Model: 1999 Jetta TDI, Manual Transmission, MkIV ALH, 170K mileage.Recent repairs: Water pump, timing belt, tb shroud, alternator belt and assembly (alternator is ok).Recent maintenance: 7K miles ago, oil & filter change; 15K miles ago, fuel filter replaced.Upcoming maintenance: clutch replacement...will be done in 4 days. Car will turn over when attempting to start. All secondary functions off (incl. A/C). Twice, the car started, but only for 2 seconds and then died. Battery is connected to a charger...so full power available as far as I know. When I turn the key, the normal lights on the instrument panel come on.I have disconnected the injectors? (metal tubes running to the block) to 'burp' engine.I have attached hand held device to draw fuel until there are no more bubbles in the line.Tank is half full of diesel. Some sites listed Relay 109 as an issue. I don't know what this is, but am willing to check it if reasonable and accessible. Am looking for any help...Thanks
Hi, my name is XXXXX XXXXX X am at your service to assist with your VW problems.How long ago was the timing belt replaced? My thoughts are that perhaps there are bubbles of air in the pump or fuel injector supply lines that have still not bled out. What you should now do is loosen the fuel supply line on top of the injectors by slacking off slightly the pipe hold down nut at each fuel injector, crank the engine until the fuel squirts out cleanly there. Re-tighten the nuts and the car should now start.Should this not resolve the problem please let me know and we can investigate further.Regards, Martin.
Martin, I have done the "loosen the fuel supply line" and let the fuel squirt out...that was my poorly described "I have disconnected the injectors? (metal tubes running to the block) to 'burp' engine " from above. I have also used a hand pump to remove the air from the line...and still no go...any other ideas?
Hi,When you replaced the timing belt did you lock the fuel pump in with a pin to keep it in #1 timed position? The pump has a tendency to move the moment you remove the belt and this will cause the pump timing to be out. This might be what has happened here so, to check this, remove the top belt cover, turn the engine by hand to fire on cylinder #1, the crank shaft mark and cam shaft mark should line up, and the pump casing hole should line up with the toothed gear hole where you can insert a pin to lock it into position. If it does not line up in this way the pump timing is out. If the pump timing requires adjusting, slacken off the belt tensioner, remove the cam belt, set the pump by locking it into position and then re-installing the cam belt ensuring that the marks are properly aligned when adjusting the tensioner.This should get you going but if you require further assistance do not hesitate to ask.Regards, Martin.