No start, no fuel in clear line.

[Carolyn's mechanic]

2002 golf cranks but will not fire, the clear fuel line has no fuel in it and there is no fuel leaking.
The car was running and starting fine, and after one week not being used it will not start, there is fuel in the tank.
An air leak allowing the fuel to run back into the tank? what is recommended to find the leak and how is the system primed or refilled after the leak is repaired?

Thanks

 

[csstevej]

Chances are that the thermostatic tee is allowing air in with the engine off or the IP head oring has dried up and allowing air in without it running.
When that seal is bad enough it will leak while running.

Quick thing is pull the thermostatic tee off and replace the o-rings or if you don’t have that lube it up generously with Vaseline.

There are several ways to prime the engine.

Some take off the return line from the IP and using a mitt vac pull suction till you see fuel come out , Reconnect and crank engine.

Another way is to pull the banjo fitting out from the top of the IP and shove a clear tubing in there that’s a close diameter and pull a vacuum till you get fuel the reconnect and crank the car.

Do a search for fuel priming and you will find several different ways to do it.
Pick the one that you can do.

 

[Carolyn's mechanic]

Replaced fuel filter and o rings, can get fuel to the filter, but not to the injection pump, seems to just pull air if I apply suction after the pump.

 

[csstevej]

Did you refill your fuel filter first ? That will help some.
Where did you apply suction?
I’ve pulled fuel from the return line from the pump , took about 10 minutes to do that but that worked for me.
You can also get an electric in line pump to help prime the system. A member on here uses that when he needs to prime.

I just recently install an in tank electric pump on my 00 NB just to avoid this hassle. One of the best mods I’ve done.

You can do an IV setup in a plastic jar and hang it on the hood , the slight head pressure and gravity will help bleed the pump. I believe Andybees member-has a good setup he uses with pictures….. might want to search him.

 

[Carolyn's mechanic]

The fuel filter is full and fuel can be pulled through it in volume, I can pull the vacuum from the metal return line on the top of the pump, (with the injectors return line blocked) and all I get is air, no fuel tries to enter the clear line.
Is there supposed to be power to to the fuel shut off unit on the pump when the key is on? I don't see any voltage to that.

 

[csstevej]

You will get voltage for a few seconds , if the engine starter isn’t engaged then the power is cut to the fuel shutoff solenoid.
If you want to see power , face the VOM towards the windshield with wires clipped to Ground and the power stud and try to start the car , you should see power while cranking .


Edited- corrected statement.

 

[P2B]

you should see power for about 5 seconds then nothing if car doesn’t start.

It must be longer than that, mine cranked for a good 15 seconds before starting after I shut it off at the diesel pump last week not realizing it was running on fumes.

 

[P2B]

The fuel filter is full and fuel can be pulled through it in volume, I can pull the vacuum from the metal return line on the top of the pump, (with the injectors return line blocked) and all I get is air, no fuel tries to enter the clear line.

I find pressure works better than vacuum to prime the pump. I use one of these:

Google Image Result for https://m.media-amazon.com/images/I/61PRfTdXX3L._AC_UF1000,1000_QL80_.jpg

 

[csstevej]

I believe that while your cranking and the ecu sees rpm then yes power stays on. If you just turn the key on without cranking then the power shuts off after about 5 seconds . I can hear my intank pump shut off when I turn the key to on but not engage the starter after about 5 seconds.

 

[BobnOH]

I've read of folks having pump prime issues, I've only done it twice, no issues. Simply connect a long clear tube to the return line on top of the pump, suck and pinch the tube until you get steady fuel, then bleed at the injector connects. If you can't get fuel from the pump, you may have blockage.
Oh yea, don't drink the diesel.

 

[Carolyn's mechanic]

I added a primer bulb as recommended, that worked very well, pushed fuel right through and started up after a couple cranks.
The issue now, is that the injection pump leaks badly at the top cover, (and maybe other places?) it was not visibly leaking before, pulling a vacuum on it, seems to have made what ever small leak that allowed it to loose prime much worse.
It really poured fuel out when pumping with the bulb, and now a good steady drip when running.
Any advise or links to the proper procedure to reseal the pump? no mention in the VW service manual.
Are these the sockets and seal kit needed for the pump ?

Amazon.com

Amazon.com

 

[csstevej]

Get the seal kits here along with the special tool and the video.
The manual doesn’t cover this nor does the dealer…..they just replace the IP.

Deluxe Injection Pump Seal Kit for TDI

Don't replace that leaky VW injection pump, reseal it. A ton of customers have fixed their leaking TDI injector pump's quantity adjuster seals with this kit!

dieselgeek.com

Flippin' Pump Socket! for Bosch Triangular Fasteners

Replace your TDI injection pump seals or adjust your TDI injection pump timing with this special socket for the anti-tamper screw on 1996-2003 Volkswagen TDI.

dieselgeek.com

INSTRUCTIONAL VIDEO (Injection Pump reseal) for 1996 through 2003 TDI Golf, Jetta, New Beetle and Passat

Dieselgeek is proud to announce one of our best, most informative, and highest production value instructional videos to date! This product is provided absolutely free of charge with purchase of our Viton Pump Head O-Ring Seal Kit, or Deluxe Injection Pump Seal Kit for TDI Complete...

dieselgeek.com

You can either buy the video or search on here for free on the forum .

Found the link.

How to video: On car VE injection pump seal replacement video

This is the one that we have been waiting for. It shows, in detail, how to replace the three most-likely-to-be-leaking seals on an ALH injection pump: the top cover, quantity adjuster & head seal. It is also applicable to the pumps on the A3/B4 cars. It is long, but some will appreciate this...

forums.tdiclub.com

 

[Carolyn's mechanic]

Update on leaky injection pump and a thank you for the input and guidance on this repair.
I finally had the time to do the reseal on the pump, I watched a couple different videos on the procedure and got a pretty good idea of what was involved, I replaced the two seals on the top and the big O-ring on the head, it was a pretty straight forward process, took a couple hours taking my time. Having the primer bulb already installed in the fuel line made bleeding/priming the system afterward a snap and it started right up.
I was very careful to make some fairly precise locating marks on the quantity adjust body/main body to return it to the same location that it was before removal, and it runs fine after the procedure.