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Discussion Starter #1
I replaced the timing belt and cylinder head on my 2003 convertible but when I tried to start the car it turned over a few times but wouldn't start. When I tried again it was just dragging as if I had a dead battery. tried 3 different batteries but it would barely turn over. Any idea where I might have made a mistake? Thanks.
 

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5/23/10 <3
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Did you turn everything over by hand before you started it up the first time? Starter connected?
 

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Is this the first time; doing a timing belt on the 1.8T? The first time, can be a challenge and it is possible, to install things, like the belt pulley, that is tensioner by the hydraulic tensioner {wrong}, which in turn, could cause things to bind or be cockeyed. I would double check things and confirm; that all your timing marks are in phase and the head/cam timing is correct as well.


If you have been down in the weeds on a repair like this for awhile; it is easy to lose your objectivity and overlook something, in your install/timing phase process. If you have a friend or family member; that is mechanically inclined, you might bring them over and have them check everything with you, having a 'fresh pair of eyes", has solved many a issue, when working on a more involved project, like a rebuilt cylinder head. I don't know, how many times; I have been stumped or others have been stuck on something; then, they look at something you have been starting at for hours, days or weeks, the issue is obvious to them, which fixes things and you then, can move forward. Just a thought and an idea; from my own struggles with fixing cars over the years.
 

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Discussion Starter #5
Actually, I've been able to turn it over but now it is almost too fast as if there is no compression. I don't have a compression tester but I will borrow one this weekend.
And I still haven't been able to actually start it.
In regards to your suggestion I already had a friend look at it but he hasn't been able to come up with anything either so far.
 

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Discussion Starter #7
No compression.
But I found the culprit. Bolt on camshaft sprocket had loosened and the woodruff key was sheered off. so when turning the engine by hand it was okay but when turning the engine fast by starter the sprocket was just turning on the part of the cam that it attaches to. So now I have to take everything part again to the timing belt again on top off fixing the cam... Something that should have been more time consuming than difficult has now turned into a massive job!
This is probably going to take a few days but I will post again when the cam issue is fixed and the timing belt is all set up.
 

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Discussion Starter #9
Probably not so i'm going to replace the entire head with another one I already have. Didn't want to do it the first time around but now I'll have to but I am not really looking forward to it...
 

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Discussion Starter #10
I have replaced the head and everything is back together. Started up on the second try!!
But now i have a bunch of trouble codes. PO102, PO177 P, PO354, PO413 and PO442.
Does anybody know what the mean? and how to fix them?
 

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Always look up trouble codes; on the ross tech wiki:


This seems like a odd code; i don't know if this applies to our vw engines, a vw scanner might give you a factory vw code vs. a generic obd code:


P0354 VOLKSWAGEN - Ignition Coil 4 Primary/Secondary Circuit

 

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P0413 VOLKSWAGEN - Secondary Air Injection System Switching Valve 'A' Circuit Open



Trouble codes, tend to build up over time; you might clear them, take a test drive, rescan and see what has come back. Let us know, what comes back and we can go from there. Thanks.
 

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I'm glad to hear; your head swap worked out ok and everything is working as it should. If you have any info, about the new/used/rebuilt head you used, needed parts, special tools you needed to purchase, repair cost or possible issues you had to deal with, in doing this pretty involved repair process. Please share anything, that might help others needing to do the same head swap; it would be greatly appreciated! It is always good to hear about people's repair experiences; especially in the deeper level ones, like this.Let us know. Thanks. :)
 

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Discussion Starter #14
Had all the codes cleared but one came back PO442. Maybe I damaged the canister when I was putting the engine mount back on. That mount was a nightmare. But it had to come of since the timing belt loops around it. It was easy when I got the cylinder head at the wrecking yard. I got it from a passat , I think . They have the engine going from front to back so I didn't have to take the mount off. But on the beetle you do. It took me 2 days just to take it off and to put it back in. Raise the engine-lower the body, then the opposite , back and forth. The other thing was the bolts from the exhaust manifold to the turbo. The first 2 were no problem but the last one, the one closest to the head was tricky. It is very shallow so I had to grind down a 17mm socket. The bolt is slightly under the top edge of the head so the socket kept slipping off it. I also had to use an extension that was ground down to were it would slightly wobble in the socket> Gotta go...
IMG_6553.JPG

I got to get that code cleared today so I can get it smogged on Monday...
 

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As noted above, it could be something as simple as a leaking seal in the gas cap; you might replace it with a new one, clear codes, take a drive and see if the code comes back. I think the gas caps; don't cost much, so that could be a cheap fix.

Beyond that, more work maybe needed; a visual inspection, pressure or smoke testing, etc. to find he source of the evap leak.

Let us know, how things go and we can go from there. Thanks.
 

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Discussion Starter #16
Any idea which fuse controls the notification beep? Can I disable that sound while i am working on it?
 

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Discussion Starter #18
Like the sound it makes when you do not completely disengage the handbrake. My sound comes on every time I hit the accelerator. I am not sure why. I only have that one po code and the check engine light is on and a yellow triangle with an exclamation mark and an arrow looping all the way around the triangle. Don't know what that one is. But the beeping is super annoying....
 

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Ok, well, what are the current trouble codes you are getting? Based upon the codes you are posting; I'm assuming, you have a generic obd II scan tool. To read ABS and other possible related problems; you probably, need a VW specific scan tool, like VCDS by Ross Tech or equivalent (OBDEleven, other VAG scan tool, etc), to read those specific VW factory trouble codes, which can narrow down the issue. If you get more codes; and/or a scan with a VW compatible scan tool, please post any codes you get and we can go from there, to figure out why you are having the "beeping" issue and the various lights are on, in the speedo cluster.

You have already, "gone deep down the rabbit hole"; in during in depth repairs on this Volkswagen, further diagnosis and troubleshooting, pretty much requires the use of a VW specific scanner with factory level capabilities, like VCDS by Ross Tech, it is a investment @ $199 but totally worth it, I have been using it, since 2007, when my factory VW warranty went out and it has saved me thousands in repair costs and my car literally, would not be on the road today without it.

At the end of the day, either you pay someone to diagnose things; and they will be using a VW factory level scan tool, costing you most likely more then buying VCDS or you fix it yourself with your own equivalent tool; VCDS, enables you, to gain control of your diagnostic, troubleshooting and repair process, which finally, completes the missing capability to truly "see", what the onboard VW proprietary diagnostic system sees and this is a very powerful way, to finally stop "flying blind", eliminate the guessing, speculation, about what is going on with the car. This will help you to finally, allow total access; to all the live data, factory vw codes and ultimately, hopefully, fix your car. When you get the tool; you can tell us the factory VW codes, that are coming up and then, do more in depth testing and if needed, look at live data, do output tests, etc. Let us know, how you want to proceed with your diagnostics, troubleshooting and repairs (get access to a vw scan tool allowing you to diy, take it to a pro shop, have then handle it or "punt", etc), we can go from there. Thanks.

 
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