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Thread: ALH TDI crank - no start

  1. #1
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    Unhappy ALH TDI crank - no start

    3 months ago, I had a timing belt shred on my 2002 TDI (ALH) jetta, I found a replacement engine out of a 1999 New Beetle also TDI (ALH).
    We sort of rushed through installing it in the car, because the PO of the engine had a video of it running, it sounded a little rough sounded like it needed a minor injector adjustment.
    The PO claimed he did a timing belt job in 2014 after pulling the engine, then it sat in his garage till I bought it 2 months ago.
    I also posted this to TDIclub;
    Really rough first start, any ideas?
    Running /slightly/ smoother, but what's wrong with the turbo??

    When I got the engine, I swapped the transmission for my original 2002 5speed tranny, and I replaced the DMFlywheel and clutch for the IDParts Quiet Clutch & Flywheel Conversion Kit which includes a simpler SMF.

    This first video is immediately after we got it in the car. Ignore the obvious flex pipe leak, I over flexed it when the engine got caught on it during install.
    1999 VW TDI 1.9L (ALH) swapped into a 2002 VW MK4 Jetta (Rough first start)
    there was absolutely no throttle response.

    So I looked at the Timing belt and noticed that the rollers and tensioner were never replaced, so I took a deeper dive and found that the cam and injector pump were out of time by 1 tooth... So I bought a High Mileage Timing Belt Kit (ALH) from IDparts and redid it. While changing the timing belt, I noticed that the cold side of the turbo was loose 1999 VW TDI 1.9L (ALH) swapped into a 2002 VW MK4 Jetta (Turbo wiggle)

    Then I took this video, 1999 VW TDI 1.9L (ALH) swapped into a 2002 VW MK4 Jetta (Lessish rough second start) and you can hear a mild improvement, there is /some/ throttle response, but not normal. There is also a misfire which I think is causing that horrible shaking.

    I plugged in VCDS to pull fault codes, and got this;
    5 Faults Found:
    • 16786 - EGR System
      P0402 - 35-10 - Excessive Flow - Intermittent
    • 17058 - Cylinder 4 Glow Plug Circuit (Q13)
      P0674 - 35-10 - Electrical Fault - Intermittent
    • 16512 - Coolant Thermostat Valve (N214)
      P0128 - 35-10 - Temperature below Control Range - Intermittent
    • 17970 - Quantity Adjuster (N146)
      P1562 - 35-10 - Upper Limit Reached - Intermittent
    • 17762 - Modulating Piston Movement Sensor (G149)
      P1354 - 35-00 - Electrical Malfunction

    Readiness: 1 5 0 0 0
    Part of the issue, I believe, is that a liberal usage of dielectric grease in the connectors may have increased the resistances at the connectors and are causing the ECU to detect issues...

    So, I thought the issue could lie in the injector quantity adjuster, so I pulled the cover off to watch it actuate on start, video here (note: I know you see a can of wd40 in frame, I didn't spray it INTO the fuel pump, just on the bolts so I wouldn't strip them.) ALH TDI fuel pump quantity adjuster operation and I don't see any issue with the movement, and the armature moves freely and cleanly with no resistance (other than spring tension). So I bolted it back together, and primed the pump by disconnecting the fuel return line off of the fuel filter and put a little plastic harbor freight transfer pump on the hose with a beer can under the outlet and pumped till fuel came out (about 100ish pumps). (I've never primed a fuel pump before, so lmk if this was insufficient)

    After that I cleared the previous fault codes in VCDS, and tried to restart the engine, and now it's cranking without starting... video here; Now it's not starting... but without the engine actually starting, I don't think I can collect new fault codes, correct?

    My next thoughts are to run some seafoam through the injector pump to try and clean the injectors... I also need to check the ASV and make sure it's actuating properly.

    What can I do in VCDS to diagnose these issues further? Does anybody have ideas about these issues?

