MK5 Golf GTI

All Things Mk5 => Mk5 General Area => Topic started by: dazza on August 24, 2023, 09:01:15 pm

Title: Some Help Broke Down :(
Post by: dazza on August 24, 2023, 09:01:15 pm: HI Guys

Don't get much time for the car these days only doing the minimum to keep it running. Maybe a little less than the minimum :scared1:

Yesterday on the motorway the car lost power and the wife and kids were stranded on the hard sholder. :sick:

The info i have.
Battey light came on
Total loss of power car came to standstill.
Engine was still running and was shut off.

The findings
Alternator belt was snapped completly birdnested. (tow truck driver ripped out old belt.)
VCDS Below

Now
I replaced the alternator belt and also checked the cambelt the cambelt is warn but its expected as i changed it 8 years ago.
Car just turns over and does not start.
EPC is on not sure if this is always on when trying to start.
Its strange how there was a loss of power.
Its very squeeky when turning over.

Any help is greatly appreciated.

Code: [Select]
Wednesday,23,August,2023,22:01:12:39050 VCDS -- Windows Based VAG/VAS Emulator Running on Windows 11 x64 VCDS Version: 23.3.1.0 (x64) Data version: 20230421 DS346.2 www.Ross-Tech.com Mileage: 233250km-144934mi Repair Order: 233 -------------------------------------------------------------------------------- -------------------------------------------------------------------------------- Chassis Type: 1K-VW35 (1K0) Scan: 01 02 03 08 09 15 16 17 19 25 37 42 44 46 52 55 56 75 77 Mileage: 233250km-144934miles 01-Engine -- Status: Malfunction 0010 02-Auto Trans -- Status: OK 0000 03-ABS Brakes -- Status: Malfunction 0010 04-Steering Angle -- Status: OK 0000 08-Auto HVAC -- Status: OK 0000 09-Cent. Elect. -- Status: Malfunction 0010 15-Airbags -- Status: Malfunction 0010 16-Steering wheel -- Status: Malfunction 0010 17-Instruments -- Status: OK 0000 19-CAN Gateway -- Status: OK 0000 25-Immobilizer -- Status: OK 0000 37-Navigation -- Status: Malfunction 0010 42-Door Elect, Driver -- Status: Malfunction 0010 44-Steering Assist -- Status: OK 0000 46-Central Conv. -- Status: Malfunction 0010 52-Door Elect, Pass. -- Status: Malfunction 0010 55-Headlight Range -- Status: OK 0000 56-Radio -- Status: Malfunction 0010 75-Telematics -- Status: OK 0000 77-Telephone -- Status: Malfunction 0010 ------------------------------------------------------------------------------- 5 Faults Found: 001393 - Brake Switch (F) P0571 - 008 - Implausible Signal - Intermittent Freeze Frame: Fault Status: 00101000 Fault Priority: 0 Fault Frequency: 7 Reset counter: 255 Mileage: 226061 km Time Indication: 0 Date: 2000.00.00 Time: 08:12:23 Freeze Frame: RPM: 964 /min Load: 17.6 % Speed: 25.0 km/h Temperature: 90.0∞C Temperature: 42.0∞C Absolute Pres.: 1000.0 mbar Voltage: 13.589 V 005634 - Power Supply Terminal 30 P1602 - 002 - Voltage too Low - Intermittent Freeze Frame: Fault Status: 00100010 Fault Priority: 0 Fault Frequency: 1 Reset counter: 255 Mileage: 0 km Time Indication: 0 Freeze Frame: RPM: 0 /min Load: 0.0 % Speed: 0.0 km/h Temperature: -40.0∞C Temperature: -40.0∞C Absolute Pres.: 0.0 mbar Voltage: 0.000 V 004243 - Bank 1; Fuel Measuring System 2 P1093 - 008 - Malfunction - Intermittent Freeze Frame: Fault Status: 00101000 Fault Priority: 0 Fault Frequency: 1 Reset counter: 255 Mileage: 233253 km Time Indication: 0 Date: 2000.00.00 Time: 11:30:55 Freeze Frame: RPM: 2327 /min Load: 4.3 % Speed: 97.0 km/h Temperature: 92.0∞C Temperature: 84.0∞C Absolute Pres.: 990.0 mbar Voltage: 12.192 V 000274 - Intake Air Temp. Sensor (G42) P0112 - 001 - Signal too Low - Intermittent Freeze Frame: Fault Status: 00100001 Fault Priority: 0 Fault Frequency: 1 Reset counter: 255 Mileage: 233253 km Time Indication: 0 Date: 2000.00.00 Time: 11:30:58 Freeze Frame: RPM: 2122 /min Load: 42.3 % Speed: 85.0 km/h Temperature: 92.0∞C Temperature: 143.0∞C Absolute Pres.: 990.0 mbar Voltage: 11.811 V 000257 - Mass Air Flow Sensor (G70) P0101 - 004 - Implausible Signal - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 0 Fault Frequency: 1 Reset counter: 255 Mileage: 233253 km Time Indication: 0 Date: 2000.00.00 Time: 11:30:59 Freeze Frame: RPM: 2066 /min Load: 40.4 % Speed: 83.0 km/h Temperature: 92.0∞C Temperature: 143.0∞C Absolute Pres.: 990.0 mbar Voltage: 11.811 V Readiness: 0000 0000 ------------------------------------------------------------------------------- Address 02: Auto Trans Labels: 02E-927-770.clb Part No SW: 02E 300 042 Q HW: 02E 927 770 AE Component: GSG DSG 070 0925 Revision: 04007000 Serial number: 00000505270296 Coding: 0000020 Shop #: WSC 01279 785 00200 VCID: 2149EDFBF851609BE4-8074 No fault code found. ------------------------------------------------------------------------------- Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.clb Part No SW: 1K0 907 379 Q HW: 1K0 907 379 Q Component: ESP FRONT MK60 0102 Revision: 00T12001 Coding: 0004738 Shop #: WSC 01279 785 00200 VCID: 408F487F131B49938B-8014 3 Faults Found: 57511 - Unknown Error Code Unknown - 015 - - MIL ON 00668 - Supply Voltage Terminal 30 002 - Lower Limit Exceeded - Intermittent 01314 - Engine Control Module 013 - Check DTC Memory - Intermittent ------------------------------------------------------------------------------- Address 08: Auto HVAC Labels: 1K0-907-044.lbl Part No: 1K0 907 044 AB Component: ClimatronicPQ35 066 0404 Shop #: WSC 00000 000 00000 VCID: 67DDB3E356F55EAB6A-8032 1 Fault Found: 00926 - Terminal 30 002 - Lower Limit Exceeded - Intermittent ------------------------------------------------------------------------------- Address 09: Cent. Elect. Labels:. 3C0-937-049-23-H.lbl Part No SW: 3C0 937 049 E HW: 3C0 937 049 E Component: Bordnetz-SG H37 1002 Revision: 00H37000 Serial number: 00000002060872 Coding: E78F0F270004180000140000140000000009FF0719 Shop #: WSC 01279 785 00200 VCID: 2B550FD38A9DBACB4E-807E Subsystem 1 - Part No: 1K1 955 119 C Labels: 1KX-955-119.CLB Component: Wischer VW350 013 0402 Coding: 00065493 Shop #: WSC 01279 Subsystem 2 - Part No: 1K0 955 559 T Labels: 1K0-955-559-AF.CLB Component: RegenLichtSens 011 1110 Coding: 00207646 Shop #: WSC 01279 2 Faults Found: 00526 - Brake Light Switch (F) 008 - Implausible Signal - Intermittent Freeze Frame: Fault Status: 00101000 Fault Priority: 2 Fault Frequency: 254 Reset counter: 110 Mileage: 226983 km Time Indication: 0 Freeze Frame: ON Voltage: 14.15 V ON ON OFF OFF ON 00446 - Function Limitation due to Under-Voltage 002 - Lower Limit Exceeded - Intermittent Freeze Frame: Fault Status: 00100010 Fault Priority: 4 Fault Frequency: 1 Reset counter: 102 Mileage: 232977 km Time Indication: 0 Freeze Frame: ON Voltage: 8.75 V ON ON OFF OFF OFF ------------------------------------------------------------------------------- Address 15: Airbags Labels: 1K0-909-605.lbl Part No SW: 1K0 909 605 N HW: 1K0 909 605 N Component: 2E AIRBAG VW8 015 2100 Revision: 03015000 Serial number: 0038ED0K027O Coding: 0012869 Shop #: WSC 01279 785 00200 VCID: 377D23A346D50E2B3A-8062 Subsystem 1 - Serial number: 6332MSME0B04370EA Subsystem 2 - Serial number: 6342MSME0B40186FH Subsystem 3 - Serial number: 6351HSME077E1667F Subsystem 4 - Serial number: 6361HSME077F0549F 1 Fault Found: 00532 - Supply Voltage B+ 002 - Lower Limit Exceeded - Intermittent ------------------------------------------------------------------------------- Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl Part No SW: 1K0 953 549 AG HW: 1K0 953 549 AG Component: J0527 634 0070 Coding: 0012122 Shop #: WSC 01279 785 00200 VCID: 77FDE3A30655CE2BFA-8022 Subsystem 1 - Part No: XXXXXXXXXXX Component: E0221 007 0050 1 Fault Found: 00446 - Function Limitation due to Under-Voltage 002 - Lower Limit Exceeded - Intermittent ------------------------------------------------------------------------------- Address 17: Instruments Labels: 1K0-920-xxx-17.lbl Part No: 1K6 920 872 Component: KOMBIINSTRUMENT VDD 1212 Coding: 0007103 Shop #: WSC 08650 572 93102 VCID: 6ED3C6C7790F8FE329-803A No fault code found. ------------------------------------------------------------------------------- Address 19: CAN Gateway Labels:. 