Stuart's Volkswagen GTE Forum

Hi Stuart, I've read with interest your article on replacing the charge flap locking actuator and intend to follow your method when the spare part arrives. My issue is that the actuator has failed in the locked position. No amount of pushing/pulling on the charge flap whilst locking/unlocking will free it. Before I get into the job, once I remove the grille, will the defective actuator be able to removed or will it need to be broken free? I would obviously not want to damage the grooves on the flap itself with which the spindle seats once closed and locked. Any help/advice you can give would be much appreciated. Michael.

Hi Michael,

Thank you for your message.

I have to admit it’s a couple of years since I replaced the charge flap locking actuator on my GTE so my memory is a bit poor.

I remember that the actuator shaft rotates as it moves in and out and so the best way to try to release a stuck actuator would be to repeatedly press on the VW emblem. This will put a little rotational force onto the actuator shaft which, after a few attempts might free it. But it sounds like you have already tried this. Can you spray some lubricant like WD40 behind the VW emblem using the little straw you usually get? You might get some on the shaft which might help. I admit I have not tried this as fortunately my actuator didn’t stick in the locked position but knowing what I do now, I think this is what I’d try.

Failing that, once you get to the back of the charge port and remove the screws holding the actuator in place, again you might be able to rotate the actuator to and fro and maybe free the shaft. Failing that, I guess all you could do is use a tool like a Dremel to cut the old actuator away. Eventually you should be able to get to the shaft and rotate it. Like you say, this should ensure the seat in the emblem is not damaged.

Good luck. Please let me know how you get on because I guess I was lucky last time and if/when the actuator stops working again, I might be in the same boat as you.

Stuart

Good morning, Stuart

Thank you for taking the time to reply so quickly. Your detailed response was extremely helpful and I am happy to say that the charge port actuator on my GTE has now been replaced.

I enlisted the help of a good friend who is slightly more accustomed to working on vehicles than I am. Within about 15 minutes and using your guide, the job was done. As we expected, the failed actuator had to be broken apart in order to free it from the port flap, but once it was out of the way, the remainder of the procedure was child's play. We used a water pump wrench to break into the old unit and the innards looked just like those in the one you removed from your vehicle. Very badly corroded!

As a preventive measure, I applied a liberal dose of grease to the plunger and the sides of the new actuator, hopefully to prevent moisture getting into it. I am reasonably confident that this will now see out my ownership of the car.

The next job will be to look into greasing up the lower arm bushes which may alleviate the creaking/groaning sounds that I hear when going over speed bumps. This is a minor annoyance but it does detract from the enjoyment of driving the car.

On the whole, I've been pleased with the GTE, if a little saddened by the apparent depreciation in value over the mere 10 months I've owned it. That said, it costs very little to run and suits my 25-mile daily commute rather well. Octopus energy have a very cheap off-peak smart charging deal and my electricity cost for the car is less than £5 a week.

With thanks again and good wishes,

Michael.