Tom's Mk5 (2000) 150s SWB 2.5L 76ps Project

[Van1968]

Before you try to start it again, pin it all up and check the timing again. The starter will get warm with prolonged use, that's not a worry. A quick spray of hair spray/ wd40 / brake cleaner into the air intake should help. Easy Start is best avoided if possible it's too harsh, and often causes more harm than good.

Thanks for your input. Timing and having it right has been on the back of my mind. It's more on the tension side of things...Now that the engine has had a good few revolutions I plan to strip back..rad off..belts, pulleys and check the tensioners' check mark. Its a pain to do emptying coolant etc..but needs must . Still dark..really want to have it stripped back by 9 this morning..checked and double checked so I can finally stop worrying about it...put everything back by 11am with new battery in place...Fingers crossed...

Thanks again

[75psT330lwb]

dont worry mate, u will get there! makes good reading this

[Van1968]

Thanks for the words of encouragement..I love sharing even through difficult times...
Ok here we go..currently working on the van as I write..even though that sounds odd as I'm typing right now
I have stripped her back and I was chuffed with the results...didn't take me long either..just under an hour
Here are a few photos of the work and my findings...I am looking for the experienced heads to confirm I have my Timing sorted...I do believe I have..as you all know, when working on projects like this one can over think and then the doubting elements come into play...so best I share and give you all the info..here goes..
stripped her back and took everything off so I could get to work

Set the TDC 13mm Drill bit Crankshaft, fuel pump 9mm and Camshaft pulley 8mm...Auto tensioner set with the check mark just above as stated by Gates 005 technical bulletin...

Took the pins out and rotated the engine two full revolutions so that I could get the timing tools back in and checked the auto tensioner..
check mark looking good..

All 3 pins went in smooth and the tensioner is still looking good...

My lovely wife is off to buy me a new battery..just left...I am going out to double check and tripple check....Probably worrying about nothing..but I'm the sort of chap that wears his heart on his sleeve..
Back in a couple of hours..I will pop in for a brew and log in from time to time.
Tom

[ake]

Yeah, all looks okay to me, but its been a while since I played with a MK5

Take the fuel filter off and make sure it is still full of fuel as well before trying again, have you stolen her hairspray yet?

[Van1968]

Yeah, all looks okay to me, but its been a while since I played with a MK5

Take the fuel filter off and make sure it is still full of fuel as well before trying again, have you stolen her hairspray yet?

Thanks again for your tips...

Been out and checked and checked again....I feel confident the timing is good..have a new battery..a little longer than the one I used to have..I will need to trim the battery tray so I can sit it in tight and bolt it down..
check this out..this ought to turn power up....

as for the hairspray...not much luck there have some brake cleaner to help me out...off to put things back together..hopefully I will be back later with some positive news and a chugging sound....

[johnsvan]

When you changed the lift pump, did you make sure that you got the fuel lines the right way around?

[oldyellar]

When you changed the lift pump, did you make sure that you got the fuel lines the right way around?

good question rookie mistake i have made myself how didnt i think of that

[Van1968]

When you changed the lift pump, did you make sure that you got the fuel lines the right way around?

Good point..fortunately I did remember..only because the left side fuel line is marked with a red tag...thanks for your input

[Van1968]

Hello again...
Continuing my story..don't want to give too much away I am a tease..here goes
putting it all together now that I was happy with the timing Thanks to Aka for the vote of confidence

Rad on and coolant back in..at this point I started to feel quite sick with nerves..

Moved swiftly on to doctoring the battery tray..angle grinder got a bit happy in the left corner..bent the ends down allowing more room..the nice lush new battery is a little longer..I was determined to get it in

Check out this puppy..well chuffed and nicely clamped..not going anywhere..bought it from Eurocarparts..well the Wife did

Back in a minute..my tea has just turned up..yummy

[Van1968]

Back again...
I refilled the Fuel filter..had no diesel left in my Jerry can so decided to use my reserve bottle of FORTE..Refitting is a pain..initially I wasn't happy so undid it refitted and it felt right..there is a knack and after several goes got there in the end.
Time to call the wife..foot down on both clutch and throttle...asked her to turn the key...as it turned over,(No sloppy turnover this time with the new battery )I sprayed a little Brake cleaner and..hey presto she came to life..what a fantastic feeling...

My nerves and sickness had gone and I was carrying out checks while it was ticking over..nice tickover too...only to find a pool of oil appearing on the road...guess where it was coming from! Here from the back end of the rocker head...(Apologies for quality of the picture)
I'm a bit gutted...new "rubber type (I know its not rubber..I cannot remember the exact material name) gasket" torqued up and followed the tightening up pattern as specified It was noticable too ooozing out as though no gasket was there. Other areas on the rocker cover were dry..I checked the tighness just in case and bolts towards the back end seemed fine.

It looks like its been a common factor/problem from all the old oil deposits before I started working on it. Not sure how to over come this problem..initial ideas are to double seal with gasket sealant..stuff I mentioned earlier and up the torques..either that or revert back to using a cork gasket and again double seal with gasket sealant. I am sure there are members that have experienced this as I understand its very typical..what I would like to know is the best fix..as ever advice and tips from those who done battle with this reacurring problem is most welcome.
Thanks everyone for your support tips and encouragement..your all ace as is the forum..its been an asset and I am truely grateful to all that have posted...
I am well chuffed I have the van running..sounds sweet too.. ..sadly I'm unable to do anything for the next few days..back to work start when its dark..finish when its dark... ..earliset I can have a dabble is wednesday morning..before my two night shifts begin..
Catch you all soon...
Thanks again for your support
Tom

[75psT330lwb]

glad u sorted it mate i would do the same and seal the seal

[Van1968]

glad u sorted it mate i would do the same and seal the seal

Thanks for that..defo going to double seal the gasket..the sealant I have is the dogs and has never let me down..

[ake]

Well done

[Van1968]

Well done

Thanks and thank you for your advice..just the job ....I apologise for incorrectly spelling your name earlier in the post..

[swbdave]

whats forte?????