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Discussion Starter · #1 · (Edited)
Ok I have searched and searched and it looks like some have had similar problems but not quite the same.

My in-laws gave my step daughter a 2001 beetle with a 2.0 for her 16th bday. Problem is it blew the number 2 spark plug out of the head and was heli-coiled but then that came out and the plug was just cross threaded in to make hold. All this done with the motor complete. So no knowing what damage was done to the motor from chunks of metal in the oil, I rebuilt the engine.

So now the motor is in, honed block, head fixed, all kinds of new parts. New oil pump, water pump, pickup tube, timing belt, tension-er. And a lot more.

I took it out and ran it for a while and it started running really rough. and the check engine light was on. I pulled into the auto parts store and it came back multiple misfires all cylinders. So I replaced the coil. Drove it to work(about 25 miles) half way there, check engine light comes on, Long term fuel system lean. I bought a can of MAF sensor cleaner and cleaned it, also replaced the upstream O2 sensor. Drive it to a friends shop with a OBD2 reader, he clears the codes. Try to start it and it will not start, tries to start then dies, and exhaust smells really rich. Finally get it to start and it is running really rough and no power. I baby it for about a mile, and it starts running fine again. I get it home, shut it off and leave it for about 2 days. Yesterday I drive it to work, again 25 miles, no problems, park it and fires right up after work. Drive it home and about 3 miles into the drive, check engine light comes on again. I get it home, change clothes, go to take it to get the code checked again and it will not start. Tried but keeps dying and smells rich again. I get mad leave it sitting there in the drive. I get in it today, fires right up and running fine, still check engine light is on. Seems to start and run fine. If you shut it off and try to restart while warm, it will not start or run really rough. Let it cool back down and it starts right up. Wouldn't be an issue, but if you drive it to work and have to stop to get gas, if you turn it off, it will not start again until it is cooled back off. Also has a new fan that I verified is running correctly, new 1/2 antifreeze 1/2 water, new thermostat, and new water pump.


Also car has 206K on it. 506 mile on new motor. Fuel pump change a few thousand miles ago... When I asked about the fuel filter, I got the deer in the headlights look, so I guess it has not been changed in probably 5 or 6 years. Dont know if that would be the issue, even though it probably needs changed, it would not cause it to only mess up when warm starting.
 

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Lots of possibilities; as this is a fresh rebuild, there are many potential issues and details, that may or may not, be overlooked when the engine was installed. A friend or pro shop; might be a real benefit, as a "fresh pair of eyes", so to speak. it can be hard to "see" things; when you have been staring at a motor for so long and wrenching on it, so much. Not seeing the forest for the trees; as it were.

As it is; what are the current trouble codes and can you look at live data with a scan tool? I recommend you get or borrow a tool; so, you can see what is going on as you are driving around and read any current trouble codes you are getting. A Volkswagen compatible scan tool; would be recommended but a generic scan tool with live data capability, could be helpful as well.

Without the benefit; of the current trouble codes or live data, a number of things come to mind. Fuel delivery in particular, seems like a strong possibility; many members are having failed fuel pumps lately!

1. clean and adapt the throttle body. Dirty TB's cause allot of issues with the 2.0L.
2. does the car run any different with the maf plugged or unplugged?
3. (lean codes): check fuel pressure; many fuel pumps can fail and cannot maintain proper pressure, when they get hot. Have you replaced fuel filter; go ahead and do that. What brand of fuel pump is the new one? We have had members; who have replaced the fuel pump with cheap brands like non oem "Airtex" and they are not able to maintain factory spec fuel pressure; even though they are brand new! We are having good luck with Bosch fuel pumps and they have good prices off of amazon.com.
4. you are getting lean codes; what are the current fuel trims?
5. crank position sensor failing? When they get hot; that is when, many times they start failing. (generally will throw a trouble code)

Fuel Trim Info - Ross-Tech Wiki

5. have you rechecked all the basics; hoses, any leaks, vacuum hoses, all electrical plugs connected as they should be, etc.?
6. do you want to fix it yourself or seek professional help?

If you end up needing a fuel pump; here is the one, that many are buying and having excellent results with.

Bosch Part #: 69740

http://www.boschautoparts.com/auto/fuel-pumps/turbine-fuel-pumps?partID=69740

amazon.com; the best deal, about $120 with free shipping: (it comes with new fuel tank seal, new redesigned fuel pump with integrated fuel level sender and filter)

http://www.amazon.com/Bosch-69740-Original-Equipment-Replacement/dp/B001C602HW
 

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Discussion Starter · #3 ·
Sounds like a few things I haven't tried. I will go through your list and see if anything changes. If not I guess it will need to go to the dealer to have it looked at. I am trying not to have to take it to a shop, but it is looking like I may have to.
 

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Do you have access; to any diagnostic scan tools or a fuel pressure tester? Both of these tools; typically, can be rented from most auto parts stores. If you do end up taking it to a professional; the VW dealer IS NOT, your only option! I would consider; a independent German/European auto specialist, if it gets to that point... let us know where you live and other members, may have recommendations for a good shop to take it to.
 

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Discussion Starter · #5 ·
Do you have access; to any diagnostic scan tools or a fuel pressure tester? Both of these tools; typically, can be rented from most auto parts stores. If you do end up taking it to a professional; the VW dealer IS NOT, your only option! I would consider; a independent German/European auto specialist, if it gets to that point... let us know where you live and other members, may have recommendations for a good shop to take it to.
I say dealer... I really mean the local expert... Here in Tulsa, OK I am told it is a place called Miguels. They specialize in VW and Audi. I try to stay away from dealers, they over price, and a lot of times are not all that great.
 
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