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2003 T4 2.5 TDI Transporter Problem

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  • 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
    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 .

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    • #3
      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 ???

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      • #4
        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

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        • #5
          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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