Advise needed for timing

[DJ_Steve]

Hello everyone. I'm looking for some advise. My car is a 1.9tdi 115 brb engine and I have recently had water pump completely collapse requiring a timing belt change (belt had not snapped but had jumped a couple of teeth ) car will now turn over and sounds like it has plenty of compression. But will not start. I'm getting an error for camshaft sensor out of range. And according to vcds measuring block 4 the timing is showing 6.3 btpc but I don't know if this is normal or not as I have no working vehicle to check against . Anyone got any ideas

[OliNix]

It needs retiming with the correct timing kit. I would also check your valves haven’t got overly friendly with the pistons after it jumped a “few teeth”.

Even one tooth can be terminal for your drivetrain

[DJ_Steve]

timing has been checked twice and seems to be fine thats whats confusing me - almost certain theirs no valve damage as engine was not ran after the pump went and it has excellent compression with no weird noises from exhaust or otherwise .

im going to recheck timing again but i need advise on exactly how the do it on a brb engine as they seem to be different to most normal PD engines for some reason

[arman123]

have a look and read through this

Removing and installing toothed belt

Special tools and workshop equipment required

t	Diesel injection pump locking pin -3359-

t	Crankshaft stop -T10100-

t	Locking pin -T10115-

t	Counterhold tool -T10172- with pin -T10172/4-

t	Locking fluid → Electronic parts catalogue

Removing – Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

– Release quick-fasteners -1- and -2- and take off front noise insulation. Leave rear noise insulation in position. – Remove bumper cover (front) → Rep. Gr.63. – Move lock carrier to service position → Rep. Gr.50.

– Unclip cover caps. – Unscrew nuts -arrows- and detach engine cover panel. Also pull out dipstick if necessary. – Remove insulation beneath cover panel (if fitted).

– Remove top toothed belt cover by releasing retaining clips -arrows-. Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. – Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. – Remove poly V-belt from alternator pulley.

– Unscrew bolts -3- and detach cover -2-. – Move charge pressure control solenoid valve -N75--item 1- clear to one side with hoses connected.

– Lever off cover cap from vibration damper. – Unbolt vibration damper; counterhold on centre bolt with ring spanner.

– Unbolt toothed belt cover (centre and bottom) -arrows-. Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise). Note Turn over the engine at the central bolt on the crankshaft.

– Turn the crankshaft to TDC. l The space between the two lugs -1- on sender wheel of camshaft must align with marking “4Z”-item 2- on toothed belt cover (rear). Note For illustration purposes, the camshaft sprocket is shown with the toothed belt removed. – Lock hub with locking pin -3359-.

– Lock crankshaft sprocket with crankshaft stop -T10100-. l The markings on the toothed belt sprocket -2- and the crankshaft stop -T10100--item 1- must align. The pin of the crankshaft stop -T10100- must engage in the aperture in the sealing flange. Note The crankshaft stop -T10100- can only be pushed onto the sprocket from the front face of the teeth.

– Mark rotation direction of toothed belt with chalk or felt-tip pen. – Loosen securing bolts for camshaft sprocket -arrows-.

– Loosen securing nut -1- for tensioning roller. Note t Make sure that stud is securely fitted. t If stud is not securely fitted, apply locking fluid onto stud and screw in as far as stop. – Using a hexagon key, turn eccentric adjuster on tensioning roller anti-clockwise -arrow- until it is possible to lock tensioning roller in position with locking pin -T10115-.

– Then turn hexagon key clockwise -arrow- until stop and tighten securing nut -1- finger-tight. – Take off toothed belt first from coolant pump and then from the remaining sprockets. Installing (adjusting valve timing) l Camshaft locked with locking pin -3359-. l Crankshaft locked in position with crankshaft stop -T10100-. l Tensioning roller locked with locking pin -T10115- and secured at right stop with securing nut. Note t Toothed belt adjustment must always be performed when the engine is cold. t The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Otherwise, there is a risk of damage to valves and piston crowns.

– Ensure that tensioning roller is seated properly in rear toothed belt cover -arrow-.

[arman123]

– Screw in bolts -arrows-, but do not tighten. l It should just be possible to turn the camshaft sprocket on the hub without axial movement. – Turn the camshaft sprocket in its elongated hole clockwise until the stop. – Fit toothed belt first onto camshaft sprocket, tensioning roller, crankshaft sprocket and then onto coolant pump sprocket.

– Adjust toothed belt tension as follows: – Remove locking pin -T10115-. – Loosen securing nut -1- for tensioning roller. Note When loosening securing nut -1-, make sure that the threaded pin is not loosened together with the securing nut. – Turn eccentric adjuster of tensioning roller clockwise -arrow- using hexagon key until pointer -2- aligns with the centre of the slot on the base plate. Note Make sure that the securing nut does not also turn. – Hold tensioning roller in this position and tighten tensioning roller nut to 20 Nm + 45°. Note When tightening the securing nut, the pointer may move up to 5 mm (maximum) to the right of the slot in the base plate. This position must not be corrected, because the toothed belt stretches slightly when running in.

– Insert counterhold tool -T10172- with pins -T10172/4- as shown in illustration and apply tension to camshaft sprocket by pressing in -direction of arrow-. – Tighten bolts -1- on camshaft sprocket to 25 Nm. – Remove locking pin -3359- and crankshaft stop -T10100-.

Checking valve timing Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise). – Turn crankshaft two rotations in normal direction of rotation until the crankshaft is just before TDC again. – Lock the hub into place with the locking pin -3359- when turning. l The space between the two lugs -1- on sender wheel of camshaft must align with marking “4Z”-item 2- on toothed belt cover (rear). Note For illustration purposes, the camshaft sprocket is shown with the toothed belt removed. – Check whether: l The crankshaft can be locked with the crankshaft stop -T10100-. l The tensioner pointer is centred or a maximum of 5 mm to the right of the slot in the base plate.

If the crankshaft cannot be locked: – Loosen securing bolts -arrows- of camshaft sprocket.

– Turn the crankshaft slightly further in the normal direction of rotation until it can be locked with crankshaft stop -T10100-. Note If the crankshaft has been rotated beyond TDC, turn it back slightly so you can then reset it to TDC by turning in the normal direction of rotation.

– Tighten securing bolts for camshaft sprocket -arrows- to 25 Nm. – Remove locking pin -3359- and crankshaft stop -T10100-. Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise). – Turn crankshaft two rotations in normal direction of rotation until crankshaft is at TDC again. – Check valve timing once again → Anchor. Assembling Installation is carried out in the reverse order; note the following: Note t Renew seals and gaskets. t Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. – Install toothed belt cover (bottom and centre). – Install vibration damper → Anchor. – Install poly V-belt → Anchor. – Fit toothed belt cover (top section). – Install lock carrier with attachments → Rep. Gr.50. – Install bumper cover (front) → Rep. Gr.63. Tightening torques

Component	Nm
Camshaft sprocket to hub	25
Tensioning roller for toothed belt to cylinder head	20 + 45°
Toothed belt cover (bottom) to cylinder block	10 1)
Toothed belt cover (centre) to cylinder block	10 1)
l 1) Apply locking fluid when installing; refer to → Electronic parts catalogue for locking fluid.