1.9 BRM crank and sputter but no start after complete rebuild

p1muserfan

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I bought this car as a project about 4 years ago. I sent the head and EGR cooler to Franks VW. I built the engine in August and installed it in January. A friend helped me prime the fuel system. I did an auto scan and cleared everything before I cranked the engine the first time. It will crank and sputter but just will not fire off. Getting black smoke from the tail pipe. Too much fuel and no air? Intake flap motor is wide open. Not sure where to start. Latest auto scan attached.

Code:
Tuesday,23,February,2021,13:35:13:40487
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 20.12.0.1 (x64)  HEX-V2 CB: 0.4529.4
Data version: 20201125 DS322.1
www.Ross-Tech.com


VIN: 3VWRT71K76M665570   License Plate:
Mileage: 214720km-133420mi   Repair Order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 1K (1K0)
Scan: 01 02 03 08 09 0F 15 16 17 19 25 42 44 46 52 56 62 72 7D

VIN: 3VWRT71K76M665570   Mileage: 214720km-133420miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: Malfunction 0010
03-ABS Brakes -- Status: Malfunction 0010
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
0F-Digital Radio -- Status: Malfunction 0010
15-Airbags -- Status: Malfunction 0010
16-Steering wheel -- Status: Malfunction 0010
17-Instruments -- Status: Malfunction 0010
19-CAN Gateway -- Status: Malfunction 0010
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: Cannot be reached 1100
62-Door, Rear Left -- Status: Malfunction 0010
72-Door, Rear Right -- Status: Malfunction 0010
7D-Aux. Heat -- Status: Malfunction 0010
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-016-BEW.lbl
   Part No SW: 03G 906 016 AC    HW: 028 101 223 9
   Component: R4 1,9L EDC G000DG  7551 
   Revision: --H01---    Serial number: VWZ7Z0E2543143
   Coding: 0050078
   Shop #: WSC 00066 000 00000
   VCID: 6492A48E52525D5BF7A-8030

2 Faults Found:
005715 - Please check DTC Memory of ABS Controller
               P1653 - 000 -
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 0
                    Fault Frequency: 2
                    Reset counter: 255
                    Mileage: 214723 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:34:06

             Freeze Frame:
                    RPM: 0 /min
                    Speed: 4.0 km/h
                    Load: 0.0 %
                    Voltage: 12.31 V
                    Bin. Bits: 11101000
                    Torque: 134.2 Nm
                    Bin. Bits: 00000100

000833 - Camshaft Position Sensor (G40)
               P0341 - 000 - Implausible Signal - Intermittent
             Freeze Frame:
                    Fault Status: 00110000
                    Fault Priority: 0
                    Fault Frequency: 3
                    Reset counter: 255
                    Mileage: 214723 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:00:35

             Freeze Frame:
                    RPM: 336 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 10.34 V
                    Bin. Bits: 00101000
                    Idle Stabilization: 0.0°KW
                    (no units): 3.0

Readiness: 1 1 0 0 1

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 02E-927-770.clb
   Part No SW: 02E 300 042 H    HW: 02E 927 770 AD
   Component: GSG DSG         070 0913 
   Revision: 00007000    Serial number: 00000505070258
   Coding: 0000020
   Shop #: WSC 00066 000 00000
   VCID: 186AC07EDE9A49BBAB2-804C

2 Faults Found:
18250 - Please check DTC Memory of Instrument Cluster
            P1842 - 000 -
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 0
                    Fault Frequency: 255
                    Reset counter: 1
                    Mileage: 214723 km
                    Time Indication: 0

16947 - System Voltage
            P0563 - 000 - Too High - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 255
                    Reset counter: 40
                    Mileage: 214723 km
                    Time Indication: 0


-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1K0-907-379-MK60-F.lbl
   Part No SW: 1K0 907 379 Q    HW: 1K0 907 379 Q
   Component: ESP FRONT MK60      0102 
   Revision: 00T12001   
   Coding: 0021122
   Shop #: WSC 00066 000 00000
   VCID: 40DA481EE68A217B332-8014

3 Faults Found:
65280 - Development code 1
            000 - -
00000 - End of output
            000 - -
00000 - End of output
            000 - -

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-820-047.lbl
   Part No: 1K0 820 047 DK
   Component: Climatic PQ35   090 0505 
   Shop #: WSC 00000 000 00000
   VCID: 70BAD8DE96AAF1FB832-8024

3 Faults Found:
00532 - Supply Voltage B+
            001 - Upper Limit Exceeded - Intermittent
00229 - Refrigerant Pressure
            002 - Lower Limit Exceeded
01316 - ABS Control Module
            013 - Check DTC Memory

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels:. 3C0-937-049-23-M.lbl
   Part No SW: 3C0 937 049 D    HW: 3C0 937 049 D
   Component: Bordnetz-SG     H37 1002 
   Revision: 00H37000    Serial number: 00000000145408
   Coding: 14010E234004180000140000001400000008730B5C
   Shop #: WSC 25117 444 54387
   VCID: 2A0E0AB670F6CB2B0D6-807E