1K0-907-530-V4.clb Part No SW: 1K0 907 530 S HW: 1K0 907 951 Component: J533 Gateway H07 0071 Revision: H07 01 Serial number: 241008F1002300 Coding: ED811F06600602000000 Shop #: WSC 35110 377 00156 VCID: 377D23A346D50E2B3A-8062 No fault code found. ------------------------------------------------------------------------------- Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb Part No: 1K6 920 872 Component: IMMO VDD 1212 Shop #: WSC 00000 000 00000 VCID: 6ED3C6C7790F8FE329-803A No fault code found. ------------------------------------------------------------------------------- Address 37: Navigation (J0506) Labels:. 1T0-035-680.clb Part No SW: 1T0 035 680 R HW: 1T0 035 680 R Component: RNS-MID H23 6270 Revision: AB001001 Serial number: VWZ6Z7P7712993 Coding: 0A0004000000000D0000 Shop #: WSC 12345 123 12345 VCID: 3D71318BA4E9247BE0-8068 Subsystem 1 - Part No: 1T0 919 859 B Component: EU West V10 8048 7 Faults Found: 00532 - Supply Voltage B+ 002 - Lower Limit Exceeded - Intermittent Freeze Frame: Fault Status: 00100010 Fault Priority: 5 Fault Frequency: 1 Reset counter: 102 Mileage: 232977 km Time Indication: 0 Date: 2000.00.00 Time: 07:09:34 00446 - Function Limitation due to Under-Voltage 002 - Lower Limit Exceeded - Intermittent Freeze Frame: Fault Status: 00100010 Fault Priority: 5 Fault Frequency: 2 Reset counter: 102 Mileage: 232977 km Time Indication: 0 Date: 2000.00.00 Time: 07:09:10 00857 - CD Changer Unit (R41) 004 - No Signal/Communication Freeze Frame: Fault Status: 01100100 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 226056 km Time Indication: 0 Date: 2000.00.00 Time: 15:14:00 00873 - Bass Speaker Rear Right (R17) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 226056 km Time Indication: 0 Date: 2000.00.00 Time: 18:03:11 00872 - Bass Speaker Rear Left (R15) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 226056 km Time Indication: 0 Date: 2000.00.00 Time: 18:03:11 00871 - Bass Speaker Front Right (R23) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 227304 km Time Indication: 0 Date: 2000.00.00 Time: 15:16:14 00870 - Bass Speaker Front Left (R21) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 227304 km Time Indication: 0 Date: 2000.00.00 Time: 15:16:14 ------------------------------------------------------------------------------- Address 42: Door Elect, Driver Labels: 1K0-959-701-MAX2.lbl Part No: 1K0 959 701 L Component: Tuer-SG 024 2469 Coding: 0000118 Shop #: WSC 01279 785 00200 VCID: 377D23A346D50E2B3A-8062 4 Faults Found: 01811 - Supply Voltage for Door Controller; Drivers Side (J386) 002 - Lower Limit Exceeded - Intermittent 00120 - Outside Warning Light/Door exit Light Driver Side 012 - Electrical Fault in Circuit 00109 - Left Mirror Turn Signal Lamp (L131) 012 - Electrical Fault in Circuit - Intermittent 00131 - Outside Door Handle Illumination/mirror Light Driver Side 012 - Electrical Fault in Circuit - Intermittent ------------------------------------------------------------------------------- Address 44: Steering Assist Labels: 1Kx-909-144-G2V2.clb Part No: 1K1 909 144 J Component: EPS_ZFLS Kl.5 D04 1606 Shop #: WSC 00000 000 00000 VCID: 326B12B7ADB7EB030D-8066 No fault code found. ------------------------------------------------------------------------------- Address 46: Central Conv. Labels:. 1K0-959-433-MAX.clb Part No SW: 1K0 959 433 AQ HW: 1K0 959 433 AQ Component: 01 KSG PQ35 G2 010 0101 Revision: 00010000 Serial number: 00000000000000 Coding: 80900A0851030638000484057008CAC6F0A040 Shop #: WSC 01287 785 00200 VCID: 7F0D0B832E65F66BB2-802A Subsystem 1 - Part No: 1K0 951 605 D Component: LIN BACKUP HORN H07 9001 Subsystem 2 - Part No: 1K0 907 719 C Component: Neigungssensor 005 0003 Subsystem 3 - Part No: 1K0 951 177 A Component: Innenraumueberw.005 0202 2 Faults Found: 01135 - Interior Monitoring Sensors 002 - Lower Limit Exceeded Freeze Frame: Fault Status: 01100010 Fault Priority: 4 Fault Frequency: 1 Reset counter: 61 Mileage: 232974 km Time Indication: 0 00668 - Supply Voltage Terminal 30 002 - Lower Limit Exceeded Freeze Frame: Fault Status: 01110010 Fault Priority: 4 Fault Frequency: 1 Reset counter: 255 Time Indication: 0 ------------------------------------------------------------------------------- Address 52: Door Elect, Pass. Labels: 1K0-959-702-MAX2.lbl Part No: 1K0 959 702 L Component: Tuer-SG 024 2469 Coding: 0000118 Shop #: WSC 01279 785 00200 VCID: 387F209F4BCB015333-806C 3 Faults Found: 01812 - Supply Voltage for Door Controller; Pass. Side (J387) 002 - Lower Limit Exceeded - Intermittent 00121 - Outside Warning Light/Door exit Light Passenger Side 012 - Electrical Fault in Circuit 00132 - Outside Door Handle Illumination/mirror Light Passenger Side 012 - Electrical Fault in Circuit - Intermittent ------------------------------------------------------------------------------- Address 55: Headlight Range Labels: 1T0-907-357.lbl Part No: 1T0 907 357 Component: Dynamische LWR 0003 Coding: 0000003 Shop #: WSC 01279 785 00200 VCID: 74E7D4AF1723A533DF-8020 No fault code found. ------------------------------------------------------------------------------- Address 56: Radio (J0506) Labels:. 1T0-035-680.clb Part No SW: 1T0 035 680 R HW: 1T0 035 680 R Component: RNS-MID H23 6270 Revision: AB001001 Serial number: VWZ6Z7P7712993 Coding: 0A0004000000000D0000 Shop #: WSC 12345 123 12345 VCID: 3D71318BA4E9247BE0-8068 Subsystem 1 - Part No: 1T0 919 859 B Component: EU West V10 8048 7 Faults Found: 00857 - CD Changer Unit (R41) 004 - No Signal/Communication Freeze Frame: Fault Status: 01100100 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 226056 km Time Indication: 0 Date: 2000.00.00 Time: 15:14:00 00873 - Bass Speaker Rear Right (R17) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 226056 km Time Indication: 0 Date: 2000.00.00 Time: 18:03:11 00872 - Bass Speaker Rear Left (R15) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 226056 km Time Indication: 0 Date: 2000.00.00 Time: 18:03:11 00871 - Bass Speaker Front Right (R23) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 227304 km Time Indication: 0 Date: 2000.00.00 Time: 15:16:14 00870 - Bass Speaker Front Left (R21) 011 - Open Circuit Freeze Frame: Fault Status: 01101011 Fault Priority: 5 Fault Frequency: 254 Reset counter: 70 Mileage: 227304 km Time Indication: 0 Date: 2000.00.00 Time: 15:16:14 00532 - Supply Voltage B+ 002 - Lower Limit Exceeded - Intermittent Freeze Frame: Fault Status: 00100010 Fault Priority: 5 Fault Frequency: 1 Reset counter: 102 Mileage: 232977 km Time Indication: 0 Date: 2000.00.00 Time: 07:09:34 00446 - Function Limitation due to Under-Voltage 002 - Lower Limit Exceeded - Intermittent Freeze Frame: Fault Status: 00100010 Fault Priority: 5 Fault Frequency: 2 Reset counter: 102 Mileage: 232977 km Time Indication: 0 Date: 2000.00.00 Time: 07:09:10 ------------------------------------------------------------------------------- Address 75: Telematics Cannot be reached ------------------------------------------------------------------------------- Address 77: Telephone (J412) Labels:| 3C8-035-730-A.clb Part No SW: 3C8 035 730 C HW: 3C8 035 730 C Component: Telefon 012 0822 Revision: -------- Serial number: 35909603374642 Coding: 020104010100110000000401 Shop #: WSC 12345 123 12345 ASAM Dataset: EV_UHVPremi A02705 ROD: EV_UHVPremi_A02.rod VCID: 2345E7F32A4D728BF6-8076 1 Fault Found: 13893632 - Function Restricted due to Insufficient Voltage U1400 00 [008] - - Intermittent - Confirmed - Tested Since Memory Clear Freeze Frame: Fault Status: 00000001 Fault Priority: 6 Fault Frequency: 3 Reset counter: 103 End-------------------------(Elapsed Time: 02:21)-------------------------- -------------------------------------------------------------------------------- -------------------------------------------------------------------------------- Address 01: DTCs cleared
Title: Re: Some Help Broke Down :(
Post by: dazza on August 25, 2023, 09:35:50 am: I don't hear the fuel pump when i open the drivers door how can i run this with vcds?
Title: Re: Some Help Broke Down :(
Post by: dazza on August 25, 2023, 11:40:42 am: Checked the cam follower there was good pressure.

