chewin up shut off solenoids

[railhor5.9]

2 in 1 week is killin me. they are washin the tip off, wats causin this?

[TWorline]

Crankin up the pump is the culprit for this condition. Time to join the pull cable club!

[KTA]

I think it can be attributed to cranked up pumps and stock injectors. I have never lost a solenoid on one of my pumps but they are all flowing through big injectors. I bought a 92 once that was already turned up with stock injectors and I had to kill it in gear as soon as I got it. I put a set of custom 370's in it and 40,000miles later it still kills with the key.

[SChandler]

I had the same problem with my 92 a couple of months ago. I had the fuel screw set to just below runaway (with stock injectors) and about every 4th time I got on it hard, that was the end of another tip. I finally turned the fuel screw down a 1/2 turn or so and that fixed it (for now) and I didn't notice a difference in power. I know that it is sacrilege to suggest turning down the fuel screw, but at $45 a solenoid, it was worth it. You can try to massage a torn tip back into shape (look up BC847 on DTR, he did a write up there). I tried it once but it didn't shut it down. I don't think I got the end flat enough, so YMMV.

Edit: A warning for you, the Delphi solenoids are not a good idea for trucks that tear tips. The rubber part is pressed onto a little ball on the end of the metal part, and you can suck the whole rubber tip off of it. Ask me how I know. It will leave you on the side of the road with just enough power to drive the truck onto a flatbed trailer in 1st gear. And all of those rubber pieces get wedged, tightly, into a very small hole. You'll need a set of seal picks to get the pieces out.

[921stgen]

Here you go $10= $4 shipping for a vw shutoff soleniod. http://dieselvw.com/PumpSolenoid.htm

[PToombs]

I tried turning the rubber down after I chipped my 2nd one. Chipped it again. So I went one better, I took all the rubber off.
I found out 2 things,
1, there's a hole in the end of the plunger that you have to weld in,
2, it works good 98% of the time, once in a while it still "diesels" to a halt,
3, you have to stretch the spring quite a bit.

4, I never said I could count!

[dragrdan]

Well, I just killed my first kill sol. Delphi's are on the avoid list, any more, or any on the to look for list? gonna try cleanin up the plunger first tho, cheapskate that I am.

pump just below runaway, no probs runnin it hard for the last mo or so.
Installed a DennyT pin, and after the first test drive wouldn't shut off with the key. Injectors are stock AFAIK. so until I get it fixed, I have joined the pullwire club(didn't have any cables available ).

Seems strange that bigger injectors(more fuel flowing) would be easier on the plunger, thinkin it would be opposite. Possibly just a better made plunger?

[KTA]

Smaller injectors create more pressure, which makes for a more violent return pressure wave from the injector to the pump plunger. If the pressure in the injection line is still above the pop off pressure for the injector then the delivery valve will not have closed before the plunger tries to create its next injection event. This results in high pressure fuel blowing back through the delivery valve into the pump plunger. When that happens the plunger is back trying to take in fuel, but pressure in the pump plunger is higher than the case pressure so by path of least resistance you have a high pressure jet blasting out across the shut off solenoid. Bye bye solenoid tip, it wasn't made to be power washed with high pressure fuel.

[dragrdan]

Gotcha,
Any tricks to gettin the solenoid to come loose? Had a wrench on it(needed to remove the throttle linkage bracket), but was slipping. Couldn't get the boxed end on it. Maybe hammer and chisel to break it loose?

[921stgen]

Three way= remove the pump from engine, remove the throttle linkage and grind the rear pump bracket so a wrench will fit on it, or bend a wrench with a torch and a vise to fit in on it.

[PToombs]

KTA, thanks, always wondered why that did that.
Pastor Bob told me once if you let off the pedal easy, it won't chip plungers. Now I know why.

Cut or bend the top of the flat bracket on the pump to break it off. Most guys use a cresent wrench and bend it back and forth 'til it breaks. Throttle bracket and linkage out of the way helps alot.

[Begle1]

Why not just take off the metal plate?

It only takes the removal of a couple bolts to take that metal plate off.

Should I not be doing that?

[dragrdan]

Plate is MIA, have no probs gettin the wrench on it, just wont budge. Wanted to make sure there wasnt somethin lockin it it(other than rust n corrosion) before I got brutal with it

[Ace]

Mine uses the holes in the plate for the IP moving tool.

[KRB64]

Is there any possible damage to letting the truck idle while the ignition is off? I mean, there is no electrical usage while the alternator is not charging while the PCM is shut off correct? I'm talking about for a '92.