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Volkswagen Jetta, Golf, GTI: 1985-1992 (A2) 92 GTI 16V No fuel out of fuel Distributor

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Last Post: Oct 21, 2009 5:35 PM Last Post By: tcovenant2000
Amanaland

Posts: 3
Registered: 01/28/07
92 GTI 16V No fuel out of fuel Distributor
Posted: Oct 5, 2009 10:10 PM
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I have a 1992 GTI 16V that won't start and run. I had let it sit for several months as I couldn't get the alternator belt tight enough, there was a broken off bolt in the bracket. I finally pulled the thing apart, got the bolt out, and its back together. A friendly mechanic suggested that I might want to clean out the fuel distributor. I pulled of the lines and removed the fuel distributor and it looked clean and the air flow sensor looks like its within spec. After fixing the alternator mounting, and putting the fuel distributor back together it wouldn't run. It cranks four compression strokes goes Varoom like it wants to start and then continues cranking without starting. If I continue to crank with the pedal floored, turn the key back and try to start again it runs briefly.

According to "the book" it has CIS-E Motronic fuel injection with the
hard steel lines

This is what I have done:
. Probably 6-9 months ago you sold me a used control pressure regulator and new o-rings. Mine was leaking gas to the outside.
. All of the boots between the fuel distributor and the intake manifold are connected, in good shape and tight
. The in-tank fuel pump seems to be working
. I replaced the under-body fuel pump with a used one. Mine was wet with gasoline and the new one runs and is dry.
. I replaced the fuel filter
. I grounded the ignition coil lead and cranked the engine, checking for voltage on the cold-start injector plug. I understand it was supposed to be hot for a couple of seconds at 68 degrees F. I quit counting after 20 seconds of cranking, it was hot all of the time. The 5th injector works and has a nice pattern. I checked the resistance on the coolant temperature sensor and it was much lower than the spec in my book, so I replaced it. The starting routine remains the same whether I have the sensor connected or not.
. We don't have a way to check fuel pressure, but I cracked a line at the (?) diaphragm pressure regulator going in and coming back out and there was pressure at both fittings. When I crack a fuel injection line at the top of the fuel distributor, it doesn't appear that I'm getting gas out of it.

All of this makes me wonder if there is enough gas coming through the 5th injector to start it but not keep it running?
tcovenant2000

Posts: 1,278
Registered: 12/09/03
Re: 92 GTI 16V No fuel out of fuel Distributor
Posted: Oct 7, 2009 5:21 PM   in response to: Amanaland in response to: Amanaland
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Yes. It's likely the 5th injector is supplying all your fuel right now and that's why it tries to start.
Fuel not coming out of the disty is related to the control rod that rides on the lever arm from the air flow plate. It's really that simple.
Pull an injector. Jump the fuel pump relay. Put the injector in a jar. Don't smoke!!!!
Use pliers to grip the nut in the center of the air plate (or use a magnet) and lift the plate up. It should lift easily and smoothly and drop back to rest position easily and smoothly.
It's quite possible the rod is simply stuck and the air can't lift the plate with enough force to push the rod in.

Thomas
Amanaland

Posts: 3
Registered: 01/28/07
Re: 92 GTI 16V No fuel out of fuel Distributor
Posted: Oct 21, 2009 1:58 PM   in response to: tcovenant2000 in response to: tcovenant2000
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The plate in the fuel distributor moves freely.

I have jumpered the fuel pump relay, pulled an injector and raised the throttle plate while actuating the fuel pumps and I don't get fuel at the injector. The "book" suggests that the ECU controls the fuel distributor. Is that were I go next, or try to find a fuel distributor?

How unique is the fuel distributor on this car?

thanks for your thoughts
tcovenant2000

Posts: 1,278
Registered: 12/09/03
Re: 92 GTI 16V No fuel out of fuel Distributor
Posted: Oct 21, 2009 5:35 PM   in response to: Amanaland in response to: Amanaland
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GTI 16V is Motronic, right? Or is it CIS-E? Sadly I don't actually have my info to hand, as I'm traveling right now. I think it must be CIS-E, because as I recall the Motronic doesn't have a fuel disty, but maybe I'm wrong.
At any rate, even CIS-E uses mechanical injectors.
Back to basics:

If you don't get fuel at the injectors when you lift the air flow plate it's one of three things, all relating to fuel pressure. All will require a fuel pressure testing kit such as described on the Bad Habit Rabbit pages, and can be purchased on Ebay on occasion.
1. Low fuel pressure from the pumps/clogged fuel filter. This is tested by putting the gauge on the inlet to the disty with a gate valve between the gauge and the disty and jumping the fuel pump relay. With key on (pump running)and gate valve closed you should have 80-100PSI.
Open the gate valve so fuel can flow into the disty. The pressure should remain above 80. If it doesn't, look for a faulty pump, plugged accumulator/fuel line/filter.
2. Low system pressure. Again as described on Bad Habit Rabbit, there is a main pressure regulator that keeps pressure entering the fuel disty from going too high. It does this by opening and allowing some fuel to return to the tank. If it's stuck open you won't get any fuel from the injectors. It's easy enough to pull apart and clean. Just search for Bad Habit Rabbit.
3. Dead fuel distributor. It's possible that the membranes in the disty are simply broken and dead. If the 4 step pressure tests listed on Bad Habit Rabbit are all correct, then this is the likely answer.

hope that helps!

Thomas
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