2.5 TDI AXE cam install TDC? HELP!

[cram]

Hi all - we are currently replacing a worn cam on our 2006 multivan (2.5 TDI AXE).

Its going well, BUT the cam looks 180 degrees out.

We are using the special tool (aftermarket kit from Germany) and Haynes manual for reference/torque values etc to set the crank and cam at TDC, however, when its all set up, the cam lobes on no.1 (i.e. driver's side) are pointing down. This has my father (a retired mechanic) confused as he is used to having the lobes point up and out (V shape). Makes sense as it closes both valves.

I have little mechanical experience, but it also goes against what I can find on www.

Apparently the tools can only fit in one way - which from our experience is seems to be the case.

So what is going on here? Any help appreciated.

[Transporter]

I’m not sure if you’re aware or not? The Cyl. #1 is on the gearbox side.

[cram]

Thanks for quick reply Transporter.

That makes a bit more sense lobe-wise.

The Haynes manual states "1-2-4-5-3 (no 1 cylinder at right hand end of engine) - Assumed this to be from driver's seat. If you take it from the front of the car it would be gearbox side.

Also, my dad is probably more family with normal petrol engines where No1 is at timing belt etc. Given that the AXE cam is gear driven then, the No1 is at cam drive end.

Thanks again Transporter.

Also out of interest, which oil (brand/type) would you recommend for the old girl?
So much debate etc out there...Can't quite get my head around it.

[Umai Naa!!]

506.01 is the correct spec for these, but it's impossible to find these days, and is horrendously expensive.

504/507 spec 5W30 is ok to run in them. Brand wise, they're a much of a muchness. It's the specs that count.

[Transporter]

I’m guessing that your van production date is before 7/2006. in which case you must use 506.01 oil
Liquid Moly Synthol 0W30 is the one to get.
The 507.00 shouldn’t be used.

See more here T5 FAQ and How to THREAD (up to August 2009).

[cram]

Thanks for feedback and link - can't believe I missed that one. Awesome resource.

Van is Feb 2006 build (July 2006 compliance).
Its a 2.5 AXE TDI SWB Manual 4motion (took a long time to find with these specs!).

So oil - was initially looking at Fuchs Titan GT1 5W-30 which is 507 approved.

But autobahn can get Liquid Moly 0W30 (special order ordered in @ $159/5L).
I don't mind paying for the right oil (cheaper and less hassle than another cam etc).

They can also get Penrite Enviro+ C2 0W-30 (@$55/5L) - so one third the price.
(although not with DPF - which I'm pretty sure are only BXX engines? pls correct me if I'm wrong...). He did say that although Penrite recommend it for 506.1 it may not be quite as good as the Liquid Moly.

Love the van but its a steep learning curve! I bought it at auction knowing it had the cam issue - it was audible and lobes were visibly worn when we took it out so knew we were in for a bit of work! Good way to get to know your van though!

[Transporter]

The Penrite 0W30 is not approved for your engine and the oil companies only guessing that the oil should protect that engine, but often they change their recommendation.
I've had 2005 4Mo T5 with the same engine, so I remember a few occasions when the Penrite change their recommendations to "refer to the dealer" and not for just an engine application. There is also Fuchs Titan GT1 with VW506.01 though it's hard to get. The Autobarn price is inflated.

[cram]

Thanks Transporter - I'm sold on the Liquid Moly Synthol 0W-30. Its the right oil for the engine.

Anyway, its $167.95/5L on their (Liquid Moly) website so figured that $159 at Autobahn was pretty much the going rate.
Feel free to point me in a more affordable direction. Have to order it regardless of where it comes from.

[Transporter]

You pay premium price at Autobarn, unless it's on sale. I'd try Supercheap Auto.

Imparts has Ravenol which is cheaper than Liqui Moly.

More on engine oil for AXE here in this post.

[cram]

As an aside, VW here in Brisbane apparently use 504, 507 across the entire VW range.

[Umai Naa!!]

Yes, it's been widely accepted that the 504/507 is a suitable alternative.

[Transporter]

As an aside, VW here in Brisbane apparently use 504, 507 across the entire VW range.

...and I can only imagine, when the engine fails couple years later, no one will raise the eyebrows, since it will be too old.
If not fitted with the DPF “Refer to dealer”

[Sunny43.5]

Conniving buggers aren't they .

[Syncrotek]

Valvoline Synpower III 5-30W has VW 506.01 rating but is not officially VW approved. Been using it for 4 years, engine runs
smooth and quiet, oil stays very clean, last purchase at Autobarn on discount was $60 p/5L.

[cram]

OK - a quick update (Have been a bit busy with a few other things).

So, new issue. The van just doesn't want to fire - yes a bit disheartening....

Everything is back together (except bumper, headlights etc). The van turns over but just doesn't fire.
Appears that its just not injecting fuel - no cough, white smoke, diesel smell from exhaust etc

Cam/crank etc were set with appropriate tools. Marking on cam drive gear was aligned with the block and torqued to spec. Engine was re-assembled including all intake hoses etc.

Tried a friend's OBD2 reader - it could see the car but couldn't connect. He is a diesel fitter with Caterpiller so we checked a few things.
(Will buy another one - if someone wants to recommend a 'good budget one that is known to work with 2.5 AXE" that would be useful).

Checked:
air flow sensor in air box.
cam sensor
new fuel filter (bled and working fine)
battery etc disconnected ignition turned on, reconnected and re-tried...

Also the temp light comes on and thermo fans turn on to max after a few seconds after ignition is turned - which I assume is due to the air temp sensor behind the from grill. Can I disable this?

So, for some reason the car is not injecting diesel.
maybe timing?
maybe a sensor?
maybe the computer just telling it not to?

Over to you gents...