This snapped with the lightest of touches :scared:

(https://i.postimg.cc/vZfGkSvj/Whats-App-Image-2023-08-25-at-12-38-07.jpg) (https://postimg.cc/sMfFZmq9)
Title: Re: Some Help Broke Down :(
Post by: dazza on August 25, 2023, 01:06:14 pm: A bit more info from the wife when changing from drive to park there was a horrible grinding/crunching noise
Title: Re: Some Help Broke Down :(
Post by: dazza on August 25, 2023, 11:06:12 pm: Its foobared

The timing mark is just gone 6 when in should be 12.

Options?

Dont leave your cam belts 8 years guys :ashamed:

(https://i.postimg.cc/zfGP2Rfy/Whats-App-Image-2023-08-25-at-23-49-21-1.jpg) (https://postimg.cc/WdxnhzgV)

(https://i.postimg.cc/sxsnSBbf/Whats-App-Image-2023-08-26-at-00-04-46.jpg) (https://postimg.cc/8JXBgC1x)
Title: Re: Some Help Broke Down :(
Post by: gj124 on August 26, 2023, 01:12:24 pm: Crank and cam turn at different speeds. The crank turns 2 revolutions and the camshaft once for 1 engine cycle. Try and turn it over once more, line up the crank pulley with the relevant mark first then have a look where the camshaft is - not the other way round. If the belt is intact and still has tension then why would the timing be out? Don't scrap it just yet :happy2:
Title: Re: Some Help Broke Down :(
Post by: dazza on August 26, 2023, 02:42:00 pm: Thanks for your input, I started over.

Set the crank pulley close to tdc.

(https://i.postimg.cc/X7y8KCsb/Whats-App-Image-2023-08-26-at-15-32-37.jpg) (https://postimg.cc/rKMxMK6n)

The camshaft is about 15 teeth before the mark (it should not be there)

(https://i.postimg.cc/B6khscmm/Whats-App-Image-2023-08-26-at-15-33-14.jpg) (https://postimg.cc/WFmmwrLZ)

One more turn and it moves opposite.

(https://i.postimg.cc/j5phBqj9/Whats-App-Image-2023-08-26-at-15-33-59.jpg) (https://postimg.cc/JDQJkLZc)

Another turn puts it back to about 15 teeth out :confused:
Title: Re: Some Help Broke Down :(
Post by: OllieVRS on August 26, 2023, 03:43:59 pm: Yeah 8 years is double VW's official service interval of 4 years / 60,000 miles, which ever comes first, but unfortunately that knowledge doesn't help your situation now. But if it turns over and does not start you can still hope nothing has collided internally.

If I were you, I'd get the timing right first (I think that's what's stopping it from firing up) with your current belt and then do a compression test. If all looks good (109-210psi), get a new belt and water pump kit in.

As for that annoying coolant pipe, I snapped mine three months ago doing the cam chain. I'm not sure about the part no. for the top pipe but the bottom one has the part no. on it:

(https://i.postimg.cc/5tp3MXWV/PXL-20230505-161912583-1.jpg) (https://postimg.cc/f3tXcTb2)

I got both mine off a scrap gti for €20.

Hope that's of some help :happy2:
Title: Re: Some Help Broke Down :(
Post by: dazza on August 26, 2023, 03:52:15 pm: Quote from: OllieVRS on August 26, 2023, 03:43:59 pm
Yeah 8 years is double VW's official service interval of 4 years / 60,000 miles, which ever comes first, but unfortunately that knowledge doesn't help your situation now.
Yes i did the belt lasttime and added a two piece cover it would have been easy second time arround, just so many other jobs to do.

