2.5tdi t4 wont start

benlawers · 30-09-2009,10:09 PM

Thanks for the hint. We are both at a stage where we will try anything. Looks like a pig of a job to do though! Any tips?

**carbon** · 30-09-2009,11:08 PM

As long as the cam timing is set correctly the only mark required to set the injection timing is the TDC mark on the flywheel. It should be visible through a small inspection hole in the bell housing and would have been required to set the cam timing.

Injection timing for the ACV engine is 0.55mm lift at TDC

benlawers · 01-10-2009,07:13 AM

Thanks. You think I'll need a mechanic? I don;t understand the 'lift' bit and what to measure at 0.55mm!

**carbon** · 01-10-2009,07:58 AM

Hi benlawers

Sorry for the confusion I thought it was one of your posts I was replying to but it was m7vlj that mentioned pump lift. Unless you have access to a dti and the correct adaptor to fit the injection pump its not something you can guess to get the engine running. Even with the dti it still can take some time to get this set correctly.

**m7vlj** · 02-10-2009,06:46 PM

i have got mine running now off the key everytime. set the motor to tdc then slackend off the cam pully to the pump and turned the pump pully anti clock wise till it stoped and tightend up the pully, cracked up first time. have a go! worth a check to see if it is right
matt

benlawers · 02-10-2009,07:27 PM

Blimey. Good on ya.

Can I just check. TDC is the 0 (zero) on the flywheel with maybe an underscore but that's not so clear. Does that sound right? Could the difference between scrapping it and not be so simple?

**m7vlj** · 02-10-2009,07:31 PM

yer there is a little notch on the flywheel and an arrow on the casing to match them up. yer i very nearly scrapped mine last week

benlawers · 02-10-2009,07:50 PM

Thanks again. Am I looking for a 0 on the flywheel or a -
?
Thanks.

**m7vlj** · 04-10-2009,11:22 AM

its the '-' that has the '0' next to it you can just see it when all the fronts off and the pipes etc are out the way

benlawers · 04-10-2009,07:56 PM

Blimey. I have spent today on the starting problem. Turn out the pump timing was one factor and the pump throttle tuning another. Process of elimintaiton - but the factory marks on the timing and the yellow paint on the pump throttle tuning turned out to be both wrong.

So close to a great 2002 van heading to van heaven! A day well spent. Just need to creep to the wife and kids now

Thanks for the motivation to keep going