2001 jetta tdi won't run after head gasket replacement

[Randal McDowell]

Basically exactly what the title says. I had the pin in the injection pump, and the flywheel was at tech for the entire time, and we reinstalled the cam with both cylinder one loves are pointed uppish. Any help is appreciated.

 

[csstevej]

I’m assuming you mean TDC on crank shaft, did you install the bar where the vacuum pump sits to ensure cam is at correct position , not just uppish?

Is the cam sprocket and fuel pump sprocket loose?

I see you said IP is pinned , was it in the correct hole and not the false one ?

With the cam sprocket loose, IP sprocket loose with hub pinned, and crank shaft at top dead center install the TB and tighten the belt tensioner to the correct spec.

Then tighten the 3 IP sprocket bolts and the cam sprocket bolt.
Remove , pin ,and bar from back if cam shaft and bar over engine by crank shaft bolt 2 full revolutions .

With a mighty vac pull fuel on the return line back to the fuel filter from the I P.

The car should start at this point , you will need VCDS to dial in your IP for optimum performance.

 

[jayb79]

Lobes pointed uppish is probably your problem, see page 31 here, valve timing is critical.

https://www.tdiclub.com/articles/pdf/a4timingbelt.pdf

 

[Vince Waldon]

Is the cam sprocket and fuel pump sprocket loose?

Just reiterating that this is a critical part of the process... otherwise the belt slack has nowhere to go when the belt is tensioned and the timing will drift off the second the locking jigs are removed.

Also as above, the sucker hole in the IP is a common gotcha... and locking the cam at exactly TDC with the jig is very important as well. The service manual suggests using feeler gauges to remove any slop in the jig (equal stacks on both ends)... so it's a critical setting.

The pdf linked above is a great step-by-step.