Before you move the pump Tim are you pulling out the cold start knob on the dash? This gives some amount of advance to the engine and may solve your problem. If indeed you do have that baby all the way out and it won't start shove it in all the way and go move the IP towards the engine the width of a pencil mark from where you are at right now. Just draw a line across the top of the pump and that index mark on the bracket. That may get you to start up. All that smoke tells me that you are either at a retard position or the glow plugs are not warming up. I think you mentioned that they all work in the initial post here.Check the pull knob, cycle the glows twice and try again. No luck? or rough after start and smokey. Bump the pump. DAS
also when i have TDC on everything and i go to Tension the belt how tight should it be on there? with how its on there now its pretty tight.. should it be alittle loose or no?
Quote from: vw-tim on June 27, 2012, 12:49:34 pmalso when i have TDC on everything and i go to Tension the belt how tight should it be on there? with how its on there now its pretty tight.. should it be alittle loose or no?The issue of correct belt tension both very simple and challenging. If the belt is wildly loose, then the pump or worse the cam can jump time potentially causing pistons to hit valves. If the belt is too tight, the injection pump bushings and the intermediate shaft bearings will wear out in short order. The pump bushings require a full rebuild ($$) to replace and the intermediate shaft bearings are no small task. Some models require engine removal for access. There is a special VW tool for measuring the tension and various brands have made aftermarket versions that are reasonably priced. For use of the VW tool (or similar) or any other objective method, the cam sprocket should be able to rotate on the camshaft and the pump lock pin should be removed. Short of the VW tool, I would say that the best rule of thumb I've come up with is to get all the slack into the tensioner area as mentioned previously, and then rotate the center of the tensioner CW as hard as I can by hand while I tighten the tensioner nut. The next best method, IMO, is to again make sure all the slack is in the tensioner area and to use a tensioner wrench to first apply a little tension to the belt and then let the tension of the belt spring the tensioner back. I'd say 5°-10° CW from where the tension of the belt springs the wrench back is just right. The test of rotating the belt as mentioned in some manuals is so subjective it is useless.
OK, now this is going to freak you out. Pull the pump all the way towards the front of the car. Some experience the same result as you with a pump that is advanced too far.I trust you have cracked the top of the injector nuts enough to release any air stored up in the lines. But the pump holds on to air like Mother Hubbard clutches nickels. It might need to get running to clear it out. Duh? That puts you in a Catch 22 right? No, some go to the extreme of pull starting the beast, Mostly because their battery is low and can't really crank it the way it should. You do have a good battery and all connections on both grounds and positive points, like the starter are cleaned up?
Is the woodruff key in place in the pump shaft/sprocket?
OK, Looks set up the correct way just turn it over by hand a few times to make sure nothing is hitting inside and warm the glows, hit the starter and give the accelerator about a third to half way to the floor push as well. Mine needs that if it has a burp inside it sometimes. Hint number 107 probably. Oh, and cold start lever out as well.DAS
White smoke not so bad now? I would pull it to the front and see if it gets worse. Then bump it towards the engine a bit at time. Crack the nuts on the back of the pump and you can get it to move real easy that way. I bought a Harbor Freight diesel compression tester kit for something like 40 bucks and the adapter fits in the injector hole real well. Just remember to always push the breaker bar or torque wrench towards the head. Don't ask me why I am having to rebuild my head right now because of a cracked injector boss. Just found it that way a few weeks ago after a good cleaning. By the way you can detail my engine like yours and I would just jump for joy. wow.