Quote from: OllieVRS on August 26, 2023, 03:43:59 pm
If I were you, I'd get the timing right first (I think that's what's stopping it from firing up) with your current belt and then do a compression test. If all looks good (109-210psi), get a new belt and water pump kit in.
I was going to take the rocker cover off and then the head. But i will try what you recomended.

thanks for the help i've already replaced the coolant pipe
Title: Re: Some Help Broke Down :(
Post by: dazza on August 26, 2023, 05:42:33 pm: so the eight year old belt was not to blame its a wire from the auxillary belt that snapped. Check your aux belts guys.

(https://i.postimg.cc/7hKPwJq6/Whats-App-Image-2023-08-26-at-18-36-47.jpg) (https://postimg.cc/rRt29m0X)
Title: Re: Some Help Broke Down :(
Post by: dazza on August 26, 2023, 09:00:58 pm: The crank is aligned, whats the best way to turn the camshaft sprocket?

(https://i.postimg.cc/GpXGMCgn/Whats-App-Image-2023-08-26-at-20-37-24.jpg) (https://postimg.cc/hJ7XjHq2)

(https://i.postimg.cc/NMLTSzZ9/Whats-App-Image-2023-08-26-at-21-58-08.jpg) (https://postimg.cc/zbZVR0z8)

(https://i.postimg.cc/mDqMsSGd/Whats-App-Image-2023-08-26-at-21-58-09.jpg) (https://postimg.cc/sQY1P7xS)
Title: Re: Some Help Broke Down :(
Post by: GVK on August 26, 2023, 10:40:55 pm: If the pistons are at TDC you'll probably find the cam won't turn becaust of valve-piston hitting

Ideally needs the pistons all halfway in their bores to allow the cam to be timed.

I would say you have bent valves anyway so I'd be taking the head off.
Title: Re: Some Help Broke Down :(
Post by: dazza on August 26, 2023, 10:57:15 pm: Quote from: GVK on August 26, 2023, 10:40:55 pm
If the pistonns are at TDC you'll probably find the cam won't turn becaust of valve-piston hitting

Ideally needs the pistons all halfway in their bores to allow the cam to be timed.

I would say you have bent valves anyway so I'd be taking the head off.

Its hard to see how there would be no damage.

What will i need to reinstall to do the compression test?
Title: Re: Some Help Broke Down :(
Post by: GVK on August 26, 2023, 11:15:26 pm: Cam belt refitted (new belt ideally) and tensioned, timed up. Bottom pulley back on so belt doesn't fly off.

As previous post, you'll need the pistons halfway in the bore to allow the top end to be timed up, then time the bottom end up.
Title: Re: Some Help Broke Down :(
Post by: dazza on August 26, 2023, 11:42:25 pm: Quote from: GVK on August 26, 2023, 11:15:26 pm
Cam belt refitted (new belt ideally) and tensioned, timed up. Bottom pulley back on so belt doesn't fly off.

As previous post, you'll need the pistons halfway in the bore to allow the top end to be timed up, then time the bottom end up.

Great thanks what about the mount, fuel/coolant lines?
Title: Re: Some Help Broke Down :(
Post by: GVK on August 26, 2023, 11:46:19 pm: Just for a compression test I wouldn't bother with the coolant/fuel lines if they are all off , I would disconnect the fuel pump under the rear seat. You'll only need to crank the engine for 5-10secs each cylinder.

Put the mount back on with a couple of bolts.
Title: Re: Some Help Broke Down :(
Post by: pudding on August 27, 2023, 11:55:20 am: Oh dear. 15 teeth off is quite likely to have resulted in the valves getting intimate with the piston(s). A compression test when it's retimed will confirm.
Title: Re: Some Help Broke Down :(
Post by: dazza on August 27, 2023, 01:42:48 pm: The cam sprocket is 2 teeth away from the mark but when I try and line it up it springs back to 2 teeth away.

Now it's sprung forward a quarter turn..

Going to take the valve cover off.

(https://i.postimg.cc/mrm8z5H8/IMG-20230827-143900.jpg) (https://postimg.cc/5HFwDppC)
Title: Re: Some Help Broke Down :(
Post by: dazza on August 27, 2023, 10:58:24 pm: I started to remove the head. But I was thinking maybe it would have stayed at tdc if I removed the plugs?

What should I be looking for now the rocker cover is off?

(https://i.postimg.cc/2S4FrHY9/IMG-20230827-222729.jpg) (https://postimg.cc/0zyJC0b7)
Title: Re: Some Help Broke Down :(
Post by: GVK on August 27, 2023, 11:17:18 pm: I'd remove the cams and check the rocker arms that are under the cams for cracking/damage, then remove the head and check for bent valves, you may see that some of the valves aren't sitting right with the cams out.
Title: Re: Some Help Broke Down :(
Post by: pudding on September 01, 2023, 08:21:57 pm: At TDC, the rounded notches in the cams should both be horizontal and all 4 cam lobes on cylinder 1 pointing up.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 04, 2023, 06:05:35 pm: Been away for a few days, all i could think about was cracking on with this :confused:

Removed the heat shield, whats the best approach for removing the exaust manifold? The haynes manual said i need to remove the turbo?

Thanks again for all your help.
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 04, 2023, 07:04:28 pm: The turbo is integral with the exhaust manifold.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 04, 2023, 07:38:15 pm: Quote from: Octoparrot on September 04, 2023, 07:04:28 pm
The turbo is integral with the exhaust manifold.

So i need to remove the turbo or i can just unbolt it from the head and leave it in place?
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 05, 2023, 11:11:16 am: https://www.pelicanparts.com/techarticles/Volkswagen_Golf_GTI_Mk_V/65-ENGINE-Replacing_Your_Head_Gasket/65-ENGINE-Replacing_Your_Head_Gasket.htm

This guide may help.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 08, 2023, 04:20:40 pm: Quote from: Octoparrot on September 05, 2023, 11:11:16 am
https://www.pelicanparts.com/techarticles/Volkswagen_Golf_GTI_Mk_V/65-ENGINE-Replacing_Your_Head_Gasket/65-ENGINE-Replacing_Your_Head_Gasket.htm

This guide may help.

Thanks!
The head comes out with the manifold and turbo attached?
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 08, 2023, 05:06:07 pm: Probably easier to remove the head with the turbo detached from it.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 08, 2023, 05:17:01 pm: Quote from: Octoparrot on September 08, 2023, 05:06:07 pm
Probably easier to remove the head with the turbo detached from it.

The pelican part tutorial said it may be easier to remove the turbo first but this looks like a pita. Can I not just disconnect the manifold from the head and leave it where it is?
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 09, 2023, 12:24:20 am: Try it, it can't hurt..
Title: Re: Some Help Broke Down :(
Post by: dazza on September 09, 2023, 08:09:59 pm: everything is now removed from the head :laugh:
anyone know the correct tool to remove the head bolts? I bought one but it did not fit :sick:
Title: Re: Some Help Broke Down :(
Post by: GVK on September 09, 2023, 08:20:20 pm: Done a bit of Googling , it appears to be a 10mm Ribe socket, which looks like a torx but has squared off edges.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 09, 2023, 08:52:55 pm: Quote from: GVK on September 09, 2023, 08:20:20 pm
Done a bit of Googling , it appears to be a 10mm Ribe socket, which looks like a torx but has squared off edges.

Thanks mate.
I just bought one off amazon for delivery tomorrow, When i did my cam chain i snapped a cheap one of these and then bought the original vw tool.
Hopefully it will not snap again.
Title: Re: Some Help Broke Down :(
Post by: GVK on September 09, 2023, 09:08:12 pm: Fingers crossed Dazza, do the bolts look like I described?
Title: Re: Some Help Broke Down :(
Post by: dazza on September 09, 2023, 09:30:40 pm: Quote from: GVK on September 09, 2023, 09:08:12 pm
Fingers crossed Dazza, do the bolts look like I described?

