2002 VW beetle GLS TDI cranks but won't start or dies 1 second later

[STDOUBT]

Yes. It's a process...but very important to do it. Doesn't have to be perfect, and there are a few
different methods. Click on "Search" in the upper right.
I put the words clean intake ports into the search field and got this page:

Search results for query: clean intake ports

forums.tdiclub.com

Enjoy!

 

[STDOUBT]

Here's a good thread from a while back:

How to I clean intake ports in head?

Hi Folks, I got the EGR cooler and intake pulled off the 03 Golf last night, and the intake is mucho plugged. Much worse than my 03 Jetta Wagon was. So, in looking at the intake ports in the cyl head, they're also very caked/dirty. I know I can't really clean them in-place, so I guess...

forums.tdiclub.com

I used loop knives as used by ceramic artists. Compressed air, oven cleaner, even a garden hose.
If I had to do it again all I would do is the knives and compressed air. And you need a mirror, and flashlight.
And of course, to make sure the valve of the port you're working on is closed!

 

[Clawfamily7]

Thank you!

 

[BobnOH]

Anything along those lines is good. Just don't allow any chucks/debris fall inside the motor (vacuum).

 

[Clawfamily7]

Is there a good video for putting cylinder 1 at TDC? I think i need to see it done, but YouTube doesn't have anything specifically for a manual 1.9l TDI ALH, and I keep finding sales posts mostly on the forum.
The cam lobes are at the top but form a straight line, not a v

I'm just getting to cleaning the intake ports. I took the IM to a local shop for cleaning and they said it was completely clogged. The EGR valve hole size was down to about a nickel or dime before cleaning.

The intake ports really aren't bad. Maybe 1/16" of buildup just at the lip. I'm going to just knock that down, but hesitate to start because I'm not sure how to set it to TDC. Passenger side tire off and compressor and air fitting ready to go

 

[jokila]

Is there a good video for putting cylinder 1 at TDC? I think i need to see it done, but YouTube doesn't have anything specifically for a manual 1.9l TDI ALH, and I keep finding sales posts mostly on the forum.
The cam lobes are at the top but form a straight line, not a v

I'm just getting to cleaning the intake ports. I took the IM to a local shop for cleaning and they said it was completely clogged. The EGR valve hole size was down to about a nickel or dime before cleaning.

The intake ports really aren't bad. Maybe 1/16" of buildup just at the lip. I'm going to just knock that down, but hesitate to start because I'm not sure how to set it to TDC. Passenger side tire off and compressor and air fitting ready to go

Look at post 18 for the diagram that shows a manual or automatic transmission flywheel marks. Simply rotate the crank with a 19mm 12 point socket until the mark lines up as indicated.

For the cam, you need the lock tool that fits in the slot on the rear where the vacuum pump attaches to verify it's at its TDC location. The V that is being referenced is if you are looking at the cam lobes and visualize a line through the centerline of each lobe. The would intersect to form a V.

 

[STDOUBT]

Yes. Pretty simple on this car, no video required, but an attempt to make it plain;
->Turn crank clockwise until flywheel mark lined up (you have to remove the black rubber stopper to see the flywheel).
->Remove vacuum pump from head, and stick the "lock" plate in there. The channel should be horizontal!
(page 39 in this document)
->Put the pin into the injection pump lock hole (beware the sucker hole). It's in-line with the squareish boss on the top of the body of the pump. (pages 91 and 92 in the same document)
If all those fit nicely, you're at TDC. You'll notice (with the valve cover off of course) the lobes on cyl#1 are pointing upwards, equally, from the plane of the lifters faces.
déjà vu!

 

[Clawfamily7]

Probably a dumb question, but where is the black rubber stopper located?

 

[STDOUBT]

Right where you'd think the flywheel would be, top of the tranny next to the block.
Might have to crane your neck a bit

 

[Clawfamily7]

So my husband finally got around to trying to weld the hole he drilled and resulting crack in the IM. Its not working, so it looks like I'll be buying a new or new to me IM. Is there really that much difference to have the PD150? What conversions, conversion pieces would I need for it?

Would it hurt To put the old IM back on improperly sealed just to see if it will crank after cleaning out all of the boogers?

I buy, fix (usually smaller less involved repairs) and flip cars. This one I'd like to keep a little longer as a run around car for me or my son, but it may not be around for too long. Or it may. I haven't decided yet. I had a '73 super beetle over 23 years ago that I loved. I have always wanted a diesel.

 

[STDOUBT]

There's an ALH manifold on ebay right now for $60.
Item #164329069061
Looks like a good seller too!
I wouldn't bother with the PD if you're at all unsure about the car as a keeper.
Get her running stock and ship shape, see where you're at. IMO

 

[Clawfamily7]

There's an ALH manifold on ebay right now for $60.
Item #164329069061
Looks like a good seller too!
I wouldn't bother with the PD if you're at all unsure about the car as a keeper.
Get her running stock and ship shape, see where you're at. IMO

Thanks STDOUBT!

 

[Mongler98]

OMG THIS THREAD
so much triggering about things you never do to a TDI. like handel the nozzles, trying to clean some of the intake without cleaning the head
OMG NO STOP PLEASE YOUR KILLING HER!

 

[Clawfamily7]

I ended up having to order a new-to-me IM. I can get all but one of the 6 bolts into the holes to attach it to the engine (all new bolts) the one that won't bite anything to start pulling in the bolt is the one I used my rocket socket on to get it out because the allen head hole was stripped. Any tips on getting a bolt back in??

 

[Clawfamily7]

It looks like the first couple of threads are stripped on the engine head. I don't know how to upload the pic. Any suggestions for the engine head threads?

 

[STDOUBT]

Welcome to the world of thread tapping.
Take the bolt with you to a hardware store, pretty sure it's a M8x45mm.
Ask for a Tap that will bore to its size, thread pitch exactly.
You might get lucky and not have to over-tap to a larger size and use a helicoil.
The critical thing is to verify the thread pitch you need.

 

[JB05]

Could the fuel sender be clogged?

 

[BobnOH]

Pretty sure this car has multiple issues. I'd get it to run first, then go after the low power. Perhaps the new intake will get it it to start, run and idle correct.
VW TDI Search Engine

 

[Clawfamily7]

Could the fuel sender be clogged?

Its possible, but I already replaced it

 

[Clawfamily7]

Pretty sure this car has multiple issues. I'd get it to run first, then go after the low power. Perhaps the new intake will get it it to start, run and idle correct.
VW TDI Search Engine

Yeah, I know its multiple issues. Trying to tackle the biggest and see where I need to go next. I'm hoping I can get it to start once I can thread tap the last engine head intake manifold bolt hole and put it all back together. It'd be REAL nice if it clears up the majority of the issues, but not counting on it. I've tried to fix up too many cars at this point to believe that

 

[drucifer]

It's easy enough to pull the sender out as long as there's a small amount of fuel in the tank. I recently cleaned mine on a bew though. 90 to 95 percent blocked but still started and ran fine. Feel the bottom of the tank while you're there.

 

[Clawfamily7]

It's easy enough to pull the sender out as long as there's a small amount of fuel in the tank. I recently cleaned mine on a bew though. 90 to 95 percent blocked but still started and ran fine. Feel the bottom of the tank while you're there.

Already did that. It was one of the first replacements I did. Hasn't run since before I replaced it