2.5 TDI AXE cam install TDC? HELP!

[Umai Naa!!]

Try the spare key.

Also with the scan tool, if it's got a non-VW radio on it, you'll need to disconnect it as it interferes with the communication network.

[cram]

Good idea, but no joy with the spare key. Will give it another crank later today....
Radio is stock unit (need to get a code from VW now!).

I think we are going to check cam, crank and cam drive gear/timing again.
Although it was double checked when it went in. Cam and crank tool in place, etc, timing mark was level with the rear of the block.
PITA though....its got to be something simple...

[Transporter]

Did you try to tow start it? If you had the cylinder head off and valves out (resurfaced), sometimes that’s all what’s needed.

[cram]

There is still no joy with this old girl:

- spare key makes no difference (no immobilizer warning light on dash either).

- the head didn't come off and not in position to tow start (small house lot, busy road out in front and the van is unregistered).

- got an OBDeleven Pro only shows low battery (at 12.4V after a bunch of cranking) and service light (haven't worked out how to change that). Still playing with it.

- Took the covers to check timing - crank and cam tools align perfectly as does cam gear mark (level with rear of top of head).

- Still not getting diesel into the engine. It coughed once when we used start ya bastard....
* New fuel filter, primed.
* Tank pump primes.
* Now, tandem pump (which was unbolted from head for cam install only gives 1 bar (measured) when cranking. I know it needs more (~8 bar). We used an exterior pump pumping straight from jerrycan into fuel rail which was doing 8-9bar. but still no joy.

So, our next step is to check cam/injector clearance using dial indicator (just haven't had one handy) so $%&& intake manifold needs to come off again....

So....
- Could is be non-return valve or some sort of fault with the tandem pump?
- I imagine if it is electrical if should give fault code?
- Or does it just need to be cranked more (I get oil pressure light and the old girls asks me to stop). I have read that sometimes it needs a few minutes of cranking?

Reaching the end of my patience with the van!

[Sunny43.5]

I am not sure if Jmac is still on the forum but he is wizz VW mechanic at Underwood , he might be worth chasing up for some clues . He used to do mobile servicing some years back , he helped me with my sons T4 when it wouldn't start after an engine swap . It was the ignition key as the original engine was diesel and the engine management system from the donor car would not register the key . Had to get the key code copied and transferred to the key and it started immediatly .

[cram]

Hey guys - back after a bit of a break.

Cam/injector clearances are spot on.
Have a new battery - cranks a bit better but still no fire!
The old battery dropped down to 10.4V during cranking so maybe one of the cells was on its way out. the battery was the only error code.
replaced the fuel filter - primed it. fuel makes its way to the tandem pump.

Kinda loosing interest in the old girl very quickly at this stage.
Have sent a message to Jmac as suggested. Will also look at getting it taken to somewhere local if that doesn't work.

Otherwise - anyone want to buy a 2006 TDI 4motion manual multivan with 185k KM? new cam installed! just doesn't start...

[cram]

Actually - jmac's in box is full so can't send him a message.

[Sunny43.5]

Sent you a PM Cram

[cram]

Sent you a PM Cram

Great - thanks sunny.

[cram]

Well. Of course the cam is 180o out.

The cam tool slid into the cam easily only 1 way. We had to grind a fair bit off the sides of the notches on the cam tool as it wouldn't slide into the cam slots at 180o - once ground and clearanced it now slides into the cam both ways. This is what confused us initially.

Once the crank too and cam tool are in it now corresponds with No1 TDC at the far end (i.e. away from the flywheel).

With the tools in place, and the timing marking on the cam gear re-aligned, we tightened it all up and she started with the second turn of the key. Runs like champion.

All back together. Just need a roadworthy and rego and a good detail....

frustrating but all sorted now and of course so obvious now....good learning experience.
I can take the cam out with my eyes closed now.

[Sunny43.5]

Funny how simple things make the difference , I know when we did an engine transplant I would never have guessed a simple thing like the ignition key would prevent the van from starting . I did a complete change over from a petrol to diesel but the one thing I didnt know was the old computer would not respond to the new engine change and the key had to be recoded . After a whole week of stuffing around Jmac told me to hold the original key near the key in the ignition and the mongrel fired up first time !!