2007 VW Transporter 2.5TDi 4motion

Joined
Mar 10, 2017
Messages
2,006
Location
South Wales, UK
Well, I may have made a mistake with this one and let my heart rule my head.

My Wife suggested a little while ago that she wanted a day van for trips out with the kids and the dogs in the summer months. We decided very early on that it had to be a VW Transporter for resaleability, parts availability and depreciation.

I spent a few weeks doing research and decided with our budget it would be a T5 with a PD engine. And, as I'm a fan of a nice sounding engine, it would need to be the 2.5 5 cylinder diesel known as the 'R5'. As we were collating a list of what we would like from the van we were to purchase, I came across and advert on Facebook for a van which I fell in love with instantly. It was a short wheel base van in a very rare colour called Limette, had been insulated and carpeted in the rear already and had a very expensive Bebb rock and roll bed already fitted. It also had the 5 cylinder diesel engine, a manual gearbox and rare four wheel drive with an even more rare rear differential lock!

I messaged the seller and went up to view the van. The van had 214k on the clock, with full service history to 180k. It looked like a very solid van, a bit of an oil leak from up top somewhere but nothing too serious. I jacked up each corner looking for corrosion and checking for play in the suspension or wheel bearings and found nothing at all. Some small sections of surface rust on the body panels common with the T5 and easily repaired as it's a single stage direct gloss paint. Everything in the van worked well apart from the screen wash, a minor issue. I then took it for a test drive, where after a few minutes the oil pressure light started flashing and a beeping. I'm starting to feel like this was a warning, a warning with deeper meaning than just low oil pressure. A sign that maybe I should have left and not returned. However, I didn't do that. On return from my test drive I spoke to the seller who seemed very surprised at the light and insisted he'd never seen it before. The engine also sounded well and I'd driven a good 5 miles or so with the oil pressure light flashing away at this point, so I figured it'd more than likely just be a sensor. The seller agreed to take it to the garage to get the sensor changed and the oil pressure verified and upon doing so, I agreed to go view the van again.

So, viewing 2. This time the seller had left the van at the garage and agreed with the garage the van could go on the ramp so I could inspect the underside more thoroughly. The garage confirmed they'd verified the oil pressure and there was a nice shiny clean sensor fitted. The underside looked clean and tidy, very tidy when you considered the 214,000miles on the clock. The only real finding was that one of the centre prop bearings had failed, no biggie. I took the van out for another 10 mile road trip and the oil pressure light stayed off. So, I parted with £7,400 and drove off with our new van.

Overall the van drove the 38miles home very well, cruising quite happily at 70mph on the motorway. BUT, 25 miles into the journey the dreaded oil pressure light came back on, briefly for around 15 seconds before going back off and then popping back up around half a mile from my home and remaining on until I turned the engine off. We've done a few hundred miles in the Transporter since and the oil pressure light has popped on briefly a few times, not a huge issue except for the fact it alarms every time it detects the issue. I'm convinced at this point there's a damaged cable and looking at the wiring diagrams there's a single cable from the sensor all the way via 1 multiplug to the instrument cluster. So, that's something I need to get around to doing. Maybe I should fit an oil pressure gauge permanently?

Thing is, buying second hand cars, especially old ones is rarely straight forward. No matter how much you look over the vehicle, no matter how much you drive it, there's things that won't rear their head or be noticed until you get it home.

So here's the current list of issues...

- Intermittent oil pressure light.
- Windscreen washer pump dead.
- Centre prop bearing shot.
- Front top mount bearings groaning.
- Oil leak probably a bit worse than I originally thought.
- Power steering pump noisier than it should be.
- Engine management light reared it's ugly head this morning. But I'm in the office and haven't had chance to plug it in yet.

Haven't taken many pictures as I've been a bit disheartened so far. But, much like the Volvo, I'm sure there's a decent vehicle in there somewhere, it just needs some love.

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I did do a little test polish of the bonnet which has come up an absolute treat as the paint is heavily oxidised.
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Oh, and it has 22" Overfinch wheels. As good as these look, they'll have to go. They're hugely impractical for what we intend to use this van for. Plus tyres are 3x the cost of a standard size tyre. In addition, the second hand price of these wheels will pay for a set of good second hand standard alloy wheels and a brand new set of all terrain tyres. I've already ordered a set of T5.1 highline 162 alloy wheels and Yokohama G015's in 215/65 R16 flavour. Not sure if I'll paint them gloss black or keep them silver.

