Damn.... Yeah there should be a disk attached to that arm that covers the exhaust bypass hole, get a flashlight and look down into you cat it is probably sitting right there on top of the honeycomb element inside the cat. I think they are rivited together, that was probably the problem all along.

Now get to drinkin'

 

Yeah you're right it was down there. Good thing I have a fiber optic thing and a long reachy graby thing. This sucks, sucks bad. The stem is definately broken. Can this part be replaced or does the entire turbo need to be replaced?

 

i cant answer this question^^^^^
but i can say ko4 is written all over it.
GL i hope you can fix it.
if you have no luck getting a response let me know... i can find out from my friend at the dealer tomorrow what you can do.

 

i cant answer this question^^^^^
but i can say ko4 is written all over it.
GL i hope you can fix it.
if you have no luck getting a response let me know... i can find out from my friend at the dealer tomorrow what you can do.

Well I hope someone can answer soon. If not there's a VW Audi dealership that I pass on my way to work in the morning so I will just ask them. Thanks though.

 

I may try and weld it back on....but I can't even figure out what it is made of. It's not magnetic. Looks kind fo weird.

 

It may be ceramic? As far as reattaching goes I have no clue but it is probably some sort of rivet. As far as replacement goes I have no clue, if your dealer doesn't have the part in stock or can't help give Richie at autobarn mt.prospect a call do a quick search to find his number. Either that or depending on where you live there may be a local turbo rebuilder that may be able to help. (they normally work on big diesels)

 

Well I hope someone can answer soon. If not there's a VW Audi dealership that I pass on my way to work in the morning so I will just ask them. Thanks though.

They probably wont do you any good sadly. If you have a faulty wastegate the dealer will tell you they dont replace just the waste gate and you need to replace the whole turbo...which is probably the answer you'll get from them if you go in with that question.

I second the K04 mention .

 

Never mind my initial post, you can replace the wastegate ACTUATOR (www.ecstuning.com) but not the wastegate, it's part of the turbo.

But since you're there.... I'll 3rd the K04.

-Cody

 

The wastegate can be replaced, but not by yourself, it has to be taken in service. But the repaircharge may be higher than a low milage k03. Get a K04, you won't regret it, I have one and I love it.

 

Check this out. You may be interested.

http://www.passatworld.com/forums/showthread.php?t=202055

 

btw, your wastegate should look like this:

 

If you didn't install the wastegate yet, return it and use it towards a K04. I saw one in the classifieds for $695 shipped.

 

ARen't those the rivets you have to heat up and bang on to expand; it's an interference fit.

The disk is likely stainless alloy, which is why it isn't magnetic. (Try it on a SS appliance; magnet doesn't stick.)

 

Alright guys thanks for the suggestions. As much as I'd like a K04 this isn't my car and I know my dad wouldn't want to spend $800 for another turbo plus $400 for software and injectors also. So here's what I did:

I drilled a 4mm hole completely through the valve and tapped it. Then ran a bolt all the way through and put a big washer around it on the arm side. Then two nuts and cut the bolt off at the end of the nuts. I also peened the end of the bolt so the nuts can't come off. So as long as the bolt/nuts don't melt it will be just dandy. It's definately worth a shot since I was going to put it back together anyways until I got another turbo. So I'm pretty positive this is going to work.

 

nice job:thumbup:
hope it works
nasa is calling

 

I think it will work... hopefully. Nice work! :thumbup:

-Cody

 

Got it all back together, drove it hard for 20 or so miles and so far so good! I'll report back if/when it blows.

 

Given the constant bombardment of high-temperature steam-laden exhaust, I unfortunately do not think your repair will last very long. However, it should hold together for some short amount of time, and I congratulate you on your ingenuity.

I'd start the shopping for a used K03...

SirWired

 

If anyone cares the turbo still works a year later.

 

Nice job. I love solutions like this one.

Oh, and Journey rocks.

 

good to know!

 

Very impressive!

 

I am impressed ,too

 

:thumbup: :thumbup: :thumbup:

Did you use SS bolt, nuts, washer?

 

thats baddass. chalk one up for a diy wastegate thiinging fix

 

nice job, the peening over of the bolt end is what separates this fix from being an ordinary ghetto fix.

excellent job :thumbup: