Golf mk4 1.9 TDI idle issues

[KingFoks]

I have a golf mk4 1.9 TDI which I recently worked over 90 percent of the engine, the car cranks on first attempt to start then start and over refs for about 5-8 seconds then die , so far I have done the following tests::
Vcds diagnosis results: 1. error code 17571- fuel temperature sensor. 2. I bought a new crank sensor from Vw. 3. Replace exhaust gaskets and head gasket, top was skeemed. 4 new relay 109, 5. diesel pump reconditioned. 6. Cleaned intake manifold

The car can stay idling only when I apply a bit of acceleration to raise the rpm to 1200 at least .

The other issue is that the air intake flap does not move at all even after I idled it for long enough to gain compression....any ideas? I heard of something called : throttle body alignment but since I am on diesel how do I allign the intake manifold?

[THANAS]

Definitely no throttle alignment to be done here.

Did you replace the fuel temperature sensor? Why was the crank sensor replaced?

The intake flap is the ASV or Anti shudder Valve and only actuates when the car is turned off.

Go onto VCDS and look at the MAF values at idle. The only thing controlling idle is the amount of fuel injected.

Which puts the problem at either a fuelling issue/injectors etc or a sensor issue like MAF or MAP. Check for air leaks after the MAF. You said you had the head skimmed? Do you know by how much and which gasket was used afterwards? Skimming a TDI head is a sensitive operation.

When you hold the rpm at 1200 does the engine sound normal? Is there white or black smoke from the exhaust?

[KingFoks]

I actually rebuild the car , I bought the cylinder head separate, I don't remember the side of the gasket now but I explained to my Vw agent when buying the gasket so I was advised before I fitted it, I changed the crank sensor because it had an error code 16705 , which was cured after that...
On the rpm issue, it excretes black smoke bt not that bad,
I did not change the fuel temperature sensor because I learned that when it fails , the ecu adjust to the default temperature and info from other sensors to adjust the amount of fuel injected

[Rudi46]

Did you adjust the Timing on the diesel pump? There is 3 bolts that you loosen and adjust. Try not to adjust more than a mm at a time.
Sounds like that is your problem.
Once that is done you can check the timing with VCDS with the tdi graph
http://www.ross-tech.com/vag-scope/TDIGraph.html

[KingFoks]

I thought the vcds timing adjustment will be the last item on my list, but no stress I am on it now , will update after

[panic-mechanic]

is the timing sensor on injector 3 working?.

[KingFoks]

When I unplug injector 3 , I get a fault code "needle lift sensor" short circuit open to +

[panic-mechanic]

Ok so at least that is ok. So do the pump timing procedure.

[Tdi jetta 4 ever]

Check if your anti shudder valve is in the open position when the engine idles and closes when you switch the engine off. It should open again after you switched the engine off. Did you bleed the air out of the diesel system before you attempted to start the engine ? How did you check if the timing is set properly ? Did you double check if the crank is on top dead center before and after the belt fit ? Camshaft and dieselpump locked in place ?
Keep us up to date.

[KingFoks]

My anti-shudder valve doesn't operate at all even when I switch the car off,but it stays open all the time..

TDC timing I'm 100 percent the crankshaft,camshaft and pump locked on place when I installed the timing belt....even now when I rotate the engine it still stands on TDC

[panic-mechanic]

Asv is not causing the idle issue. Forget about that line of thinking. It literally only ever operate for a few seconds after you have turned the key to the off position.

[panic-mechanic]

I am not talking about tdc timing. Talking about PUMP timing. You Adjust it with a vernier style gear on the pump itself using vagcom or suitable scan tool like vas and then adjusting it accordingly.

[KingFoks]

I have done vcds TDI timing....
The problem still persists , no idling., Today I unplugged the accelerator pedal now it idle but @ 1200rpm, any threads for troubleshooting pedal wiring harness?

[Tdi jetta 4 ever]

Did you do a fault scan ? The scan should show you any faults.

[KingFoks]

I have one fault left , fuel temperature sensor, code 17571, g81.....can it be the cause? I am getting a new sensor tomorrow will update again

[Tdi jetta 4 ever]

Any updates ?