2007 Crafter Suspected Injector Issue Diagnosis

[MiniMental]

Howdy All,

I’ve just bought what I’ll call, a fixer-upper for what I think is a bargain, though there’s a fair list of bits to sort out. Main one being the engine not quite running properly.

2007 MWB Crafter 134bhp 2.5 R5 TDi BJL Engine.

Intention is to fix it, tidy it up and kit out out for my business, In my spare time I’m a Mobile Mech mainly working on older VAG vehicles. I’ve been using a 2011 Kuga for the last 6 months but I’ve outgrown it and needed something more suitable and with more space etc.

I’ve had a quick look through it after it was delivered today, re-plugged the side door wiring as it was disconnected and both factory plugs ruined beyond repair. The side door does now work but it’s missing the plastic chain for the cable to run in.

The interior lights also don’t work, and the radio powers up but the screen won’t come on so probably gonna replace it with a cheap android CarPlay one.

Does anybody know where I can get the track and it’s fittings without buying the full harness as I’ve cut the factory plug off the van side now and put my own on.

I also need to figure the engine out. I’m used to PD’s and old petrols . Seller said he had it diagnosed as two bad injectors, it does run but is lumpy.

VCDS doesn’t pick up any faults on the ecu, I’ll attach a picture of the injector readings at idle. It’s not overly noisy. Just sounds like it’s missing, though iirc they are known to wear big end bearings out when injectors fail?

How do I interpret the injector readings on this? (Picture at idle below)

Any insight from people who have spent more time on them welcome. Itll be getting fixed regardless even if I have to pull the engine out and rebuild it.

I also need to replace the key, I usually do this on Passat B5.5’s etc with vagtacho and VCDS. Can anyone advise me on the procedure for this with the crafter as I’m not sure vagtacho will retrieve the SKC.

All the best,
Aidan.

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[Crasher]

That looks like 4 out of five have a problem but I would do 1 and 4 first. VAG doesn’t sell recon injectors for these and new ones at £874 each is daft but can get the Bosch exchange 0 986 435 352 for £150 although bear in mind the cost of shipping the old units back to Germany from certain suppliers.

[MiniMental]

That looks like 4 out of five have a problem but I would do 1 and 4 first. VAG doesn’t sell recon injectors for these and new ones at £874 each is daft but can get the Bosch exchange 0 986 435 352 for £150 although bear in mind the cost of shipping the old units back to Germany from certain suppliers.

Thanks mate. Much appreciated. I’ve found a company in the UK that seem to sell remanufactured Bosch injectors for the BJL at £99ea if I return the replaced unit to them.

WTDiesel.com

It does start and run. Had a quick look this afternoon before work and as follows. Injectors 1/2/3/5 if I pull the plug off, it nearly stalls.

Injector 4, no change if I pull the plug off it.

This is a cold start.

Diagnosing an apparent injector issue on our “new� Crafter project. Inj #4 Not working.. - YouTube (https://youtube.com/shorts/-V5L1aul810?si=xVIn2XiGZ-B-uhG2)


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[Crasher]

That is less than factor price never mind trade, tread carefully.

[MiniMental]

Well,

This is the list I’ve come up with thus far. Big list. But nothing catastrophic this far I think.

The Crafter

MOT List:
◦Fix Engine (Injector #4 Hopefully)
◦Major Service
◦Timing Belt & WP
◦New Header Tank
◦Polish Headlamps
◦All 4 Shocks & Front Dust Covers
◦Number plates
◦Replace tail light units
◦Offside rear inner wheelarch/floor edge replacement
◦Both sides outer wheel arch replace
◦Both rear wheels bearings & seals
◦Rear Brake Pads
◦Wiper Blades
◦Rebuild drivers mirror

Main Roadworthyness Jobs
◦Replace head unit
◦Get interior Light module repaired
◦Replace Keys
◦Deep Clean
◦Passenger door Check Strap
◦Side Door Cable Chain
◦Rebuild Aircon System and recommission
◦Retrofit Cruise Control
◦Replace Cluster if Possible (or bezel)
◦Fix Drivers door microswitch

Cosmetic OCD Points
◦Get the wrap replaced where damaged
◦Replace side door (rotten inner bottom panel)
◦Replace rear drivers door (rotten lip)
◦Replace Seats
◦Replace Shift Boot
◦Replace Document Clip
◦Replace Window Switches

Parts to order/Source
◦Timing Belt & WP Kit
◦Expansion Tank
◦Service kit
◦Front Shocks
◦Front Dust covers
◦Rear Shocks
◦Offside Rear inner Arch Panel
◦Both outer rear arch panels
◦Headunit (CarPlay)
◦Pressed plates & Holders
◦Gear Shift Boot & Frame
◦Offside rear door
◦Side door
◦Passenger door check strap
◦Air con pump/lines/condenser/exp valve etc
◦Nearside rear door inner trim panel
✓Fuel Injector
✓Document clip repair kit

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[MiniMental]

Well,

Following up I’ll start by saying I need to go out the lottery on…

I don’t think it ever had a significant injector issue.

I changed the injector on #4 and it was the same. So did a compression test which resulted in

Cyl1- 23.5Bar
Cyl2- 24Bar
Cyl3- 24Bar
Cyl4- Absolute Zero. Not even a needle flicker.
Cyl5- 23.5 Bar

On a cold engine as I couldn’t exactly run it to warm it up.

Going off the assumption that I couldn’t see any debris in the cylinder on borescope through the injector port, and even with bad rings it should show some pressure. Assumed it was a valve issue.

Blew compressed air through the compression testing adapter at TDC Comp Stroke and it blew straight out of the EGR Takeoff.

So pulled the head today and found the exhaust valve spring had snapped on Cyl4 and wasn’t letting the valve close. It’s evidently been kissing the piston as shown by the incredibly clean face under said valve.

How it never dropped the valve or snapped it off is beyond me. Lucky lucky me [emoji256]

So all in all, I’ll sort the head issues out and send it. Hopefully should be golden once it’s reassembled.

Since I’m now waiting for parts etc, figured I’d do some turd-polishing and stick the new plates and surrounds on. What a difference small details make. [emoji108][emoji28]



Vid1 That’ll be why there’s no compression on #4 then 😅🤦*♂� #repair #mechanic #automobile #vwcrafter - YouTube (https://youtube.com/shorts/zFlTs697z20?si=OOfFuT6qPaACMEA_)

Vid2 The Reason my “New� Crafter wasn’t running properly. - YouTube (https://youtu.be/x8TMc2xBzaY?si=vkCoJVVjHv0Wx21J)

Vid3 Suspected Spring issue 👀 #mechanic #repair #vwcrafter - YouTube (https://youtube.com/shorts/NUlGWaPpEg0?si=uP7fVsLA-7EVTnb_)

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[Crasher]

I would start with a new AMC casting, it looks to me like it isn’t the first time the head has been off.

[MiniMental]

I would start with a new AMC casting, it looks to me like it isn’t the first time the head has been off.

I’m curious what makes you think that mate [emoji851] Always on a knowledge quest. Not often I dive this deep into engines.


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[Crasher]

The machining on the head face looks very unoriginal, VAG explicitly state to not reface their Diesel heads.