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Fixed it!!!! It's was the egr valve!?!? Timed it all up again today, same prob. Whilst scratching my **** I pulled the vac line off the egr and now she runs like a dream! I wonder if it's blocked with crap as I cleaned the inlet manifolds up while it was all apart. Main thing is it's done now...

Still no joy. Tried a new batt. Checked as much live data as I could, immob seems ok, it's chucking fuel in, can see fuel spurting out if I crack an injector pipe. It's so strange that it'll run for a few seconds then die, almost like the ecu doesn't like something. Still no fault code. Soooooo...

Gonna chuck a fresh battery on it this morning. Might try recoding the pump again. The batt has gone flat a few times so I wonder if that's causing a problem?

Cheers for all the comments! It almost feels like an immobiliser fault, but no codes relating to it, even in the instruments section. It's strange that it seems to play up when left overnight. Is it a cold start or a fault due to something in the immob resetting? The battery isn't the best but...

Hello! I'm looking for some help before I have another heart attack!! Car is a 2002 A4 2.5 V6 TDi AKE It's had a new fuel pump (diesel bob), a new needle lift sensor/no 3 injector (Bosch) and a coolant temp sensor. Timed up and was running ok but a little smokey (white), sat for an hour...

I've got a spare sump with oil level sensor if its any use? No baffles tho :-(

Great thread, that turbo makes me feel all funny downstairs!!! I feel your pain as my engine's in much the same state :-( Hope you get it sorted, nice tip on the oil pressure valve, gonna check mine tomorrow!

I used vag bearings and the caps were the right way. It all adds to the confusion. I'm soooo glad to know I can get a single rod, gonna email IE this evening. Will ask about the markings as well. Thanks to the power of the Internet I've already been offered a spare crank and some rod bolts!!

I was just thinking of the fact that I can reuse them, will price up some more oem ones, only done 450 miles on the engine when it seized. Thanks for the offer, will see what the engine builder says/if the rod (IE) can be saved. Will be in touch if it can, cheers!!

Torque wrench is less than six months old. Gonna get a mate to test it this week and see if its reading right

Thats great to know, thanks! I'm going to take the block to a local engine builder this week and see what he can do. Interestingly 3 of the rods are marked with the number 446 and the failed one is 935, i'm sure it's nothing but I wonder what it means? Took the cap of the offending rod this...

I'm looking at getting some ARP main bolts, poss some 2000 conrod bolts as well. Still not sure what the plan is until I take my mullered block to my engine builder. Cheers for the info!!

Sooooooooo, managed to drain the oil and get the engine onto a stand today. Safe to say its ****ed. See below: Obv number four big end has got a bit hot. Found lots of swarf in the sump: I'm feeling rather stupid and extremely gutted at the mo. I've done no more than you can see in...

Have you looked at the rotrex chargers? I'm fairly sure the c63 can be made to fit where the aircon pump sits on a 20vt. Ask Issam at INA they did a kit once!

Can't see anything in the bell housing. Thought I did when I took the starter out but nothing obvious once I got the box out. Can still feel some compression when I crank it. I'm going away to see family for the next few days, prob won't stop thinking about it but I'm sure the break will do me...

Haha, yes mate!! Trying to get as much info as poss to stop the mild heart attacks I keep having thinking about my poor little engine :wacko:

Intergrated engineering rods. Hope I haven't cocked them up, that'd be an expensive mistake! What happened when you spun a bearing? The only job I didn't do my self was installing the crank.

input shaft is fine. Sump off next I think

really not sure on both counts!! will check the input shaft tomorrow

head blagged!! jacked it up and took off the starter. found a few little swarfs of metal but nothing serious, however I cranked it by hand and it moved about half a revolution then locked up again. managed to check the timing marks and they're all spot on. removed the box and got it to crank...