I appreciate any ideas ahead of time. I'm stumped.
The short: I have a manual 2003 Jetta TDI (ALH motor), and I just finished changing the timing belt. On trying to start, it cranks away, but doesn't quite start. A handful of times, it sounded like it was JUST about to start, but then didn't. Nothing but cranking now. I followed all instructions exactly, so I'm not quite sure what I should do next to figure out what's up.
The long: I followed the timing belt change articles here: (http://www.myturbodiesel.com/1000q/a4/ALH-engine-timing-belt-change-VW-Jetta-TDI-1.htm and http://www.myturbodiesel.com/forum/.../how-install-new-timing-belt-jetta-new-beetle-golf-alh-engine-1998-2003-a-2976/). I referenced http://www.tdiclub.com/articles/pdf/a4timingbelt.pdf as well. I used the metalnerd ALH tools. I changed the timing belt, both small rollers, the large roller, the tensioner, the water pump (and put in new coolant), and the serpentine belt. While changing the belt, I pulled off the valve cover to verify that the position of the first cam lobes were both in the up position and put in the lock bar. I made sure the flywheel was at TDC, and used the crank lock tool to keep it there. I put the pin into the injector pump, and double checked with a light and mirror that the pin was in the slot and exactly in line with the center of the injector pump. When I put on the new timing belt, I double-triple-quadruple checked that the flywheel remained at TDC while the cam was locked and the pin was in. When I was done tensioning the belt (after pulling the pin and lock bar and crank lock), I made sure I was still at TDC. When I was done, I did a few manual rotations of the engine, and felt good compression, and nothing was hitting anything else. On re-assembly, I replaced the vacuum pump seal, having greased it lightly to make sure I didn't pinch it. I torqued down every bolt to spec. On re-connecting hoses, I made sure there was nothing that had fallen into them (I stuck a rag in the end of each to make sure I didn't screw up and drop anything in).
Before trying to start the engine, I bumped it a few times to center the timing belt on the gears. On trying to start, it just cranked and would not start. After cranking a handful of times, it sounded like the engine was JUST about to start, but it wouldn't quite take. I checked VCDS, and the engine is throwing no codes. I did a full scan, and the only error code was a short in the circuit for the antenna for the radio.
Unless there's something I'm missing, I'm pretty sure everything was timed properly. The flywheel stayed at TDC, the IP pin was in, and the cam lock bar was in place (with the lobes up on that first position). What else should I check?
I really appreciate any ideas anyone might have! I searched around for similar threads, but didn't quite find an answer. Thanks again.
The short: I have a manual 2003 Jetta TDI (ALH motor), and I just finished changing the timing belt. On trying to start, it cranks away, but doesn't quite start. A handful of times, it sounded like it was JUST about to start, but then didn't. Nothing but cranking now. I followed all instructions exactly, so I'm not quite sure what I should do next to figure out what's up.
The long: I followed the timing belt change articles here: (http://www.myturbodiesel.com/1000q/a4/ALH-engine-timing-belt-change-VW-Jetta-TDI-1.htm and http://www.myturbodiesel.com/forum/.../how-install-new-timing-belt-jetta-new-beetle-golf-alh-engine-1998-2003-a-2976/). I referenced http://www.tdiclub.com/articles/pdf/a4timingbelt.pdf as well. I used the metalnerd ALH tools. I changed the timing belt, both small rollers, the large roller, the tensioner, the water pump (and put in new coolant), and the serpentine belt. While changing the belt, I pulled off the valve cover to verify that the position of the first cam lobes were both in the up position and put in the lock bar. I made sure the flywheel was at TDC, and used the crank lock tool to keep it there. I put the pin into the injector pump, and double checked with a light and mirror that the pin was in the slot and exactly in line with the center of the injector pump. When I put on the new timing belt, I double-triple-quadruple checked that the flywheel remained at TDC while the cam was locked and the pin was in. When I was done tensioning the belt (after pulling the pin and lock bar and crank lock), I made sure I was still at TDC. When I was done, I did a few manual rotations of the engine, and felt good compression, and nothing was hitting anything else. On re-assembly, I replaced the vacuum pump seal, having greased it lightly to make sure I didn't pinch it. I torqued down every bolt to spec. On re-connecting hoses, I made sure there was nothing that had fallen into them (I stuck a rag in the end of each to make sure I didn't screw up and drop anything in).
Before trying to start the engine, I bumped it a few times to center the timing belt on the gears. On trying to start, it just cranked and would not start. After cranking a handful of times, it sounded like the engine was JUST about to start, but it wouldn't quite take. I checked VCDS, and the engine is throwing no codes. I did a full scan, and the only error code was a short in the circuit for the antenna for the radio.
Unless there's something I'm missing, I'm pretty sure everything was timed properly. The flywheel stayed at TDC, the IP pin was in, and the cam lock bar was in place (with the lobes up on that first position). What else should I check?
I really appreciate any ideas anyone might have! I searched around for similar threads, but didn't quite find an answer. Thanks again.
