ok, what is the best tool and way to remove the fuel cutoff switch on the IP

[peterdaniel]

HOLY tight as all hell Batman... what do I need to do and how to get this damn cutoff switch off the IP???

 

[Nero Morg]

Are you talking about the nut that holds the wire in, or the entire solenoid itself? I usually use vice grips on the nut, but if it's the whole solenoid, deep well socket and a biiiiig ratchet.

 

[peterdaniel]

Yah the entire 24mm nut.. sheezus its super flipping tight

 

[PakProtector]

Use a good 6-point on it. You will be decidedly unhappy if it gets rounded off...

Of course I spent most of my tool collection money on 6-point...due to their better ability to deliver torque to a nut...and VW seems to have some special affinity for 12 points.

Douglas

 

[tdidieselbobny]

If you have a 6 point socket and an impact driver(get some adapters to fit socket if needed, not sure if they have 3/8" drive 24mm 6 point sockets). I think I used a box end wrench when I did mine years ago, was a real PITA with the hard fuel lines....

 

[peterdaniel]

Yah, Im thinking Im gonna have to use a open ended special box type of wrench.. unless I take the fuel lines off which cant be that hard...

 

[burn_your_money]

I don’t think you can get the box end of a wrench around the stop solenoid with the QA on the pump. Even a thin wall socket is unlikely.
Why are you removing it?

 

[peterdaniel]

ive pretty much determined its the cause of my low power because of it restricting my fuel flow..

 

[Andyinchville1]

HI,

Just curious but of you remove the fuel cut off solenoid from the pump is it possible to eliminate the solenoid alltogether by plugging it with a bolt or something and shut the pump of in a more manual way ? (like an old school choke cable on a shut off lever or some mod to the hole that the solenoid was removed from?).

The reason I ask is because on the first gen dodge pickups , the Cummins rotary pump fuel shut off solenoid could be removed and the pump had a shut off lever you could rig a choke cable to to manually shut off the engine (I'm not sure our pumps have something like that (in theory , the first gen dodges could run forever without a battery or alternator for hard core reliability if that mod was done .... I know our TDIs would die once juice ran out and the electronics in the computer died but I figure removing one more electric draw may let it run a little longer in a worse case scenario),

Andrew

 

[Nevada_TDI]

Andy, you ask some of the best questions here.

 

[PakProtector]

No lever for these beasties Andy. The 12mm pump head is not w/o its charm, but they are a bit big to fuel all the way if you turn them past 3000 rpm I think. The dose of fuel they could deliver at lower speed would make clutch selection a bit more difficult...LOL
cheers,
Douglas

 

[burn_your_money]

HI,

Just curious but of you remove the fuel cut off solenoid from the pump is it possible to eliminate the solenoid alltogether by plugging it with a bolt or something and shut the pump of in a more manual way ? (like an old school choke cable on a shut off lever or some mod to the hole that the solenoid was removed from?).

The reason I ask is because on the first gen dodge pickups , the Cummins rotary pump fuel shut off solenoid could be removed and the pump had a shut off lever you could rig a choke cable to to manually shut off the engine (I'm not sure our pumps have something like that (in theory , the first gen dodges could run forever without a battery or alternator for hard core reliability if that mod was done .... I know our TDIs would die once juice ran out and the electronics in the computer died but I figure removing one more electric draw may let it run a little longer in a worse case scenario),

Andrew

The AAZ engine from 92?-97? had a lever that you could modify to do as you describe. It had nothing to do with the shut off solenoid though, it manually pushed the governor assembly to no fuel.
I think some of the Bosch pumps have push solenoids that would fit in place of the pull one. I’d bet you could rig that up.

 

[fatmobile]

Right, and you wouldn't replace the stop solenoid with a bolt.
You would just remove the plunger and screw it back into the pump.
Then if there isn't a stop lever on the pump you could also kill it with the clutch.

 

[Mongler98]

Low power from fuel issue at ip? Sounds like you need a keystone mod

 

[tdidieselbobny]

Low power from fuel issue at ip? Sounds like you need a keystone mod

Never heard about doing that on ALH pump, only on the 1Z/AHU pumps....

 

[KLXD]

Why bother trying to mod the solenoid at all? The TDI shuts down by the QA setting the fuel to zero, the solenoid is redundant. Then there's the Anti Shudder valve also on the ALH.

No manual replacement is required.

Just remove the plunger if it's causing a problem.

 

[peterdaniel]

I WOULD... if could get the damn thing OUT.. PITA!!!

last thing im trying is a flare nut wrench because a simple 24mm aint gonna cut it.. will totally strip and round the sides

 

[jimbote]

I WOULD... if could get the damn thing OUT.. PITA!!!

last thing im trying is a flare nut wrench because a simple 24mm aint gonna cut it.. will totally strip and round the sides

smear some valve grinding compound on the flats of the nut and wrench then give it a try.