    Appreciatively,
    Ian

  2. #2
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    AND the fresh autoscan;
    I did notice on the first autoscan I did, I had 1J selected, not 9M, so that may have also caused a couple codes.
    should I be calling it a beetle though, since the engine is out of a beetle?
    Code:
    Monday,23,March,2020,14:12:48:04807
    Chassis Type: 9M (9M - VW Jetta IV (1998 > 2014))
    Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
              75 76
     
    VIN: 3VWSP69M02M112730   Mileage: 359970km-223674miles
    -------------------------------------------------------------------------------
    Address 01: Engine        Labels: 038-906-012-AGR.clb
       Part No: 038 906 012 FD
       Component: 1,9l R4 EDC G000SG  4102  
       Coding: 00002
       Shop #: WSC 00066  
       VCID: 57EB8B48A61C48CFD8F-4B3C
       3VWSP69M02M112730     VWZ7Z0A4233190
    
    No fault code found.
    Readiness: 0 0 1 0 1 
    
    -------------------------------------------------------------------------------
    Address 03: ABS Brakes        Labels: 1C0-907-37x-ABS.lbl
       Part No: 1C0 907 379 J
       Component: ABS FRONT MK60      0103  
       Coding: 0004097
       Shop #: WSC 00066 000 00000
       VCID: 313F15D0ED3876FF76B-5184
    
    1 Fault Found:
    00668 - Supply Voltage Terminal 30 
                008 - Implausible Signal - Intermittent
    
    -------------------------------------------------------------------------------
    Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
       Part No: 6Q0 909 605 F
       Component: 04 AIRBAG VW6  0202 0004  
       Coding: 12340
       Shop #: WSC 00066  
       VCID: 3A2D32FC354EB5A7C71-513C
    
    1 Fault Found:
    00532 - Supply Voltage B+ 
                07-10 - Signal too Low - Intermittent
    
    -------------------------------------------------------------------------------
    Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
       Part No: 1J0 920 906 L
       Component: KOMBI+WEGFAHRSP VDO V62  
       Coding: 07232
       Shop #: WSC 06411  
       VCID: 313F15D0E83876FF76B-513C
       3VWSP69M02M112730     VWZ7Z0A4233190
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
       Part No: 6N0 909 901 
       Component: Gateway K<->CAN    0001  
       Coding: 00006
       Shop #: WSC 00066  
       VCID: 70B9D0D423B23FF7395-513C
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 46: Central Conv.        Labels: 1C0-959-799.lbl
       Part No: 1C0 959 799 C
       Component: 1H Komfortgerát HLO 0003  
       Coding: 00258
       Shop #: WSC 00066  
       VCID: 372B2BC8065CA8CF38F-4B1E
    
       Subsystem 1 - Part No: 1C1959801A
       Component: 1G Tőrsteuer.FS KLO 0202  
    
       Subsystem 2 - Part No: 1C1959802A
       Component: 1H Tőrsteuer.BF KLO 0004  
    
       Subsystem 3 - Part No: 1C0959811A
       Component: 1H Tőrsteuer.HL KLO 0002  
    
       Subsystem 4 - Part No: 1C0959812A
       Component: 1H Tőrsteuer.HR KLO 0004  
    
    3 Faults Found:
    01330 - Central Control Module for Central Convenience (J393) 
                53-10 - Supply Voltage Too Low - Intermittent
    00914 - Window Regulator Switch; Rear Left; Driver (E53) 
                27-10 - Implausible Signal - Intermittent
    00915 - Window Regulator Switch; Rear Right; Driver (E55) 
                27-10 - Implausible Signal - Intermittent
    
    -------------------------------------------------------------------------------
    Address 56: Radio        Labels: 3B7-035-1xx-56.lbl
       Part No: 3B7 035 180 
       Component:    Radio NP2        0055  
       Coding: 00401
       Shop #: WSC 00066  
       VCID: 5DE79960C420A29F823-513C
    
    No fault code found.
    