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Once the mechanically bits are all put right it will be getting a kitchen installed with a single ring gas hob, fridge, small sink etc. But we are a way off that yet.

At least it's the right colour for a lemon.
 
An 18 YO vehicle is going to need some love. As long as you bought it well and the issues aren't catastrophic and you can do the fixes it should work out. Are you polishing random panels or has it been a few scuffles? Can you go places there where you need the AWD?
 
An 18 YO vehicle is going to need some love. As long as you bought it well and the issues aren't catastrophic and you can do the fixes it should work out. Are you polishing random panels or has it been a few scuffles? Can you go places there where you need the AWD?

I think I'm just a bit annoyed that I didn't look at this one as closely as I usually do because I was a bit blindsided by the fact it was a rare combination. Of course, if we sell it in a few years it will go in our favour anyway, especially the four wheel drive. But there's a few things I absolutely should have noticed.

So I've polished the bonnet and front bumper so far. The sliding door has had paint upto the first swage line, but the paint has been lacquered so it hasn't faded at all. I did polish a little above the swage line and thankfully when polished the new paint is an exact match for the old.

We have 'green lanes' in the UK which are old roads that haven't been maintained. I've had some fun on them in the past with our Defender and my Duster. Not sure I'd take the van on them though, It's a bit low. It'll be handy in wet muddy fields if we go camping though, and often there's lots of wet muddy fields to camp in in the UK. :ROFLMAO:
 
Well the engine management light was a nice easy fix. Plugged the van in and had P0675 with no description. A quick google and found out that's VW's code for cylinder 5 glowplug circuit.

When I delved into the engine bay I noticed very quicky that the cylinder 5 glowplug was totally unplugged and the cable just hanging there. I must admit my thoughts got rather negative and I jumped to the conclusion that clearly the previous owner snapped a glowplug and never mentioned it.

The 2.5TDi is angled with the top towards the front of the van. To make things more difficult, the top of the engine is no more than 4cm's from the radiator fans making access difficult. There is a procedure where you can pop the front bumper off, insert some special pins and slide the radiator forward on the pins 20cm for access. However, at 9pm in the dark, that wasn't an option.

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As hard as I tried I couldn't find a glowplug. It must be snapped, right? In a last ditch effort, I sent my phone down the front of the engine dangling by a charger wire with the video recording and the flash on. A quick view of the video and I found the glowplug buried deep between the side of the inlet manifold and a rib of the head.

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The only way I could feel it was to stand with my back to the front of the van and with my arm behind me, slide it down the front of the engine. Then by feel, I managed to locate the plug and little by little guide the cable over to the plug and plug it back in. Harder than it sounds when you have just a few cm's to play with and are unable to look.

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The van leaves no more than 2 drips on the drive every day. Yet this was my hand when I pulled it out. The entire front of the engine is caked in oil. I think the leak has been there an awful long time and been left to accumulate. I'll attack it with some degreaser and a hot pressure washer soon which will hopefully let me see with a bit more certainty where the oil is coming from. My current bet is the oil cooler.
 
Gonna be fun when that PD needs a new cam

I believe it only plagued early 2.5TDi models with the engine codes AXD and AXE. Later BLJ, BNZ and BPC don't really suffer the same issues. This is a BNZ.

Interestingly, when VW introduced the 507 oil spec, they insisted that all TDi engines could use 507 but made specific reference to pre-2006 'R5' and V10 diesel engines still requiring 506.01. The R5 TDi and the V10 TDi are very closely related and had a full overhaul post-2006.

That said, general consensus with any PD engine is that if you use an oil with a suitably high HTHS you'll never run into problems. If it hasn't flattened itself after 214,000miles, it's not going to fail any time soon.
 
I believe it only plagued early 2.5TDi models with the engine codes AXD and AXE. Later BLJ, BNZ and BPC don't really suffer the same issues. This is a BNZ.

Interestingly, when VW introduced the 507 oil spec, they insisted that all TDi engines could use 507 but made specific reference to pre-2006 'R5' and V10 diesel engines still requiring 506.01. The R5 TDi and the V10 TDi are very closely related and had a full overhaul post-2006.

That said, general consensus with any PD engine is that if you use an oil with a suitably high HTHS you'll never run into problems. If it hasn't flattened itself after 214,000miles, it's not going to fail any time soon.
Makes sense. We didn't get the PD here after 2006

I'm running T5 15W-40 in mine right now.
 
Still feeling a bit unsure about the Transporter. However, progress is being made. I think despite knowing the oil pressure light issue isn't anything serious at this point, It's making me feel uneasy. Anyway...

