Volkswagen Passat (2001 - 2005) - 05 tdi 1.9 Won't start after new head gasket

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Tue 13 Jan 2009 14:14
05 tdi 1.9 Won't start after new head gasket - Passatman
After removeing and replacing the Head and the associated jobs I find that the engine shows no sign of firing. Before attempting to start I ran a fault check on the engine and no faults were displayed. I have checked that fuel is returning from the tandem pump (about 25 ml for 2 - 4 sec cranking). The live data appears reasonable but is obviously limited as the engine can only be cranked. I have discussed the problem with the man on the vag-com helpline and we are faily sure that the problem is not electrical. That said I have not yet run a full fault check or looked at the engine immobilizer module. Does anyone have experience of this kind of problem? any help would be greatly appreciated.

Edited by Pugugly on 13/01/2009 at 20:40

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Wed 28 Jan 2009 13:51
05 tdi 1.9 Won't start after new head gasket - Passatman
I fixed this by pressurizing the return line from the tandem pump. The system was evidently airlocked somewhere. The engine started at an estimated pressure of 1 - 2 bar. I don't know how VAG mechanics deal with situations like this. The standard proceedure outlined in the manual would not cover it.
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Wed 28 Jan 2009 14:31
05 tdi 1.9 Won't start after new head gasket - 659FBE
I use a vac pump to pull the fuel through the filter and to fill the tandem pump. I think this is outlined in the VAG data - certainly after replacing the tandem pump following a recall. Once the system and particularly the tandem pump is free of air, these engines start easily.

Gerotor type pumps will not self-prime.

659.

Edited by 659FBE on 28/01/2009 at 14:32

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Wed 28 Jan 2009 15:05
05 tdi 1.9 Won't start after new head gasket - jc2
Same on modern Fords;fuel needs to be sucked thro';there is also a cut-out in the fuel system which should stop the engine before the tank runs dry to stop these priming problems.
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