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Thread: 2003 T4 2.5 TDI Transporter Problem

  1. #1
    Join Date
    Jul 2010
    Location
    Gympie Queensland
    Posts
    172
    Users Country Flag

    Unhappy 2003 T4 2.5 TDI Transporter Problem

    Hi fellow enthusiasts.
    My Transporter suddenly without any warning signs lost power and stopped on my driveway this morning .
    Cranks over OK, no other signs of anything not normal . Found the fuel pump fuse under the dash-its OK.
    I'm out in the bush near a country town where VW knowing mechanics are rare . .
    Nearest VW workshop is over 100 ks away and I'm reluctant to have it shipped on the back of a truck if I can avoid .
    Any advice on what things to look for or at first would be greatly appreciated .
    While I suspect fuel pump maybe theres something else that someone else may have encountered?
    Thanks in anticipation

  2. #2
    Join Date
    Oct 2008
    Location
    Mt Cotton
    Posts
    3,752
    I know yours is not a petrol but I know in my 2000 t4 2.5 petrol there is a relay that packs up its in the fuse box , its fairly common problem . In mine it would just cut out anytime anywhere if I waited for a while it would miraculously start again and go for weeks or days or hours and then do it again . I cannot for love of me remember which one but I think its relay number 30 fuel pump you will need to get it from a VW dealer . I don't think there is a generic one but I could be wrong .Good luck .

  3. #3
    Join Date
    Jul 2010
    Location
    Gympie Queensland
    Posts
    172
    Users Country Flag Thread Starter
    Thanks Sunny43.5
    Looks like the one marked 109.
    See them for $24 delivered on E Bay so I ve got one ordered . Beats a $240 truck ride-if that cures it ???

  4. #4
    Join Date
    May 2006
    Location
    Adelaide South Australia
    Posts
    1,295
    Yes, sounds like relay 109. In my early T4 days I was talking to another owner in a caravan park & he carried the 109 in his travelling kit after reading about it on the forums. Here's a link for some reading from the T4 forum. His is the AJT where as yours will be the ACV or AUF.
    Trouble shooting tips on relay 109 engine not starting - VW T4 Forum - VW T5 Forum
    Understand how it works, troubleshoot logically BEFORE replacing parts.
    2001 T4 TRAKKA Syncro 2.5TDI,2006 Mk5 2.0TDI Golf manual,2001 Polo 1.4 16V manual [now sold], '09 2.0CR TDI Tiguan manual,
    Numerous Mk1 Golf diesels

  5. #5
    Join Date
    Jul 2010
    Location
    Gympie Queensland
    Posts
    172
    Users Country Flag Thread Starter

    The $240 truck ride to the nearest VW dealership turned out to be the action after my search for a quick fix led me nowhere
    Apparently a mouse had made its home adjacent to the timing belt ; got caught and rotated between the pulley and the belt, lifting the belt, allowing it to slip a couple of notches and thus putting the fuel injection out of synch , effectively stopping the engine .
    A new belt and 4 hours labour later..... they tell me its a goer again.
    Thanks for the help guys.
    Happy VW motoring !!!

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