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Stuck Plunger for Engine Control Valve
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tsimek2
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PostPosted: Mon Jan 14, 2019 4:33 am    Post subject: Stuck Plunger for Engine Control Valve Reply with quote

I have a 1965 VW Type 1.

I have a stuck Engine Control Valve Plunger.

I am not sure how I can get it out. All the things I did ended up scoring the tunnel.

Any Ideas would be appreciated.

Thank you,

Tom
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FreeBug
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PostPosted: Mon Jan 14, 2019 10:27 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

I assume you're talking about the oil pressure/cooler control valve?

Well, There is a special tool sold in VW places, or some do it successfully with a wooden dowel, or you can tap and thread the bottom. Why is the oil channel getting damaged?

It's entirely possible that I've completely misunderstood your question, though.
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jason
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PostPosted: Mon Jan 14, 2019 10:39 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

Leave the spring out and start it for a second. It may dislodge itself. Only for a quick amount of time. If it dislodges you wont have oil pressure.
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tsimek2
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PostPosted: Mon Jan 14, 2019 10:44 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

FreeBug wrote:
I assume you're talking about the oil pressure/cooler control valve?

Well, There is a special tool sold in VW places, or some do it successfully with a wooden dowel, or you can tap and thread the bottom. Why is the oil channel getting damaged?

It's entirely possible that I've completely misunderstood your question, though.




You are correct. It's the oil cooler control valve.

It's getting damaged, because I have been using a flat head to take it out and it slips down the channel scoring it.

How would you do it with a wooden dowel?

Thank you,

Tom
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tsimek2
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PostPosted: Mon Jan 14, 2019 10:45 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

jason wrote:
Leave the spring out and start it for a second. It may dislodge itself. Only for a quick amount of time. If it dislodges you wont have oil pressure.


I'm rebuilding this engine. It's nowhere near being able to start. I'm essentially putting all new components to a shell.


Thank you,

Tom
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FreeBug
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PostPosted: Mon Jan 14, 2019 11:03 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

I guess the idea with the wooden dowel (I've never done it myself) is to whittle down the diameter so it's a very tight fit, maybe a chamfer to help it in. Then wedge it into the plunger, the wedge needs to be stronger than the plunger's resistance.

Maybe substitute the oil pressure with compressed air? Not sure how assembled/disassembled this engine is.
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evolks13
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PostPosted: Mon Jan 14, 2019 11:14 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

Try a drill bit or tap that’s close to the same size and see if you can get it to bite.
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PostPosted: Mon Jan 14, 2019 3:28 pm    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

If apart use compressed air
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PostPosted: Mon Jan 14, 2019 3:31 pm    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

Image may have been reduced in size. Click image to view fullscreen.

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tsimek2
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PostPosted: Wed Jan 16, 2019 4:59 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

Dangermouse wrote:
Image may have been reduced in size. Click image to view fullscreen.



The plunger is 4-5 inches into the channel. My taps aren't that long.

This is great to know though.

Thank you.
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PostPosted: Wed Jan 16, 2019 5:00 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

evolks13 wrote:
Try a drill bit or tap that’s close to the same size and see if you can get it to bite.



Thank you.
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PostPosted: Wed Jan 16, 2019 7:29 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

FreeBug wrote:
I assume you're talking about the oil pressure/cooler control valve?


I suspected that too when I first read this, but I typically do not respond when I cannot understand the post. I had never heard the term "Engine Control Valve" in 45 years with these VWs.
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PostPosted: Wed Jan 16, 2019 7:31 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

A 12 point socket on a short extension will fit on the square tang of an M12 tap.
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PostPosted: Wed Jan 16, 2019 8:13 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

I've always thought that the bottom should be tapped for a bolt from the factory. This way, there would be no mysterys, or special tool needed to get it out.
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PostPosted: Wed Jan 16, 2019 9:43 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

esde wrote:
I've always thought that the bottom should be tapped for a bolt from the factory. This way, there would be no mysterys, or special tool needed to get it out.


Yes, and a great idea to tap it before installing it in our engines!
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PostPosted: Wed Jan 16, 2019 9:50 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

What I have done for almost 40 years with these...

I have a few large good quality screwdrivers that are used for the tin screws... These are larger than most you'll see or buy in a set.

I custom ground 1 on the sides so it can be driven into the bottom of the plunger and grabs it firmly with a good interference fit.

I have always been able to retrieve any plunger out of a case... The stuck ones usually have some corrosion built up around them. A little W-D40 and some patience + a back-and-forth twisting action will free them.

-And no, this has never damaged or deformed any of the plungers or damage the plunger bore in any way.
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PostPosted: Wed Jan 16, 2019 10:10 am    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

^^^^^^^
When I worked in a VW shop a big screwdriver was the only thing we used.
They pop right out.
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PostPosted: Wed Jan 16, 2019 1:16 pm    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

Just put a tap on an extension, thread it and pull. Works 99.9% of the time....
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PostPosted: Wed Jan 16, 2019 1:33 pm    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

FWIW - here's a photo of one instance where I put a M12 tap into a stuck plunger, prior to grabbing onto it with a vice grip and yanking it out:

M12x1.75 tap:

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Wed Jan 16, 2019 4:01 pm    Post subject: Re: Stuck Plunger for Engine Control Valve Reply with quote

Cusser wrote:
FreeBug wrote:
I assume you're talking about the oil pressure/cooler control valve?


I suspected that too when I first read this, but I typically do not respond when I cannot understand the post. I had never heard the term "Engine Control Valve" in 45 years with these VWs.


I think "engine control valve" is the exhaust valve. If it drops, it takes control of your engine.
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