91 TSI no start - help please

[rsofedm]

I've got a 91 TSi that I can't seem to get started.
It's been torn apart to do the headgasket, timing belt, and all related parts.

Fuel:
- replaced fuel pump
- replaced bad ground on fuel pump carrier
- replaced MFI solenoid
- can now smell unburnt fuel
- don't see any leaks

Spark:
- pulled cylinder 1 plug and placed near ground - sparked.
- new and gapped spark plugs

Timing:
- belt was changed and checked, checked, and rechecked before finishing assembly
- crank/cam sensor - made sure it was installed properly
- still need to lookup how to test the CAS but I'd assume if I'm getting spark it's fine.

Air:
- all the vacuum hoses and intake hoses are securely fastened
- throttle pedal seems very stiff - not sure if that's normal on these


One of the other issues it's having (not sure if it's related) is that the low coolant light is on and the fans instantly come on and stay on when the car is put to the "run" position on the ignition switch. Makes me wonder if there's another grounding problem somewhere but I'm not really sure where to start...

 

[Tyeler18]

There should be an on/off toggle switch to kill the remote start.

 

[rsofedm]

There should be an on/off toggle switch to kill the remote start.

I've looked and looked but can't seem to find one

 

[rsofedm]

ok, so I've tested the voltage doomabob and the coolant temp sensor. Both seemed within spec. Next I'm going to test the coil pack, CAS, and MAP for proper voltage/resistance/continuity. I'm also going to have a look at the ECU.

One thing I keep forgetting is that there is a compustar remote starter in there. I was told when I bought the car that it didn't work - could that be an issue? I do not know how to go about removing it (I won't use it even if it does work) but if there's a way to eliminate that from the troubleshooting I'd like to hear it.

The following have been tested:
-voltage sender
-coolant temp sensor (3 times!!!)
-CAS
-MAP

All were perfect. I took the ECU out and looked at it. There were no leakings cap's and no burn marks. looked pristine.

Any other ideas? I'm this close to giving up on the car and finding something else...

 

[ChiTownHussla]

Hey I had a similar problem on my 1g. It was a bad ecu. Find someone and borrow thiers. Seems dumb, but mine cranked right up with a new ecu. Hope this helps

 

[Benshooter]

Try ripping out that remote start (or at least disabling it) before you dump the car.

 

[dsm4life91tsi]

my friend had all the same problems found out it was the ecu

 

[ty92dsm]

I battled my car for weeks and couldn't figure out why it wouldn't start and why I couldn't here the injectors clicking ...it turned out to be that my ecu was junks so check the caps.....I knew as soon as I pulled it out because of the nasty smell.....I put a new ecu in and it started right up and runs perfect

 

[rsofedm]

well I broke down and replaced the coolant temp sensor
... no change

 

[rsofedm]

any more suggestions? I'm at a loss now...

 

[Tyeler18]

Pull the ecu.

 

[rsofedm]

Pull the ecu.

other than looking for leaking cap's and burn marks?
I looked for that. looks pristine.

 

[Tyeler18]

Just read that. Sorry.

Next thing I'd do is rent a fuel pressure tester. You may be getting some fuel into the cylinders, but it might not be enough.

One easy way to test this is just pull the fuel rail out and turn the car over while watching for fuel to spray out the injectors. It should be a pretty serious amount.

Actually, have you sprayed starter fluid into the intake and tried cranking it? That will determine if it's fuel/spark related for sure.

 

[rsofedm]

We do have a fuel pressure tester and it's certainly getting plenty of pressure. If I have the CAS plugged in and not bolted in, if I spin it the injectors click as though they are firing. We have tried starter fluid in the cylinders and it just sputters once and then keeps cranking.

 

[Tyeler18]

What was your fuel pressure at?

So without starter fluid = crank and crank?

With starter fluid = sputter then crank and crank?

One more thing to consider testing (don't know why I didn't think of this before). Test your resistor pack and make sure it's within spec (4.5ohms if I remember right).

 

[ChiTownHussla]

Just ### you cant see sumthing wrong with the ECU doesnt mean there isnt...swap it out, no cost to you and who knows, night be the fix you need

 

[ty92dsm]

Just ### you cant see sumthing wrong with the ECU doesnt mean there isnt...swap it out, no cost to you and who knows, night be the fix you need

+1

 

[rsofedm]

so the car finally runs!

The issue?
watch:
YouTube - DSM Graveyard 4g63 Timing Belt Tutorial
@ 3:00 onwards

Now I need to set the timing but the inductive timing light I have isn't working...