T4 van start up issues

[BB]

Hi
 I have been working on a T4 non turbo 2.4 I5 diesel van.
 It was overheating in traffic and pressurizing the cooling system so the head came off.
 New valve guides on the exhausts and new seals and head gasket and its all back together.
 Had the injectors serviced as well.

 Timing is pretty easy, TDC for crank, cam has a slot at the back that you put a flat bit of metal into that aligns straight with the head top. And the fuel pump has a notch.
 I aligned everything and have turned by hand several times and everything lines up bang on.
 The van starts but runs very rough and blows huge clouds of smoke. Stalls as soon as I get off the gas.
 There are no filter hand pumps on this car So I am to believe that its just bleeding the air out............but its taking to long and I'm worried.

 Has anyone else done a VW diesel and had this experience or know any tricks?
 I will try to crack the injector hoses as my flatmate cranks it, but would be good to hear of any other experience.
 Thanks.

[b0000st]

Did you paint mark the diesel pump before you stripped it down or check that when the flywheel was on TDC that the notch on the pump lined up? I cant remember exactly as its been a while but I think when the engine is on tdc and the notch lines up turn the pump approx 6mm anti clockwise and put the belt on. For some reason on the five pots if you use the timing marks on the pump they dont run or run badly.

Matt

[BB]

I think you mite be onto something.
 No I didn't put paint marks but I did look to see all the factory stuff lined up but maybe the injector pump does need some adjustment.
 I asked Frank Pronk and he hadn't donr one but really the only thing must be the timing so i will have another go.
 Both cam pulleys have no key ways and the cam position is set by a falt bar at the Fuel pump end yet the front pulley does still have a mark on the rear of it that lines up with a hole in the cam cover
 I pretty much got everything lined up easy enuf but yea....
 Thanks Booost.

[b0000st]

No worries I think the hole in the back of the cam cover is to knock the pulley off the taper. The mark on the pulley just be due to parts sharing?
I did the same as you on my 1st one and it took me a while to sort it out.

[BB]

Thanks man it is so good to here stuff like that.
 And yes part sharing can get you into some real crap on the VAG stuff.
 Tho this hole has a pointer and there is a mark on the cam wheel but yea maybe its for a different model or something.
 Its annoying they don't have the hand pumps on the filters.
 All the jap stuff does.

[80 Vert]

It will be the diesel pump timing Jem.

[BB]

Yes thanks John I think it has to be too.
 I did note in the cambelt book that the turbo model needs the pump turned 6mm or something but not the non turbo.
 Was the one you did turbo or non turbo Booost?

 Regardless it must be the pump timing.
 I'm back on it today.

[b0000st]

It was on both turbo and NA and they even carried this peculiarity over to the 2.5 in the T5 and LT.

Hope you get it sorted.

[BB]

Well its going pretty good now.
 
 They are a pain as you have to remove everything to redo anything.
 But in the end I found my cam timing was a little out, so I sorted that and then redid the pump to just exactly on the mark.
 It seems to run fine and idles great.
 Still a bit of smoke on revs but it is a diesel.
 Fans kick in and all is well.
 There seems to be endless small differences in these motors. The rocker gasket I was given with the head set is wrong.
 And there is endless stupid tools your supposed to use and im not even sure we had the right engine code in the cambelt book as even tho it says its a 2.4 the engine AAB only goes too 97 and this van is a 98 and I'm not even sure it was an AAB engine.
 But much of the idea is the same.
 All a big pain in the ass compared to all the Jap diesels Ive done as usual.