List Your Homemade VW Specialty Tools Here!!!!!!!!

Technical questions and answers concerning all models of VW diesel vehicles.

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Re: List Your Homemade VW Specialty Tools Here!!!!!!!!

Post by Nevadan »

Right on the misalignment, the picture above that one looks like it's lined up good so I'm not sure what he did. I just know it's difficult to get that inner one in the correct position.

He did take some excellent procedure pictures showing all the detail.
1985 Jetta 1.6 TD
1981 Caddy (getting a 1.6TD)
1987 Quantum Syncro Wagon, converted to 2.0 TD August 2020
1986 Passat TDI
2006 Touareg V10 TDI
1996 CHevy 6.5 TD
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Voltmeter hack

Post by sgnimj96 »

portable voltmeter

81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
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Re: List Your Homemade VW Specialty Tools Here!!!!!!!!

Post by 30dodgeboy »

I needed to change the head O-ring on another VE pump while it is on the car, previously I used the procedure from libbybapa (thank you!) ... sc&start=0

but wanted a little more forgiving procedure to hold the parts in place with a spring while the head is separated enough to change the O-ring.

tawney has designed really nice tool but I wanted one simple enough that I could make up quick with parts and tools I had around - essentially hardware-store type stuff. Of course this design requires welding.
business end.jpg
M8x1.0 Hex Head Cap Screw (HHCS), ~25mm long, fully threaded
M8x1.0 plain hex nut
1/4"NPT steel coupling
3/8-16 coupling nut
3/8-16 HHCS ~1.50 in long
compression spring, ~5/16 OD x 1.75 long, rather stiff
duplex nail (16d ??) with top head ground away

I drilled the M8 HHCS through the center on the drill press with a 3/16" bit. I cut off the pointed end of the nail so that when it is bottomed out in the HHCS, it projects 1.62" into the pump (to ensure it keeps pressure on the pump parts when the head is separated just enough to completely expose the O-ring). The M8 nut is to lock the tool in place in case it can't be threaded all of the way in. The 3/8" HHCS is threaded in or out to adjust the amount of spring pressure. When it is threaded in substantially, its barely possible to compress the nail plunger with your thumb. These dimensions were determined to be used when the pump was stopped on the "top" of its cam stroke.

This tool made the in-the-car job quicker and easier, so I figured I would share it here in case anyone else wanted to make their own or offer suggestions to improve upon it.
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Re: List Your Homemade VW Specialty Tools Here!!!!!!!!

Post by tedshark »

I have these tools most are custom made for timing, compression checking, and valve guide compressor.
I have no need for these tools I have them for sale on offerup, but I'm willing to give them away to someone on here if you want to pay shipping.
If you contact me on offerup type the word FREE1 so I know its someone on here.
80 VW Rabbit Pickup 1.6 Hydraulic with 1.5 Non Hydraulic head
98 Subaru Legacy Wagon AWD
94 Ford Bronco F351/5.7
99 Plymouth Grand Voyager
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Radiator cap tester

Post by sgnimj96 »

Just take a bicycle pump and take the end off the fill hose.
Remove the overflow hose from the nipple on the reservoir.
Push the bike pump hose onto the reservoir nipple.
Hold the end of the overflow hose closed with your finger and
pump the system up.
The pump gauge will tell you at what pressure the radiator cap is releasing
and you should hear it leaking air out at the cap.

Gotta love the ease of this one and the value of knowing the rad cap actual pop-off pressure!
81' Scirocco 1.6D (conversion)
86 Golf 1.6D
85' 300TD
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