2003 ALH No Start

JackG

Well-known member
Joined
Jan 23, 2005
Location
Flemington, NJ
TDI
Jetta 2003 Silver
Performed 3rd timing belt change at 270,000 miles. Started and drove fine. A few weeks later the car started to lose power, eventually emitting white exhaust. Finally, no start. Checked the timing belt first to ultimately figure out that the HUB on the fuel pump slipped. I’m not talking about the pulley that is driven by the timing belt but the hub that connects the pulley and the fuel pump. The position setting on the hub to the fuel pump is set by the factory and cannot be successfully adjusted by us mere mortals. I understand that the older fuel pumps had a key that kept it from turning. I guess they saved a lot of money, by eliminating that key. The shaft and the hub are connected similarly to the camshaft and the cam pulley. So, we bought a remanufactured pump rebuilt by Bosch and warranted for a year.

Installed the pump. Bled the pump and the injector lines. Would not start. Replaced all the fuel lines between the firewall, the filter and the injection pump and return. Installed new thermo fitting on the filter while changing the filter. Installed an inline, reciprocating, solenoid auxiliary pump between the filter and the IP inlet operated by a new relay, triggered by the shut off valve on the IP. It works great but the friggin’ car still won’t start. We’ve swapped the CPU. NFG. New crank trigger, N75, N109, MAF, MAP. Etc, etc!

With the new auxiliary pump, priming the feed lines and filter is a breeze. Still no start. Pulling fuel thru the system, disconnected from the IP inlet and fuel exiting into a clear container, air in the line was noted. Probably a small leak at the elbow at the firewall. Focusing on getting the engine started, we disconnected the fuel lines at the filter on the IP side and stuck them in a container with about a quart of diesel fuel and tried to start the engine. NFG!

Bleeding the injector lines again (1\2 turn open on each tube fitting) produces a lazy flow of fuel. No start. Sprayed some ether into the inlet. Got the engine to turn over briefly. Then nada.

It would be easy to say that it is the rebuilt by Bosch IP and warranted for a year but I don’t want to pursue that yet until I have exhausted all my options. In the back of my mind its something simple … or unfixable. I lean to the former and ignore the latter. I need HELP for my next troubleshooting approach. Please help!
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
No ideas, but replying to get notifications on this thread and (hopefully) find out what the resolution here turns out to be. Sounds like you covered all of the bases I could think of.
 

03TDICommuter

Veteran Member
Joined
Dec 8, 2016
Location
So. Cal
TDI
01' NB, 5spd
Any chance you have the pump out 180 degrees from the cam? That would result in it running with ether but then dying.
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB
Are you getting a glow plug light when key first turned to on position if not then 109 relay.
Are you sure mechanical timing is correctly set , using the lock out tools?
 

JackG

Well-known member
Joined
Jan 23, 2005
Location
Flemington, NJ
TDI
Jetta 2003 Silver
Good thought. That would explain the ether scenario but we were careful to have the cam squared with the tool on the vacuum pump end and the cam lobes facing up in a "V" fashion on the number one cylinder and the fuel pump was pinned in its location point. The flywheel mark was also on line. I think that covers the belt timing but I'm open to any thoughts. Glow plug light comes on when first cranking - not flashing.
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB
The IP pin wasn’t in the “ sucker hole “? That happened to me once , swore I had it in correctly until I verified it with an inspection mirror.
Can you run a separate jug of fuel hanging from the hood directly to the IP, and re-bleed everything, and see if delivery is better at the injectors?
 

JackG

Well-known member
Joined
Jan 23, 2005
Location
Flemington, NJ
TDI
Jetta 2003 Silver
My son and I have questioned each other, step by step on the belt timing, especially the "sucker hole" to no avail. Pumped fuel from an open container of diesel fuel directly into the IP to isolate everything from the filter on back. See paragraph 3 on the original posting, above, for full details. Bled IP and injector lines again. No start. Going to take apart the shut off valve next although it has power.
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB
Ahh I missed that you had a separate fuel container…..
Out of curiosity…… have you run a full scan to see if there are any codes that would prevent the car from starting?
 

JackG

Well-known member
Joined
Jan 23, 2005
Location
Flemington, NJ
TDI
Jetta 2003 Silver
I have the Ross-Tech cable. Being unable to start the engine I get a ton of codes. Too many for my comprehension. Chalked it up to non-start engine. Maybe there is a clue there? Any thoughts would be appreciated.
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
My son and I have questioned each other, step by step on the belt timing, especially the "sucker hole" to no avail.
As mentioned above, have you done the step of putting a mirror at the IP window to confirm that you're looking at a circular hole?


If you've had the pump off, you've probably figured all of this out, but here's the "where's what" on the pump for anyone else who's curious.
 

Genesis

Top Post Dawg
Joined
Feb 26, 2003
Location
Sevier County TN
TDI
'03 Jetta Wagon
Yep.

See that raised square boss on the pump? That's where the correct hole is. If the pin does not align with it you're in the sucker hole. That other hole is far enough off the correct location that it will NOT start.
 

crockit

New member
Joined
May 27, 2023
Location
Gods Country
TDI
03 Jetta
My 03 Jetta quit on the road and i found the wire harness had rubbed through on the top of the transmission fixed with tape and down the road again ! I now have been fighting with the glow plug relay , and have read on TDI FORUM about removing the temp sensor you will get 2 codes , Well i took off the temp sensor and bam my glow plug trouble is gone , so im back the the wire harness on top of the transmission to trace temp sensor wire shorts ! test this - Take the glow plug harness off of the glow plugs put a test light in one of the holes and to- battery turn key to on position for cold start do you have power there ? if not unplug the temp sensor and retest... What has happened to my 03 is the glow plugs work on engine run but not on cold start that ***** wont start with out power there! I have been running a switch by hand into the car for cold starting until to day I was helped by the site so im trying to pay it forward my old girl is still going with 615669k and a Ross-tech cable sent to Canada is about $500 so im hammer mode the IP I found full rich position man does she fly, so now im tapping my way back to fast cold start getting there...... getting there
 
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