Broken turbo stud

n0.j0y

Active member
Joined
Jan 19, 2024
Location
connecticut
TDI
2002 jetta gls tdi
hello everyone as you already read i’ve snapped a turbo exhaust stud and i honestly don’t know what to do; would it be possible to remove it and put in a new one? or what would be better?.

it is the stock turbo and was bolted on to the stock down pipe i needed to replace the flex pipe end but ended up snapping the stud with the nut.
 

ts888

Veteran Member
Joined
Feb 18, 2023
Location
PNW US
TDI
03 ALH
Do you have room to drill it in situ? If not, you can remove the turbo and drill it on the bench.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
Pretty sure you would need to pull the passenger side axle and use a right angle drill to attempt it in situ.

I would try welding a nut to the broken stub.
 

n0.j0y

Active member
Joined
Jan 19, 2024
Location
connecticut
TDI
2002 jetta gls tdi
update i got the broken stud out it’s took a blowtorch and some pb blaster, i also welded my egt sensor to where the egr cooler would get the exhoust gas from it isn’t the best placement and it won’t get the exact temp but i will be replacing the turbo to a 17vnt so i’ll weld it on to tht ; On a different topic where would be the easiest and smartest way to get boost readings (it’s for a boost gauge).

Also i know there’s a way to simplify the vacuum lines and all the stuff to the n75 thingys ( i don’t know what there called atm) does anyone know how?
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
The hard plastic pipe that runs from the intercooler to the intake manifold is a good place to tap for a boost gauge, or you can tap the manifold itself.

EGR delete vacuum diagram is here:

 

Shenandoah

Veteran Member
Joined
Jan 9, 2008
Location
Shenandoah Valley, VA
TDI
2005 Jetta Wagon; 2005 Beetle; 2004 Jetta; 2002 Golf (three of them); 2002 Jetta Wagon; 2000 Audi TT->TDI; 1999 Beetle
You might consider getting rid of the vacuum ball also.

Eric
 
Top