2.5tdi t4 wont start

[m7vlj]

iv just put the engine together on my t4 and got it running with the aid of easy start the other day, sounded ok, was a bit slow reving up but took no notice, let it warm up with everything sounding as it should, turned it off and went to try and start again. now it wont go at all and doesnt seem to have power to the stop solinoid on the injection pump, iv tried putting a live to it but still no difference. had diognostics on it and is coming up with code 17978 ecu blocked. there is fuel at the injection piped and is smoking when cranking so i know there is fuel getting to the cylinders, im stumped now, really need help
matt

[Rake]

ECU blocked does not sound too good.

You need to find out what that means.

[harris921]

Id still set the pump timimg properly even though you have fuelat the rail. It's critical on these engines.

[m7vlj]

the timing is right, there seems to be some sort of electrical fault with it that is stopping the injection pump to work or function.

[m7vlj]

Right, i have unblocked the ecu, got rid of all the codes that where coming up and everything is as it should be, iv checked all sensors manually checking resistances and again everything is as it should be, but still wont start.
any ideas, is it likely to be the injector pump?

[benlawers]

Hi. did you get anywhere with your atarting problem yet? I took a good working engine from a knackered van, put it in mine and have EXACTLY the same problem as you. Runs on easy start, tries to fire without but just won't quite bite. I got a mechanic out to it who spent 3 hours on it yesterday and he gave in in the end. Frustration:aargh4:

[m7vlj]

Hi. did you get anywhere with your atarting problem yet? I took a good working engine from a knackered van, put it in mine and have EXACTLY the same problem as you. Runs on easy start, tries to fire without but just won't quite bite. I got a mechanic out to it who spent 3 hours on it yesterday and he gave in in the end. Frustration:aargh4:

have you ensured the key is linked to the reader and ecu. once mine had blocked i had to re connect the key with the immobalizer. im gona have a close look at the pump timing, gona set it properly using a dti to find the lift piont. anyone know of the measurments of pump lift?

[m7vlj]

please keep me updated if you get yours going, mine is starting to do my head in now

[benlawers]

I will , although I can't see what there is left to try. It's already done my head in. I am no expert on the immobiliser possiblility - as I said, I have removed the plunger from the solenoid. Any other suggestions?

Good luck with fuel pump timing. There appears to be a lack of marks for both fuel pump and cambelt timing!

[harris921]

How do you know your pump timming is right? Ive heard all this before and it's pump timming every time, especially if it runs off easy start.

[benlawers]

:beerchug: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]

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]

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

[carbon]

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]

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]

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?:p

[m7vlj]

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]

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

[m7vlj]

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]

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:beerchug:

Thanks for the motivation to keep going:biglaugh:

[m7vlj]

Thats really good to hear, glad your moving in the right direction. so is the van running now?

[benlawers]

Yes - running and after lots and lots of messing with both fuel pump adjustments it appears to be fine - but will be a few days before I can spare the time to put the van back together and see how it drives. The really really annoying thing now is that it appears that my original engine, on inspection yesterday, had only slipped a tooth or something similar and would have been a relatively easy fix whereas I thought it was seized.:aargh4:

[m7vlj]

Ah man thats absolutly gutting, at least you got a spare engine if anything did go wronge. how did you set your pump up in the end, did you use a dial gauge?

[benlawers]

No specialist tools - just lots of trial and error. Not easy with both timing and throttle to set up but who needs tools whan you can spend three hours of trial and error!

I'm sure there is a good reason (?) but I am confused why there appear to be no accurate marks on anything useful - for the timing belt and the fuel pump drive belt. Anyone any ideas?

[carbon]

Hi benlawers

VW have used this way of timing there diesel engines since at least 1985 to my knowledge. The six cylinder engine in the LT’s was similar to time as the 5 cylinder T4’s. The flywheel is marked at TDC, the camshaft has a machined slot in the injection pump end for a setting tool to be positioned. The injection pump pulley has a little v cut into one edge which roughly aligns with a line cast into the injection pump mounting bracket, accurate setting of the injection timing is set with a DTI initially and can be checked with vagcom or the VW equivalent once the engine is running and up to operating temperature (2.5TDi's not 2.4D). Small adjustments can then be made by adjusting both of the injection pump belt tensioners.

[harris921]

Carbon is correctt, you may have got it running but if you were to put it on a 5051 I bet its miles out. It will either smoke or have a real lack of power or both, Ive had them sound sweet on idle but then you connect it to 5051 and it's miles out.

If it was a runing engine you can lock the pump up before you take the belt off, there is a gold 13mm on the side of the pump with a black horse shoe clip behind it. Simply slacken the bolt off, remove the clip and then tighten 13mm till it stops. You can now remove the pump belt and the pump will not jump round.