S6 No Spark

[UrS4boy]

Read this.. https://www.picoauto.com/library/cas...ilure-to-start

So, in my opinion, the real take-aways from that article for an UrS AAN (or ABY or ADU) owner without any distributor *OR* a "tuna can" hall sender are:

1. the front cam belt pulley (the one at the crank) can get broken and mess things (timing) up royally. We knew that. But always good to be reminded.

2. The only real way to get the timing spot on is to use the tiny mark on the edge of the flywheel (NOTE: Sometimes these seem to be missing - maybe just rusted over). - we knew that too but often get lazy and use the one on the vibration damper and lower cam belt cover. Bad idea in retrospect.

[audi660]

Thanks guys for all your help, just got car started.
The timing mark on the crank pulley was 2 teeth out, so when the mark lined up the timing was out by 2 teeth

[UrS4boy]

Thanks guys for all your help, just got car started.
The timing mark on the crank pulley was 2 teeth out, so when the mark lined up the timing was out by 2 teeth

Good news. Was the crank pulley broken?

[audi660]

No but the timing mark was incorrect, I couldn't find the TDC mark on the flywheel so pulled out spark plug number 1 and turned the motor till the piston was all the way up

[newsh]

Thanks guys for all your help, just got car started.
The timing mark on the crank pulley was 2 teeth out, so when the mark lined up the timing was out by 2 teeth

I was sure it would be this

Are you certain the keyway is still ok on the crank sprocket? I would suggest checking the timing again after a few miles.

The crankshaft pulley must be tightened with a crank locking tool and not with a rattle gun. You can also buy a billet steel sprocket that will not break.

[macspring]

Glad you got it solved / started.

A steel pulley on the front end of the crank would be good insurance going forward.

[audi660]

The car does have a steel pulley fitted, that might be why the timing mark is out

[UrS4boy]

Some Issues with Steel Cam Belt Crank pulleys

The car does have a steel pulley fitted, that might be why the timing mark is out

Based on a recent Project Pad thread/post comparing the steel pulleys to OE cast that was linked from here last week, there were indeed some issues with the location of the bolt holes for the front AAN Serpentine belt pulley and harmonic damper with some steel pulleys. Personally I was not aware of that issue and obviously neither were you. Made finding the issue almost impossible for you. The lesson that we should all learn is to use the TDC mark on the flywheel.

One example of this issue from that Project Pad thread:

http://theprojectpad.com/viewtopic.php?f=10&t=1776&p=74097

It's out but I don't think it is 2 teeth out. Probably the rubber in the isolation portion of the harmonic damper has failed, allowing that timing mark on the front edge of the serpentine belt to shift, e.g. 2 teeth. Again, timing off the flywheel = fool proof.

[audi660]

The problem I had was that there was no TDC mark on the flywheel, which was strange as I used engine cleaner and a toothbrush to try find it

[UrS4boy]

The problem I had was that there was no TDC mark on the flywheel, which was strange as I used engine cleaner and a toothbrush to try find it

Yeh. I had a look at a brand new-in-a-box LUK made AAN Dual Mass Flywheel (not mine) I couldn't find the timing mark either. I need to have a look at my new one. I am guessing no mark either. So don't feel bad.

I am working on a procedure or solution to this issue. Stay tuned.

[audi660]

Now the car starts but it sounds like the lifters aren't getting oil and my oil light comes on.
Yesterday I revved it to 2000rpm and the oil light went out and car idled quietly

[audi660]

Found the problem, was the relief valve on the oil pump. The piston was getting stuck so polished it with fine sand paper.
No car sounds great

[UrS4boy]

Found the problem, was the relief valve on the oil pump. The piston was getting stuck so polished it with fine sand paper. No car sounds great

Two things:

1. Found the timing mark on my New-in-box (NIB) Dual Mass Flywheel. It wasn't 23.25 teeth from G4 pin. It was 38.25 teeth away. Not sure why the literature says the G4 is 62 degrees away from the TDC mark (= 62/360 x 135 = 23.25 teeth). 38.25 (ish) = 102 degrees. (!!??)



2. First time that I heard of an issue with the pressure relief valve on the oil pump. So you polished the pressure relief piston? Any before and after photos for the archives?

Oil Pump and Pressure Relief Valve info:

http://forums.quattroworld.com/s4s6/msgs/93029.phtml