problems need urgent help

[daypass72]

This am I changed the engine oil and filter in my 2006 Jetta TDi, started it up to check the oil level and topped it up to specific level. My wife drove the car few blocks away to get some lunch. She called me and said the car will not start. I went over and the battery was dead. I boosted it and drove it home. I charged it up and load tested it and and its dead. I bought a new battery and installed it and it fired right up.

1hr later I was out with the car, came out of the store and it will crank but will not start.
There was a slight smell of burning rubber coming from inside the car near the fuse panel. I checked all the fuses and they are all ok. even the ones under the hood on the drivers side. There is a possibility i may have put a fuse in the wrong spot while checking them but slight chance.

I am lost here and need the vehicle asap, its the only one we have
any idea's what could be the problem??

Thanks

[Seatman]

Check the 109 relay bud. It's usually located in the same fuse box on most cars. It might be what's making the smell. Also have you checked the 1000 faq and index for your car? I would think there'd be some helpful info in there.

[daypass72]

Thanks seat man, there are more relay an such under the sterring column, I have not cecked the 1000 faq yet i will see if i can locate that.. Is there a procedure to check the relay (109) after I find it?

[Seatman]

Most people just try a new one but you could prise the cover off carefully and you'll see a coil thing with a thin, flat piece of metal at one end. In between this and the coil thing is a set of contacts, try giving them a clean with some fine sand paper, ideally wet and dry. You could also check this trouble shooter.

http://www.tdiclub.com/TDIFAQ/TDiFAQ-8.html

[daypass72]

from what I have read so far, 109 relay's are found an older model TDI?

[Seatman]

And here

http://forums.tdiclub.com/showthread.php?t=31030

[chittychittybangbang]

Originally Posted by daypass72

from what I have read so far, 109 relay's are found an older model TDI?

Correct, your car doesn't have a relay 109. None did after 2003. It was a common failure point which was fixed but it's possible your car is still having a relay problem.

And FYI, the FAQ linked to on the other site was last updated in 2003...his car is 2 major changes newer than when it was last updated (2004,2005.5) so some of the information there can be misleading such as checking the fuel filter T or injection pump, or the fact that each GP on his car has a separate wire instead of all running off the same wire.

Burning rubber smell could be an electrical problem. Does your car have any mods?

Some possibilities are the lift pump in the fuel tank not working (electric fuel pump) - can you hear the pump prime when you go to start the car?

Does the glow plug light on the dash board light up as intended?

If you had a code reader it would help to figure out what the problem is.

Did you leave a tool in the engine bay which damaged the wire harness? Maybe something got moved and shorted out? Check for cracks in the wire harness.

Check the wire harness going into the head on the driver's side. It runs the injectors.

It shouldn't cause it, but does your door wire harness have any cracks? http://www.myturbodiesel.com/1000q/a...tta-repair.htm Maybe the alarm is preventing the car from starting. I don't know if it will prevent starting but allow cranking because the anti theft system is built into the central electric module.

This may sound strange, but if you leave the car on and let it sit there for a while, does it make any difference? Changing the battery or adding oil shouldn't cause any problems. And because it won't start at all, it's not the immobilizer system.

[shftdrvr]

Is the new battery the correct rating? If the battery cranks the engine too slowly it won't start.

[Seatman]

SlightlyIs there a problem starting faq on here Chitty? I haven't found one yet to direct people to. I like to try and help where possible and the more faq things I can find the better because I don't know the modern cars like others do.

[daypass72]

no mods all stock, no tools left in the engine bay, glow plug indicator is not showing up at all,
from what I have read mine is a 2006 but build date was oct 2005 making mine a 2005.5
I assume a relay for the glow plugs is stuck closed causing the draw. I disconnect every fuse and disconnected the alternator and still a draw..

I am about to give up on this, its driving me mental lol, looks like I am renting a car until i fix it or take it the dealership and get hosed.

Any other suggestions??

Cheers