Car won't start after removed injection lines - Troubleshooting - VWDiesel.net The IDI, TDI, and mTDI source.

• Car won't start after removed injection lines by lowandslowdiesel on 20 Feb, 2011 21:09
• Hi I just changed my glow plugs on my 91 jetta 1.6na and removed all the hardline injection lines to access the glow plugs... I put it all back together and now it seems like i can't get the air out of the lines to start the car... I cranked it multiple times and cracked the injector lines and used staring fluid but no luck...
  
  is there any trick on pumping the air out of the system? I have drops of fuel coming out of the pump if i crack the hard lines..
  
  Thanks
• #1 by maxfax on 20 Feb, 2011 21:18
• Step one, PUT THE ETHER DOWN!!!!  You'll nuke those new glow plugs real quick!!
  
  Typically you should be able just to crank till the air works out and it starts..   Were you replacing the glow plugs as routine maintenance, or were you having some variety of problem??
• #2 by coke on 20 Feb, 2011 21:22
• I keep the lines at the injectors loose, hold the throttle to the floor and crank till every injector is wet with fuel. Then, tighten the injector lines, let the glow plugs warm up, and start. Works every time. I have manual glow plugs, so I don't activate them until the fuel is present at each injector and I have tightened the lines back up.  You can accomplish the same thing if you want by removing the glow plug fuse, cranking till fuel is present at each injector, retighten lines, reinstall fuse, glow, and crank.
  
  If your injector pump emptied itself and didn't suck any new fuel in, which it shouldn't have, you can refill the pump with diesel fuel through the OUT bolt on the top of the pump.  Mine lost all its fuel as it sat over a month on a head gasket job because the o-ring in the preheated fuel filter thingy was missing. But, when I went to restart it I just primed the pump, cranked till fuel at each injector (throttle to the floor), tightened the lines, glowed, and fired right up.
• #3 by 8v-of-fury on 20 Feb, 2011 21:51
• Starting fluid is a big no-no on these engines for a reference in the future. It can blow the ends of your new glowplugs in short order.. and bend the connecting rods.
  
  If you have cracked the fuel lines.. did you crank until you saw fuel coming from all the injectors.
• #4 by rabbitman on 20 Feb, 2011 22:10
• I tighten two lines and loosen two, after fuel get's to the loose ones and tighten them up and start it. Misfires till the lines clear.
  
  btw no starting fluid EVER!!!
  
  Didn't I hear that ether can blow the prechambers out too? After all it is a rather violent explosion inside 'em
• #5 by maxfax on 20 Feb, 2011 22:16
• Quote from: rabbitman on 20 Feb, 2011 22:10

  Didn't I hear that ether can blow the prechambers out too? After all it is a rather violent explosion inside 'em
  

  
  I've heard something about that once upon a time.. I think it had to do with something about the ether hitting the hot GP..
  
  
  Kids, save your ether for old DI farm tractors!!
  
  
• #6 by 745 turbogreasel on 20 Feb, 2011 23:30
• I tighten them up as they drip, until it starts, then I tighten the rest.
• #7 by macka on 21 Feb, 2011 12:22
• WD 40 is the only starting fluid your gonna need. It works just fine, and doesn't blow stuff up.
• #8 by lowandslowdiesel on 25 Feb, 2011 00:31
• Thanks for all the replies...
  
  Car still not starting... tryed the method with the pedal to the floor..
  
  still no fuel going to the injection lines
  
  checked the sending unit in the tank, it is not blocked
  bypassed the filter so its not a clogged filter causing it
  took off the bolt on top of the injection pump where the return line goes... the pump is topped with fuel
  drained the water out of the water separator...
  i guess the only thing it could be is an air leak somewhere? checked the lines from the tank to the motor they look alright
  siphoned the fuel line although it seemed a bit a hard, got fuel to come out the end so its not blocked
  
  the car did have trouble starting before replaced glow plugs that's why i replaced them and tested the old ones on a battery charger and none of them worked but now my fuel pump doesn't seem to be pumping fuel
  
  appreciate the helpful replies
• #9 by theman53 on 25 Feb, 2011 05:40
• make sure you didn't knock the 12v power wire off of the seliniod. OR jump it from the battery to make sure it works. Sometimes when messing around the general area of these cars they tend to act up in that area. It is like some parts get jealous that you are touching other parts.
• #10 by 8v-of-fury on 28 Feb, 2011 11:26
• Now I see you repeat that the injectors are not receiving fuel, have you verified this or are you just saying this because it is not starting?
  
  Do you have the injector lines cracked? While you are cranking is there any fuel dribbling out?
  
  There is a small gauge wire on top of the pump, is it still hooked up? Does it receive voltage when you turn the key on?? Any smoke out the tail pipe when cranking?
• #11 by lowandslowdiesel on 02 Mar, 2011 08:50
• Thanks for the replies, figured it out last Sunday
  
  Hooked the supply line to a bottle a of fuel and it started up, turns out it was the water separator was blocked up.. so I bypassed it and got rid of it. 
  
  Thanks for all the help everyone!
  starts right up with those new glow plugs... although idle is a little rough if the choke isnt pulled out a little bit, i can see bubbles in the return line so obviously theres a little air leak somewhere, I believe it's one of the injector's return line cuase they sort of teared when taking them off, so I'll replace the lines and see if the bubbles disappear.
• #12 by Smokey Eddy on 05 Mar, 2011 00:06
• $6/meter at germanautoparts.com
  under fuel injection (or fuel delivery... i dont remember)
  sometimes in a pinch you can snip the ends off and if they are still long enough keep using them.
  They get brittle from the temp change being on the injectors.