VW Golf NO Start

Wayne Owner/Technician Australia Posted   Latest   Edited  

Vw golf 6/2006 bkd Original customer complaint was lack of power and free revving?

Check engine light on. vehicle diagnosed in for EGR issues, egr was replaced. I wasn't part of the job initially and i didn't road test it prior. Was a little difficult to start at time before i was involved. I serviced the vehicle, inlet manifold removed and cleaned, was a little carboned up but not that bad. Inlet valves were closed when cleaned timing belt was also replaced along with tensioner, idler pulleys, water pump using correct, locking tools were used was my first belt on this series my only issue was understanding the locking of the tensioner prior to installation to get the belt on once i understood this belt went on ok.

Vehicle started ok initially noted that was noticeably harder to start when hot, road tested down local expressway and vehicle stopped - - cranked but no start no noises heard just loss of power crank only vehicle towed back to workshop

Items rechecked cam/valve timing was checked all locking tools went in with no issues sounded like compression not good rechecked correct oil used correct oil filter used.

Removed tappet cover to see if any noticeable issues found that centre exhaust valve lifters and all cylinder collapsed all valve height look similar but difficult to measure accurately checked oil pressure ok went to 20psi on crank.

Check low pressure fuel supply fromm filter has low pressure pump in tank and tandem pump on end of camshaft.

Removed injectors couldn't work out a easy way to check compression, put a normal type petrol gauge with rubber that seated at he base injector hole in head - noted that compression ranged from 150psi 200 psi which indicated low compression thought it must piston kissed some valve somehow

Rechecked options decided to remove head

remove head removed two valves out if suspect cylinder, not issue found used metho down exhaust and inlet ports no leakage all valve compressed with no binding

NO Obvious issue with Piston / rings 

Fitted 4 x exhaust rocker arms and one inlet arm which incorporates lifters

Reassemble head with new gaskets, bolts etc redo cam belt timing rechecked code - found code for inlet manifold throttle flap ( code to follow ) found blown fuse that also supplies cooling fans found intake flow motor causing blown fuse internal short - replaced throttle motor - cancel codes and fans motor now works no other codes stored or reappear on crank vehicle still not starting did sound better compression but that may have been hopeful adding aero start didn"t help at all decided to make an adapter up to check compression via glow plug holes did leak down test not conclusive did compression test similar test to do via injector hoses via glow plugs used adapter and hose to use wp500x pressure transducer

attached are waveform from pressure transducer and injection timing pd type injection electrically control hydraulic style injector

looks like injection timing out i need to determine what the waveforms are showing- i need a better understand of the peak pressure and injector timing

i have yet to check fuel supply to the injector again need to understand how the tandem fuel pump, vacuum pump works doesn't have a pressure gauge for scan tool for after tandem pump

disconnect cam sensor logs code but no start Scoped Crank and Cam - Compared to known good 

cam gears are adjustable but hub is keyed

Cranking RPM is only 150 - will be checking this in more depth 

Crankshaft cogged timing pulley wasn't removed yet to confirm if this is keyed

Injection Timing is to late - 

I will need to use WP500X and Cam Crank waveform is my next step 

Can anything move on the Crank sensor pickup / Flywheel ??

Need to understand if Compressions are to low 

really lost a to why, or what i have done wrong any input please from vw specialist who are familiar with these motor

really seems like a compression or timing issue as aerostart doesn't help much time spent tunnel vision has taken over

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Interesting
Dwight Owner/Technician
California
Dwight
 

Some VW/Audi engines engine use hydro-formed camshafts. The camshaft lobes are slid on to the camshaft tube and then hydronically expanded to hold the lobes in place. If you inspect the camshaft lobe where it mounts to the shaft, if you see a parting line, it's pressed on. If it has a machined radius, it's not. Not to send you on a wild goose chase, but I have seen pressed lobes move, if you…

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Wayne Owner/Technician
Australia
Wayne
 

Thanks, cam lobes are not pressed

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Joel Diagnostician
California
Joel
   

Is that vw diesel? I see is diesel . Perform intake sealing, plug the throttle body during taking the capture to very cam / crank timing . Thay way you can obtain vacuum in the intake manifold, also a pulse sensor or absolut pressure sensor in the inaked to very valves activity

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Wayne Owner/Technician
Australia
Wayne
   

Yes it is a Pd diesel Thanks

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Jordan Technician
Nevada
Jordan
 

I am not sure if this applies to your VW or not. I don't see BKD as an option in the US. But this video shows to set-up the Start of Injection timing. Start of Injection - YouTube

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Wayne Owner/Technician
Australia
Wayne
 

It is a pd injection, different system Thanks

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Brandon Diagnostician
Arizona
Brandon
 

I believe you said when you did the timing belt that you did not remove the crankshaft cog. Ive seen the key way get worn and shift can can cause problems of long crank , crank no start , start /stall. lack of power could be right there too. the adjustable camshaft gear must be set correctly as well as the HPFP gear. maybe resetting the injection quantity adaptation could be useful. good luck.

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Wayne Owner/Technician
Australia
Wayne
 

Crankshaft Cog wasn't removed - Have confirmed TDC is correct with piston at TDC and crankshaft locking tool is correct indicating TDC - It is PD Injection system so has a Tandem pump More Files Uploaded sorry if I have duplicated

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Wayne Owner/Technician
Australia
Wayne
 

Second Hand engine fitted - at some point engine will be dismantled to find out what the cause was - thanks for all comments

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Wayne Owner/Technician
Australia
Wayne Resolution
 

Second hand motor fitted, when time permits, mother will be dismantled to investigate what was the cause on no compression

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