2.5 TDI AXE cam install TDC? HELP!

[Umai Naa!!]

Yes, it's been widely accepted that the 504/507 is a suitable alternative.

[Transporter]

As an aside, VW here in Brisbane apparently use 504, 507 across the entire VW range.

...and I can only imagine, when the engine fails couple years later, no one will raise the eyebrows, since it will be too old.
If not fitted with the DPF “Refer to dealer”

[Sunny43.5]

Conniving buggers aren't they .

[Syncrotek]

Valvoline Synpower III 5-30W has VW 506.01 rating but is not officially VW approved. Been using it for 4 years, engine runs
smooth and quiet, oil stays very clean, last purchase at Autobarn on discount was $60 p/5L.

[cram]

OK - a quick update (Have been a bit busy with a few other things).

So, new issue. The van just doesn't want to fire - yes a bit disheartening....

Everything is back together (except bumper, headlights etc). The van turns over but just doesn't fire.
Appears that its just not injecting fuel - no cough, white smoke, diesel smell from exhaust etc

Cam/crank etc were set with appropriate tools. Marking on cam drive gear was aligned with the block and torqued to spec. Engine was re-assembled including all intake hoses etc.

Tried a friend's OBD2 reader - it could see the car but couldn't connect. He is a diesel fitter with Caterpiller so we checked a few things.
(Will buy another one - if someone wants to recommend a 'good budget one that is known to work with 2.5 AXE" that would be useful).

Checked:
air flow sensor in air box.
cam sensor
new fuel filter (bled and working fine)
battery etc disconnected ignition turned on, reconnected and re-tried...

Also the temp light comes on and thermo fans turn on to max after a few seconds after ignition is turned - which I assume is due to the air temp sensor behind the from grill. Can I disable this?

So, for some reason the car is not injecting diesel.
maybe timing?
maybe a sensor?
maybe the computer just telling it not to?

Over to you gents...

[Umai Naa!!]

Try the spare key.

Also with the scan tool, if it's got a non-VW radio on it, you'll need to disconnect it as it interferes with the communication network.

[cram]

Good idea, but no joy with the spare key. Will give it another crank later today....
Radio is stock unit (need to get a code from VW now!).

I think we are going to check cam, crank and cam drive gear/timing again.
Although it was double checked when it went in. Cam and crank tool in place, etc, timing mark was level with the rear of the block.
PITA though....its got to be something simple...

[Transporter]

Did you try to tow start it? If you had the cylinder head off and valves out (resurfaced), sometimes that’s all what’s needed.

[cram]

There is still no joy with this old girl:

- spare key makes no difference (no immobilizer warning light on dash either).

- the head didn't come off and not in position to tow start (small house lot, busy road out in front and the van is unregistered).

- got an OBDeleven Pro only shows low battery (at 12.4V after a bunch of cranking) and service light (haven't worked out how to change that). Still playing with it.

- Took the covers to check timing - crank and cam tools align perfectly as does cam gear mark (level with rear of top of head).

- Still not getting diesel into the engine. It coughed once when we used start ya bastard....
* New fuel filter, primed.
* Tank pump primes.
* Now, tandem pump (which was unbolted from head for cam install only gives 1 bar (measured) when cranking. I know it needs more (~8 bar). We used an exterior pump pumping straight from jerrycan into fuel rail which was doing 8-9bar. but still no joy.

So, our next step is to check cam/injector clearance using dial indicator (just haven't had one handy) so $%&& intake manifold needs to come off again....

So....
- Could is be non-return valve or some sort of fault with the tandem pump?
- I imagine if it is electrical if should give fault code?
- Or does it just need to be cranked more (I get oil pressure light and the old girls asks me to stop). I have read that sometimes it needs a few minutes of cranking?

Reaching the end of my patience with the van!

[Sunny43.5]

I am not sure if Jmac is still on the forum but he is wizz VW mechanic at Underwood , he might be worth chasing up for some clues . He used to do mobile servicing some years back , he helped me with my sons T4 when it wouldn't start after an engine swap . It was the ignition key as the original engine was diesel and the engine management system from the donor car would not register the key . Had to get the key code copied and transferred to the key and it started immediatly .