Jetta 4 1.9 tdi

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Mozart
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Jetta 4 1.9 tdi

Post by Mozart »

Hi there,

Please guys I really need your help.

My 2002 Jetta 4 1.9 tdi sprung a leak by the diesel pump, so I change all seals and placed the pump back in, did the timing and bled the system to remove all air. Now the car just swings and refuses to start.

Any ideas?
Ashveer03
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Re: Jetta 4 1.9 tdi

Post by Ashveer03 »

Recheck pump timing

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Mozart
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Re: Jetta 4 1.9 tdi

Post by Mozart »

How do I check pump timing, tried looking in the Internet no info showing how to set timing
Ashveer03
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Re: Jetta 4 1.9 tdi

Post by Ashveer03 »

Strange that u can't find anything. ALH is all over the internet.

https://www.myturbodiesel.com/wiki/alh- ... 03-part-1/

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Mozart
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Re: Jetta 4 1.9 tdi

Post by Mozart »

My engine code is AHF, are they same
Ashveer03
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Re: Jetta 4 1.9 tdi

Post by Ashveer03 »

Yeah pretty much the same

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Mozart
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Re: Jetta 4 1.9 tdi

Post by Mozart »

thanks, let me try this
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panic-mechanic
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Re: Jetta 4 1.9 tdi

Post by panic-mechanic »

is it delivering fuel. Many people has broken a pump by not following the vw recommended procedure by removing the pump and working with it upright rather than trying to o it in place.
If there is fuel delivered then you have a timing or a firing order issue.
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Mozart
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Re: Jetta 4 1.9 tdi

Post by Mozart »

Yes pump was removed and seals replaced,
Timing was set to tdc, pump timing was set too
After priming pump and cranking a few times, diesel is coming to injectors.

Maybe I am missing something, maybe you can explain the timing setting so I can double check to make sure it is all correct and try again
Ashveer03
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Re: Jetta 4 1.9 tdi

Post by Ashveer03 »

Crank tdc is set from the hole in the gearbox to the flywheel.

Cam tdc needs a locking tool.

Pump timing is locked with a 6mm (I think) pin.

Explained very easily in the above link.

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Cass
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Re: Jetta 4 1.9 tdi

Post by Cass »

out of interest ,why did you opt for replacing seals.

These diesel leak can be stopped by priming the pump with 500pm diesel and some diesel conditioner.
See the seals dry out with the lower sulpher diesel. give them some old truck diesel they seal back up again
current: vw Golf mk4
1.9 Tdi

Ex: 92 citi rocketship (stolen)
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VAG Fan
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Re: Jetta 4 1.9 tdi

Post by VAG Fan »

@ Cass: I don't trust a seal that has leaked once. So I replaced mine too.

@ Ashveer: yes, the locking pin is 6 mm. A drill bit shank does just fine. BTW, the above link appears to be broken.

@ thread: I turned the engine clockwise (to put normal tension on the various cambelt sections), stopping the moment the lock pin dropped into the pump. Did this a few times to check that I could find the point reliably. Then I took detailed notes on the position of the crankshaft and camshaft sprockets (crank was close to TDC but not quite on TDC) and made a few marks with tippex on the cambelt and camshaft/crankshaft sprockets. I didn't break loose the camshaft sprocket. Then I removed the pump and did the seal repair, reinstalled the locked pump with its sprocket slightly loose, tensioned the cambelt, checked that the belt was back on the same camshaft and crankshaft teeth, brought the the engine shafts as close as possible to the original position, and tightened the pump sprocket bolts. Then I unlocked the pump, turned the engine 720° by hand and did a few fine adjustments until the lock pin dropped into the pump at exactly the same point as before.

That was definitely good enough to get the engine to start on first swing.

[Edit: sorry, this obviously doesn't help you much if you've already lost your timing reference.]
Mark R.
- - - - - - - - - -
2004 VW Golf TDI, type 1J, AHF, 317k (2016-current) --- daily
1990 VW Fox, type 16, HM, 304k (2005-current) --- spare runaround
Previous:
1992 Audi 500 SE, type C4, AAR (2001-2020) --- nice while it lasted
1983 VW Golf GTS, type 17, FR (1992-2005) --- most fun car I've ever had
1978 Audi 100 GLS 5E, type 43, WC (1991-92) --- died in the side of a Rekord who cut me off
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