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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old September 13th, 2018, 14:49   #1
WildChild80
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Default 3 point socket

If I had a junky 6 point 24mm socket and ground every other flat spot all the way to round, would that work to get that plug out? Maybe I'm a cheap'o but 20 bux is expensive to rent a tool...I understand some of that is shipping but if I can make one for almost free I'm all about that and I'm out in the boonies so no help from bigger shops that might actually have one

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Old September 13th, 2018, 17:07   #2
AndyBees
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What plug are you trying to get out?
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Old September 13th, 2018, 17:26   #3
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That big plug in the middle of the injection lines

I've got a leak on the IP and I think it's that plug or whatever it is

Already changed the pump head seal twice and the QA is sealed now...replaced the crush seals under the nipples in the pump head, still a fast drip

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Old September 13th, 2018, 17:52   #4
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You need to leave that plug alone.

If you have a leak it is the O-ring on the pump head ... the cast iron thingy with the four injector line fittings!

To my knowledge, there is zero Threads here that guide you through removing that big nut or what ever it is called.

The re-seal kit, which has more than you'll ever need, costs less than $20.00 shipped. Also, Runobeer has a very good video and write-up how to change the pump head O-ring.

Lastly, the rubber gasket for the top piece (forgot the name) and the next one down also comes in the kit. The top one is known to leak.
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Old September 13th, 2018, 17:56   #5
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Scroll down the page in this link for pics and narratives of when I changed the big O-ring on the pump head. It is fairly easy but can become a catastrophic goof if you mess up (pull the head out too far).

http://forums.tdiclub.com/showthread...276798&page=52
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Old September 13th, 2018, 18:12   #6
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I've already changed that seal

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Old September 13th, 2018, 18:12   #7
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Twice, I thought I messed the new seal up

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Old September 13th, 2018, 18:16   #8
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There is a wet spot coming from that plug down to the bracket and that's where it drips, I took the bracket off to confirm it's not coming from the pump head seal

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Old September 13th, 2018, 18:25   #9
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Hmm.

Well, I'm at a loss as I've never seen anything about removing that plug for a re-seal.

Maybe an experienced guru will chime in here.

BTW, I'll send out those notes, etc., on the schematics in the morning.
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Old September 13th, 2018, 18:53   #10
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Thanks Andy

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Old September 13th, 2018, 21:08   #11
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It can leak from there (3 sided)

http://forums.tdiclub.com/showthread.php?t=346928

Check out the other link in there too (post 3)
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Old September 13th, 2018, 23:14   #12
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It's just a plug, nothing will fall out when it's removed. Has an o-ring that sees case pressure and a knife edge seal that sees injection pressure. I've read it's a one time use part but I've reused it.

Grinding a socket will work but I don't know what size.

You sure it's not the leeetle center plug?
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Old September 14th, 2018, 06:35   #13
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While it's not as common of a seal to leak, they do fail. As mentioned, that plug is technically a 1 time use. When I worked at a fuel shop, we would inspect it and most often it was safe to reuse again. The knife edge gets crushed so depending on how crushed it was determined whether or not it would be reused. Odds are you'll be fine.



I think that plug gets torqued to 100 ft-lbs.



If you search on VWdiesel.net you'll find the proper sized socket to cut down. It's the same plug on the older IDI engines. It might be in the FAQ over there.



Or spend $33 and have all the tools you need
Amazon link
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Old September 14th, 2018, 15:25   #14
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I looked and I couldn't find anything using Tapatalk anyway...I found some chrome vanadium sockets in my toolbox, 15/16 and 1 inch and I'm sure I can make one of those work...and I had 20 bux store credit on my AutoZone card and their Dremel was on sale, didn't want the Dremel just the tools inside but it didn't cost me anything...

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