   Subsystem 1 - Part No: 1K1 955 119 C  Labels: 1KX-955-119.CLB
   Component: Wischer VW350  012  0402 
   Coding: 00065493
   Shop #: WSC 25117 

10 Faults Found:
01493 - Bulb for Blinkers; Front Left (M5)
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

01497 - Bulb for Blinkers; Front Right (M7)
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

00987 - Lamp for Brake Light; Left (M9)
            012 - Electrical Fault in Circuit
             Freeze Frame:
                    Fault Status: 01101100
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 196
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

00988 - Lamp for Brake Light; Right (M10)
            012 - Electrical Fault in Circuit
             Freeze Frame:
                    Fault Status: 01101100
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 196
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

02394 - Parking Light Left Front (M1)
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

02395 - Parking Light Front Right (M3)
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.10 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

01495 - Bulb for High-Beams; Left (M30)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.50 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

01499 - Bulb for High-Beams; Right (M32)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.50 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

00978 - Lamp for Low Beam; Left (M29)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.50 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF

00979 - Lamp for Low Beam; Right (M31)
            010 - Open or Short to Plus - Intermittent
             Freeze Frame:
                    Fault Status: 00101010
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.50 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF


-------------------------------------------------------------------------------
Address 0F: Digital Radio        Labels: 8E0-035-593-XM.lbl
   Part No SW: 8E0 035 593 E    HW: 8E0 035 593 E
   Component: SDAR XM         H03 0080 
   Revision: 00000000    Serial number: AUZ4Z7E3032367
   Shop #: WSC 00000 000 00000
   VCID: 2B000FB27F0CD223F60-807E

3 Faults Found:
00003 - Control Module
            014 - Defective
             Freeze Frame:
                    Fault Status: 01101110
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 198
                    Mileage: 70634 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:43:25

02788 - Internal Communications Error
            000 - - - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 7
                    Fault Frequency: 11
                    Reset counter: 236
                    Mileage: 214723 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 18:55:51

             Freeze Frame:
                    Bin. Bits: 00000010
                    Bin. Bits: 00000000

01304 - Radio
            008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 5
                    Fault Frequency: 8
                    Reset counter: 40
                    Mileage: 214723 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 18:25:11


-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 E    HW: 1K0 909 605 E
   Component: 1S AIRBAG VW8R  024 6300 
   Revision: 03024000    Serial number: 0037KD03C1JZ 
   Coding: 0012627
   Shop #: WSC 00066 000 00000
   VCID: 2E0606A64C1EA70BD1E-807A

   Subsystem 1 - Part No: 1K0 959 339 E
   Component: BF-Gewichtsens. 006 0005

   Subsystem 2 - Serial number: 6332MSME0B2734413

   Subsystem 3 - Serial number: 6342MSME0B3122630

   Subsystem 4 - Serial number: 6351HSME080A077DC

   Subsystem 5 - Serial number: 6361HSME077E1D48M

   Subsystem 6 - Serial number: 63727SME07354F622

   Subsystem 7 - Serial number: 638  SME        

1 Fault Found:
01739 - Crash Sensor for Front Airbag; Pass. Side (G284)
            010 - Open or Short to Plus - MIL ON

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 AH    HW: 1K0 953 549 AH
   Component: J0527           034 0070 
   Coding: 0010021
   Shop #: WSC 00066 000 00000
   VCID: 78AAE0FEFEDAA9BB4B2-802C

1 Fault Found:
00447 - Function Limitation due to Over-Voltage
            001 - Upper Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No: 1K0 920 952 D
   Component: KOMBIINSTRUMENT 3HL 1212 
   Coding: 0023203
   Shop #: WSC 00066 000 00000
   VCID: 2B000FB27F0CD223F60-807E

1 Fault Found:
01316 - ABS Control Module
            013 - Check DTC Memory

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels:. 1K0-907-530-V1.clb
   Part No SW: 1K0 907 530 F    HW: 1K0 907 951
   Component: Gateway         H10 0120 
   Revision:   H10       Serial number: 280010570288E6
   Coding: 3F3F0B60071002
   Shop #: WSC 00066 000 00000
   VCID: 2A0E0AB670F6CB2B0D6-807E

1 Fault Found:
01304 - Radio
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 2
                    Fault Frequency: 50
                    Reset counter: 196
                    Mileage: 214723 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 18:25:16


-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No: 1K0 920 952 D
   Component: IMMO            3HL 1212 
   Shop #: WSC 00000 000 00000
   VCID: 2B000FB27F0CD223F60-807E

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels: 1K0-959-701-MIN2.lbl
   Part No: 1K0 959 701 K
   Component: Tuer-SG         024 2377 
   Coding: 0001269
   Shop #: WSC 00066 000 00000
   VCID: 36362EC6B44E9FCB99E-8062

