You are correct that basic settings are the problem as the ECU no longer adjusts fuelling/timing etc. Your best bet is to look at the adjusted timing the ECU is giving. It should be advanced beyond .55 when cold but when hot that's your number. Higher is too advanced lower is retarded. Avoid going into basic settings whilst you calculate which way to go on the static timing.

 

My van had all the belts done at a well respected indepenent vw specialist a couple of years ago as I was wary of the timing issue .I believe the timing is dynamic and the ecu adjusts according to load etc .But getting it right to begin with is the problem .The garage in question got it running but only on about two thirds power .I took it back and they played with it for a day .Net result could not get it going at all!Well,fair play, they did the right thing and took it on transporter to a diesel injection specialist who I am told got it back to full power simply by the feel of the pump as it began to compress the fuel .Anyway no expense to me and has run perfectly ever since .The pump timing is seemingly very difficult and seems to take knowledgeable experience .Other garages I tried before seemed to know and would not look at it !Have you got a diesel injection specialist nearby ?The one that did mine was Mcalister of Cumbernauld ,but you are probably hundreds of miles away.I would look your nearest one up and with any luck they might have a man that knows how to do it .It is very tricky and the movements of the timing are tiny ,between no go,poor running ,and correct.It takes someone who has experience of that particular sort of pump ,i think

 

There are quite a few videos about this and I seem to remember it being shown done with diagnostic equipment and the moment of injection being shown as a series of dots on a screen which should hit a particular spot on the screen showing whether the moment is early,late ,or just right .you would need the software ,which was a few hundred pounds I think or have great experience to "feel" it .

 

The only software you need is VCDS....FREE, BUT, you need to register it ($99) to be able to do the timing.
It's a "tool" every TDi owner should have!
Cheap (XP even) laptop, the 10 quid lead, and the registered software (which it sounds like you already have).
I never go anywhere (even to the local shops) without it.
Lives on an old laptop, under the seat, with a 12v adaptor (as the battery lasts about 5 mins on it!).
One of the "best regarded" mechanics for doing timing is Simon at Brickwerks (even had a 2 page write-up in one of the motoring magazines), and that is the "tool" he uses.

 

Have you succeeded in doing the timing yourself using this vcds software?How difficult is it if one had to do again ?I have a few old but working laptops

 

Unless it's really far out (like belt slipped a tooth!), it's a 2 spanner and an allen key job.
1 spanner to remove the cowling, another to slacken the nut on the tensioner pully, and the allen key to turn the inside shaft.
Done with the engine running and up to temp....just watch out for knuckles/belt contact.
Need to be able to see lappy screen whilst doing it (or have extra person).

There's an old thread somewhere where Simon details the method.

 

Thanks

 

Thanks guys, update here the van never fails to impress as it seems to have fixed its self a bit over the weekend!

I have VCDS in block 4 the timing is about 2.2 BTDC but I am running at about 90% duty cycle I can now get the van into basic setting but it only just about runs and smokes like a steam engine the timing is bouncing from 36 - 155 which I think could mean I have a needle sensor issue? what I should have added to the post is I am running AHY injectors so I am wondering if this is the problem, I changed the timing to about 12 BTDC and it run great starts first flick of the key and only at 10% duty I think I need to get the ECU mapped and timing sorted by someone that knows what they are doing.