Cannot Start 2002 Audi Allroad 2.5TDI Automatic AKE after cam belts changed

[ceilidhalfie]

I have finally completed the timing belt change. All cambelts, v-belts, tensioners and rollers together with new thermostat and water pump. Bushes on power steering bracket also changed and new bearings fitted to the air con compressor pulley. Put everything back together with lock carrier in service mode.
Fingers crossed I turned on the ignition - the engine cranks but no cylinder fires. Tried about a dozen times but nothing. This is 10 days after starting the job - ok I'm slow but I took my time trying to make sure everything done according to the manual!
Before I started the job, I ran VCDS to dynamically check the timing. It was 100%, retarded and 3.5 degrees, ie. just within spec.
When fitting the new cambelts, tensioners and roller, I had the TDC, crankshaft locking tool and both cam-locking plates and the fuel injection pump locking tool in place. On removal, two complete rotations and the crankshaft lock and cam plates all went back in again. The fuel injectionpump locking tool would not go in though. The end of a wire coat hanger did though and I could feel that the pump pulley was just short of the hole. This was the only thing slightly out of spec with the manual. The two pointers on the tensioner are aligned.
I know I can make a small adjustment to the fuel injection timing by loosening the 3 bolts on the cam sprocket and then rotating the injection pump clockwise or anti-clockwise. But should I adavance or should I retard the timing? Or is it likely to some other problem? The car started fine before the job. The engine cranks ok now and there are no warning lights on the dash.
Any comments would be most welcome.
Thanks.

[bagpipingandy]

Any fault codes?, have you left something unplugged?if you are Sure all belts and timing are correct, I think pump timing only out a slight bit would not stop it starting, I may be wrong there but i would check for fault codes, or did you remove or loosen any diesel lines? If so they are tough to bleed, crack open an injector pipe or 2 to check for diesel while cranking.

Andy

[Crasher]

Have you opened up the fuel system at all, filter, pump etc?

[ceilidhalfie]

Any fault codes?, have you left something unplugged?if you are Sure all belts and timing are correct, I think pump timing only out a slight bit would not stop it starting, I may be wrong there but i would check for fault codes, or did you remove or loosen any diesel lines? If so they are tough to bleed, crack open an injector pipe or 2 to check for diesel while cranking.

Andy

Hi Andy. I have run VCDS and it only comes up with a Climate Control Fault 00819 High Pressure Sensor (G65) 30-00 Open or short to plus. I think I may have forgotten to plug in the connector to the side of the condenser. No other codes. I will have a look again to morrow to see if I have missed something, check the pointers of the tensioner are in alignment. In the event of nothing turning up I think I might try advancing the timing - nothing to lose!
Thanks again for your comments.

[ceilidhalfie]

Have you opened up the fuel system at all, filter, pump etc?

Hi crasher & thanks for the comment. Only time I went near the fuel system was to lift the fuel filter up a bit to get to the plug at the back of the right cam for the locking plate. I also removed the WATER hose at the fuel heat exchanger to bleed the coolant fill. So no, I never opened the fuel system (I see what you are getting at - I had great problems last service (last year) getting rid of air when I changed the fuel filter. I had to crank the engine for an eternity before it fired.) Only thing I can add is that the car has not been started for 10 days - when I started this job.

[Crasher]

Give it a gentle sniff or two and try it but be bloody careful, a runaway is scary! If it runs (I use brake cleaner) it is not getting fuel, if you have screwed up the cam timing doing this will wreck it even more so take care.

[ceilidhalfie]

Give it a gentle sniff or two and try it but be bloody careful, a runaway is scary! If it runs (I use brake cleaner) it is not getting fuel, if you have screwed up the cam timing doing this will wreck it even more so take care.

Crasher, can you explain "Give it a gentle sniff or two and try it but be bloody careful, a runaway is scary! If it runs (I use brake cleaner)". I don't know what you mean. Thanks.

[kite]

A sniff if easy start ir brake cleaner.
A runaway is an engine that just keeps revving until something major breaks..

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[bagpipingandy]

We are thinking air in the fuel, maybe as it has sat so long, or you disturbing the fuel filter, and as you have experienced, they don't like to start, it is just a hunch though. also tripple check those timing pins/locks, don't want to cause any damage. try easy start carefully as too much and the engine will rev high, even out of control, maybe safer to open a fuel line at an injector, watch while somebody turns it over until you get fuel out and retighten, do a few if there was no fuel at the 1st.

Andy

[Crasher]

If it runs on some form of accelerant into the intake you can assume you have the basic timing right so you have compression and then the problem is fuel delivery. If the system has not been interrupted you need to fault code read it, there is every possibility that the fuel pump has failed but this may not leave a fault code. I had the pump on an AKE engine fail a few weeks ago and leave no code, it turned out to have a split internal diaphragm which I had repaired at a Bosch specialist and was much cheaper than a new pump. For other people, having the pump repaired is also advantageous as it will not need recoding to the car.