T5 FAQ and How to THREAD (up to August 2009).

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VW TRANSPORTER T5 128kW R5 AXE Engine

Which engine oil to use?

For all up to and include 6/2006
It must be VW506.01 APPROVED.

LiquiMoly SYNTHOIL LONGTIME PLUS 0W-30
Ravenol WIV SAE 0W-30
Fuchs TITAN SUPERSYN LL PLUS 0W-30

From 7/2006 use VW507/00 5W30 approved oil.

Sump capacity incl. oil filter .................................................. 7.4L

Tyre Pressure front .................................................. ....... 50PSI when fully loaded (max. pressure)
Tyre Pressure rear .................................................. ........ 50PSI when fully loaded (max. pressure)

Wheel bolts Torque .................................................. ......... 180 Nm

Tyre size .................................................. .....................235/55/17 (O.D. 692mm)
Tyre size.............................................. ..........................215/16/17 108/109
Tyre size .................................................. .....................215/65/16

16”Tyres discussion ........ Link to thread
17”Tyres discussion .........Link to thread

Battery .................................................. .......................12V/80Ah 380A DIN, 640A EN/SAE

SERVICING PARTS / FILLING CAPACITIES

Oil Filter……………………………………………………......................... .... VW P/N 071 115 562 C (Purflux L267A) (Mann HU719/7) (Mahle OX 188 D)
Air Filter………………………………………………….......................... ..... VW P/N 7H0129620A or Mahle LX864
Fuel Filter………………………………………………….......................... ... VW P/N 7HO 127 401B or Mahle KL 229/4
Coolant VW G12+…………………………………………………………................ 7.0L
Automatic TransmissionVW p/n G 055 025 …………………………..... 7.0L
Gear oil………………………………………………………………….................... 2.7L 70W75
Transfer case oil……………………………………………………….................1.2L G052145A (TOTAL Trans. Dual 9 FE90 75W90)
Haldex Oil VAG 055 175A…………………………………….....................1.1L
Haldex Oil Filter……………………………………………………….................. 02D 598 574
Diff Oil……………………………………………………………………….................. 1.2L (SAE 75W-90 API GL-5)
Power Steering Fluid G002000…………………………………............... 0.7L - 0.9L
Brake Pads front OEM ATE 13.0460-7240.2.............................Min TH 2 mm
Brake Pads rear VW p/n 7HO 698451 OEM ATE 602882..............Min TH 2 mm
Brake disc front
Diameter: 308mm Vented
Brake disc thickness: 29.5mm
Minimum thickness: 28.5mm (17"wheels /2E4)
Height: 55mm
Centering diameter: 65mm
Inner diameter: 154.6mm
Brake disc rear OEM ATE 24.0112-0169.1
Diameter: 294mm Vented
Brake disc thickness: 21.9mm
Minimum thickness: 19.5mm (FN44 brake caliper = 18mm)
Centering diameter: 65mm

Brake Fluid…………………………………………………………………................ DOT4

Windscreen washer additive .............................................. VW Part No: G 052 164 M2
Sonax ClearView

Suspension
Rear Springs
King Springs P/N KVRR18 rised springs from Repco or Pedders are useful and economical (~$350) addition to raise ground clearence at the back (by 50mm approx.). Anything beyond that seems to get into big money.
Rear Shockers: VW p/n 7H0513029D MONROE made in Belgium or more heavy duty Pedders P/N 120216 designed to match
Bilstein options for the rear shockers
12.5600-S. is for low weight
12.5600-M is for medium weights
12.5600-H is for frequently carrying heavy load
Rear shock part number: Sachs 313031

Pedders Heavy Duty coil springs P/N 7891 (are also raised springs)

4MOTION off road capability
Hill climbing 37 deg
Approach angle 21 deg
Departure angle 17 deg
Ramp angle 14 deg
Wading depth 300mm
all measured with standard equipment and full load (sourced from VW)

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Bull bars

Heavy Duty TOW BAR

Bull bars and nudge bars: J & J Bullbars - Bull Bars Brisbane, Nudge Bars Brisbane, Roof Racks Brisbane, Roof Baskets, Side Steps - Slacks Creek - (07)3808 1444

http://www.formulaoffroad.com.au/bullbars.html

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How to

• Resetting Transmission Control Module
  
• EGR Solenoid EGR Solenoid controls vacuum to EGR valve. Control signal is a variable duty cycle at fixed frequency of 15Hz.
• Test for tyre radial runout or brake discs runout (pulsating brake pedal)

DIY

• Installing MANN PROVENT (Blow by Oil/Air Separator)
  
• Dual Mass Flywheel Tip: Don't park with transmission in the gear, leave it in "N" use handbrake ONLY! CAUTION! Use wheel chocks when parking on the incline!