I have this lot sitting in the dining room ready to go on the van...

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I've also started using some fuel additives to try clean things up a bit. Although not convinced it needs it. Archoil 6400DMax is a heavy duty cleaner and the Archoil 6900DMax is a continuous use cetane booster, lubricant and detergent. I put the two bottles of 6400D into a full tank and once emptied the van will continue to get 6900D.

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I've discovered the main oil leak to be coming from some kind of valve in the rocker cover. I've managed to find a replacement in the aftermarket as VW don't sell the valve on it's own and you have to buy an entire rocker cover. And while I don't mind spending the money on a new rocker cover, It's not the easiest job to change as the inlet manifold needs to come out. Once the valve is changed I'll be able to give the engine bay a thorough clean and hopefully this will be the only place it's leaking from.

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The windscreen washing pump wasn't working. For some reason all the local car parts places only had a pump available with two outlets instead of one. So had to blank off one end with a bit of 4mm hose and a stainless bolt.

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Also, this is Fred, one of our two miniature Dachshunds....

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I started inspecting the oil pressure sensor and loom. Weirdly, the plug had somehow been installed around 90° out and wasn't clipped in. I thought I'd nailed it and this was the issue but unfortunately not. I was able to inspect the first few inches of loom and the plug which had no issues at all. I think the next step is to get a meter or test lamp on either end of the loom and start poking and prodding and see if we can find the issue that way. If that doesn't work then I'll be pulling the loom out of the van to physically inspect it on a table. The sensor is a nightmare to get to without putting the van in service mode of dropping the compressor.

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So while out on a test drive after playing about with the oil pressure sensor and washer pump, the rear N/S brake started making some rather wicked noises, so out came the tools again.

Rear N/S wheel off...

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Calliper off and noise found...

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Stripped everything off and thoroughly cleaned. Backing plate was a bit rough but a good wire brush and a few coats of a lanolin based spray will hopefully keep it going for a while longer.

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Went out and grabbed some Brembo OE rear discs and pads...

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I then went to retract the piston in the calliper and found the reason the pads on this side had worn out far quicker than the other...

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I will say, getting parts for the Transporter is a doddle! Nearly all regular service parts are available within a 20 mile radius of my house. So running out to grab a replacement calliper was a non-issue...

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And reassembled...

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Then came bleeding. The fluid in the reservoir looked a bit neglected...

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There was also a black sludge in the bottom of the reservoir when I drained it...

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I did my best to clean this out by filling it with fresh fluid, scrubbing with a small kids paint brush then sucking the fluid back out.

I pulled 250ml out of the rear N/S caliper. It got nice and clear towards the end but the initial fluid pulled through was dark and full of dirt particles...

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Then onto the O/S.

The O/S had a lot more meat on the pads...

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But also looked like it has recently had a new calliper fitted...

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Again, everything stripped, cleaned and what's left of the backing plate given a few coats in Bilt Hamber Dynax UC...

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The sliders were cleaned and greased...

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And reassembled...

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Again, I pulled 250ml of fluid from this caliper. You can see here as it started the amount of junk that came out of the lines. This jug was cleaned before I started...

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And the fluid reservoir after looking a lot healthier

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The front brakes look new. But I'd still like to strip them down to inspect, clean, grease and pull some fresh fluid out of each of them. That said, after 18 years and 214k, I'm not sure how amenable the bleed nipples will be.
 
The power steering pump has been offensively loud since we bought the van and the power steering assistance somewhat erm... variable? And not variable in a good way.

I've ordered a replacement Mahle power steering pump and waiting for it to arrive. In the meantime I've started flushing out the system to ensure all the fluid is fresh and clean ready for the new pump.

The old fluid was black and I suspect the original.

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Trained the reservoir and this was a sample of what came out.

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I removed the reservoir and gave it a flush with lots of brake clean and compressed air. Lots of rubbery sludgy bits came out of the filtered side of the reservoir with a few bits of swarf for good measure.

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Refitted.

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Filled up with the Comma MVCHF as it worked very well in our Volvo XC70.

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I then took the van for a drive for 10 minutes around our housing estate. Lots of lock to lock, three point turns etc to get the fresh fluid to mix in with the old stuff.

I then did another drain and fill of the reservoir, the old fluid looking a tiny bit more green.

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The plan is to do daily drain and fills until the fluid is fresh and clean before the new pump gets fitted. I'll probably flush the reservoir again when I fit the new pump too.

