new headgasket and Giles pump, wont start (now with video)

[somedumbjerk]

just put in a metal headgasket, ARP bolts and a Giles pump on my 1.6 and i can not get it to fire. timed it correctly using tools to 1.01. i make sure the clear line from the fuel filter to the pump has fuel in it, and i'm cranking it for 15 seconds, letting it cool, cranking, letting it cool etc etc. i've had to recharge my battery twice now. today i took off the little line on the bolt that says "out" and popped a clear line i had in there and sucked until diesel came out, reattached and fired again. no luck i had the hard lines disconnected from the injectors earlier and could not get any fuel coming through them. i'm about to try this again, wish me luck.

any advice would be appreciated. i did a search and have not done the ATF thing yet, i don't have any ATF. oh and the solenoid clicks when the ignition is turned on. getting frustrated! any advice would be appreciated. i'm going to go try and fire it up again with the hard lines loose. wish me luck...

video for those who don't want to go to page 2

[somedumbjerk]

started to kick over. originally firing on one cylinder, not it sounds like tow or three. cranks for like 8 seconds and sounds like it wants to catch but belches black smoke and just ownt catch. i'm taking a break for my neighbors sake, the smoke is thicker than hell. 

[steevz]

Did you double check your timing?

[RabbitJockey]

Yeah I would do a triple check on your timing and go get some ATF fluid that makes a big difference on an empty pump

[theman53]

That timing setting seems way too high for a Giles pump. He told me to not go above .0374" which IIRC is .95mm...still should start though.
I would recheck timing and make sure you get fuel coming out of the lines. You can remove the fuel seliniod and put it back in with out the plunger then you are sure that it isn't a problem, BUT you have to stall it or run it out of fuel to shut it off.

[burn_your_money]

Your issue sounds more like a fuel delivery problem but just to cover the bases, how warped was your head and block?

Crank with the injection lines at the injectors loose until you get fuel coming out of all 4. As fuel comes to one line tighten it up and wait for the others. You should probably drop your timing to the 0.90-0.95mm range as well but once it's running you'll hear if it has too much advance.

[somedumbjerk]

thanks guys! i'll head out there in a bit and try to get it coming out of all the lines. i'll try and find someone who is open that has ATF. i really really hate going to walmart but i think that's my best bet.

i went on the 1.01 based on vince waldons site:   turbo pumps:         1.00mm to 1.05mm (0.039" - 0.041")

why slightly retarded timing for a Giles pump? i'm just curious

[starrd]

why slightly retarded timing for a Giles pump? i'm just curious

From Giles:
i like to tell people to set their timing to .95mm but every engine
is diferent and you might have to change it a little bit after.

that is a good starting point. i build into your pump lots of dynamic
timing so you don't need to add static timing like a stock pump.

Giles

[somedumbjerk]

Are you 180° out?

no, i shouldn't be. the tool fit in perfectly and everything lined up well according to Vince Waldons site and my bentley. Unless i'm mistaken the cam locking tool won't fit in if you're 180 out?

and thanks for the Giles Quote! i actually bought this pump off of another member. the head didn't seem too warped, but my test for warpage was a straight edge and feeler gauges. not the most exact test. the engine had just under 100k original miles on it. the head looked great! really clean and the cracks in it are very small. just finished enough of my honey do list to get back at it again. i'll try and get a video of it as i fire it up, once now and once when running.

[theman53]

The pump can be 180 out. IIRC the woodruff key should be at the 10 o'clock position. The IP locking tool will fit in 2 spots.

[RabbitJockey]

Yeah check for the line on the pump side of the sprocket it should line up with the pump bracket

[ORCoaster]

You would have thought that VW in there infinite anal wisdom would have taken the time to either paint the inside of the correct hole on the IP or made some sort of marks around the outside of it.  That way none of us could go wrong with the pin being in the "wrong" hole.  I think that I will go around the outer edge of mine with a Sharpie or something tomorrow if I am out there under the hood.  I need to do a timing belt soon and marking the pump now while I am thinking about it might just save me some head scratch, cussin later on.

So why didn't VW mark this pulley in some fashion, in addition to the teeny mark on the top of the pulley?

Going to paint that white as I never have enough light under the hood to see that stupid blue mark.

DAS

[somedumbjerk]

my pump sprocket definitely has two holes. to check that i'm 180 out i need to go through all of the timing steps again to ensure TDC, right?
i have a video of it turning over with sound, but Vimeo is making me wait a half hour for it

[CRSMP5]

its got a detent/v mark in the pully... it lines up with the mark on the mount...

[somedumbjerk]

- here is the video of it not running. all four injectors are getting fuel.