Car wont start after rebuild, HELP!
 

the car just cranks and cranks, the timing belt is on right but it seems to spin over kind of sluggishly, did a comp test and was at about 120 across the board im assuming that will go up when the car starts up and the rings set.
I had to take a CAS off and I didnt really know if it had to be in a certain position to work properly, but when I turn it all the way towards the firewall, the car will "pop" and want to start, but only every so often. I cannot locate the crank sensor, or is that built into the coil pack setup? theres is a small round plug that is not connected, it is on the same bundle of wires that the injectors and coil plug goes, like I said its about 1 inch and round.
I guess the first question is what should I do to test if my cas is bad? also, when I turn the key to the on position the fuel pump does not prime, but after i am done cranking it primes.

HELP!

Re: Car wont start after rebuild, HELP!
 

also, I checked and have spark. car is a 91 tsi

Re: Car wont start after rebuild, HELP!
 

Plug wires on wrong?

There is no crank sensor on a 1G.

Re: Car wont start after rebuild, HELP!
 

plug wires are on right, I double checked. then I literally took them off and put them on again using the manual.

Re: Car wont start after rebuild, HELP!
 

When you take the CAS off there is a piece that has 2 ends on it. That part slides into the cam. Turn that 180* and try to start again.

Re: Car wont start after rebuild, HELP!
 

tried spinning it 180 with no success.

I am wondering if I am not getting fuel? when I cycle the key the fuel pump does not turn on, during cranking it does not turn on, but after cranking, the pump will cycle for approx 1 second.
any advice? thanks guys

Re: Car wont start after rebuild, HELP!
 

You could make sure it is getting fuel by taking off the return line, putting a new return line over the regulator and to a 5 gallon fuel jug and seeing if any fuel comes out.

Re: Car wont start after rebuild, HELP!
 

I dont know I would have someone check the plug wires for you. Not saying your doing it wrong its just good to have a second opinion.. I ran into this with my car and it was just the wires that were wrong...

Re: Car wont start after rebuild, HELP!
 

I followed the diagram in the manual.

Re: Car wont start after rebuild, HELP!
 

Motor to body ground okay?? Just take a ground & hook it from block to ground.or neg bat. terminal. Had a friends car not start because of a broken ground

Re: Car wont start after rebuild, HELP!
 

I also replaced the ground wire, it was all melted?

Re: Car wont start after rebuild, HELP!
 

hmmm melted.. check for short?? or test the ground like this... http://www.ehow.com/video_2327356_us...light-car.html

you can use a test light to check for a short or draw on the battery by removing the negative cable and hooking the test light between the negative battery cable and the negative post... should not light up or only for a second but dim to almost being out immediately. If it lights up, then you know you have a short or draw somewhere.

Re: Car wont start after rebuild, HELP!
 

I will do that, I am also wondering if I should pick up a new CAS.. how much is one new?

Re: Car wont start after rebuild, HELP!
 

I wouldn't buy new... I will try and check tonight, I probably have one at the house in hopkins you can have. Where in Minnetonka are you?

Re: Car wont start after rebuild, HELP!
 

Can you take a pic of the unplugged connector? Was the car running before the motor came out?

Bad ecu???

Re: Car wont start after rebuild, HELP!
 

heres a pic of the plug.

http://i248.photobucket.com/albums/g...im/mystery.jpg

Re: Car wont start after rebuild, HELP!
 

a little update on the CAS. when I have the ignition turned on and spin the crank dampener to TDC on cyl 1 I can hear the fuel pump cycle for 1 second, so im assuming the cas is ok. I also added another ground from the engine to chassis, the car sounds like it wants to start but I cant get any repeatable near starts. so like the car will spin over and crank crank crank, pop, crank crank crank pop like its all loaded up. I tried un plugging the injectors and cranking it to clear it out if it was flooded, it popped a few times and then stopped, after plugging the injectors back in i got no popping just crank crank crank...
the car did run before the engine was out, well electricly anyways lol

Re: Car wont start after rebuild, HELP!
 

Have you checked for spark and fuel yet???

It has been a while for me but that plug looks like the oxygen sensor. My car is out in Shakopee so I can't go and check though.

Re: Car wont start after rebuild, HELP!
 

I am guessing the timing is off. You may think its on but double check again with the cover off. It sounds like it may be off by a few teeth or something.

Re: Car wont start after rebuild, HELP!
 

I dont think its an o2 sensor, its on the drivers side right by the coil pack.
when I checked for compression, I checked for spark while the plugs were out, spark is good and strong. I will double check the timing, but the top cover is off and the timing marks line up perfectly, ill throw a screwdriver down the #1 spark plug hole just to make sure its tdc
thanks for the help guys

Re: Car wont start after rebuild, HELP!
 

Well if I get time I will drive down to shakopee and check wht that connector is for on my other car. Shouldn't be the 02 on the drivers side. If I remeber there is only the power transistor and coil on the drivers side...

Check fuel yet?

Re: Car wont start after rebuild, HELP!
 

well, I took the hose off and cranked it into a beer bottle and it just kind of dribbled out.
that would be great if you could check where that connector is on your car.

Re: Car wont start after rebuild, HELP!
 

Take the fuel line off, have someone start the car and see if it comes out upon cranking the motor. Should shoot out quite good as it is under pressure. May want to get a bucket for the check.

If you did this and it "dribbled" you have the reason it won't start. This is most likely an electronic issue though. Did the ground strap that melted just happen or was it like that?

Re: Car wont start after rebuild, HELP!
 

This is john on James' computer.

I found a couple CAS sensors. I don't think that is the problem but you can borrow one. I pulled a 90 CAS (one with Cord) and a 91/94 (no cord) and will leave them outside at the hopkins house. Give me a call and I will give you directions.

952-412-6084

Re: Car wont start after rebuild, HELP!
 

You have to make sure that all of the timing marks line up not just on top.

Re: Car wont start after rebuild, HELP!
 

Well I didn't get your call but call tomorrow if you want to try. The two times I have had a non-running DSM with fuel and spark were:

-Timing skipped
-Bad ECU

You need to figure out the fuel issue though. Maybe the ecu.

Re: Car wont start after rebuild, HELP!
 

well, the head I purchased for the car was from ebay, and it looked to have brand new spark plugs in it. after literally every other test I could possibly come up with I switched the plugs from the head that was previously on it (had bent valves) and it fired right up and ran great, the plugs were autolite 13's? idk some kind of autolite plug. I have no idea how this made any difference because I checked for spark on the autolite plugs and they were more than good in my opinion. I threw some NGK's in there and it fired right up..... wtf? thats crazy. maybe I have a weak coil pack?

Re: Car wont start after rebuild, HELP!
 

also, thank you VERY MUCH john for your offer. its peope like you that make forums like this a good place to be.

cheers

Re: Car wont start after rebuild, HELP!
 

Glad to see you got it running. Giver her hell :)