2.5 TDI Won't run with cam sensor. SOLVED Timing gear issue

Hello all,

I’m looking for some advice / help with my vans engine (2006 2.5 TDI AXE 174) I've had a little search but can't find much

Shortly after I bought my van I had no issues with the engine and it was running good, decided to do a VCDS scan and found 3 codes stored they were;
19463 - Camshaft Position Sensor (G40) : No signal - P3007
19464 - Camshaft Position Sensor (G40) : Signal out of range - P3008
16705 - Engine Speed Sensor (G28) : Implausible Signal

So I cleared codes and after starting the engine was left with ;
19463 - Camshaft Position Sensor (G40) : No signal - P3007

I then replaced the cam sensor with a genuine febi sensor. Doing this cause the van to start and then immediately shut off. I then looked at the fault codes on VCDS and found:
19464 - Camshaft Position Sensor (G40) : Signal out of range - P3008

I then decided to unplug the sensor and it started up and drove fine, and I proceeded to drive the van like this for over 12 months and it’s been fine.

The last couple of weeks I’ve been going over the engine and trying to get to the bottom of this problem as well as a couple of other things like boost leaks.
I took the rocker cover off and checked the cam, that was showing signs of wear so I decided to replace the cam and tappets. I used the tool for the engine and a Haynes manual
to time it up and it all appears to be in time.

Cylinder 1 (furthest from gearbox) the cam lobes are pointing up (valves closed)
The cam gear mark is in line with the back of the head
Tools are in place (cam tool doesn’t quite fit but it's in the right position)

Other checks I’ve done:

Confirmed there is 5v to the cam sensor
Checked the crank sensor for debris and confirmed its working as it won’t start with it unplugged and tacho seems to be true
Checked the wiring from the sensor to where it meets the loom, this seems fine up until this point

Not really sure what else to try at this moment in time! I've seen links where they recommend you use and sciascope to read the cam and crank sensors but don't own one.
Can this be done on registered VCDS-Lite?

I did read a few threads that suggested that the cam could be 180deg out but if cylinder 1 valves are both closed then surely this means the cam is in the correct position?

I've attached a couple of photos to show the cam position and the cam gear mark. These were taken with the engine locked at TDC and the cam tool lock position (Lobes up on cylinder 1)

Any help would be much appreciated!

Thanks, Curtis

2.5 TDI Won't run with cam sensor. SOLVED Timing gear issue

Micka86

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