Yes its a ribe socket I have a set of these but they are too short. Will let you guys know how i get on tomorrow :scared1:
Title: Re: Some Help Broke Down :(
Post by: dazza on September 10, 2023, 05:39:09 pm: The head is off. Some pics.
(https://i.postimg.cc/k5vqbrxM/IMG-20230910-174830.jpg) (https://postimg.cc/GBtZW576)

(https://i.postimg.cc/fLHs8x26/IMG-20230910-175340.jpg) (https://postimg.cc/Hc7Fx7C2)

(https://i.postimg.cc/636wVH0r/IMG-20230910-175347.jpg) (https://postimg.cc/xkZWn3B8)

(https://i.postimg.cc/rs3kkqLj/IMG-20230910-175352.jpg) (https://postimg.cc/CnGtCT5n)

(https://i.postimg.cc/2jKmv7BW/IMG-20230910-175400.jpg) (https://postimg.cc/MXVhJR5Z)

(https://i.postimg.cc/cLqSk1h4/IMG-20230910-175410.jpg) (https://postimg.cc/jLhmLbBG)

(https://i.postimg.cc/qMWJfxJr/IMG-20230910-180427.jpg) (https://postimg.cc/XpcSdFB1)

(https://i.postimg.cc/YCgptL0W/IMG-20230910-180528.jpg) (https://postimg.cc/Yvrc391r)

(https://i.postimg.cc/T295XSF6/IMG-20230910-180552.jpg) (https://postimg.cc/8s7zRyTK)

(https://i.postimg.cc/14hp2N4K/IMG-20230910-180645.jpg) (https://postimg.cc/BPpL1bT8)
Title: Re: Some Help Broke Down :(
Post by: GVK on September 10, 2023, 07:42:47 pm: Can see the valve to piston contact on top of the pistons!
Title: Re: Some Help Broke Down :(
Post by: dazza on September 10, 2023, 08:34:27 pm: Quote from: GVK on September 10, 2023, 07:42:47 pm
Can see the valve to piston contact on top of the pistons!

this?

(https://i.postimg.cc/6qws0JP3/Whats-App-Image-2023-09-10-at-18-08-53.jpg) (https://postimg.cc/LYy0972K)

Also all the intake valves have some skuffed spots.

(https://i.postimg.cc/jS2pvhMz/Whats-App-Image-2023-09-10-at-21-15-48.jpg) (https://postimg.cc/HrGvkbDx)
Title: Re: Some Help Broke Down :(
Post by: GVK on September 10, 2023, 08:41:30 pm: Yep - Are the cams out of the head? If so put some petrol around the valves to see which ones leak.

Can see most of the inlet valves are bent from the pics but they all need removing to check properly
Title: Re: Some Help Broke Down :(
Post by: dazza on September 10, 2023, 08:57:04 pm: Quote from: GVK on September 10, 2023, 08:41:30 pm
Yep - Are the cams out of the head? If so put some petrol around the valves to see which ones leak.

Can see most of the inlet valves are bent from the pics but they all need removing to check properly

I have not taken the cams out. Can this be done without removing the cam adjuster? I lent my locking tool and socket to some members and never had it back :sad1:
Title: Re: Some Help Broke Down :(
Post by: GVK on September 10, 2023, 08:59:04 pm: Not sure as never done the job on a TFSI personally.

They'll need removing and the rocker assemblies checking for damage too.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 12, 2023, 05:40:34 pm: Not having much luck with this locking tool will not fit

(https://i.postimg.cc/hPt6JCPd/IMG-20230912-183917.jpg) (https://postimg.cc/XXtQmk5j)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 12, 2023, 08:31:37 pm: The cams are out will have to remove the cam adjuster another day.

The lifters look good

(https://i.postimg.cc/pdzqX48H/IMG-20230912-201736.jpg) (https://postimg.cc/7CPgKBms)

(https://i.postimg.cc/tJC5kgcq/IMG-20230912-201743.jpg) (https://postimg.cc/R6yKVv9y)

(https://i.postimg.cc/yxQTbHqF/IMG-20230912-203400.jpg) (https://postimg.cc/fSdXV1RL)
Title: Re: Some Help Broke Down :(
Post by: GVK on September 12, 2023, 10:23:21 pm: Just the valves to remove now then Dazza! :congrats:
Title: Re: Some Help Broke Down :(
Post by: dazza on September 13, 2023, 07:07:19 am: What tools will I need to get these valves out?
Title: Re: Some Help Broke Down :(
Post by: dazza on September 13, 2023, 10:20:13 am: Hopefully these are what is needed.

https://www.amazon.es/dp/B07BSH32PX?psc=1&smid=A1AT7YVPFBWXBL&ref_=chk_typ_imgToDp
https://www.amazon.es/dp/B01KZ8UBGY?psc=1&smid=A18U3DCLRWZRI3&ref_=chk_typ_imgToDp

(https://i.postimg.cc/T3YD2RW5/Screenshot-from-2023-09-13-11-17-30.png) (https://postimg.cc/D8HZB367)

(https://i.postimg.cc/yN2gTcp0/Screenshot-from-2023-09-13-11-17-43.png) (https://postimg.cc/Z9F5bBSq)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 13, 2023, 05:01:25 pm: someone mentioned this could be oil? I think its just coolant from removing the head.

Should i test with some petrol/diesel?

(https://i.postimg.cc/YCgptL0W/IMG-20230910-180528.jpg) (https://postimg.cc/Yvrc391r)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 13, 2023, 07:02:51 pm: I leak tested the valves.
no 7 on the intake side is leaking a lot.

after 30 mins 1,2,4 and 8 on the exaust side have a small damp patch around the stems.

Its hard to see on the intake side.

Surely the 8 valves that hit the pistons need to be changed?

I tried blowing with the compressor, depending on where you put the air you can get bubbles but from a distance only 7 on the intake side has bubbles.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 14, 2023, 08:20:02 pm: The valves from the intake side are out. Is there a way to test if they are bent? Or should I just replace them all as they hit the pistons?

(https://i.postimg.cc/25ZRQMw3/IMG-20230914-195649.jpg) (https://postimg.cc/gwmTdM1P)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 14, 2023, 10:19:47 pm: need to start ordering everything thats needed. I cannot afford to buy from the stealers.

Any particular brands i should use? there are so many and the prices vary a lot.

would Elring be ok for the gaskets?

https://www.autodoc.es/elring/207029
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 15, 2023, 09:22:48 am: Roll the valves along a flat table, that'll easily show any that are bent. Elring are a good make I believe.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 15, 2023, 11:30:49 am: Quote from: Octoparrot on September 15, 2023, 09:22:48 am
Roll the valves along a flat table, that'll easily show any that are bent. Elring are a good make I believe.

Tried rolling on the table could not see any bent ones. Even the one that was really leaking.
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 15, 2023, 11:48:07 am: I'd replace them all, you don't want to be doing all this work twice.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 15, 2023, 09:26:49 pm: Ordered most of the parts I need. Just need to order the bolts.
Are aftermarket head bolts ok?
The liquid gasket has gone hard and there a lots of bits in the top of the head. Could I give it a blast down with hot pressure washer?

Everything is out apart from the injectors.

