Need input on turbo issue. K03?

[veedubcanuck]

  So my 93 golf (aaz) has a seized wastegate, I tried everything. Took the downpipe off to access the actual valve, soaked the shaft with penetrating oil and let it sit and tried to work it loose...nadda. Then I heated the housing at he bushing and bushing with an oxy/acetylene torch until it was red hot and still could not get it to budge so I finally gave up before I break it. Right now it is stuck closed. The issue is it runs like 20-25 lbs of boost all the time which can't be good! Sooooo, what I have done is replace the rubber elbow between turbo and intake with a copper elbow and hose. I added a barb to the elbow and made an adapter to fit the diverter(BOV) off a 1.6td from another engine. It doesn't let the boost go over 14lbs now. Will this be ok or am I still going to kill the turbo??? I don't know what else to do.... from the looks of it pulling the turbo is a royal pain..... Should I be ok like this?

Thanks guys.
 

[jtanguay]

the bov is a bad way to control boost.  the wastegate is the best option.  i filled the inlet of the wastegate on my turbo with penetrant to free up the wastegate.  just take off the hose and spray some into it.  i wouldn't use wd40 as i heard it eats seals.  it might work for you.  you also might want to try applying shop air pressure and testing for leaks etc.  also check the linkage arm as it might be seized up a bit too.

[veedubcanuck]

It's seized IN the turbo(the actual shaft of the wastegate), not the actuator or linkage.

[jtanguay]

It's seized IN the turbo(the actual shaft of the wastegate), not the actuator or linkage.

how did you verify that?

[veedubcanuck]

Because with the linkage disconnected I can move the actuator rod and not the shaft in the turbo.

[burn_your_money]

The K03 turbo is not that hard to remove. You need a 12mm 12pt 3/8th socket.

The last 3 K03s I had all had seized wastegates as well. I managed to get mine loose though

[jtanguay]

Because with the linkage disconnected I can move the actuator rod and not the shaft in the turbo.

hmmm theres a rust check product at cdn tire to free up rusty stuff.. might wanna give that a try.  i forget what its called, but it freezes the part so it shrinks.  sounds good in theory 

[zukgod1]

Remove the turbo and fix it.

Your over speeding it the way you are running it now.

Over speeding will result in a broken shaft. If you dare ask me how I know...

[Rabbit TD]

Do you all up in Canada have PB Blaster, it seems to work about 98% of the time.

[OM617]

A BOV to limit boost is a guaranteed way to grenade your turbo from over speeding.