1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)

[CRSMP5]

looks like it is somehow "completing" a ground and welding/arcing the plunger.....

good laugh for ya... got back fri... a few nights ago i turned it off to fill up and it did not die... scratched my head.. tried again and shut off... im like hmmmmmm... well sat i goto take a passenger home.. no go.. nothing.. no smoke.. but got power... need to pull mine now to see what wrong.. my guess stuck.. since it stuck open... few nights ago... but 6500ish miles.. 10 days of driving...

oil... all i can say i hate little turbo... the 10-15psi constant boost for 6k+ has caused oil consumption issue... started before towing... but a good 2500 in... ~1qt to 250ish miles... or a oil seal failed in the turbo... every boost pipe connection is moist... breather too..

she gettin few days off... deserves it... only screwed me thurs am... checked my coolent level wed.. pinched the rad cap o-ring.. this made a leak.. abt 1am in bfe i camped at wally world till i could find a solution... junk yard next day, $20 bill... parts stores = 8$ but 2 days away.. used cheap vs motel... freeken cold...

[8v-of-fury]

Haha yeah man I read your thread and checked out your site! Awesome roadtrip!!

The plunger is fully rubber so I dont see arcing as the issue.. Ill be pulling number two today to check it out.

[theman53]

Maybe that rubber is the issue? The one in my Giles pump I swear was all metal.

[8v-of-fury]

How would metal seal off the fuel flow?? I an sure you just thougt it were metal. So did I until recently.. And Ive had like 75 of these apart lol

[theman53]

no, I am not 100% sure, but I swear it had the black coating peeled off to reveal a shiney substance underneath. Probably not, but could swear it was.
If yours is getting ate that bad, you should find it easily. I would wonder if the 12v is consistant. Maybe run a jumper for 3 days and pull it to see if there is any kind of wear. Easy enough to try. I am guessing that maybe if it is not getting the perfect ammount of 12v it could be half open and just eating away?

[libbydiesel]

The end that seals against fuel flow is rubber.  The tube the spring is in is metal.

[CRSMP5]

yea i can reply...... think how it works... gotta be metal... ive never seen one with rubber/plastic... oil pumps work metal on metal... all it does is restrict flow till dies..

[8v-of-fury]

yea i can reply...... think how it works... gotta be metal... ive never seen one with rubber/plastic... oil pumps work metal on metal... all it does is restrict flow till dies..

Lol well it is most certainly rubber!

[libbydiesel]

LOL!  Anyone doubting the rubber-ness needs to pull their stop solenoid plunger, scratch the end of it with a utility blade and post up a pic of the shiny metal... 

[RabbitJockey]

LOL!  Anyone doubting the rubber-ness needs to pull their stop solenoid plunger, scratch the end of it with a utility blade and post up a pic of the shiny metal... 

It's shiny rubber not metal duh

[8v-of-fury]

Yeah it took me ten days.. But I have since replaced my plunger yet again with a good used OEM. So here is what I bring from my findings..

The second one has been destroyed in the same fashion as the first. Upon replacing the plunger i took a good strong light and took a peek in to the distributor head. No burs sharp edges or anything that is chewimg these up.. I also cleaned out my OUT bolt with shop air, but it was already free of debris. I have not since rechecked my case pressures, but I know I did when i installed it and I had normal pressures then. Another thing I thought that maybe the actual solenoid is at fault not pulling the plunger in enough and it getting sucked down.. So i put in a known good spare.

With a new solenoid, plunger and clean mating surface as well as out bolt.. I dunno what else it could be if it happens a third time.

[theman53]

If you are just replacing the plunger each time, then it is the stop seliniod itself. Change the entire thing if it happens again.

[8v-of-fury]

This time I have replaced the solenoid, plunger and spring with a different good unit.

[TylerDurden]

As bizarre at it may sound, it looks like the stopper is being chewed off by the HP plunger. That would mean the bore/seat is bigger than normal, letting the end drop all the way into the plunger barrel. I'd pull it and measure the seat & bore vs. the stopper.

I'm surprised the ground up junk isn't plugging the injectors.

[ORCoaster]

Tyler, don't you know that will be his next thread.  How do I get embedded rubber gunk outta my nozzles.  Maybe it hasn't run long enough for him to notice it.