Car stalled while going 45mph

Tylas

Member
Joined
Nov 4, 2010
Location
Fowlerville, MI
TDI
2002 Jetta Sedan
I was going down the road at about 45mph on Thursday night about 5 miles from the house. Didn't hear a sound, just saw my engine lights turn on and coasted to a stop. It was able to turn over, but not start.

Initially I was thinking that it may have been the cold as it was -3F Thursday night and may have a bit of gelling problem. I replaced my fuel filter yesterday and attempted to heat the engine with a heater today, but still can't get it to start. I am now thinking the cold may not be an issue, as it is 24F right now and the heater seemed to warm it up enough to not be a gelling problem.

Can anyone give me any pointers of what to look for to get this thing started? As long as I get the engine to spin and fuel to it it should start right?

Would like to get this fixed before the next bout of super cold weather hits Michigan...
 

Tylas

Member
Joined
Nov 4, 2010
Location
Fowlerville, MI
TDI
2002 Jetta Sedan
I reset my engine light to see what was going on (it's always on). Only the usual water temp sensor I need to replace. My timing belt has about 80k, was planning on doing it this spring summer. Think this may be an issue?


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Tylas

Member
Joined
Nov 4, 2010
Location
Fowlerville, MI
TDI
2002 Jetta Sedan
The car turns over fine enough. I have had to recharge the (very new) battery because of the cold and the attempts to start it.


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Jesus Is Lord

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Jan 24, 2014
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Hersey, MI
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2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
No Start

Hi
Do you see lots of smoke out of the tailpipe when you are cranking?
 

Tylas

Member
Joined
Nov 4, 2010
Location
Fowlerville, MI
TDI
2002 Jetta Sedan
Looked at the belts, all seems and turns as it should.

On Thursday night when I stalled I tried to get it going. I was able to get it going under high rpms but as soon as I came off the accelerator it stalled. When doing so it threw a ton a smoke. Today it doesn't have anything out of the tailpipe.


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Jesus Is Lord

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2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
How long (approximately) does your glow plug light stay on?
 

Tylas

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Joined
Nov 4, 2010
Location
Fowlerville, MI
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2002 Jetta Sedan
About 10 seconds. To try to get it warmer in this cold weather I will sometimes turn ignition on and off a couple of glow plug cycles. They were replaced last summer so hopefully they are still good...
 

Jesus Is Lord

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Jan 24, 2014
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Hersey, MI
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2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
Do you know how to set engine to TDC (Top Dead Center)? If you can, check and make sure the injection pump did not jump a tooth.


If it is not smoking, check and make sure there are no air bubbles in the clear line to the injection pump.
 

Tylas

Member
Joined
Nov 4, 2010
Location
Fowlerville, MI
TDI
2002 Jetta Sedan
I will see if I can figure out the TDC, see if everything is up to snuff.

That is interesting, because there is pretty much no smoke coming out. I did replace the fuel filter yesterday thinking it may be a gelling problem. I am also going to put some Diesel 911 in the tank to make sure.

I did unplug injector 2 to make sure diesel is coming out and it is flowing. I'll let you know, but probably won't work on it until tomorrow - it is dark and now so cold!
 

Jesus Is Lord

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Jan 24, 2014
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Hersey, MI
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2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
To set engine to tdc. there is an inspection window over the flywheel housing.

the number one cylinder needs to be on compression stroke so if everything does not match up turn the engine over one revolution.

If it is an automatic transmission you align the mark on the flywheel to the bottom of inspection window.

If it is a manual transmission there is a mark in the middle of inspection window that you align the mark to.

After you set engine to tdc
There is a hole in the injection pump pulley that goes through to the engine block. If you can slide a pin through the pulleys hole into the block then timing is ok. If the pump is off a tooth it will be very obvious.

Also did you check for air bubbles in fuel line?
 

Jesus Is Lord

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Hersey, MI
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2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
If you want to see if cam is in time you can pull off the vacuum pump. The notch in the end will be parallel with the head when engine is at tdc. If it does not line up rotate engine on revolution.

And the fuel sending unit that was mentioned in previous post. I replaced it in our jetta as a precaution. but it will not make the car shut off while driving. It will only make the car hard to start.

If you need any more help with tdc I can probably help.
 

curtludwig

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Winchendon, MA
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1998 Jetta, 2005 Golf
I had what I think was a case of icing the other day where my Mercedes wouldn't start. I got the engine good and warm (warm to the touch) and it still wouldn't start. I think the pickup in the tank has ice on it preventing any fuel flow. You might try pulling the line from the tank, put a vacuum on it and see if you can get any fuel.
 

CopaMundial

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Jan 30, 2011
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Southeastern PA
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03 Jetta Wagon 5sp (New to me Oct 2014) 03 Jetta 5sp (RIP Aug 2014)
And the fuel sending unit that was mentioned in previous post. I replaced it in our jetta as a precaution. but it will not make the car shut off while driving. It will only make the car hard to start.
No drama, but this is not accurate information.
If the fuel sender gets clogged then it presents all of the symptoms of fuel starvation and yes, it can stall a running engine.

That's not to say that it's the cause in this case, just pointing it out as a reference point for others.
 

MyAvocation

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Jun 9, 2004
Location
Hoffman Estates, IL
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2017 Passat SEL TSI
If the fuel sender gets clogged then it presents all of the symptoms of fuel starvation and yes, it can stall a running engine.
+1. Happened to me while cruising down the highway at 15*F.
If your fuel sender part number ends in a letter less than "H", I'll bet defective check valve is the problem. Drill it out or replace the sender. Part number is on top of sender, so remove black access panel under back seat to eyeball it.
 
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AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
There's no need to glow the GPs two or more times .... just zaps the battery! One glow gets the tip cherry red. Of course, if the engine doesn't fire-up on the first attempt, the GPs must be glowed for a second attempt!

Most likely the issue was either the fuel tank sending unit thingy or gelling in the fuel filter. If the problem was/is in the tank, the temp will have to raise above freezing to solve the problem for now.

If the problem was in the fuel fitler, we will never know....OP changed the filter. So, now, we don't know if he botched the change and filled the Injector lines with air.

So, I'd start by bleeding the Injector Lines ....... he did say fuel was flowing at #2.... that, in of itself doesn't mean there isn't air in the lines. Air compresses, thus no high pressure injection.

BTW, I cannot imagine a circumstance where the timing belt would jump time on the Injection Pump Sprocket... Gees, give me a break! Yes, if the TB broke, but helk, it would jump on all spockets! Unless one of the rollers dies or the tensioner dies, the TB is not going to jump timing....but, if it did, logic says it will jump on the very small sprocket on the Crankshaft!
 

Tylas

Member
Joined
Nov 4, 2010
Location
Fowlerville, MI
TDI
2002 Jetta Sedan
It was frozen completely, had to put it to a salamander for a few hours with a tarp on it and added Diesel 911 to tank and fuel filter. Started up like a champ and was running great today until my current issue.

Thank you all for your help, this cold is killing me!

Now it stalled on me at the local Lowe's due to a no crank no start issue, will have to troubleshoot that tomorrow. I get all my lights and 2 clicks in the engine from the starter and fuel injector, but nothing else. The joy of old cars in the bitter cold...
For summation, I remembered that my last fill up on Wednesday came up very thick. It even overflowed on me to make a stain on the quarter panel, which is the first time it ever happened on this car. If this happens, use additive!! it should have additive, but if you see anything strange with the fuel get some immediately.
Diesel 911 will now always be in my trunk during the winter.
 
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