Medic!! 2002 Golf TDI not turning over
February 18, 2012 - 3:59pm
Hey everyone, I could use some advice.... my 02 Golf TDI isn't starting.
Things I've tried:
1. external heat to the injection pump
2. bypassing the selector valves
Symptoms:
4 weeks ago, it would take 5 tries to get it started. It has gotten worse until now it won't start.
February 19, 2012 - 9:44am
#2
Hey thanks for the advice. I will check that stuff out. yeah, I was worried that I was burning out my starter too. I'll repost here when it all gets straightened out.
February 19, 2012 - 11:13am
#3
I spoke too soon. The #**#$ thing started leaking again. I just ordered a replacement Viton o-ring seal kit from dieselgeek.com. They have nice instrux and suggest that if you don't take apart the IP, which is a scary thing to do because internal parts come loose, and if you use the OEM rubber o-ring it stretches too much and doesn't snap all the way back. Viton is supposed to allow a slip-over-the-top fix.
http://www.dieselgeek.com/v/install_guides/TDI_Injection_Pump_Head_Seal_Replacement.pdf
February 23, 2012 - 10:02pm
#4
Thanks again for the link Don. Much appreciated! I figure a job like this would take all weekend if I go slow and do it right, so I may just bite the bullet and take it to the dealer. I'm still going to research the options though. -Mark
February 24, 2012 - 1:27am
#5
I just did it tonight. I stopped for dinner and several breaks and was ridiculously slow and careful with it. It only took a few hours and while it was tough to prime it finally did and it's running fine. I'll know in the morning if all is well if there are no more puddles under the IP.
So, moral to the story, if you see any fluid at all underneath your IP then what I've done might well be your fix also.
Good luck!
March 1, 2012 - 9:56pm
#6
that's great news! I'm glad you got your greaser running!
March 4, 2012 - 12:24am
#7
some good news: i got her running. it was a stuck EGR valve. I might have some build-up that will eventually need attending to, but for now, Frenchy runs again! www.frenchycar.com
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My 02 Jetta TDI had similar issues and I burned up the starter trying to get it going- because it would start sometimes after long cranks. There was a small leak on the underside of the injector pump. I don't know exactly what it was other than my mechanic put some o-rings and a retaining clip in there.
It could be your glow plugs.
The Jetta TDI has a relay that plugs in under the kick panel that needs to be replaced sometimes when it won't start. I dunno if that'd be the same on the Golf.