Engine wont turn well with wrench on Crank shaft

redsamyxj

Member
Joined
Sep 6, 2004
Location
Rottordam, NY (Albany)
TDI
03 Jetta
My 2003 Jetta won't start and the engine won't turn over or binds even when using a wrench on the Crank shaft.
First is this normal?

The car was showing a MIL and one code was the injection timing so last Sun. I adjusted it to 3.7 deg it was at 20 deg. advance. Car had lots more power but under load made a vibration noise.

Yesterday my wife was driving the car and it sputtered and then died on here on the highway and she could not restart it. She also said that she tried downshifitng the 5 speed and it would not go back into gear. The thing roles in nutral (had to get it on tow dolly). Then the battery was dead so I had it charged. Then put it back in the car. It would not turn over but the starter tried turning it. The starter does hang up some times and I took it off and the gear is always out. I tried turning it over after starter removed and that did not help.

Any help would be great thanks,
Signed: Walking to work
 

jasonTDI

TDI GURU Vendor , w/Business number
Joined
Apr 26, 2001
Location
Oregon, WI
TDI
04', 05', 06' TDI's. Audi SQ5, RAM Rebel
Don't mess with timing. You are playing with fire....

The main issue. The DMF in the transmission has failed. Order a new clutch.
 

KLXD

Top Post Dawg
Joined
Aug 22, 2009
Location
Lompoc, CA
TDI
'98, '2 Jettas
Not clear from your post if the light's been on a while and you got around to addressing it or if you had a sudden light and power loss.

If it's a new condition why a sudden shift in timing? Belt slip? Though I'd expect it to be retarded.

When it binds does it always stop in the same place like a piston's hitting a valve?

I'd take look at the timing belt.
 

Mavrick

Veteran Member
Joined
Feb 16, 2012
Location
Ontario
TDI
2003 VW Jetta TDI
First check crank and cam timing, make sure the belt has not skipped or the cam pulley has not slipped.
 

redsamyxj

Member
Joined
Sep 6, 2004
Location
Rottordam, NY (Albany)
TDI
03 Jetta
So are there timing marks on the cam pulley? I don't see any. Do I have to pull the valve cover to see if the cam pulley slipped?

By the way does anyone need a TDI body/transmission? I live near Albany Ny and if you want to see it you can PM me.

Thanks
 

kd7iwp

Veteran Member
Joined
Jun 27, 2009
Location
Abbotsford, BC, Canada
TDI
2002 Golf GLS
So are there timing marks on the cam pulley?
Thanks
No, there are no marks on the cam pulley as it is removed from the cam when installing a new timing belt. You would remove valve cover and get the cam at TDC for #1 cylinder. Then check if the crank is at TDC via the window in the transmission bell housing.
 

KLXD

Top Post Dawg
Joined
Aug 22, 2009
Location
Lompoc, CA
TDI
'98, '2 Jettas
Look at the timing belt PDF to see how to check timing belt installation.

Maybe take a minute and answer the questions in #3.
 

redsamyxj

Member
Joined
Sep 6, 2004
Location
Rottordam, NY (Albany)
TDI
03 Jetta
Thanks for all the help.

I looked at the PDF before but was just hoping I was confused when it appeared I would be taking of the valve cover.

To answer #3
The MIL has been on for 5 years. It was the temp sensor I replaced that two weeks ago. I just got it down to two glow plug codes but it did have the over boost code before that. The glow plug codes are still in the computer and over boost but nothing else.

The timing belt looks ok (the teeth on the belt don't look worn).It is not that tight it has ~1/2 inch of play when you push between the cam pulley and the pump pulley.

The crank will turn 270 deg either clock wise or counter clock wise but it is a little hard to turn in some other spots.
 

whitedog

Veteran Member
Joined
Jul 12, 2004
Location
Bend, Oregon
TDI
2004 Jetta that I fill by myself
Pull the vacuum pump and check the cam to crank to injection pump timing. Or just pull the valve cover and that might tell you the whole story. Time to get dirty.
 

migbro

Veteran Member
Joined
May 19, 2010
Location
Lincoln, Mass.
TDI
2003 Golf GL
The timing belt looks ok (the teeth on the belt don't look worn).It is not that tight it has ~1/2 inch of play when you push between the cam pulley and the pump pulley.
I'm surprised no-one has commented on that already. The timing belt should be very tight between the cam and pump pulleys. With a 1/2 inch of play you definitely have a timing belt problem, possibly a failed tensioner.

The crank will turn 270 deg either clock wise or counter clock wise but it is a little hard to turn in some other spots.
I'd have to say it's not looking good for your cylinder head.
 

jasonTDI

TDI GURU Vendor , w/Business number
Joined
Apr 26, 2001
Location
Oregon, WI
TDI
04', 05', 06' TDI's. Audi SQ5, RAM Rebel
Thanks for all the help.

I looked at the PDF before but was just hoping I was confused when it appeared I would be taking of the valve cover.

To answer #3
The MIL has been on for 5 years. It was the temp sensor I replaced that two weeks ago. I just got it down to two glow plug codes but it did have the over boost code before that. The glow plug codes are still in the computer and over boost but nothing else.

The timing belt looks ok (the teeth on the belt don't look worn).It is not that tight it has ~1/2 inch of play when you push between the cam pulley and the pump pulley.

The crank will turn 270 deg either clock wise or counter clock wise but it is a little hard to turn in some other spots.

That is as far as it will turn when it is interfering with the valves. Pushing through it it colapsing the lifters all the way. Not good.

My money is on a failed tensioner. Either not locked in the hole or tensioned backwards.

Look at the tensioner. There be a half round piece next to the nut. That has two 2mm holes in it. The center of that should be at about 11 o'clock. If it's at 3-5 o'clock it's tensioned backwards and the body (back side) is likely cracked.
 

redsamyxj

Member
Joined
Sep 6, 2004
Location
Rottordam, NY (Albany)
TDI
03 Jetta
Checked the glow plugs

I checked the tensioner and the moon shape is on the left side and the top hole is at 11 o'clock and the bottom hole is at 7 o'clock.

pulled the glow-plugs and it is hard to see in the head but:
The electrical connector of one glow-plug popped down. another glow-plug left the bottom half in the head and just the threaded part came out. Would this be caused by the vibrations?

Thanks
Aaron
 
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redsamyxj

Member
Joined
Sep 6, 2004
Location
Rottordam, NY (Albany)
TDI
03 Jetta
I pulled the injector in the cylinder that glow-plug would not come out off. I must have dropped a valve.

If I am looking for a donor motor can it be from an AT ALH?
 

gquenstedt

Veteran Member
Joined
May 26, 2006
Location
San Antonio, TX
TDI
'06, '03 x 2, '00
I pulled the injector in the cylinder that glow-plug would not come out off. I must have dropped a valve.

If I am looking for a donor motor can it be from an AT ALH?
You should remove the cam and lifters to get a better picture of what happened.

An engine from an auto will work
 

redsamyxj

Member
Joined
Sep 6, 2004
Location
Rottordam, NY (Albany)
TDI
03 Jetta
I pulled the valve cover and one of the lifters broke into pieces.

Can I pull the head with the intake and exhaust manifolds attached?

Would it be ok to just replace the head now that there is metal parts in the oil?

Thanks for all the help,
Aaron
 

Mavrick

Veteran Member
Joined
Feb 16, 2012
Location
Ontario
TDI
2003 VW Jetta TDI
Yes you can pull the head with the manifolds attatched, and then remove them on the bench.

It would be OK to repair it, drain the oil and continue, although dropping the oil pan would be recommended to get rid of the ramaining debris.
 
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