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Engine Won't Start After Camshaft Replacement (A4 2.5 AKE)

 
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mat40k



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Post21-03-2009, 18:34    Subject: Engine Won't Start After Camshaft Replacement (A4 2.5 AKE) Quote

Hello and have a wonderful day.
Unfortunately, I'm experiencing a rather significant problem with my Audi A4 2.5 TDI (AKE).
Background: Like with many other cars, the camshafts have worn out in mine.
By chance, I was able to prevent more significant damage (7 control linkages had already detached).
I performed the repair myself. Unfortunately, due to limited time, the whole process took 2 months. So far, everything went well; the new water pump is installed, the timing belt is on, and the engine started right away.
Okay, so I'm now preparing for the initial test run (temporarily). That means I haven't installed any lights or anything like that yet.
I just want to know if the car starts so that I don't have to disassemble or remove everything again if there's a problem.

My problem is that the car simply won't start. Diesel is reaching the lines before the injectors, there's diesel in the return line, the engine is cranking, but I can't detect or read any significant error codes.
What comes to mind is that the battery was disconnected for charging at some point... could that be related?
Could it be that I over-revved the engine after installing the timing belt? I wanted to see if anything was blocked (the fuel injection pump wasn't on the belt; however, the engine was brought back to top dead center and then the belt was attached to the pump).
Since I had good access, I also immediately cleaned the intake manifold with the intake ports... I felt like I removed about 10kg of dirt/soot icon_eek.gif. The engine was running without problems before... Does it store old calibration/measurement values? Could the dirty air intake and the missing valves have led to certain values that the engine/control unit stores, and now is the engine overwhelmed by the new data?
I also experimented with the ignition timing. At least, I changed it, and I subjectively feel that the engine runs "smoother"... although it still won't start.
I also read that you can check the setting using VagCom... but unfortunately, the engine isn't running, and I'm not very familiar with the program yet (that's why I haven't used it).
Anyway, I'm at a loss now; fiddling with the organ isn't getting me anywhere, and I don't want to keep stressing the battery and starter motor.
My current idea is to try to tow the car. Or should I just leave it alone?
Are there any other tips?

Thank you very much for your help.
Best regards,

EDIT: Here's the first error log:

VAG-COM Version: Release 311.2-N.


Chassis Type: 8E - Audi A4 B6.
Scan: 01, 02, 03, 08, 09, 15, 16, 17, 26, 36, 37, 45, 46, 55, 56, 63, 76

Address 01 -------------------------------------------------------
Controller: 8E0 907 401 B
Component: 2.5L V6 TDI 0000SG 0002
Coding: 02015
Shop #: WSC 63351
00001059 130 106HC150_1.R76491691181
1 Fault Found:
00523 - Intake Air Temp Sensor (G42) icon_arrow.gif ***The error disappeared after being cleared.***
30-00 - Open or Short to B+ icon_arrow.gif ***The error disappeared after clearing.***
Readiness: Not applicable.

Address 03 -------------------------------------------------------
Controller: 8E0 614 517 A
Component: ABS/ESP, all-wheel drive. D1320.
Coding: 04455
Shop #: WSC 06435
4 Faults Found:
18265 - Load Signal: Error Message from ECU icon_arrow.gif ***The error disappeared after being cleared.***
P1857 - 35-10 - - - Intermittent
01826 - Sensor for Steering Angle (G85): Supply Voltage Terminal 30 icon_arrow.gif ***Error already known***
35-00 - -
18036 - Powertrain Data Bus: Missing Message from Steering Angle Sensor icon_arrow.gif ***The error disappeared after being cleared.***
P1628 - 35-10 - - - Intermittent
01206 - Signal for Duration of Ignition: OFF icon_arrow.gif ***The error reappears after clearing it.***
27-00 - Implausible Signal

Address 08 -------------------------------------------------------
Controller: 8E0 820 043
Note: Excessive communication errors.

