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2.5 BNZ Battery Light - Alternator

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joncorry View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Topic: 2.5 BNZ Battery Light - Alternator
    Posted: 16 May 15 at 19:34
I went to pick my van up from storage today and noticed the battery light was on and stayed on for the 1.7 mile drive home.

First check was to put my black & decker charger on it as its got an alternator check facility...
Sure enough it returned there's a fault.

Then, I ran a full scan using my full fat VCDS:

005379 - Load Signal from Alternator Term. DF 
               P1503 - 000 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 262729 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 777 /min
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 12.01 V
                    Bin. Bits: 00000000
                    Load: 0.0 %
                    (no units): 0.0

Readiness: 0 0 0 0 1 

Has anyone else had this problem? 

I'm guessing the alternator is fubar but I thought I'd ask on here just in case.

'08 T5 LWB + '04 SWB + '89 T3 JX Westy
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Posted: 16 May 15 at 19:52
And... having just seen its location, I'd like to meet the designer of this engine and offer my non technical appraisal of its fitment....

FFS, it looks like the front has to come off....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 16 May 15 at 22:47
No need to take the front off, I've just done mine. (See the 'Freewheels and couplings' thread). Smile  It's very tight but it's a hell of a lot better than taking the front off.  I found it really was worth taking the power steering pump off to give you more room, you can leave the pipes on.  Yours could just be that the coupling is stripped, if it is then make sure to check the freewheel isn't seized.  I think most serious cases of damage to alternators and A/C compressors are down to seized freewheels.  

Testing the water here..  I'm seriously thinking of offering a service for replacement freewheels, couplings, water pumps and powers steering pumps in the North Cornwall/South London areas because plenty of garages either don't understand these gear driven engines or don't want really to work on them.  I'm semi-retired these days but I am qualified and insured so what do you guys reckon?  





Edited by T5 TDI - 16 May 15 at 23:39
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 03:10
Originally posted by T5 TDI T5 TDI wrote:

Testing the water here..  I'm seriously thinking of offering a service for replacement freewheels, couplings, water pumps and powers steering pumps in the North Cornwall/South London areas because plenty of garages either don't understand these gear driven engines or don't want really to work on them.  I'm semi-retired these days but I am qualified and insured so what do you guys reckon?  

If the demand is there it could be a goer.  These engine ancillaries are so crowded if you have lots of experience and know all the tricks you can most likely offer a better (and cheaper) service than someone who doesn't really know what they are doing.  

Pity you don't live near me - I'm seriously considering replacing pretty well all these components to ensure I'm not left immobile on the side of the road 10 or more hours drive from home in the middle of nowhere (we have lots of nowhere in Oz).
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 09:30
We do have literally hundreds of T5's here in Newquay especially in the summer :-)

I've already changed my water pump once even though it wasn't leaking.  It was about ten years ago when it was still under warranty.  Even though R5 pumps were leaking all over the place, VW wouldn't do anything until it actually filled up the sump with water.  (Even the guy on the service desk agreed that it was probably a matter of when not if)  So I did it myself.  So now, ten years/50k down the line I'm going to do it again.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 09:37
It sounds like quite a job, possibly beyond my capabilities. I'd readily pay for it to be done but alas I think my radius is limited to local garages due to the battery and as its one of the rental vans and going out next Saturday...
I'll check out the fuse under the battery tray as well, when I looked last night the gates coupling was just visible and seemed to be spinning.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 12:26
Checked the fuses under the battery tray and all are good. I disconnected the split charge system too, just to check there was no issue there, alas the battery charger alternator test function still said it wasn't enough.

Sadly, I think its garage time.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 14:56
Originally posted by joncorry joncorry wrote:

..... when I looked last night the gates coupling was just visible and seemed to be spinning.

If the gates coupling is chewed out on the inside on alternator side the exterior of the coupling will rotate, but it won't be driving the alternator.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 18:00
Originally posted by gregozedobe gregozedobe wrote:


If the gates coupling is chewed out on the inside on alternator side the exterior of the coupling will rotate, but it won't be driving the alternator.

