, I cant rev it while in the engine bay, so dont know if vacuum comes when engine is reved.

From what I can see, it takes vacuum from the brake booster? But havnt investigated that much yet.

[xlipower]

Ahhh I learned something now, and fixed it.

Realized, something must be making the vacuum, like a pump. So figurede out where it was, and confirmed vacuum was generated to the brake booster. Then i saw a small t-splitter, and thought maybe that one is causing the problem, so I unscrewed it, tried blowing into the place where the tube for the actuator was connected, and as expected there was a blockage. So, i cleaned it out, tried blowing again, and now there was flow. Reinstalled, checked actuator was now moving when starting engine.

Out for a drive, and wonderfull turbo boost is there again..

Yes, all this might seem logical for the average mechaninc, but I am actually a electronic machaninc, normally working on radars and radio equipment on ships, so this is a little out of my area;)

Thanks for all the inputs..

[Keith]

Well done  xlipower! 

[Phil №❶]

 

[tohis]

I can imagine the feelings if complete turbo would have been replaced like suggested by mechanic, only to find out that few thousand Euros were just spent for nothing... 

Anyway, nice to hear that you found out what the real problem was, but you should still try to find new actuator.

[Asterix]

Well done  xlipower! 

 

[agentr31]

good on ya champ! i would be contacting a turbo shop and organising a new actuator asap!

[Dazzler]

 

Funny thing is, I have a second car, a 2005 Suzuki Swift, and this is in much better shape everywhere than the newer i30. So starting to be a bit disapointed by the quality of Hyundai:

Does the suzuki get as much driving on the salted roads though?

[xlipower]

Yep, they are exposed to more or less exactly the same driving, as my girlfriend drives the i30, and I the Swift. We work 2 miles from each other, but my work time varies, so we have to have two cars. But the miles they cover each day are very similar and same conditions.. So fear I have to say, the Suzuki is a bit better quality. However the Hyundai is a way better overall car, sooo much more comfy.. The swift is like a go cart :-D

[Dazzler]

Yep, they are exposed to more or less exactly the same driving, as my girlfriend drives the i30, and I the Swift. We work 2 miles from each other, but my work time varies, so we have to have two cars. But the miles they cover each day are very similar and same conditions.. So fear I have to say, the Suzuki is a bit better quality. However the Hyundai is a way better overall car, sooo much more comfy.. The swift is like a go cart :-D

Thanks, that is interesting.. Bit of a fan of Suzuki. we had a 1986 ML Holden Barina (which was a rebadged Suzuki Swift) and that was really well put together and went really well. Just a bit small when my first Daughter arrived. 

[Doggie 1]

So glad we don't have salt on the roads over here.

[Aussie Keith]

So glad we don't have salt on the roads over here.

Sure we do:

http://www.patrol-log.com/2013/01/29/video-car-emerges-from-foam-almost-hits-two-officers/

[Zhangster]

oh boy...

i just noticed this on my car... still going fine... but the actuator is rusted badly and the host connected to it... seems... " Loose" i think is matter of time before it pops.....  would be nice locate a replacement ... and not a complete turbo....
:-/

any news on this subject would be nice...