Engine non-starter after rebuild

[jonnyb]

Hey folks,

I've got a problem with my 1.9 tdi ALH.  It's recently been rebuilt from top to bottom.  The electrics have all be checked, and no error codes are being produced, but the car won't run.  Fuel is reaching the injectors, so we believe that isnt the problem.  It's managed to run for 20 seconds when primed, but then will stop.

Any ideas? 

[EsSeX dAn]

is the fuel pump timing ok?

[jonnyb]

I'm not 100% sure. Is there a good way to check? It is highly possibly the timing is off. Im not too familiar with the details as its a friend who is doing the work.

[gazareth]

is the tdi a common rail fuel system??? if so then the sprocket timing is irrelevant.

[jonnyb]

Erm is the 1.9 (non PD) engine. ALH so not sure if that's common rail or not.

[EsSeX dAn]

i dont think its common rail engine.
but the fuel pump posistion is all relevant to the engine posistion. best thing to do is set the engine to top dead centre according to the flywheel then line up the camshaft and fuel pump to the tdc posistion and refit then tension the belt. show your friend this:
http://forums.tdiclub.com/showthread.php?t=284004

[gazareth]

if it has wiring going to fuel injectors then normally the pump sprocket doesn't need timed to crank/cam. does it have a fuel pump in tank/ if so that could be faulty. check for fuel at the injectors after the engine has cut out.

[billabong]

Ive rebuilt 2 ALH engines now (1 valve went the first time and turbo ran out the second time!).
When doing the timing belt, was the pin put in the fuel pump sprocket? This will set the Top Dead Centre (TCD) of the pump, to match the TDC of rest of the engine.
In the past ive found that I can run it by spraying a slow mist of easystart in - Its then a case of tweaking the fuel to get it right.
There are three bolts on the fuel sprocket which can be LOOSENED (dont remove) and allows the sprocket to move forward and backwards slightly. If I was you I'd set it to the min or max position in the oval holes and tighten, try to start the car. (maybe with easy start if it helps and see if it runs). If it doesnt start or run then loosen and adjust very slightly, until you get it running. Once its running it needs plugging in to VagCom and then use the TDI timing tool/graph which draws a line of how advanced/retarded the fuel timing is. You can then use this to fine tune into the correct bounds.
I hope this helps.
Check out this website too, its a great help:
http://www.myturbodiesel.com/1000q/a4/Injection-pump-removal-ALH-2.htm