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Another v6 3.0 tdi wont start

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captain Curly

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Discussion starter · #1 ·
Hi all. I have rebuilt a v6 engine and have got to the starting stage.
The good points.
I have delphi so can scan
Cranks fine
Fuel pressure 250-350 bar.
Glow plugs work fine if I cool the water temp sensor.
So I know I have fuel and glow plugs working.

Bad bits
Don't know if timing is correct but I followed diagram. I'm an engineer and mechanic so I believe I've done it correctly.
I can't check compression because of how deep the glow plug holes are( my tool doesn't reach)
It seems the exhaust is 'pressurerising as fuel comes out of the exhaust manifold gaskets under pressure ? Actually spraying out ???
Only have exhaust connected up to the turbo. Never seen this before.

Any ideas

Lee
 
Discussion starter · #3 ·
I thought maybe do however the fuel has to go out the exhaust if its not burnt. Just can underground why it pressurises the exhaust like its blocked. I have p1018 boost control circuit electrical malfunction. Would the vanes in the turbo being stuck stop exhaust gases getting past ? If its timing no idea how to check if its correct I.e. injecting in the right cylinder at the right time.
No other codes
 
#6 ·
Agree ^^ What RPM is it holding while cranking?

Is it just fast-cranking without any indication to start?

Why did you have to rebuild the engine? That is suuuuuuuuuper uncommon with these engines.. you might be one of the first I've heard of rebuilding it vs replacing it.
 
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Discussion starter · #8 ·
Rebuilt it because it had water in a cylinder from a leaking head gasket which I took too long to get around to so the bore pitted. Will check cranking speed from delphi which is s pc based diagnotic software but it sounds about right. And yes turning over giving good fuel pressure at over 250 bar and glow plugs work but not a sniff of trying to fire. I'm also going to disconnect manifolds to the turbo to see if it stops pressurising the exhaust unless there is another reason fuel would squirt out of the manifold gasket!!!.
The way I see it...
Induction inlet open and sucks in air and injector fires. I know its getting air because there is terrific suction at the intake. Not sure when injector is firing but it makes sense its working.
Compression.......
Fire ... not working
Exhaust fuel being pushed into exhaust with exhaust outlet valve open

Doesn't make any sense. If timing was wrong and the injectors fired at the wrong time would it throw a code ? I can't see how it would cause high pressure in the exhaust.

Is there anyway to check the injectors are firing when the should ? Do they fire if you turn the engine by hand if ignition is on?

I've rebuilt several engines. Never had this issue
 
#9 ·
Plasma coated cylinders cannot be bored out.... please clarify how the pitted bore was corrected.....
If I'm following what you're saying, there's a restriction in the exhaust.... pull the downpipe off the turbo
 
#10 ·
Ya I'm 100% interested in the cylinder/ring work myself, thats where I was headed with this.

So far my parts-cannon bet is compression issues.
 
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Discussion starter · #12 ·
To answer your question. I honed the bores so if they are coated i may have buggered it. I've not see that screen on delphi. It's the cheap d150 lead so maybe I don't have full access but I have been in the engine section only, not all systems which looks like your page. The down pipe is not connected. Both manifolds just connected to bottom of turbo. I'm 99 percent sure I've timed it correctly. The holding pins can only go in one place.
I will try and find that screen tonight and post back
 
#15 ·
Let's attempt to stay positive.
What engine code do you actually have? As far as I know, all 3L TDIs have the plasma coated bores.... how much did you remove or open them up by? Did you use the factory service manual? What rings did you put back in? Was everything still in factory specs?
 
Discussion starter · #16 ·
Bks engine code. Put standard rings back in. Hardly touched the good cylinders just put a hatch in them to take off the shine as I've always done. To be honest probably overdone the bad cylinder. May result in piston slap
 
#17 · (Edited)
lmao. Dawg. You cannot bore out plasma bored blocks. And if somehow you CAN bore them out, you need to install sleeves. Which, I haven't looked lately, but I bet you cant even buy sleeves for these. That engine is fubar. I bet theres zero compression which is why raw fuel is coming out of the exhaust.


I'm not 100% the 3.0TDI is plasma bored like the v10, but it's definitely a CGI block with UV photon honing... so even if you CAN bore them out, you definitely need oversized rings, which, i'm not even sure you can buy for the 3.0TDI since the bores are already fairly close together
 
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#19 ·
If you had pitted bores, there's no way on this planet that simply honing them (without a bore-over and oversized rings) would work.....

The fact that you have literal fuel pouring out of your exhaust tells me there is no compression
There's a reason people never rebuild these blocks.
 
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