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Old August 7th, 2010, 22:02   #1
DaveLinger
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Arrow Help removing VNT actuator from ALH without removing turbo

I'm replacing the turbo actuator on my car, and I've removed the two 10mm nuts holding the actuator "ball" on, but I can't seem to get the circlip off. I have the car on a lift so I can stand under it and see the whole actuator (although it's still hard to get to)

Surely I don't have to pull the turbo to swap the actuator?

Will the circlip come off if I try to pop it off with a screwdriver, or will it spin? Any advice?
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Old August 7th, 2010, 22:12   #2
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No. It'll pop off or spin like most circlips. Have you seen the writeup on my site? http://www.myturbodiesel.com/1000q/a...ate-adjust.htm Many more good info there. Hope this helps.
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Old August 7th, 2010, 22:19   #3
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Yep, I've been using the writeups on there like the bible; extremely useful.

But as far as removing the clip goes, all it has is "There is a small clip holding the rod to the lever arm, remove it."

How would you recommend removing that clip with the turbo on the car? Screwdriver?
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Old August 8th, 2010, 05:30   #4
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I had a tough time removing that when replacing the actuator on a 99 Jetta TDI that I work on. I left it there and disassembled the linkage instead. I just reused the end of the linkage.
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Old August 8th, 2010, 05:56   #5
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Quote:
Originally Posted by rackaracka View Post
I had a tough time removing that when replacing the actuator on a 99 Jetta TDI that I work on. I left it there and disassembled the linkage instead. I just reused the end of the linkage.
ditto that
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Old August 8th, 2010, 07:08   #6
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The only problem I have with that is I will be unable to match the length of the new actuator rod to the old one, as per the instructions. I guess it's do-able as a last resort though.
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Old August 8th, 2010, 09:03   #7
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Quote:
Originally Posted by DaveLinger View Post
Yep, I've been using the writeups on there like the bible; extremely useful.

But as far as removing the clip goes, all it has is "There is a small clip holding the rod to the lever arm, remove it."

How would you recommend removing that clip with the turbo on the car? Screwdriver?
Hello DaveLinger,

Just either use a small screwdriver or dental pick and hold a little magnet next to the clip so when it comes off you have a better chance of retrieving it.

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Old August 8th, 2010, 09:06   #8
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I adjusted the locknut to a similar number of threads on the new actuator arm, and then adjusted the linkage using a mightyvac checking the vnt movement starting at 4 and fully opened at 18 if I recall.
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Old August 8th, 2010, 09:33   #9
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I marked the locknut and threads under it with fingernail polish. Once it's set, I'll remove the actuator from the upper arm as suggested.
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Old August 8th, 2010, 11:05   #10
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you still want to use a vacuum gauge to set the length of the new one.
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Old August 8th, 2010, 16:11   #11
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DaveLinger: I don't know if you got the e-clip off but I took off the EGR and removed the e-clip from the top with a pair of small pliers, actually they were my mini-leatherman. Putting the e-clip back on was a pain make sure you have a couple handy in case you lose one.

I'm trying to adjust actuator right now, but my hand vacuum only seems to pump to 13 inHg and I thought I had the original and new actuator matched. But alas I'm getting overboost conditions in VCDS, so it's trial and error for me. Takes a while as I have to let the engine cool before I adjust the actuator, I burnt my thumb earlier trying to adjust it before letting it cool.
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Old August 8th, 2010, 16:24   #12
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Quote:
Originally Posted by DaveLinger View Post
Will the circlip come off if I try to pop it off with a screwdriver, or will it spin? Any advice?
http://forums.tdiclub.com/showpost.p...50&postcount=4
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Old August 9th, 2010, 00:27   #13
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i used a scribe to pop that clip off...beware, it likes to bounce/fly in odd far away places or get stuck in the tightest spots on your subframe. Keep a magnet, mirror, and flashlight handy incase it does take flight and you need to search for it.

its kind of a pain to put back on because it takes a bit of pressure to snap it in place and due to the tight working space it can take a few attempts to reinstall.
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Old August 9th, 2010, 07:49   #14
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The circlip will probably break if you remove it, have a new one ready
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Old August 20th, 2011, 12:56   #15
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Mine broke when removed via considerable wiggling--and left about a quarter of it behind which eventually fell out after more wiggling. Of course, I dropped the new one when I almost had it on, and now I can't find it!!
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