No start problem 2003 GOLF GLS TDi

[wild3bill]

The history began with a couple of mornings after a cold night -10°F to +10°F. After I tried to start I notced the trip odometer reset to zero and the dash clock reset to 12:00.
An hour of charge from A 2-4-6 Amp battery charger and outside temp rose over 15 to 20°F engine started right up and was good for the rest of the day.
Then, at night, I noticed the radio was dark at night (no illumination) when head lights and dash lights were on. Monsoon radio would not turn on.
One Saturday going 60 MPH the Engine just died on the highway as if no fuel. I had it towed home as it was late Saturday afternoon.
I drained the fuel filter: no water or dirt in the fuel which came out from the filter drain, it appeared clean. I could draw fuel from the almost full tank through the filter with an external pump. Engine cranked over fine and fast but would not start or run. I tried the second Master key. I noticed a little red LED blink on the radio. Radio now illuminated when I turned on headlights. Radio worked but engine still will not start!
Any help of suggestions appreciated !!!

[Fatmobile]

Sounds like a charging problem.
What voltage does your battery read?

[wild3bill]

I neglected to mention I assume the Battery was 2003 Oruginal (2009 -2003= 6 Years for a 5 year battery so it is past its expiration. Low Volt condition during COLD start attempt corrupted OTHER data in compiter At the time dash clock and trip milage reset to zero.
After charging the battery shows 12+ volts
At this point I assume I beed a new Battery and I HOPE the starting problem is something the dealer can fix with a scan tool !

[wild3bill]

Mechanic says timing was right on OK, but the injection pump does not pump, no suction. He reccomends Replace Injection Pimp!

[Fatmobile]

I wonder how they came to that conclusion., and how hard fuel pulls from the tank.
Maybe there is a fuel line restriction keeping the pump from pulling fuel.

I only mess with the old 1.6s but I have never heard of,
and have a hard time imagining the vane pump going out while driving down the road.
Usually happens after they have sat for awhile and the vanes stick in place.

[coke]

Common problem with them is relay 109, engine computer relay. This will in fact cause a no start condition. And if I'm correct, I also believe it will not let fuel into the engine. But it should still suck fuel.

I would suspect his assumption that the injection pump is bad. Try the 109 relay, its a 20 dollar item and its easy to change.

[wild3bill]

Replaced Relay 109 last week. Mechanic says he primed the pump with fuel. Timing is right on. He says it should start not does not start! I used an external 12 volt pump to pull fuel from the tank through the lines and filter before I had it towed to mechanic. While it was in my driveway I tried to start it with the rxternal pump in line with 2 to 3-1/2 Psi Diesel on the in fuel line. After it did not start there was still residual pressure on the input line. The injector pump did not draw fuel with 2 or 3 psi at the inlet!

[Fatmobile]

I wonder if the "OUT" bolt screen is clogged,...
or if the TDI "OUT" bolt even has a screen hmmm.

On the 1.6s the "OUT" bolt has a screen so the small restrictor hole in the output banjo won't get clogged.
I've seen one and heard of a few on here that were clogged and not allowing fuel to flow through the pump.

[wild3bill]

VW dealer promised my mechanic a factory rebuilt TDi Injection Pump a week ago.New date is today Waiting on parts!!!

[wild3bill]

But next Fall:

Next fall I plan to switch my Mobil 1 from 5W40 to 0W40 (Also rated VW502.0 & VW505.0)by Thanksgiving and park overnight in tke shed. A New Battery in any event seems wise!