Exhaust manifold stud.. What is going on with this?

lamboworld

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Feb 16, 2014
Location
Tarheel
TDI
2006 Jetta TDI
I bought an engine cover for my BRM and I was removing the rubber inserts and found this when I was removing the one on at the rear of the engine. How has this stud pulled out of the head? I guess that could have missed screwing it in when I installed my turbo earlier this year but that seems unlikely since the nut is on the stud. It also appears that the stud is stripped and it also looks like I have an exhaust leak. This stud is on the drivers side and the one closest to the top of the motor. It looks like the stud is possibly broke. Ideas?

 
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hughesjasonk

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2002 Jetta MK4;
I was a betting man I would say that the stud backed out which is not necessarily uncommon

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lamboworld

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Tarheel
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2006 Jetta TDI
Looks broke. Can’t you reach it with some needle nose or something?
I attempted to pry it out with a screwdriver and that didn't work, but I haven't had a lot of time to deal with it. I plan on removing that heat shield to see what is going on. I agree that it looks broke and I am not sure what I should do if it is.

I am not sure how an 8mm stud could just break.
 

banshee365

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FL
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06 Jetta
It probably wouldn’t break unless it was over torqued. I’m work on Ford mod motors a lot so broken manifold studs are an everytime occurrence. Lol

Hopefully it backed out as mentioned above.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Nissan, Ford, and even a few Toyota and GM products are notorious for that sort of thing. Volkswagens are not. So I'd say it is due to an improper install. There should have been a flanged nut or a washer behind the nut on there.
 

lamboworld

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2006 Jetta TDI
Nissan, Ford, and even a few Toyota and GM products are notorious for that sort of thing. Volkswagens are not. So I'd say it is due to an improper install. There should have been a flanged nut or a washer behind the nut on there.

I installed a new PD140 this year and Andrew Rodriquez suggested that it is not necessary to replace the studs. This was probably a mistake.

I am not sure why it would be necessary to use a washer if using a new crimped copper new. Maybe that is what the manual calls for but not sure why it would be necessary.

Regardless, it looks like I am going to at least have to remove the heat shield and see if I can replace the stud. If not, then I am going to have to pull the turbo and just replace all of the studs.
 

oilhammer

Certified Volkswagen Nut & Vendor
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Location
outside St Louis, MO
TDI
There are just too many to list....
Every VAG engine built in the last ~25 years or so that I am aware of uses a fat steel washer with that type of nut on the manifold/turbo to head OR uses a flanged self locking nut. Never like you have.

Since I have never seen the OE way (above mentioned) fall apart as in your picture, I can only call on Occam's Razor and say that the incorrect use of hardware is the reason why it came apart.

You did not need to replace the studs.
 

lamboworld

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Location
Tarheel
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2006 Jetta TDI
So here is the update. I removed the turbo and the stud was broke. I was able to get a hole drilled in the stud and I got lucky and was able to extract it.

I bought new gaskets and a good stud kit. I believe that this stud kit is for a Porsche, but I was able to get it for about $40

I removed my EGR cooler and cleaned my intake manifold when I installed this turbo earlier this year. As you can see my intake is as clean as it was when I cleaned it 15k miles ago.









 
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