Address 09 ------------------------------------------------------- icon_arrow.gif ***Okay, since the front is "missing," it shouldn't cause any problems, right?***
Controller: 8E0 907 279 E
Component: int. Last Module, RDW 0305.
Coding: 00001
Shop #: WSC 00547
10 Faults Found:
01494 - Bulb for Parking Lamps: Left (M1)
57-00 - Electric Circuit Failure
01498 - Bulb for Parking Lamps: Right (M3)
57-00 - Electric Circuit Failure
00978 - Lamp for Low Beam: Left (M29)
57-00 - Electric Circuit Failure
00979 - Lamp for Low Beam: Right (M31)
57-00 - Electric Circuit Failure
01495 - Bulb for High-Beams: Left (M30)
57-00 - Electric Circuit Failure
01499 - Bulb for High-Beams: Right (M32)
57-00 - Electric Circuit Failure
01496 - Bulb for Fog Lamps: Left (L22)
57-00 - Electric Circuit Failure
01500 - Bulb for Fog Lamps: Right (L23)
57-00 - Electric Circuit Failure
01493 - Bulb for Turn Signals: Front Left (M5)
57-00 - Electric Circuit Failure
01497 - Bulb for Turn Signals: Front Right (M7)
57-00 - Electric Circuit Failure

Skipping Address, 15 Airbags.

Address 16 -------------------------------------------------------
Controller:
Note: Unable to synchronize baud rate.

Address 17 -------------------------------------------------------
Controller: 8E0 920 900 E
Component: KOMBI+TRAVEL. RB4 D12
Coding: 03000
Shop #: WSC 08461
WAUZZZ8EZ1A050620 AUZ6Z0A0085109
No fault code found.

Address 46
-------------------------------------------------------
Controller: 8E0 959 433 K
Component: Comfort Device T01 0112
Coding: 06752
Shop #: WSC 63351
5 Faults Found:
00912 - Window Regulator Switch: Front Left (E40) icon_arrow.gif ***The error is known, and it reappears after some time after being cleared.***
27-10 - Implausible signal - Intermittent.
00913 - Window Regulator Switch: Front Right Driver (E81)
27-10 - Implausible signal - Intermittent.
00915 - Window Regulator Switch: Rear Right: Driver (E55)
27-10 - Implausible signal - Intermittent.
00914 - Window Regulator Switch: Rear Left: Driver (E53)
27-10 - Implausible signal - Intermittent.
01333 - Door Control Module: Rear Left (J388) icon_arrow.gif ***Not previously noticed, and the error code remains even after clearing it.***
80-10 - Single-Wire Operation - Intermittent.

End -------------------------------------------------------


Translated on 05-10-2026, 14:37.
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bastion
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Post21-03-2009, 20:42    Subject: Engine Won't Start After Camshaft Replacement (A4 2.5 AKE) Quote

You wrote that you turned the engine without the pump. Is the pump setting still correct? Please check it. That's the first thing to check, especially since the diesel is reaching the injectors.

How about the parking brake? Does it work?
A4 Limu 07/96 AHU@110PS 192tkm 08/05-05/08
A4 Avant 08/01 AWX 05/08-


Translated on 05-10-2026, 14:49.
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christians
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Post21-03-2009, 21:08    Subject: Engine Won't Start After Camshaft Replacement (A4 2.5 AKE) Quote

You apparently didn't disconnect the pump motor when installing the pump belt. That might be the problem. As Bastion already mentioned...
Gruß Christian
A6 BPP, Ex-A6 AKN (Gurke), Ex-Audi100 92 AAT (5Zyl.)


Translated on 05-10-2026, 14:49.
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mat40k



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Post22-03-2009, 4:56    Subject: Engine Won't Start After Camshaft Replacement (A4 2.5 AKE) Quote

Yes, the pump was disconnected. As I said, I first installed the belt for the water pump, then checked that it was properly seated on the freewheel, and then I started working on the ESP (Electronic Stability Program). The belt tension is also fine, and later, as I mentioned, I fiddled around with the "fine adjustment" (thinking I could get it running that way).

Anyway, I can now say: The towing had an effect icon_biggrin.gif.
It's running again! There wasn't a large cloud of smoke or anything like that... which surprised me a lot... the engine sounds good... it now starts on its own with the starter... the only thing that could be criticized is the throttle response. At least, I found it a little strange. It could also be because I haven't been in the car for a long time.
Otherwise, I'm going to have to take a closer look at the start date of the funding. And since I'm already here... I might as well just ask icon_rolleyes.gif.

I'm going into the Engine Control Module (ECM) using VagCom, specifically address 01.
Then, go to basic settings - 04.
"And then I can check in channels 1-4 to see at what degree before/after Top Dead Center (TDC) the injection starts?"
According to my understanding, the target values were early: less than 12° valve opening angle (VOA), and late: 0-4° negative valve opening angle.

Thank you again for your quick responses.


Translated on 05-10-2026, 14:51.
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