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I have a 2002 jetta tdi and about a month ago I sent my car to my Father-in-law to replace the transmission filter. In doing so he tried to help out and filled the radiator resivoir with dextron antifreez. Causing things to turn brown and clog up. After a couple of days my thermostat warning light came on and started a main leak on the water pump seal. within two weeks I have had to add up to 2 gallons a day. Only able to drive about 20 miles before stoping to fill up again.
This has now led me to changing the water pump with the help of my Father-in-Law(Who has owend his own 4X4 shop for the past 35 years). While in the bay I noticed during TDC check the He had used the injection pump to Locate TDC causing the belt to jump one tooth. Without installing the IP lock pin he continued to rotate the pump jumping teeth untill he was at a full revolution "42 teeth".
After He saw my frustration. I put the components back together and did not get to the leaking water pump. Now the Engine will not start.
I have checked the fuel line to make sure I do not have an airlock. but in trying to suck the fuel back to the fuel filter. I have complete suction but no movement. the compression I'm using is not being lost even after 10+min. No fuel movement.
Do I need a new Injector pump or just a New Father-in Law and a water pump.
 

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I'd go for the new father in law and water pump personally, it sounds like he's trying to helpful (bless him) but is actually making an arse of things, go into the faq and look in the 99-2004 jetta faq, you'll find the guide in there for doing the belt properly and also how to replace the waterpump. People like to be helpful but sometimes they just don't have the knowledge, I've almost fallen out with some over engine stuff. One guy, an old mechanic supposedly argued silly with me about hone marks in the cylinders, he reckoned you just did a rebore and that was that, he wouldn't accept you have to use a special tool to hone the cylinders after reboring. (Honing makes cross hatch marks on the cylinder walls to help with holding the oil on the walls to aid compression.) I don't know if it's to do with marbles and losing them or what.:)

welcometomyturbodies
 

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Ouch! If I were you I'd redo the etntire timing belt. You don't know if the tensioner or belt teeth have been stressed to the point of early failure and you already have to replace the water pump anyways which means it's not any more work, just the parts. The timing belt has to come off and be reset correctly because the pump is timed off. It should be OK to reuse though. Show him the correct way to do it here and if he refuses, politely have it towed elsewhere http://www.myturbodiesel.com/1000q/a4/ALH-engine-timing-belt-change-VW-Jetta-TDI-1.htm
 

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Discussion Starter #4
Thanks for the help. A New kit has been ordered. Father-in-Law is paying for the big kit. "Redemption":nana2:

Good to hear the IP should still be good.
Is there a proper way to get the pump back into proper alighnment?
Does the vw tool alighn the pump with itself?
I bielieve something is clogged. When I put suction on the fuel return line there is no movement at all. :ugh

Time to get things set for the kit.

Thanks for the help guys.
 

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The pump aligns to the same place as the cam so they both do two revolutions to one for the crank but when you line everything up with the tools it all sits perfect. The fuel thing sounds a bit wierd, maybe need the ignition on to pull the fuel through the pump because of the shut off solonoid, doubtful but can't think of anything else off hand.:)
 

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But if the pump has been manually moved out of position, it won't be in alignment. I think that's the problem.

With the TB off and the rest of the stuff at TDC, set the pump with the lock hole. Just turn it clockwise (in normal wear direction), insert the pin, and install the belt. That's all it needs to be aligned since the rest is already at TDC. Do not loosen the gray hub on the pump! But you can remove the sprocket, just not the hub.
 

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Discussion Starter #7
So, after a full day of sitting back and taking deep breathing. I looked back at the engine and noticed the injector pump has not been realighned. ( thanks for the Help, Seatman\50mpg\CCBB) all things are buttoned up right now.

Now, since we put things back together in wrong timming with just the IP out of position. Trying to start the car with the ignition. Have we created engine damage to the heads and pins? Or, Have we just starved the chamber of fuel?
 

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Doubtful there's any damage, more like frustration and tearing out of hair (pressuming you're not bald:D), the fuel will just go in at the wrong time and go out the exhaust or into the inlet manifold if anything.:)
 
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