COMMON FAULTS

• Leaking water pump ..... engine can seize, if overlooked, first signs: at the very early stage rusty looking stains like drips from small dia black hose hanging at the back of the engine, sudden need to top up 1/2L of coolant and coolant contaminated with engine oil, overheating.
• Leaking power steering pump ..... PAS fluid gets contaminated by the engine oil not the other way round.
• Turbocharger failure if used for hi speed driving.
• Cracked exhaust manifold

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Electrical

Dual batteries and other useful info for vehicle 12V systems incl. L.E.D. trailer light solutions.
Adding Auxiliary Battery under the seat DIY

http://www.redarc.com.au/index.html

Main Battery is .................................................. ........................ 12V/80Ah 380A DIN, 640A EN/SAE
Can use Century Battery
DIN65LMF (CCA580A) 277mm x 175mm x 175mm
DIN75LMF (CCA730A) 315mm x 175mm x 175mm
DIN85LMF (CCA780A) 353mm x 175mm x 175mm
DIN92LMF (CCA730A) 353mm x 175mm x 190mm

Second battery STD with the electric sliding doors............................ 12V/80AH 320mm long, 180mm wide, 190mm high with recessed. Bigger battery will most likely not fit. Battery has a flange at the base that bolts the battery down.

Aero wiper blades
7H6998002 - Wiper Blade Set
7H6955409 - Aero Wiper Arm
7H6955410 - Aero Wiper Arm

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T5 FAQ and How to THREAD (up to August 2009).

Resetting AT control module

To reset the Trans Control Module (TCM) follow these steps:

1. Turn ignition to ON (do not start engine)
2. Press the gas pedal to the floor till it clicks
3. Hold the pedal for 15 seconds
4. Release pedal gently
5. Turn Key to Off
6. Start engine and drive as normal

by resetting the TCM, it will re-adapt to your driving style.

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T5 Fuses

For these who don't have the fuses layout for their T5. Normally located when you remove cover under the ash tray (placed at the back of the cover)



1st raw Basic

1.(25A/30A) Heather A/C (some models)
2.(5A) Steering position sensor
3.(10A) Multifunction control module1
4.(10A) Headlamp adjustment
5.(15A) Headlamp
6.(15A) Headlamp
7.(15A) Multifunction control module1 (interior lamp)
8.(5A) Data link connector (DLC)
9.(15A) Brake pedal position
10.(10A) Windscreen wipers (rear)
11.(5A) Licence plate lamp
12.(15A) Cigarette lighter
13.(5A) SRS control module
14.(30A) Auxiliary heather, heather / A/C
15.(7.5A) Air conditioning
16.(5A) Multifunction control module 1
17.(5A) Rear fog lamps
18.(5A) Instrumentation control module
19.(5A) Audio unit, Instrumentation control module1, navigation system,
20.(5A) Side lamp left, LH Stop lamp, LH Tail lamp
21.(5A) Side lamp left, RH Stop lamp, RH Tail lamp
22.(10A) Airbag assembly deactivation warning lamp, (DLC), Instrumentation control module.
23. (25A, 40A) Starter motor (some models with M/T)
24. (5A) Steering position sensor
25. (5A) Air conditioning
26. (30) Headlamp switch
27.(15A) Headlamp Right
28.(15A) Headlamp high beam warning lamp, Headlight Right
29.(10A) Load area door signal relay
30.(10A) Heated windscreen washer jets, rear screen wiper motor
31.(30A) Multifunction control module 1 (Horn)
32.(25A) Multifunction control module 1 (windscreen wiper motor)
33.(15A) Audio unit, Navigation system, Traffic information control module
34.(25A) Automatic transmission, Fuse box/relay plate engine bay 1 (F3, F12, F14-F17, F19, F20, F24)
35.(5A) Instrument illumination
36.(25A) Multifunction control module1 (Indicators)


#12 (15A) fuse is Cigarette lighter fuse very often blown and asked for location - blue fuse, top raw, 3rd from the right.

Second raw Options


At the engine bay close to the battery - remove the battery cover.


Under the passenger seat
Fuse (Amps) Circuit
F1 (15A) Auxiliary power socket(s) (some models)
F2 (15A) Auxiliary power socket(s) (some models)
F3 (15A) Auxiliary power socket(s) (some models)
F4 (15A) Refrigerator box (camper van), special vehicle equipment
F5 (5A) Aerial module
F6 (25A) Auxiliary heater
F7 (30A) Heater/AC blower motor (ATC)
F8 -
F9 -
F10 -
F11 (40A) Door function control module, right rear (some models)
F12 (80A) Auxiliary battery (some models)
F12 (80A) Split charge relay (some models)
Location Component
1 -
2 Split charge relay (with auxiliary battery)
3 Special vehicle equipment
4 Special vehicle equipment
5 Special vehicle equipment

NOTE: Fuses F1-F7/F11/F12 - During assembly these fuses may be fitted in alternative positions, depending on
vehicle specification.

http://www.caravanandmotorhomebooks.com/articles/wiring_woes.htm

http://www.vwcruise.com/119.html

CAN BUS upgrade for T5 from 1.6 to 2.0
ScanGauge

DLR lights for T5 up to 2009 http://www.subzeroautomotive.com/sit...t/VW-T5-5000_1

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Adding second battery and 240V inverter into T5