    End----(Elapsed Time: 05:11, VBatt start/end: 12.1V/12.1V. VIgn 12.0V)-----

  3. #3
    NostraJackAss Jack@European_Parts's Avatar
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    Codes indicate a faulty injection pump how about using the old one from blown motor that lost belt?
    European Parts Emporium/Performance / Immobilizer Solutions EPE
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    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
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  5. #4
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    Quote Originally Posted by Jack@European_Parts View Post
    Codes indicate a faulty injection pump how about using the old one from blown motor that lost belt?
    where do you see that?

    It's not a terrible idea, I have it all taped up and sealed...

  6. #5
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    when im installing it, should I put the cam lock plate in to make sure the timing doesn't move?

  7. #6
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    actually, before I do that, can I use VCDS to turn on the fuel pump to prime the injector pump?

  8. #7
    NostraJackAss Jack@European_Parts's Avatar
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    where do you see that?
    5 Faults Found:

    • 16786 - EGR System
      P0402 - 35-10 - Excessive Flow - Intermittent
    • 17058 - Cylinder 4 Glow Plug Circuit (Q13)
      P0674 - 35-10 - Electrical Fault - Intermittent
    • 16512 - Coolant Thermostat Valve (N214)
      P0128 - 35-10 - Temperature below Control Range - Intermittent
    • 17970 - Quantity Adjuster (N146)
      P1562 - 35-10 - Upper Limit Reached - Intermittent
    • 17762 - Modulating Piston Movement Sensor (G149)
      P1354 - 35-00 - Electrical Malfunction


    Readiness: 1 5 0 0 0

    JPPSG Yet ? ............

    https://forums.ross-tech.com/showthr...uot-JPPSG-quot
    European Parts Emporium/Performance / Immobilizer Solutions EPE
    Certified Master Trained NY/BAR/BAD 7076062/ASE/SAE/NASTF Legal Factory Authorized/Licensed GeKo/FaZit # 403738
    Specializing in Custom Services IE: "welding-fabrication" / EPA-SMOG Update or Pass-Thru-Programming / Data Transfer / Immobilizers & OEM Quality Parts
    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
    www.FixMyEuro.com <<<<<CLICK HERE! or vwemporium@aol.com ( JPPSG & Unverified members need not PM me & Please don't email or call facility for free tech support...use the forum )
    Getting you CONTROL again of your property - TAKE IT! In Conjunction with.........

  9. #8
    Ross-Tech Employee Dana's Avatar
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    Quote Originally Posted by Colleen DeMenna View Post
    when im installing it, should I put the cam lock plate in to make sure the timing doesn't move?
    Yes, you will want to pop the cam gear sprocket loose so proper timing belt tension can be achieved as well. In short, treat it like (another) timing belt replacement in that regard.

    Quote Originally Posted by Colleen DeMenna View Post
    actually, before I do that, can I use VCDS to turn on the fuel pump to prime the injector pump?
    No, PD and CR TDIs used an in-tank electric fuel pump but VE's didn't so there isn't an electric pump to operate via VCDS.

  10. Likes Jack@European_Parts, Uwe liked this post
  11. #9
    NostraJackAss Jack@European_Parts's Avatar
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    As always ref RTFB when performing a belt and pump setup with VCDS.
    European Parts Emporium/Performance / Immobilizer Solutions EPE
    Certified Master Trained NY/BAR/BAD 7076062/ASE/SAE/NASTF Legal Factory Authorized/Licensed GeKo/FaZit # 403738
    Specializing in Custom Services IE: "welding-fabrication" / EPA-SMOG Update or Pass-Thru-Programming / Data Transfer / Immobilizers & OEM Quality Parts
    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
    www.FixMyEuro.com <<<<<CLICK HERE! or vwemporium@aol.com ( JPPSG & Unverified members need not PM me & Please don't email or call facility for free tech support...use the forum )
    Getting you CONTROL again of your property - TAKE IT! In Conjunction with.........

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