Forge actuator to fit kkk24

[dtp]

This actuator available from Forge Motorsport is an uprated performance part. It has been developed by Forge with the help of Tim Williams,and Pyaap off T5D5. I bought one to try on my KKK24 (tired turbo). I have copied and pasted from T5D5

Details of this actuator are now on Forge web site

http://www.forgemotorsport.co.uk/con...oduct=FMACS60R

This is a copy of an email I received from Forge about the spring rates

T2 actuator spring selection guide

The following is general information regarding Forge actuator spring tensions and are important considerations when making a decision on which spring you install, especially if you are running a boost controller or planning an ECU upgrade.
The 4 springs we offer are listed below under their relevant colour codes and related pressures. Running pressure is the lowest or minimum pressure the spring will operate at, which is important when considering which spring you choose. The spool up pressure relates to the vacuum pressure required to lift the spring from its static position, at which point the turbo waste-gate will start to open (spool up).
The actual rating for these springs is as follows, the lower pressure being the spool up pressure and the higher pressure being the running pressure:

RED 17 psi (spool up) - 20 psi (running pressure) our product code FMAS049R.
BLUE 14 psi (spool up) - 18 psi (running pressure) our product code FMAS049B.
YELLOW 9 psi (spool up) - 15 psi (running pressure) our product code FMAS049Y.
GREEN 5 psi (spool up) - 10 psi (running pressure) our product code FMAS049G.

The spool up can be altered to a higher pressure by adding more tension to the spring. Be careful not to add too much tension to the spring as it will become coil bound, affecting the rod travel and thus affect the waste-gates ability to open effectively. Running pressure cannot be adjusted by adding pressure to the spring.
Mount the actuator to the actuator bracket on the turbo and wind the turnbuckle into a position 3mm short of the spigot on the waste-gate arm, requiring you to pull the rod into position over the waste-gate spigot.
Do not add more than the recommended tension as this will cause the spring to become coil bound, preventing the waste-gate from opening properly. There is a common misconception that the operating pressure of the spring can be increased by mounting the actuator rod to the waste-gate arm in such a way that the spring is under more load than the recommended above.


I have a S60R with a 2.4 engine, ported head, forged rods, FMIC, water injection, (currently injecting 80% methanol & 20% water with an Aquamist HSF2 progressive injection system) Farrita down pipe/cat back, cleaned Std green injectors and a MTE custom map The last rolling road showed 370 bhp, but the car was only boosting to 1.2 bar. My turbo is very tired and on it's last legs.

I bought an actuator last week off forge

Update....

I have had the Forge actuator on my desk for about a week now. Tim advised me not to fit it to my knackered turbo. My turbo is on it's last legs.It whistles quite bad. Tim has a second hand KKK24 that he is going to fit to my car with the Forge actuator when he has time.

Well as the wife was working and I was left babysitting I was a a loose end. I decided to fit the actuator as I thought my turbo is already knackard it can't really do any harm.

I stripped everything out, air box, MAF heat shield, top engine mount bar, and MAF to turbo pipe. When I took this pipe out, the thingy-me-bob valve where the big breather is clamped on was not seated in the pipe properly so it was pulling in air. This couldn't have helped things.
i removed the original actuator and put the new shiny Forge one on.

I had previously put 3 turns on my old actuator as I have always had less boost than was mapped for the car 1.2 bar instead of 1.45. Even when I put the extra turns on, it still only boosted to 1.2 bar, I had to take my foot off the loud pedal then floor it to make it go up to 1,45 bar, but then almost immediately it settled back to 1.2 bar. Taking the old actuator off I had to pressurize it to 10 psi (0.7 bar) to undo the adjusting nut. That is almost double the pressure from standard.I set the new actuator to 7 psi (0.5 bar) because if 0.3-0.4 bar was not enough I would have to wait till the engine cooled down to make any further adjustments

The new actuator came with a red spring fitted as requested by myself and a blue spring in the box because I did not know which spring would suit my map.

I fitted a new TCV as I change them every two years and it was due.

Now the test drive.

The first 15 miles of gentle driving so the ecu could learn. I held it at about 0.5 bar . I had my DiCE connected and was running live data for: TCV duty cycle, Boost pressure, Air intake temperature, Fuel pump pressure, And AFR. I don't know why I selected these because I don't really know what I am doing with the DiCE yet. Anyway the car has been transformed. When the car is under load I get 1.55 bar spike then it settles to 1.45 bar mid range is smoother. it was difficult to watch the data, but the maximum TCV duty cycle I saw when car was in 5th gear at 5000 rpm foot planted was 68% i didn't see it go over the figure. Ambient air temps were 26c and air intake was 33c.

To say I am well chuffed is an understatement. When Tim can fit it in for the turbo I am sure that he will be able to fine tune my set up.My old actuator must have been knackered for quite some time because all the maps that I have had on the car have always (to me) seemed lazy compared to others with the same mods.

I was seriously considering a Garratt 3071R turbo before I fitted this actuator, but for now I am going to put this idea on hold. I want to see how it drives on track.

Thanks to Tim, Ashok, and Forge for developing this brilliant piece of kit. The Forge actuator has brought the best out of my map. Highly recommended......

[ROZER]

i have been looking at replacing my actuator for a while but they dont seem to do one for my s60 t5 2003 16t

[Santa]

Thanks for the info Dave. Heres a pic of it fitted.

[graemewelch]

Did you notice any difference when you fitted yours. Im considering one

[dtp]

They make one for the 19t. When I picked up my actuator John Withers said they have developed actuators for other turbo's but not had time to update their web site. Phone John Withers at forge and ask him

[MattM]

Sorry for the stupid question, but what is the benefit of this over the standard part?

[dtp]

I can only say through my experience. The kkk24 actuator is not available on its own you can only buy it with a brand new turbo. Actuators get tired, springs go weak then they don't do the job they are ment to do. I have proved this in my 1st post. Ok mine is mapped to 1.45bar my actuator had done 100,000 miles and it was so tired it could not hold the boost. I was getting 1.2 bar and holding. As soon as I changed the actuator I got the full 1.45 bar boost and it could hold it.

Even std tune cars will Benifit from replacing the actuator

[960kg]

Don`t understand why you cannot get the actuator seperate for the KKK24......you can for the 12..T14T..16T..18T..19Tetc and it is direct from Sweden for about £202 with 10%off + 20% VAT

I went for the Forge Recirculating Valve first as no point in losing extra boost that you have paid for by buying the adjustable actuator first.

This valve suffers the same extremes as weak spring / tired diaphragm.......I found by doing this my boost was holding steady at what i set it at without the more expensive actuator. As it`s a piston valve it holds all the boost given by the turbo and keeps it steady.....

I suppose i may still get the actuator for the 16T when available, although you can fit the Nissan one to your own actuator bracket and save about £50....

[dtp]

I also have the Forge recirc valve. The Forge actuators are £138 + vat. Very good price for an actuator.