Car wont start after a timing belt change.

**minny** · 14-09-2016,07:11 PM

So after the biggest nightmare in the world putting everything back together, I turned the car over on the ignition, the car was turning over and the timing belt was going around but the car wouldn't spark into life.

I used the correct locking tools, with the two notches lined up, on the lower crank sprocket and locking tool, at the same time the two things behind the cam sprocket lined up with the arrow marked 4z i think it is, then put that pin in. Nothing moved during instalation except the cam sprocket which you are suppose to move to get the tension correct.

I used a new belt, tensioner, roller and a tensioner activator. I set the gap between the activator and tensioner pully at near enough exactly 4 mm as directed, made sure I used the exact tourqe values, new bolts when it said get new bolts; checked and double checked everything several times over.

When everything was back together, I turned the engine on the crank sprocket several times with no problem.

So I'm wondering why no spark and it's making me a bit paranoid that something some how went wrong and I smashed my valves; although there was no lurch when I turned the car over it just wouln't fire.

The only thing I can think of when i put the locking tool on the crank sprocket, though lined up with the line on the crank sprocket it didn't go into the hole so I turned the engine back very slightly, 2 or 3mm to push it home.

I've looked high and low to see it i accidentally knocked a wire off any where and I cannot see anything amiss.

This is very worrying.

Thanks.

**FrenchAudi** · 14-09-2016,08:37 PM

The procedure you describe above is not familiar to me. I have an AEB engine. It might be a good idea to put details of your car. particularly the engine code, in your signature.

**FLAPPERJACK76** · 14-09-2016,08:41 PM

Check out the timing again. Are you sure that the locking pin in the cam wheel was completely in.

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**minny** · 14-09-2016,10:01 PM

Originally Posted by FLAPPERJACK76

Check out the timing again. Are you sure that the locking pin in the cam wheel was completely in.

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Completely in? I wouldn't go completely in, I did notice on the ilustrations that it was fully in, but the timing marks were completely aligned so I thought it was ok inserted as far as it would go.

If this is the case, one, have I wreacked the engine? I did turn the engine over several times with glow plugs in and there was no resistance or blocking whatsoever, it turned freely and i also tried to started the car several times with any lurching.

How would I put this right? Rotate the engine by hand till the locking pin goes all the way it? what if the crank mark is out of kilter with it? Do I take the belt off and then rotate the crank alone till it alinges with the lower locking tool? Would this put the cam and crank in synch again?

Very worried now, this will be the second time I've had this happen, before a belt snapped on me and the car lurched forward and stoped, this time it will be me without not puting the locking pin in fully.

thanks.

**minny** · 14-09-2016,10:02 PM

Sorry about that, It's an AJM PD engine from an Audi A4 B5 1.9 TDi year 2000

**FLAPPERJACK76** · 14-09-2016,10:13 PM

Leave belt on. Use a mirror and a torch to see the inner hole turn it till the 4z lines up put the pin in the cam, rock it back and forth gently whilst pushing the pin in it will go right into the hilt of the ball on the pin (some are tighter than others due to rust and dirt even had to gently tap some in with a small hammer ) once that's in loosen the 3x 13mm bolts then remove the belt. Lock the crank refit the belt, tension it up, remove pins, rotate 2 full revolutions put the pins in if they go in ok then remove pins refit everything and fire it up.

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**FLAPPERJACK76** · 14-09-2016,10:15 PM

One tooth out and it won't fire. Don't panic just yet

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**minny** · 14-09-2016,10:28 PM

To be a bit clearer The locking tool and mark on the crank sprocket have to be lined up picture one, which they were, at the same time the two things behind the cam sprocket have to be lined up with 4Z picture 3, which was the case. The cam has to have the locking pin in as picture 2, but has said it would not go fully all the way in to start, but was in two thirds of it's length, and with the other two being in place i thought this would be ok.

At this point, when the locking tool was on, the locking pin was in and the 4Z mark was lined up nothing was touched or rotated again until the new timing belt was on to check. So even witth he pin not fully in I don't know how it can have moved off that much, unless of course it's locking something behind the sprocket.

**minny** · 14-09-2016,10:31 PM

OK, I'll do that friday; and trying to turn the engine on via the ignition wont have caused any more damage? I did try several times thinking it was a battery low or some other lose wire i had knocked off.

Thanks.

**FLAPPERJACK76** · 14-09-2016,10:33 PM

Had a garage call me in a few years back. Same scenario as yours. They never got the pin fully in. So I checked it out by putting the crank lock in when timed up and looking through the cam pulley could see it was not quite in the right place so took it all off and redone it for them. Long story short it fired straight up.

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