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Thread: 2.5 TDI Transporter BPC 2009 info thread

  1. #51
    Join Date
    Jan 2008
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    OK been a while but I've still had no luck getting it to actually go.

    The mechanics Taiwan "HCB-B1419" tool set ( $1k ) definitely puts the cam several degrees more advanced ( clockwide ) compared to the China tools, but there is a fair bit of freeplay in the China cam tool. This fancy tool set still shows no special TDC on the crank, so I'm at a total loss what VW were on about. Mechanic suggests 5 cylinders is the reason, but the better tool has no specific TDC.

    I plan to spend this weekend diagnosing the injectors, as I pulled them recently and three had surface rust on the god damn tips thanks to all the rain we have been having. I wire brushed them back to shiny and penetrating oiled them, but the actual injector holes may be rusted up, so I've got to pull the inlet and see if fuel spray is coming out of each inlet hole. I've three good old injectors so may swap them back in just for ****s and giggles.

    I'm still convinced there is something wrong in the fuel circuit given the fact the return line is pressurizing, gonna drop the tank and pull the pump and test it. Still should at least start a bit though. That too makes no sense.

    PD injectors and the internal nature of the loom and fuel supply make it hard to diagnose, but I have put my multimeter across all the wiring and checked for continuity. I guess a oscilloscope is the next thing to check they are actually firing.

    Probably going to have to send the injectors back to the UK to get them tested, will be the quickest and most reliable way, my VAG mechanic doesn't know of anyone decent who does PD injectors in Australia.

    I've got all new stretch bolts so my final step is to pull it down to the head gasket and get my mechanic build it up from there bit by bit.

    Gotta say when this engine doesn't want to play ball, trying to work it out can indeed be a nightmare. SO wish I'd saved a bit more and just gone for a low power 2.0, which is so much easier all round ( apart from some EGR etc issues on certain models ).

    I'm at 6 months since I bought the van now, hilarious from this perspective to think I thought it would be running in a few weeks, as I've never had this much struggle with any type of motor before this, ever, and I've seen a lot of types!
    Last edited by Greg Roles; 08-06-2022 at 10:23 AM.
    2014 Skoda Yeti TDI Outdoor 4x4 | RD Technik ECU / DSG | Garrett GTC1549vz | Darkside dump pDPF | Wagner Comp IC | Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Michelin 4s | Golf R subframe | Lots of Octy VRS / GTI bits |
    2009 2.5 TDI T5 Transporter Crewie campervan, powered by nightmares.

  2. #52
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    Well Fook me it FINALLY runs, and it started right up from bone dry injectors once happy.

    I've been busy at work / unmotivated to keep slogging it out with this engine, but I DID buy a "smart hook" powered probe tester that has injector pulse and oscilloscope functions, and used this to check all my injectors. They all fired fine when sent various signals, so I figured there had to be something else. My "new" reco injectors had some mild surface corrosion on the tips from all the time they have been sitting, and this led me to think, how are the fuel orifices? I got out my jewlers loupe/monocular and low and behold, half the god damn holes were clogged up, most likely from me brass wire brushing the tips back. I got the finest needle I could find in the missus's sewing kit and poked them all, there's 6 holes in the end of each tip, about half way down the "cone". They are tiny, and even a super small needle point only just went in. I cleaned up all the holes, soaked them in injector purge overnight, and put them back in.

    I replaced the injector loom with a cheap China one ( $34 ) just as an added precaution, given I had plugged and unplugged the new VAG one I had put in way back at the start, and thought there may have been a bad connection. I did check continuity with the multimeter and it said all was fine across the plug, but why not for $34. Seems the same as the $150 I got from Darkside anyway!

    So in hindsight I reckon I solved some problems, which lead me onto new problems, and all the time the injector tips were rusting away creating still more problems. Getting decent cam timing tools was no doubt a key part. Anyway it was amazing how easy it started, just cycled the key about 20 times and cranked for 30 seconds and away she went. Got her up to temp, have an oil leak from the crank timing cover to fix and one of the rockers is knocking a bit so I'll go back in and reset all of those when hot, but she is amazingly quiet for what it is, smooth, and happy to rev up. WAY quieter than all the going motors I've heard, hardly any gear noise, must have gotten the lash just right!

    SO this ends my journey with this engine, it's been emotional. If anyone out there is still considering one of these, just don't, the 2.5 and 5.0 PD TDI's have a reputation for a reason. I reckon it will run forever now, it's built like a Panzer tank, but when it plays up, well by GOD it plays up and is very very challenging to diagnose, get parts for, and find info on!

    AVOID!
    Last edited by Greg Roles; 25-07-2022 at 06:11 PM.
    2014 Skoda Yeti TDI Outdoor 4x4 | RD Technik ECU / DSG | Garrett GTC1549vz | Darkside dump pDPF | Wagner Comp IC | Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Michelin 4s | Golf R subframe | Lots of Octy VRS / GTI bits |
    2009 2.5 TDI T5 Transporter Crewie campervan, powered by nightmares.

  3. #53
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    I'm glad you've fixed it. Great job there. Yeah, it pays to look after them. I've been very happy with my T5 4mo AXE for 11 year, I wish I've never sold it, it was great van. Pity they don't make them anymore.

  4. #54
    Join Date
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    Quote Originally Posted by Transporter View Post
    I'm glad you've fixed it. Great job there. Yeah, it pays to look after them. I've been very happy with my T5 4mo AXE for 11 year, I wish I've never sold it, it was great van. Pity they don't make them anymore.
    Nice to hear from you ol' mate, yeah it's been the most challenging engine I've ever come across, but thankfully now all I have to do is maintain it. At least the struggle has left me quite educated on this engine, so I do know it backwards. Keeping it cool, and swapping the oil a lot is my plan!
    2014 Skoda Yeti TDI Outdoor 4x4 | RD Technik ECU / DSG | Garrett GTC1549vz | Darkside dump pDPF | Wagner Comp IC | Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Michelin 4s | Golf R subframe | Lots of Octy VRS / GTI bits |
    2009 2.5 TDI T5 Transporter Crewie campervan, powered by nightmares.

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