(https://i.postimg.cc/ZR5hpPCY/IMG-20230915-203557.jpg) (https://postimg.cc/GBVN1yF6)

(https://i.postimg.cc/YCQkHq57/IMG-20230915-203604.jpg) (https://postimg.cc/qNBWc0BD)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 17, 2023, 07:00:28 pm: Trying to find the part number for this pipe. Break booster I think.

https://volkswagen.7zap.com/en/rdw/golf+variant+4motion/golf/2005-420/6/611-611076/

(https://i.postimg.cc/132Wy16c/IMG-20230917-195349.jpg) (https://postimg.cc/mP33Sqmt)
Title: Re: Some Help Broke Down :(
Post by: rich83 on September 17, 2023, 08:21:29 pm: Blimey…. I go away for 2 minutes and we’ve got open heart surgery going on…. Hope you are well dazza and hope you get the engine built back up without too much bother.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 17, 2023, 09:10:12 pm: Quote from: rich83 on September 17, 2023, 08:21:29 pm
Blimey…. I go away for 2 minutes and we’ve got open heart surgery going on…. Hope you are well dazza and hope you get the engine built back up without too much bother.

Thanks Rich, all good here. I'm putting a few hours in each night, its nice to be working on the old girl again. What i really need is a new car for the ball and chain.
Hope all is well with you and the family.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 19, 2023, 10:43:54 am: I tested the piston seals with some diesel. Filled to the bottom of the caliper in the pics.

Within 1 hour 45 mins all had dropped 3 were nearly empty.

Maybe this is why I needed to top up the oil often.

(https://i.postimg.cc/yYTSjBST/IMG-20230919-111748.jpg) (https://postimg.cc/1fftRkBg)

(https://i.postimg.cc/8cmsZBsC/IMG-20230919-111757.jpg) (https://postimg.cc/bSdzJnxX)

(https://i.postimg.cc/8cSjdnp3/IMG-20230919-111842.jpg) (https://postimg.cc/62MWtcGL)

(https://i.postimg.cc/k482bdmK/IMG-20230919-111848.jpg) (https://postimg.cc/gXzzCQr2)
Title: Re: Some Help Broke Down :(
Post by: LC5F on September 20, 2023, 03:45:35 am: I managed to do this same thing with mine - after swapping my intercooler I managed to nick the edge of my drive belt on the AC union and the belt thread unravelled itself and posted itself into the timing belt.

Despite the financial impact, it was possibly the best thing I have done to my Mk5 - head rebuild & injector clean seemed to restore power. new valve guides & stem seal + DIY Turbo rebuild also helped - now my engine barely uses oil.
As its off, get a vacuum pump rebuild kit from ebay.

If I had to do this again, the only thing I would change is to remove the misery with both timing belt and chain - I managed to get both a tooth out in opposite directions - correctly installed, my BWA belt seems to always be 2/3 of a tooth out comparing cam & crank timing marks.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 21, 2023, 07:49:30 pm: Pistons are out what should I be looking for here?

(https://i.postimg.cc/wTBh2xwL/IMG-20230921-203600.jpg) (https://postimg.cc/9zvRF25Q)
Title: Re: Some Help Broke Down :(
Post by: GVK on September 22, 2023, 12:06:08 am: Do the rings spin freely by hand? If no they could have been squashed when the valve/piston contact occured.

Any damage to the ring lands (the gaps and part of the piston around the rings)

Now is the time to fit new rings and hone the cylinders.Especially if had high oil consumption.
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 22, 2023, 09:32:28 am: Quote from: dazza on September 21, 2023, 07:49:30 pm
Valves are out what should I be looking for here?

(https://i.postimg.cc/wTBh2xwL/IMG-20230921-203600.jpg) (https://postimg.cc/9zvRF25Q)

Those my friend are pistons.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 22, 2023, 09:42:31 pm: Quote from: Octoparrot on September 22, 2023, 09:32:28 am
Those my friend are pistons.
I'm so tired :indifferent:
Title: Re: Some Help Broke Down :(
Post by: dazza on September 22, 2023, 09:56:07 pm: Quote from: GVK on September 22, 2023, 12:06:08 am
Do the rings spin freely by hand? If no they could have been squashed when the valve/piston contact occured.

Yes they all spin easily by hand.

Quote from: GVK on September 22, 2023, 12:06:08 am
Any damage to the ring lands (the gaps and part of the piston around the rings)

Not that i can see but going to clean them up tomorrow.

Quote from: GVK on September 22, 2023, 12:06:08 am
Now is the time to fit new rings and hone the cylinders.Especially if had high oil consumption.

Regardind the honeing is there a resonably priced tool i can buy to diy this?

This has the highest reviews of what amazon has to offer

https://www.amazon.co.uk/BGS-1265-Honing-Tool-flexible/dp/B07XZS9Y1D/ref=sr_1_8?crid=6PB0G9DVIE7L&keywords=honing%2Btool&qid=1695419927&s=diy&sprefix=honing%2Btool%2Cdiy%2C93&sr=1-8&th=1

(https://i.postimg.cc/CKjpkMJ9/Screenshot-2023-09-23-at-0-00-57.png) (https://postimages.org/)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 22, 2023, 10:03:21 pm: Quote from: LC5F on September 20, 2023, 03:45:35 am
I managed to do this same thing with mine - after swapping my intercooler I managed to nick the edge of my drive belt on the AC union and the belt thread unravelled itself and posted itself into the timing belt.

Despite the financial impact, it was possibly the best thing I have done to my Mk5 - head rebuild & injector clean seemed to restore power. new valve guides & stem seal + DIY Turbo rebuild also helped - now my engine barely uses oil.
As its off, get a vacuum pump rebuild kit from ebay.

If I had to do this again, the only thing I would change is to remove the misery with both timing belt and chain - I managed to get both a tooth out in opposite directions - correctly installed, my BWA belt seems to always be 2/3 of a tooth out comparing cam & crank timing marks.

Thanks for the encouragement.

Regarding the valve guides these are easy to remove/replace.
Title: Re: Some Help Broke Down :(
Post by: GVK on September 22, 2023, 11:31:23 pm: I've never used that type myself, the garage ones I've used are the 3 x stone type. Can get them for under £20 off eBay I've seen.

Both types will do the job.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 22, 2023, 11:40:05 pm: Quote from: GVK on September 22, 2023, 11:31:23 pm
I've never used that type myself, the garage ones I've used are the 3 x stone type. Can get them for under £20 off eBay I've seen.

Both types will do the job.

Thanks!
To do the honing do i need to take the crankshaft out? There are also the oil feed at the bottom of the cylinders
Title: Re: Some Help Broke Down :(
Post by: GVK on September 22, 2023, 11:46:43 pm: Just got to be careful at the bottom of the stroke not to hit the crank and oil squirters. The squirters can be removed , see Ollievrs thread about his oil pump woes.
Title: Re: Some Help Broke Down :(
Post by: LC5F on September 23, 2023, 11:46:21 pm: Quote from: dazza on September 22, 2023, 10:03:21 pm
Quote from: LC5F on September 20, 2023, 03:45:35 am
I managed to do this same thing with mine - after swapping my intercooler I managed to nick the edge of my drive belt on the AC union and the belt thread unravelled itself and posted itself into the timing belt.

Despite the financial impact, it was possibly the best thing I have done to my Mk5 - head rebuild & injector clean seemed to restore power. new valve guides & stem seal + DIY Turbo rebuild also helped - now my engine barely uses oil.
As its off, get a vacuum pump rebuild kit from ebay.

If I had to do this again, the only thing I would change is to remove the misery with both timing belt and chain - I managed to get both a tooth out in opposite directions - correctly installed, my BWA belt seems to always be 2/3 of a tooth out comparing cam & crank timing marks.

Thanks for the encouragement.

Regarding the valve guides these are easy to remove/replace.

I just sent my head to an engine shop for rebuild - £225 for full rebuild, including new guides.

