shut-off solenoid gets destroyed!

[carrizog60]

hello

have a friend that installed a aaz pump on his tdi but he has this problem of the shut-off solenoid doesent stay in one piece for too long.
he changes for a good one,averything is ok but if he pulls harder he cant turn if off later because the valve gets destroyed...
never heard of it,anyone can help?

some pics of the solenoid
http://imgur.com/5BIt1q3
http://imgur.com/blet6L1

[410]

Chances are the internal pump pressure is too high.  I would start with the return bolt orifice to make sure it isn't plugged. 

[carrizog60]

wouldn't the pump seals go first?

[410]

Checking the orifice in the out bolt is easy to check without making things complicated.  If the seals are in good shape, they can handle a lot of pressure.  The first thing that seems to be affected is the stop solenoid if internal pump pressure is too high.  The engine might sound a little louder than usual since fuel timing increases with internal pressure.  Tapping in the plunger too far on the fuel pressure regulator can have the same effect.

[carrizog60]

well,might be just that.
he went checking and the orifice was full of rubber bits.

never thought that the seals could resist further than other parts!

thanks!

[410]

well,might be just that.
he went checking and the orifice was full of rubber bits.

never thought that the seals could resist further than other parts!

thanks!

Thanks for posting some results!  Always nice to hear feedback, good or bad. 

[ToddA1]

Was the fix, cleaning out the OUT bolt?

-Todd