I use 75A Deep Cycle UPS Telecom battery to run my 12V air compressor, 240V/1000W inverter for electric tools, laptop and a small laser printer.

http://lh5.ggpht.com/_std7SMZaoXg/S7R_Y5KFt0I/AAAAAAAAA1M/_2RXbNtUSIw/s400/T5%20second%20battery.JPG

Remove the battery plate and weld 2 nuts for the battery holder or figure out how to safely hold the battery by other means.

http://lh5.ggpht.com/_std7SMZaoXg/TOIhy6Ar6gI/AAAAAAAABIU/zt92l6CEFbI/s400/R0030419.JPG

I originally bought RedArc SmartStart solenoid ($90) to charge the second battery but decided not to use it, because I drive mainly short trips, so the battery wouldn’t receive enough charge. Advantage of the Smart Start solenoid is its low cost and with just adding override switch, the second battery can be used for starting as well (handy when the main battery fails to start).

The 12V to 12V multistage battery charger is a better way of charging and maintaining the deep cycle batteries. Charging starts as soon as the engine is running, the Smart Start solenoid and other dual battery isolating relays will start charging the battery when the main battery is charged.

I’m sure there are more, but these 12V to 12V chargers are easy to get:
PROJECTA around $200, C-Tek D250s DC-DC charger, REDARC BCDC1220 and BMS1215 (that charges from 240V AC, 12V main battery and Solar panel and it is the most expensive one)
Application Error
Application Error
Page not found | REDARC Electronics

http://redarc.com.au/static/files/BCDC1220-Instruction-Sheet-A5-1.pdf

REDARC BCDC1220 is much smaller than PROJECTA and also allows you to select the type of the battery for optimal charging, but can cost you double than PROJECTA. The C-Tek is priced in between the two and has temperature sensor, which allows charging smaller battery. There is also C-Tek D250S Dual ($395) http://www.batteriesdirect.com.au/sh...FQMjbgodZlcRPA Which allows solar panel to be connected as well.

Other material needed:
3m of cable at least 4.8mm2. 10x cable terminals (Lugs), Fuse holder for 30A fuse, Fuse holder for 150A fuse, 1x flat female connector, Heath shrink tubing, plastic ties, Insulation tape, M5 bolts, Nuts to fasten Charger.

Wiring it:
Use 4.8mm2 wire for charger input 12V positive wire and 14mm2 wire for output.

http://lh5.ggpht.com/_std7SMZaoXg/TOINRSRdQYI/AAAAAAAABIM/3v6ivlx_Kls/s800/R0031193.JPG

http://lh4.ggpht.com/_std7SMZaoXg/TNaNBCUtU2I/AAAAAAAABGk/TZltHgpemHo/s400/Inverter%20in%20T5%20Projecta.JPG

In engine bay;

http://lh4.ggpht.com/_std7SMZaoXg/TNaPoFtJ9AI/AAAAAAAABGs/Hsgy2wsY2pc/s400/T5%20back%20battery%20plate.JPG

Remove: battery cover, M8 bolt that secures battery to battery plate and slide the battery forward to create more space, cover battery positive terminal with insulating material or remove the battery out, lift the bonnet seal above the battery to expose 2 bolts and unscrew them, then slide the plate behind battery out of the engine bay.
Inside; feed the wire behind the inner guard and into the opening in the area behind the plate that you removed and punch hole into the rubber blanking plug in the firewall pull the wire in and under the carpet (you need to remove the plastic step to lift the carpet on the passenger side. Than feed the wire under the seat base and connect it to the charger positive input. Connect charger negative input and output to the chassis (undo one nut which holds the seat base in the corner). Make connecting wires as short as possible.

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Which oil for early 5cylinder PD engine?

It must be VW506.01 APPROVED. Not meets, accedes or similar word trickery as used on some labels.

Other than from the VW dealer, the chance is almost “0” that you can get the VW approved oil for your AXD or AXE engine as fitted into before July 2006 built T5s (also in 5cyl Touareg from the same time), from common parts stores without ordering it first. So, it's smart to keep 2 5L bottles for your next oil change handy, if you do that you have plenty of oil left for top ups.

The oils that are approved and somehow available from the parts stores are.

From Imparts and HSY you can get:
Liqui Moly SYNTHOIL LONGTIME PLUS 0W-30
Ravenol WIV SAE 0W-30

From Repco, SCA and Autobarn
You should be able to order Liqui Moly
From Burson, I was still able to get Fuchs TITAN SUPERSYN LL PLUS 0W-30
if you’re lucky they still might have some left, though I’d be checking production date on these and if close to 5 years old, don’t buy it.

There’re many cheaper oils on the shelves that say meets or exceeds, however IMO they will fail and the oil companies would wipe their hands clean, since your engine is now more that 12 years old.
The repairs to these engines aren’t cheap and savings you’ve made will be short lived.

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Rear shockers for T5 from 2003

Bilstein has rear shockers that are made to for how much load you carry.

P/N
12.5600-S. is for low weight
12.5600-M is for medium weights
12.5600-H is for frequently carrying heavy load