However, 75% of the noise we were experiencing has gone. It's still louder than it should be, but the steering is smooth and much much quieter. Actually, had I known how much quieter it would be with just a fluid flush, I probably wouldn't have ordered a new pump. I suspect the filter/strainer was blocked causing the pump to get a bit starved.
 
More progress!

I changed the two PCV valves in the rocker cover as they seemed to have a lot of oil around them. Currently not sure they were actually leaking, but the old membranes were hard and brittle so probably not a bad thing they were changed.

New valves at the ready.

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Smaller of the two removed.

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New vs old.

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Second one out.

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And two new valves fitted.

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Drain & fill of the PAS fluid number 4!

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Still black! Although I'm sure there is now a green tinge to it?

I also noticed there's a black sludge all in the reservoir now. You can see where I rubbed against the bottom with my suction tube.

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And here I'm starting to join up some dots. I've noticed the power steering fluid level drops. Not much, a few mm a day, but it's noticeable. I'm still getting oil over the rocker cover, however, now that I've given the rocker cover a good clean, I can see the oil looks like it's been 'blown' there. And the radiator up front is wet too. I'm suspecting a leak in the PAS cooler. Watch this space!

More excitingly, the new wheels and tyres have just been fitted!

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I must admit they look like coasters on the bottom of a sofa, but they're the correct wheels and correct tyre size for this. It's so much nicer to drive too. The steering is lighter, it's more comfortable, it pulls off with a little more zip but the A/T tyres are a little noisy.
 
Still feeling a bit unsure about the Transporter. However, progress is being made. I think despite knowing the oil pressure light issue isn't anything serious at this point, It's making me feel uneasy. Anyway...

I have this lot sitting in the dining room ready to go on the van...

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Nice work!

Is the bluish model car in your display case a 1960ish Ford Anglia?
 
Bailes: Off topic but I notice you no longer have the Dacia in your signature. Did you sell it and if so why? I really liked that vehicle and am wondering what happened.
PS: You're lucky to have the talent to do all that mechanical work and save a fortune on labor.
 
Nice work!

Is the bluish model car in your display case a 1960ish Ford Anglia?

It is! My Wife is a Harry Potter nut and I got the cabinet so she had somewhere to put all her HP paraphernalia. It's a Lego model of the Anglia from HP! Well spotted.

Bailes: Off topic but I notice you no longer have the Dacia in your signature. Did you sell it and if so why? I really liked that vehicle and am wondering what happened.
PS: You're lucky to have the talent to do all that mechanical work and save a fortune on labor.

Unfortunately not. I loved my Duster but I was offered someone else's company car through work for no additional cost (other than company car taxes we have in the UK) and it made financial sense at the time to sell the Duster and replace with my my company Cupra Born. That said, I'm having difficulties selling my Wife's Volvo so I may hand the Cupra back and use the Volvo for a little while?

I do enjoy working on cars. I'm lucky in a way to live in the era that we do, where information is so freely and easily available.
 
Unfortunately not. I loved my Duster but I was offered someone else's company car through work for no additional cost (other than company car taxes we have in the UK) and it made financial sense at the time to sell the Duster and replace with my my company Cupra Born. That said, I'm having difficulties selling my Wife's Volvo so I may hand the Cupra back and use the Volvo for a little while?

I do enjoy working on cars. I'm lucky in a way to live in the era that we do, where information is so freely and easily available.
I've said it before on this site.....I wish they sold simple, inexpensive vehicles like your Dacia here.
Good luck with the VW.
 
Those wheels you installed look exactly like what was on my 2012 VW Routan. It was fun to see a bit of familiarity on your van.

I wish we could get that van here. If the current VW van was not electric, I would have ordered one rather than the Hybrid Toyota I have on order now. Your vehicles are very lucky to be owned by you!

This is another thread that I will look forward to seeing updated, along with Dad's Lincoln and the Cobra!
 
It is! My Wife is a Harry Potter nut and I got the cabinet so she had somewhere to put all her HP paraphernalia. It's a Lego model of the Anglia from HP! Well spotted.
Thanks for the confirmation!

I don't know much about Harry Potter, but way back in high school friend Tim had an old Anglia. It was slow to come up to temperature in the winter (and thus produce heat for the passenger compartment), so Tim's uncle fashioned a steel shroud which fit over the top of the engine.

Once the temperature gauge was up in the normal range and the heater was putting out good heat, Tim would pull over, pop the hood, remove the shroud, and stow it in the trunk.

Most of us were less handy - we would block off part of the radiator with cardboard instead.
 
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