One other tip - when reinstalling the Turbo - bolt on all the pipework that connects to the core before you mount the turbo - it will save a lot of swearing
Title: Re: Some Help Broke Down :(
Post by: dazza on September 24, 2023, 08:55:38 pm: Cleaned the pistons up today.

(https://i.postimg.cc/LXP1VkFv/IMG-20230924-192644.jpg) (https://postimg.cc/vgQTYVB6)

(https://i.postimg.cc/9XG9RBpQ/IMG-20230924-192651.jpg) (https://postimg.cc/fkRy1mpG)
Title: Re: Some Help Broke Down :(
Post by: dazza on September 24, 2023, 08:57:51 pm: Where is the best place to get the bolts? Are vag bolts on eBay well priced?

https://www.ebay.co.uk/str/vagbolts
Title: Re: Some Help Broke Down :(
Post by: OllieVRS on September 25, 2023, 11:06:32 am: Quote from: dazza on September 24, 2023, 08:57:51 pm
Where is the best place to get the bolts? Are vag bolts on eBay well priced?

https://www.ebay.co.uk/str/vagbolts

For faster delivery and original quality I'd go straight to your local dealership's parts department, usually there similarly priced to eBay but you're guaranteed quality. In Ireland parts collection usually takes 2 working days (parts are shipped from the UK), so I'd expect it's next day or same day collection in the UK.

You can also go to Skoda dealerships, they sometimes sell the parts cheaper (or so I hear).

Best to call the parts departments of each just to get quote for prices, double check with them that they are quoting with VAT included, ask for estimated collection time, and then compare with eBay.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 25, 2023, 05:27:10 pm: As always thanks for all your help guys.

While I wait for parts to arrive I've been trying to clean up the mating surfaces.

I've seen some videos where people use 3m disks on the block. Any tips would be appreciated?

(https://i.postimg.cc/MTLnqDLJ/IMG-20230925-182117.jpg) (https://postimg.cc/r0SV9Scf)
Title: Re: Some Help Broke Down :(
Post by: Octoparrot on September 25, 2023, 06:45:26 pm: I'd avoid at all costs anything like abrasives that will throw gritty stuff everywhere, you'll never be able to get it clean down all the passages. Use a plastic or metal scraper.
Title: Re: Some Help Broke Down :(
Post by: terrier on September 25, 2023, 07:03:42 pm: Look at 0000 grade wire wool or 3M non woven pads The white ones are the finest I think :thinking:
Title: Re: Some Help Broke Down :(
Post by: dazza on September 25, 2023, 07:10:03 pm: I've ordered a carbide scraper. I think I have some fine wire wool. Will give it a go.
Title: Re: Some Help Broke Down :(
Post by: dazza on September 26, 2023, 09:37:05 am: Got a price of 264.02 EUROS from the stealers :surprised:

Head to block bolts    06D103385D   10
Adjuster Bolt   06D109281D   1
Head frame bolts   N10554005   23
Crank pulley bolts   N91143901   6
Timing belt   N90945002   3
   N90628303   2
   N90597005   1
   N91029602   1
   N90596906   1
   N10552402   2
oil pump bolts   WHT000360A   1
   N91149501   3   m7x58
   WHT000006   4   m7x70
   N10430502   1   m7x40
   N91149601   1
Title: Re: Some Help Broke Down :(
Post by: dazza on September 27, 2023, 06:59:57 pm: Did a bit more scraping. Are these mating surfaces clean enough?

(https://i.postimg.cc/9QNpYm9W/IMG-20230927-190523.jpg) (https://postimg.cc/zyKKJ1pM)

(https://i.postimg.cc/wvDQzDGv/IMG-20230927-185616.jpg) (https://postimg.cc/sQDh9Gyd)

(https://i.postimg.cc/wBCQnwFZ/IMG-20230927-190645.jpg) (https://postimg.cc/mcS9HNvy)

Did one pass with the honing tool. Hopefully this Is ok :scared:

(https://i.postimg.cc/HsgPrkwR/IMG-20230927-194316.jpg) (https://postimg.cc/kDTyZ9hv)
Title: Re: Some Help Broke Down :(
Post by: LC5F on September 28, 2023, 03:13:39 am: Just get a Victor Reinz head bolt kit & Head gasket set.
Timing belt, VW change supplier like shirts - get a kit from continental/gates/Dayco/INA all have been OEM suppliers, whatever kit comes cheapest with water pump
Title: Re: Some Help Broke Down :(
Post by: dazza on September 30, 2023, 08:04:21 pm: Had another go at the bores with a different honing tool.
Much happier now.

(https://i.postimg.cc/XJh176MS/IMG-20230930-200001.jpg) (https://postimg.cc/R67LX8VX)
Title: Re: Some Help Broke Down :(
Post by: GVK on September 30, 2023, 11:24:58 pm: Looking good :happy2:
Title: Re: Some Help Broke Down :(
Post by: dazza on October 05, 2023, 09:13:26 pm: Started lapping the valves.

(https://i.postimg.cc/MKbvXN1G/IMG-20231005-193926.jpg) (https://postimg.cc/rKs8Phn6)

(https://i.postimg.cc/y8LxyRQ4/IMG-20231005-194014.jpg) (https://postimg.cc/CRfwFRpm)
Title: Re: Some Help Broke Down :(
Post by: dazza on October 22, 2023, 11:17:58 am: Made a tool to remove the exhaust cam sprocket.

Hopefully next week all the parts will arrive

(https://i.postimg.cc/1Rj7jgxT/IMG-20231022-103707.jpg) (https://postimg.cc/Dm1cWwwd)

(https://i.postimg.cc/CxyPwWxs/IMG-20231022-104727.jpg) (https://postimg.cc/w7VcV4J1)
Title: Re: Some Help Broke Down :(
Post by: skkane on October 27, 2023, 08:41:35 am: Set it like that myself. Hopefully timing will be correct when we start it up and check with vcds.
Title: Re: Some Help Broke Down :(
Post by: dazza on October 27, 2023, 11:05:52 am: Something is wrong I cannot get the exhaust cam to tdc mark it will spring forward of back and not stay on it.

(https://i.postimg.cc/g0yGZSb1/IMG-20231027-120334.jpg) (https://postimg.cc/gwJ99KJK)
Title: Re: Some Help Broke Down :(
Post by: GVK on October 27, 2023, 01:50:42 pm: I have heard of that happening on the 2.0 TDI motors, but not the TFSI.
Title: Re: Some Help Broke Down :(
Post by: RBS on October 28, 2023, 12:42:40 am: Just red the whole story…😱 but…
You’re on the right track :happy2:
Now what I can See on your head…is your intake cam mounted correctly??
The cam locking tool must go in between the spares from the cams… I don’t see the openings in the intake cam?? Or am I wrong??
Title: Re: Some Help Broke Down :(
Post by: dazza on October 28, 2023, 07:17:34 pm: :scared1: I marked the chain correctly but put it one the wrong way round.

I still can't get it to stay at tdc it spins forward or backwards?

Going to buy some new bolts on Monday.

