Engine not start without applying power to fuel cut off solenoid.

[Nickmix]

I have an issue with my newly rebuilt engine. I installed it over the weekend and had a really hard time bleeding the pump and the injectors. I eventually figured out through some trouble shooting that the fuel cut off solenoid on the injection pump was not getting voltage. Also, the fuel quantity adjuster inside the injection pump is not doing a sweep when the key is turned on. Only reason I know this is because I had to change the top cover to the injection pump due to the original top having damaged threads and leaking fuel. I was able to start it after applying 12V straight from the battery to the fuel cut off solenoid, but it idles high (approximately 1200 rpm) and lopes/surges badly. It will only run with the voltage applied. I know I still have to adjust the timing and fuel quantity adjuster due to disturbing the top cover. I have had to charge my battery several times so that could be an issue too. I scanned the engine codes with VCDS and came up with the following:



Address 01: Engine Labels: 038-906-012-AGR.clb
Control Module Part Number: 038 906 012 GN
Component and/or Version: 1,9l R4 EDC G000SG 4308
Software Coding: 00002
Work Shop Code: WSC 00066
Additional Info: 3VWRP69M63M178568 VWZ7Z0C7259287
VCID: 629DB9919D5EBD7A79F-4B1E
9 Faults Found:

16612 - Throttle Pedal Position Sensor (G79)
P0228 - 35-10 - Signal too High - Intermittent
16609 - Throttle Pedal Position Sensor (G79)
P0225 - 35-10 - Circuit Malfunction - Intermittent
16567 - Fuel Temp. Sensor A (G81)
P0183 - 35-10 - Open or Short to Plus - Intermittent
17971 - Quantity Adjuster (N146)
P1563 - 35-00 - Lower Limit Reached
17762 - Modulating Piston Movement Sensor (G149)
P1354 - 35-00 - Electrical Malfunction
17055 - Cylinder 1 Glow Plug Circuit (Q10)
P0671 - 35-10 - Electrical Fault - Intermittent
17056 - Cylinder 2 Glow Plug Circuit (Q11)
P0672 - 35-10 - Electrical Fault - Intermittent
17057 - Cylinder 3 Glow Plug Circuit (Q12)
P0673 - 35-10 - Electrical Fault - Intermittent
17058 - Cylinder 4 Glow Plug Circuit (Q13)
P0674 - 35-10 - Electrical Fault - Intermittent

Readiness: 1 9 0 0 0

Just looking for some ideas. Maybe there is a common cause for this. I will look at the wiring harness for possible damage and swap out the 109 relay but due to my schedule I can really only work on it on the weekends. The glow plug faults are do to my not having them plugged in.

TLDR version:
- fresh rebuilt engine by me
- new injectors
- original injection pump top cover swapped due to fuel leak at end fitting
- no voltage to fuel cut off solenoid
- fuel quantity adjuster does not sweep (does not move at all)
- will only run with 12V applied from battery to fuel cut off solenoid
- engine surges badly

Thanks in advance for any help

 

[Nickmix]

Just an update...I checked the wiring between the injection pump and the ecu for damage and did not see anything obvious. My plan now is to ohm out the wiring between the plug and the ecu to see if I find any open wires. I am also going to purchase a new battery as this one is and H6 and not the right size.

 

[Drooque]

Hey Nickmix,
Did you figure anything out with this? I have the same problem (as well as others), except when I jump to the fuel cut off, the car runs well. I know the power to the cut off comes from the computer, so I assume if you figure that out, some of the other problems will be resolved also.
Thanks,
Andrew

 

[mittzlepick]

Fuel solenoid is black white wire. The 14 pin plug near under baterry tray goes from pump to that plug then to pin 120 on ecu. Inspect that plug conti uity test from that to the pump and see how inerds of that plug look like

 

[Nickmix]

Fuel solenoid is black white wire. The 14 pin plug near under baterry tray goes from pump to that plug then to pin 120 on ecu. Inspect that plug conti uity test from that to the pump and see how inerds of that plug look like

I actually started to ring out the wiring harness and decided to check out the fuse box for any blown fuses. I did not find any blown fuses, but I did find fuse # 32 (ECM) was missing. I installed a fuse, and the fuel solenoid and quantity adjuster are powering up now. I have no idea how the fuse came out. The car ran before I parked it to rebuild the engine. Only thing I can think of is maybe it fell out when I took the dash apart to change the heater core and fix the blend doors. I did have a 30A fuse on the floor but thought it was a spare. Previous owner must have had the 30A fuse in the spot for the ECM which is 15A. Now I just need to hammer mod to adjust the qa and set the timing via VCDS.