Got 8 fault codes on newly built engine, help please.

[k.alle]

Use a piston stop, as you say, very accurate.

And there is no interference issues with the valves doing this on 20VT I5 engines?

[Bowie69]

When I made mine, I trimmed the bolt end right down to a few mm across, that would minimise any chance of this happening.

It's in the middle of 4 valves, so no I wouldn't think there is a chance of anything happening.

[k.alle]

Oh, great. I'll do just that then!

Thanks for your input.

[k.alle]

Alright, I did a piston stopper. I had no issues using it.
I did not do full rotation with the piston stop fitted. I removed it and refitted it for after have turned it the other way.

See the pictures for my results.
The pictures show true TDC.
Still not sure wether to move the cams sprocket.
Any ideas?

Got MOT tomorrow so all help today is greatly appreciated.

uploadfromtaptalk1432898434738.jpguploadfromtaptalk1432898452957.jpguploadfromtaptalk1432898464897.jpg

[irishs2]

It does look like your timing is off.
The Camshaft looks to be right for ADU, but the flywheel and front timing marks are a little bit away from their mark.

http://s2central.net/Timing_Belt_Renewal_Rev1.pdf

[k.alle]

They are I agree. But this is true TDC for this engine since I have checked and measured it with a piston stop.
If I would align the flywheel like the pictures you posted I would no longer be at TDC.

I use a 7A flywheel, perhaps that is my issue with the bellhouse window not lining up?
I dont know.

[k.alle]

I think that I hopefully have found my idle issues


Broken insulations on almost all the wires to the coils.
Had to remove them and bend around to see them.

uploadfromtaptalk1432904292123.jpg

[k.alle]

Weekend update.

I have now bought and swapped over to tfsi coils.

Idle is still rough though

It goes OK (not great) when im out driving.
Idle is missing/hunting all the time.

One thing I have noticed is that the turbo seems to make more noise on idle since rebuild.
Its sounding lik a big hair dryer (low pitch), only on idle.

The engine is also sounding like a diesel. Probably a lifter that isnt up to it.

[andy10v]

Did you fit a billet crank pulley? They can have the keyway slightly off.

[k.alle]

I have now pressure tested the inlet system, including crank breathing system.
There was a small leak at turbo to IC hose, tightened clip and it got good.

Watched the voltage meter at idle and it is acting up. Jumping from 12V to 14V at no apparent pattern.

Fitted the stereo face as well and the stereo is going bananas at idle and while driving. Coming on and off.
One interesting observation was that the stereo comes to life every time I got boost. I could reproduce it every time.

I dont know what to do anymore..
It is effin frustrating.

[k.alle]

Did you fit a billet crank pulley? They can have the keyway slightly off.

Yes tommis billet.
As I described before the cam wheel seems to be aligned when I put it at true TDC.
So the keyway misaligning shouldn't matter in that case right?
Or is this just brain farts on my part?

[rxl]

havent had time to go to garage. but i also use 3b flywheel and the points do alighn on front.. and there is only one way to put a flywheel so...

[k.alle]

havent had time to go to garage. but i also use 3b flywheel and the points do alighn on front.. and there is only one way to put a flywheel so...

Yes the flywheel can only be fitted one way. It is idiot proof, which is very fitting for me

Question is what is important here:

TDC and then zero the cams

or:

Flywheel marking lining up and then zero the cams.

If I line my flywheel marking up right at that window then my engine piston #1 is not at true TDC.

[k.alle]

Oh and if I blip the throttle to 4500 rpm and let it come down to 3000 rpm I here some exhaust bangs.

[k.alle]

Problem is solved.
As some of you already suggested the timing was off by a tooth. Probably due to the tommis billet sprocket.

Diesel sound is gone and idle is much much happier, also runs quite good.

However, during my test run the water warning came up.
Stopped at a suitable place and it had emptied all water.
On climate control cars there is a plastic tube with a sensor in it in matrix return hose. Plastic had sheared off.
Got help and fitted a copper pipe instead.
Had to fill water through big top radiator hose, the plastic coupling of course broke and there was no hump left to hold the hose.

Drove carefully back to the garage and turned off engine.
Opened the hood and had a chat with my mother and my cousin who helped med.

Then suddenly all hell broke loose, the hose blew off the radiator because of the pressure and spewed steaming hot water over my belly, thighs, hands and unfortunately my d.I.c.k.

Conclusion car at last runs fine and I got 1st to 2 nd degree burns on thighs, belly and my *****
Happy times!

Let this be a warning not to be around a defective cooling system when hot.
Please learn by my mistake because it hurts like effin hell!