Cylinder Head Replacement

I recently had a water pump seize on my daughter’s 2000 VW Beetle TDI. The exhaust valves bent so I got the head inspected for cracks and rebuilt. Using careful instructions from this forum, I timed the cam shaft, locked it and did the same for the crank. Long story short, I have it all together now but it won’t start! I did follow the timing belt PDF to a tee (profound thanks to the author). I turned over the engine manually twice as prescribed and everything stayed aligned.
My only hypothesis is that maybe the injector pump got out of time or glow plugs are not working as the the harness looks like hell.
Sincere thanks for any help the forum can offer

Tony

Tony

Did you lock the IP with the pin or just eyeball it?

Did you purge all the air out of injector lines?


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Are you sure you locked the IP in the correct hole and not the false one?
With the pin installed it should be in the 1:00 position.
Verify it with an inspection mirror.

Crack the lines at the injectors and place rags around them and crank the engine a couple of times till fuel comes out then tighten them up, if bled and timed correctly it will fire.

GP’s are not really needed to start the car.......it helps but not really needed.
I’m assuming your doing this in your garage so temps are not be.ow freezing.

Hello, well, I did lock the injector pump! I didn’t purge air! How do you do that? Just loosen one of the injector lines?

Loosen all of them and crank till you get fuel spraying out re tighten and start...use rags to contain the spray

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Awesome! I am confident that the IP was in the correct one o’clock position. I will definitely bleed the fuel system right now! Thanks again

Well, I was just removed the lines and #4 wasn’t even wet. Not sure what is going on but still won’t start. Note: I did remove the IP gear as part of overhaul but it was easier to see the alignment to align the pin. Thanks again

You just took off the belt driven gear and not the hub below it right?

Yes! I did not touch the center bolt! I just removed the belt driven gear

Are you getting any fuel to the injectors?
If not try hanging a bottle from the hood like an IV with a hose to the inlet of pump and try re-priming it.

Got clear fuel lines.
Can you see fuel coming from the tank into the pump?

Not on the NB’s for some reason.

In my case (because I installed a rebuilt IP) I used a MityVac to pull fuel through the IP.
A bit of cranking and she lit.

If timing is correct, my troubleshooting always goes back to checking and verifying these three things:

Fuel - car should start, even if one of the cylinders isn't getting fuel (for whatever reason)
Air - if you had the head off, i'm guessing you looked at the intake and cleaned it up if needed (?)
Heat - check compression. Not enough compression = no heat.

Also, make sure the electrical connector for injector #3 is clean.

Thank you Csstecej, Flee, and Nuje. I verified the fuel lines are clear. I need to investigate why it is not getting fuel. I will keep trying to bleed the system and if that doesn’t work, compression tests and the like. Really appreciate your help and I will follow up when I get it running so it can be there if someone else experiences the same in the future.

Tony

Hey guys- just want to offer sincere thanks to each of you for taking the time to share. You were right - the injector pump was dry as a bone. I bought a cheap harbor freight vacuum pump and started pumping. It fired up as you guys said it would and runs like a top!

That’s what this community is here for....to help one another.
Glad you got it fired up!

I second that

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You guys are the best. Really appreciate everything. This forum makes me love the car even more

Tab3538@hotmail.com said:

You guys are the best. Really appreciate everything. This forum makes me love the car even more

Click to expand...

This forum is a big reason I have my 3 and know so much, not that I know that much but most of my knowledge came from here...I do my best to give back when I can so things like this happen. These cars are amazing and I dread the day I have to try to find another car that I enjoy as much as my mk4s

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Update: Car is running like a top! And after oil change, I didn’t find any metal in the oil which makes me feel better that I didn’t mess up the installation. Thanks again guys!