Zip tie mod how to?

Mozambiquer

Veteran Member
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI
I've been trying to find a how-to on the zip tie mod, I guess there used to be one on myturbodiesel, but it appears to be gone. I've used the search function both here and with regular old Google and I find a lot of people talking about it, but no how-to. My main question is how much vacuum to use. I kinda get the jist of the rest of how it works and all.

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dae06

Veteran Member
Joined
Oct 27, 2009
Location
Rushford, Minnesota
TDI
Jetta 2005.5 1.9
I've been using this mod for 4-5 years now. Every once in a while the zip tie breaks and I need to redo it.

Good luck, it's really not too tough once you do it.
 

Mozambiquer

Veteran Member
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI
I've been using this mod for 4-5 years now. Every once in a while the zip tie breaks and I need to redo it.

Good luck, it's really not too tough once you do it.
How much vacuum did you apply before installing the zip tie?

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dae06

Veteran Member
Joined
Oct 27, 2009
Location
Rushford, Minnesota
TDI
Jetta 2005.5 1.9
It was a trial and error process. When I finally got it tuned in, I ended up using 11" (I believe) zip ties and used 3 clicks on the zip tie.

For some reason I don't recall needing the vacuum pump (its been a while since I did this), I think the actuator is up until vacuum is applied and then lowers and this is when the zip tie limits the actuator from going too far.

After knowing the correct length of zip tie needed, I sized my zip tie, squeezed the zip tie to make it long and flat and pointed to push down and lassoed the actuator on the turbo from the engine compartment and hooked the other part of the zip tie over the vacuum port as shown in TDI73's first picture. (his zip tie mod was done with the turbo off, so he didn't need to form (squeeze) the zip tie to lasso the actuator)

I hope this makes sense. It still takes a little patience to get it hooked, but really isn't too tough.

I can definitely tell when the zip tie breaks, I lose power at take off and produce black smoke.

I hope this helps
 

prsa01

Veteran Member
Joined
Aug 16, 2000
Location
mpls,mn usa
TDI
14 jsw 6m, 96 B4v, miss my a4 :(
FWIW - because I had read of people's zip-ties breaking and it was easier for me to get around the actuator I ended up using fairly heavy stiff wire. Got it the shape needed to loop around and back up.

I didn't have a vacuum pump available so just forced the actuator fully extended and then sized the wire to shorten its extension by ~ 3/8 inch. If that amount didn't do the trick I would have adjusted more.

Apparently I hit close enough. It ran great that way for the 2 years I owned it.
 
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