- Thread starter Olderisbetter
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Olderisbetter
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Well its been a long busy day, new belt kit is on and got a new front.pulley as the old one was starting to fail, tomorrow is test day after double checking all the bits as it was late when we finished.
Moose McAlpine
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For some reason i thought it was a T4. LTs are easier but still awkward. Working through that hole in the doghouse is always fun. I never took the whole front off unless pulling the engine, but it does give you loads of room to work in.
Olderisbetter
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To be honest it gives us the chance to look for yin worm and clean out behind the wings, its amazing how much crud gets trapped.
premmington
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I done loads of these 2.5 engines.
I even got the proper tool to do up the bottom crankshaft bolt up (shaped thing that fits into the pulley - long bar onto the floor to hold it).
Murder tight these crankshaft bolts have to be (160Nm +180degrees on a new bolt).
Local garage to us had two of the these snap the crankshaft after working on them and the bottom crank damper pulley came loose in service.
If there is anything that needs to be loctited ever - it is a bottom pulley crankshaft bolt in one of these engines.
Amazing how good these CR 2.5 5 cylinder engines are on fuel thou - I had one a SWB 08 plate crafter. Could never work out how it was so good on fuel and the gearing in the gearbox was so "short" - "low" in the lower gears - made a good tow vehicle thou.
I even got the proper tool to do up the bottom crankshaft bolt up (shaped thing that fits into the pulley - long bar onto the floor to hold it).
Murder tight these crankshaft bolts have to be (160Nm +180degrees on a new bolt).
Local garage to us had two of the these snap the crankshaft after working on them and the bottom crank damper pulley came loose in service.
If there is anything that needs to be loctited ever - it is a bottom pulley crankshaft bolt in one of these engines.
Amazing how good these CR 2.5 5 cylinder engines are on fuel thou - I had one a SWB 08 plate crafter. Could never work out how it was so good on fuel and the gearing in the gearbox was so "short" - "low" in the lower gears - made a good tow vehicle thou.
Moose McAlpine
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My 2.5 Crafter drank like it was going out of fashion. 27 to the gallon at very best. My 2.1 Sprinter after that did 38-45. Current Sprinter with tow pack is shocking. 24 empty, 18-21 towing.
premmington
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The SWB 08 plate 2.5 Crafter I had did 36-44 mpg (it was a 88bhp one - manual).
The MWB 11 plate 2.0 Crafter I got now does 24-29 mpg. 163bhp CKUB engine DSG gearbox (thirsty beast).
Have you seen the price of new VW Crafter van? Shocking!
Olderisbetter
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The T4 i have seems amazing on fuel considering it is a 102hp 2.5, when i get time i am doing a lower 5th gear swap on it to see how much better it can be made.
Moose McAlpine
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The SWB 08 plate 2.5 Crafter I had did 36-44 mpg (it was a 88bhp one - manual).
The MWB 11 plate 2.0 Crafter I got now does 24-29 mpg. 163bhp CKUB engine DSG gearbox (thirsty beast).
Have you seen the price of new VW Crafter van? Shocking!
Mine was a 163, DPF removed and remapped to 215bhp. Loads of torque and power but very thirsty.
My Sprinter's remapped to about 190bhp, slightly better on fuel than it was, but not much.
New van prices are insane.
premmington
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Your quote "New van prices are insane.".
I need a new van for work - I really do. But just can't afford one!
Inflation - where will this end up?
I need a new van for work - I really do. But just can't afford one!
Inflation - where will this end up?
mangocrazy
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I was interested in doing the same on my 2.5 TDi T4 (ACV engine) but was told that the 5th gear cluster wasn't available for my engine/box. If you have information to the contrary I'd like to hear it...!
Olderisbetter
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@mangocrazy The set up i looked at was a .622 5th gear from dark side developments it was around £250 when i started looking but has gone up a bit like most things, but it looks pretty easy to do.
https://www.darksidedevelopments.co...92-622-658-681-700-717-744-5th-gear-sets.html
https://www.darksidedevelopments.co...92-622-658-681-700-717-744-5th-gear-sets.html
5th Gear upgrade and more MPG's - VW T4 Blog
So now being a motor caravan and legally being able to travel at 70mph I often find myself sat between 55mph to 65mph on the motorway as doing long distance with the engine screaming can get a bit tedious. Ever since I upped the fuel and boost I have wanted to put a high ratio 5th gear […]
www.t4blog.co.uk
5th Gear Upgrade How To - VW T4 Blog
PLEASE NOTE THIS IS NOT MY CONTENT Original source Aggie on the T4Forum (link), I had noticed the images had not been working so wanted to archive these great instructions so they never disappear. You will need a 3 leg puller and similar 2 leg puller to remove the syncrohub from the mainshaft...
www.t4blog.co.uk
Olderisbetter
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So good news the VW LT is back together and started just about so we got the lap top and a KKl lead to talk to the ODB using VCDS from ross tech and after a few goes got the timing almost bang on the centre line which is good enough for us, all the fault codes have been cleared and tomorrow it is out for a local test and rescan, the N75 turbo control valve is still suspect but that is an easy swap, thanks all for input and interest.
I don't know if your software will allow it but you can get VCDS to cycle the turbo wastegate or vane system via the N75 valve at idle. This was my T5
Or just see if the actual boost produced matches the expected boost by making a log on the road. If the N75 (boost control valve) is faulty it should affect the boost level.
mangocrazy
Italian V-twin nutjob
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That's rather odd. It was Dark Side that told me that there is no 5th gear upgrade available for my van... Perhaps I need to go back to them and see if things have changed on that front. It was 4 or 5 years ago that I asked the question.@mangocrazy The set up i looked at was a .622 5th gear from dark side developments it was around £250 when i started looking but has gone up a bit like most things, but it looks pretty easy to do.
https://www.darksidedevelopments.co...92-622-658-681-700-717-744-5th-gear-sets.html
5th Gear upgrade and more MPG's - VW T4 Blog
So now being a motor caravan and legally being able to travel at 70mph I often find myself sat between 55mph to 65mph on the motorway as doing long distance with the engine screaming can get a bit tedious. Ever since I upped the fuel and boost I have wanted to put a high ratio 5th gear […]www.t4blog.co.uk5th Gear Upgrade How To - VW T4 Blog
PLEASE NOTE THIS IS NOT MY CONTENT Original source Aggie on the T4Forum (link), I had noticed the images had not been working so wanted to archive these great instructions so they never disappear. You will need a 3 leg puller and similar 2 leg puller to remove the syncrohub from the mainshaft...www.t4blog.co.uk
finyuk2005
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dont think there is an upgrade for the 2.5 gearbox, its different to the 1.9 and 2.4's
i did the tallest 5th gear ratio on mine, the parts where only 120 quid off ebay,
even with a top and mid box full of tools plus argon bottle and grinders welders etc i averaged 38-40 around the fort william area,
an empty van on a longer run, my best was 46mpg, and i did the calculations several times as i could hardly believe it!
Only annoying thing is getting stuck at 40-45mph, its just at the bad spot in 5th of being out of boost, so often needs the T*Ts reved off it in 4th to get a bit of speed up for 5th
Olderisbetter
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Well the N75 valve has been swapped and still all the same issues are there so the ECU has been removed and it is off for testing as i need the van this weekend, it has become a real pain in the rear 
Olderisbetter
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Ok for anyone following this we have a result, the ECU was faulty and after a repair the van started and ran like a dream, there was 2 codes still one saying "engine start blocked by immobilizer " P1570 and another saying "Quantity adjuster lower limit reached " P 1563 but that was before it had a run around, i will retest tomorrow
