Figured out how to fix a fuel shut off solenoid with some pics a link confirming this and of course Josh pointing out the link to me! I'll post pics as soon as I can, tweaking right now and will post pics ASAP. I basically tore off and drilled out the stock rubber on the "stopper" and "plunger", so, I also tapped it for a screw and put a modified valve cover grommet in and will have to remodify one so it will fit better, like I stated pics will follow so all can save anywhere from $80 to $120 and reuse their Bosch one.

Fix your fuel cut-off solenoid - Dodge Diesel - Diesel Truck Resource Forums

Pics of my own and my fix to follow tomorrow or tonight, whichever may occur!



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Fixed it, but with epoxy, the screw kept the grommet from sealing so, and did not have enough grommet to go around to play with so I had to epoxy it in place, thinking now to use the manual kill lever to stop the engine though, and use this port as a larger fuel inlet port.

 

There are plenty of $10 FSS available from many VW TDI parts houses that work just fine.

Personally, I've had very good, reliable results with simply sanding down the original plunger tip.

 

Mine had too big a chunk missing to do that with unfortunately, I tried that first. LOL

 

Brandon, BC847 is the one who made that link on dtr.

 

I had a friend machine me an all metal one. It worked in my old pump but I have a new II pump and I'm not opening it up until after the warranty is up.

 

OK?

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The link is a first option, what's the big deal?

 

I did it on mine n ran it for 8k km with no problems.

 

I wasn't saying my idea was better, I was just pointing out ways to fix the damn problem.

 

If you really want to fix it just get bigger injectors, and then you won't have back pressure from little stock injectors blowing your plunger. Just a thought.

 

That's in the plans, LOL!