3 Faults Found:
01811 - Supply Voltage for Door Controller; Drivers Side (J386)
            001 - Upper Limit Exceeded - Intermittent
00100 - Drivers Interior Locking Button (E308)
            008 - Implausible Signal
00109 - Left Mirror Turn Signal Lamp (L131)
            012 - Electrical Fault in Circuit

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-144-G2V2.clb
   Part No: 1K1 909 144 J
   Component: EPS_ZFLS Kl.5   D04 1606 
   Shop #: WSC 00000 000 00000
   VCID: 323E12D6582683EBB56-8066

2 Faults Found:
00625 - Vehicle Speed Signal
            013 - Check DTC Memory - MIL ON
             Freeze Frame:
                    Mileage: 4720 km
                    Temperature: 10.0°C
                    Voltage: 12.40 V
                    Voltage: 12.20 V

00778 - Steering Angle Sensor (G85)
            000 - -
             Freeze Frame:


-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels:. 1K0-959-433-MIN.clb
   Part No: 1K0 959 433 AF
   Component:    KSG              0401 
   Coding: 137803281B09050F880F048051A0
   Shop #: WSC 00066 000 00000
   VCID: 74B2D4CEE2B2CDDB67A-8020

   Subsystem 1 - Component:   Sounder n.mounted    

   Subsystem 2 - Component:       NGS n.mounted    

   Subsystem 3 - Component:      IRUE n.mounted    

2 Faults Found:
00668 - Supply Voltage Terminal 30
            001 - Upper Limit Exceeded - Intermittent
01312 - Powertrain Data Bus
            013 - Check DTC Memory

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels: 1K0-959-702-MIN2.lbl
   Part No: 1K0 959 702 K
   Component: Tuer-SG         024 2377 
   Coding: 0001269
   Shop #: WSC 00066 000 00000
   VCID: 372823C2B34466C3828-8062

2 Faults Found:
01812 - Supply Voltage for Door Controller; Pass. Side (J387)
            001 - Upper Limit Exceeded - Intermittent
00110 - Right Mirror Turn Signal Lamp (L132)
            012 - Electrical Fault in Circuit

-------------------------------------------------------------------------------
Address 56: Radio
Cannot be reached

-------------------------------------------------------------------------------
Address 62: Door, Rear Left        Labels: 1K0-959-703-GEN2.lbl
   Part No: 1K0 959 703 D
   Component: Tuer-SG         021 2434 
   Coding: 0000144
   Shop #: WSC 00066 000 00000
   VCID: 313C1DDA5D20B8F3CCC-8064

1 Fault Found:
01813 - Supply Voltage for Door Controller; Rear Left (J388)
            001 - Upper Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 72: Door, Rear Right        Labels: 1K0-959-704-GEN2.lbl
   Part No: 1K0 959 704 D
   Component: Tuer-SG         021 2434 
   Coding: 0000144
   Shop #: WSC 00066 000 00000
   VCID: 323E12D6582683EBB56-8066

1 Fault Found:
01814 - Supply Voltage for Door Controller; Rear Right (J389)
            001 - Upper Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 7D: Aux. Heat        Labels: 1K0-963-235.lbl
   Part No SW: 1K0 963 235 E    HW: 1K0 963 235 E
   Component: PTC-Element         0404 
   Revision: 00800000    Serial number:              
   Shop #: WSC 00000 000 00000
   VCID: 2D0401AA4118DC13E84-8078

1 Fault Found:
00361 - Heater Element for Auxiliary Heater (Z35)
            014 - Defective

End----------(Elapsed Time: 01:12, VBatt start/end: 12.5V/12.5V)-----------
 

Jack@European_Parts

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18980BTTF_outatime_plain.jpg
 

Jef

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And following up Jack's statement.... did you use the correct tools when installing the timing belt?
 

Jack@European_Parts

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Was the tapered hub for cam sprocket removed from the camshaft set correct?


Is lash timing set correct for PD unit injectors for helical operation?

JPPSG
Mech minutes start your engines again this week!

 
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p1muserfan

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I have removed the timing belt covers and checked the timing. I had bought the Metalnerd kit from KermaTDI before I started the job. The crank lock I have is the one that replaced the older style, its purple/pink with the pin that slides into the hole in the block and the allen bolts that screw into the crank. With the crank at what I believe to be TDC, the cam sprocket toothed window is at about 11 o'clock the the cam lock pin slides into the hole at about 8 o'clock right into the hole in the head. Just like it did when I first timed the engine. But can I still be 180 out? I turned it over by hand numerous times after the belt was installed and it turned very smoothly.
I also redid the adjuster screw process on each injector per my Bentley manual, making sure as best I could that the roller of the rocker arm was at it's peak because I don't have the special tooling. I had a friend watch as I turned the engine to look for peak position.
But the question remains, is my timing 180 out?
 

p1muserfan

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I had to remove the hub from the cam because some of the tabs were bent (probably the cause of the cam sensor code). That probably happened when I removed the hub from the cam years ago without the proper tooling. Today I had the correct puller. The cam and hub are notched, only 1 way to go on, so ok there.
 
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