(https://i.postimg.cc/mZm4JsJD/IMG-20231028-182025.jpg) (https://postimg.cc/JtHSH91V)
Title: Re: Some Help Broke Down :(
Post by: dazza on October 29, 2023, 07:36:22 pm: My adjuster is sitting two teeth furter out. If i take off will it go back to normal?

from video i followed
(https://i.postimg.cc/wvH28hdD/Screenshot-2023-10-29-at-20-32-22.png) (https://postimages.org/)

Mine

(https://i.postimg.cc/hjydyx4D/IMG-20231029-202605.jpg) (https://postimg.cc/HcMnjr7R)
Title: Re: Some Help Broke Down :(
Post by: dazza on October 31, 2023, 06:47:13 pm: Mystery solved :sick:

(https://i.postimg.cc/hjHQw6zG/IMG-20231031-190558.jpg) (https://postimg.cc/qhx76mGf)
Title: Re: Some Help Broke Down :(
Post by: dazza on November 01, 2023, 03:16:19 pm: Pistons are in

(https://i.postimg.cc/3xXmDbBV/IMG-20231101-131648.jpg) (https://postimg.cc/SnKJBdHf)

(https://i.postimg.cc/MpSt4Brk/IMG-20231101-144219.jpg) (https://postimg.cc/xc6KNX2g)

(https://i.postimg.cc/DysBB66d/IMG-20231101-155336.jpg) (https://postimg.cc/yk1mNFwk)
Title: Re: Some Help Broke Down :(
Post by: dazza on November 10, 2023, 10:29:34 pm: Not long now :party: the 18/19 link method was not good for me.

(https://i.postimg.cc/yxG7FKcv/IMG-20231109-212409.jpg) (https://postimg.cc/WqMRvQ9k)

(https://i.postimg.cc/1RVRQnQd/IMG-20231110-212634.jpg) (https://postimg.cc/Rq9x10q1)

(https://i.postimg.cc/Sxdkrc6n/IMG-20231110-212643.jpg) (https://postimg.cc/TKKz2LHx)
Title: Re: Some Help Broke Down :(
Post by: GVK on November 10, 2023, 10:53:49 pm: Looking good. fingers crossed for a happy start-up!
Title: Re: Some Help Broke Down :(
Post by: dazza on November 12, 2023, 09:26:11 pm: Good news and bad news.

It runs :jumpmove: :pomppomp: :star:

Bad news
Coolant leak from the elbow that connects to the block.

In vcds block 93 phase position is -18
Title: Re: Some Help Broke Down :(
Post by: skkane on November 13, 2023, 03:59:04 pm: Timing seems off. Are you getting ~28kw actual in group 94? Here's how mine look.

(https://i.postimg.cc/25pccnp9/IMG-20231027-175615-resized-20231113-055741750.jpg) (https://postimg.cc/bZT9dDw1)
Title: Re: Some Help Broke Down :(
Post by: dazza on November 14, 2023, 12:59:38 pm: maybe i should try the 18/19 method again? Currently its 19/20
But i could not get the locking tool in.
Title: Re: Some Help Broke Down :(
Post by: skkane on November 14, 2023, 02:26:09 pm: 18/19 is what we did when we put it back together. We had no locking tool to check but it turned out to be spot on.
Title: Re: Some Help Broke Down :(
Post by: dazza on November 16, 2023, 09:13:48 pm: :sick: :sick: :sick: :sick:

With 18/19 link method it's worse

(https://i.postimg.cc/FKVMTrP0/IMG-20231116-210815.jpg) (https://postimg.cc/wt34vpYB)

When I did 19/20 links

(https://i.postimg.cc/05XbtxFg/IMG-20231112-WA0004.jpg) (https://postimg.cc/xqHf8r9g)

Why is the 18/19 link method not working?
Title: Re: Some Help Broke Down :(
Post by: skkane on November 17, 2023, 09:40:37 am: Damn, that looks way worse. Only things I can think about are the actual camshaft install into the head, the locking tool should slide in there without any force or wiggling if all is set properly. Either that or the timing belt side, are you certain that it's on spot? Here's two photos of how my cam positions looked with the current timing I have.

(https://i.postimg.cc/BQPY07gS/IMG-20231020-162315-edit-250004807265878-resized-20231117-112453589.jpg) (https://postimg.cc/Whj6mnCC)

(https://i.postimg.cc/RZrPV1sc/IMG-20231020-164333-edit-250011384083011-resized-20231117-112453132.jpg) (https://postimg.cc/0bfGVSqQ)
Title: Re: Some Help Broke Down :(
Post by: dazza on November 17, 2023, 10:44:16 am: Quote from: skkane on November 17, 2023, 09:40:37 am
Damn, that looks way worse. Only things I can think about are the actual camshaft install into the head, the locking tool should slide in there without any force or wiggling if all is set properly. Either that or the timing belt side, are you certain that it's on spot? Here's two photos of how my cam positions looked with the current timing I have.

(https://i.postimg.cc/BQPY07gS/IMG-20231020-162315-edit-250004807265878-resized-20231117-112453589.jpg) (https://postimg.cc/Whj6mnCC)

(https://i.postimg.cc/RZrPV1sc/IMG-20231020-164333-edit-250011384083011-resized-20231117-112453132.jpg) (https://postimg.cc/0bfGVSqQ)

Thanks for the pics
The belt side looks good.
Even when the head was off i could only get the locking tool in at 18/19 links with a lot of wiggling.
I suppose i will set back to 19/20
Title: Re: Some Help Broke Down :(
Post by: dazza on November 18, 2023, 02:31:02 pm: Now it's back to 19/20 pins

(https://i.postimg.cc/TYhZwLQ3/IMG-20231118-151133.jpg) (https://postimg.cc/YhKXDSJ5)
Title: Re: Some Help Broke Down :(
Post by: dazza on November 18, 2023, 08:38:06 pm: Checked my bottom timing mark.

(https://i.postimg.cc/kgcxX9M7/IMG-20231118-173316.jpg) (https://postimg.cc/k22Vf0tH)

After a spin to the shops phase position bank 1 is now -16
No other errors

(https://i.postimg.cc/vBXjWCvy/IMG-20231118-211746.jpg) (https://postimg.cc/YGGb7nVD)
Title: Re: Some Help Broke Down :(
Post by: skkane on November 19, 2023, 12:52:03 pm: Mine used to be -9kw on group93 with the old engine. I'd run it but fk do I know :stupid:. Group 91 looks good with actual meeting requested. A bit baffling though as mine and all the others i've seen request 28kw at idle vs your 24kw, was that with the engine up to temp? Maybe someone with more experience can chime in.
Title: Re: Some Help Broke Down :(
Post by: dazza on November 20, 2023, 01:10:46 pm: Quote from: skkane on November 19, 2023, 12:52:03 pm
Mine used to be -9kw on group93 with the old engine. I'd run it but fk do I know :stupid:. Group 91 looks good with actual meeting requested. A bit baffling though as mine and all the others i've seen request 28kw at idle vs your 24kw, was that with the engine up to temp? Maybe someone with more experience can chime in.

Yes it was up to temp. The motor is an axx maybe this is why some readings are different.
Going to drive it for a few days to see if it improves.
Title: Re: Some Help Broke Down :(
Post by: skkane on November 20, 2023, 01:32:36 pm: AXX being a bit different makes sense since they used slightly different cams vs my older BYD and this CDL, had CDL cams on the BYD aswellso maybe that's why I'm getting the 28kw.
Title: Re: Some Help Broke Down :(
Post by: dazza on December 18, 2023, 08:28:13 pm: The car has done a thousand km now. The fluid levels were good until yesterday when I noticed a patch on the floor. I think it's from the water pump.

(https://i.postimg.cc/y83LpZVx/Whats-App-Image-2023-12-18-at-19-19-39.jpg) (https://postimg.cc/0zxGbrK1)
Title: Re: Some Help Broke Down :(
Post by: dazza on January 14, 2024, 05:12:00 pm: Replaced the water pump with an original one. No leaks so far. I triple checked the timing belt. Still the same cam adjustment readings.

I would like to replace the cams if anyone has a set of second hand cams please let me know.