Exactly Thumbs Up  The couplings always strip in half like this-


If it is just the coupling stripped and you are 80k-plus get the freewheel changed.  If it's a new alternator needed most of them come with a new freewheel anyway.  Ask the garage to check if the freewheel on the old alternator was actually working just out of interest.

There have been a couple of reports on the other forum where the alternator drive gear has undone itself.  This is really bad news and if any damage is done to the rest of the geartrain it's RIP engine.  I think this (rare) fault could be due to a seized freewheel.  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 15 at 18:10
Cheers chaps for the info, that makes perfect sense to the technical ludite like me! I'm getting a few prices, including from VW Van centre in Liverpool. 
Having seen the price of the alternator and the coupling.. I'll make sure I'm seated when they deliver the quotes. 


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Let us know how it goes and of course, how much they are charging!  Evil Smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Posted: 21 May 15 at 11:25
Its all sorted. I used a chap from facebook 'ME Automotive' to do the job for the simple reason that I'd have cocked it up. 

He elected to remove the front:

The alternator is in a stupid spot in my non technical opinion but there for a reason...:

Anyway, I got a new alternator for £130, the coupling was £60 and labour was £240. The job was done on my drive, absolutely no mess during or after it and all is well again.
Mark is a top chap, very professional and knowledgeable and I'd recommend him. He even travelled from Staffordshire up to Warrington. 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 21 May 15 at 18:18
Excellent result Thumbs Up
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 21 May 15 at 20:58
Yes, and thanks for reporting back. Smile  162,000 miles isn't too bad for an alternator if it was the original. Any news on the state of the freewheel on the old alternator?  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote joncorry Quote  Post ReplyReply Direct Link To This Post Posted: 21 May 15 at 21:04
Originally posted by T5 TDI T5 TDI wrote:

Any news on the state of the freewheel on the old alternator?  

I've got the old alternator in the garage, the teeth on the pulley are in good nick as was the gates coupling. The freewheel seems ok, spins freely and no play.
I'm guessing its the bit on the back (plastic) that has failed.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote T5 TDI Quote  Post ReplyReply Direct Link To This Post Posted: 21 May 15 at 22:45
If you stick something through the cooling holes of the old alternator to lock the shaft (you can use a splined tool to hold the centre of the shaft if you have one) the pulley should then still be able to 'slip' in one direction if the freewheel is working.  If the freewheel is seized, once the shaft is locked the pulley won't turn either way and just behaves like an old skool solid pulley. 

Edited by T5 TDI - 22 May 15 at 08:58
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 15 at 12:37
Originally posted by joncorry joncorry wrote:

Anyway, I got a new alternator for £130, the coupling was £60 and labour was £240. 

Those prices look excellent value to me.  T5 parts are rather more expensive in Australia.  I've just received quotes from my local VW dealer for parts only (no labour) (all prices $AU):

Alternator:  $1,019.48
(Gates) coupling: $214.02
Air con compressor: $1947.07
Freewheel:  $326.37
(Gates) coupling: $214.02
DMF $1,661.75
Power Steering pump:  $ 736.98
Water pump: $475.62

Labour to install all the above would add significantly to the total.

I have been considering replacing all the above as a "pre-emptive counter-strike" to ensure maximum reliability.  I do lots of interstate trips away from home so I want a very reliable van.  My T5 hasn't really inspired me with lots of confidence (it has been carted home on the back of a flat top truck 3 times so far, and had several other non-mission-critical faults).  In the past I've been covered by VW's warranty and then the extended (Allianz) warranty, but now I have to foot all the bills regardless.

Considering my options has led me to seriously consider one of the new model M-B Vitos.  Such heresy on a VW forum, I know.  Wink  I'm not worried about rust (where I live is quite dry).

I looked at Hyundais when I was waiting (months) for the gearbox to be fixed on my T5 but didn't like them much, and I have read too much about Transit and Renuualt problems to go there.

And of course the T5.1 seems to possibly even worse than my T5 (EGRs every x,000 miles anyone ?

I suppose I'll look at the new Vitos when they finally get around to selling them here and decide one way or the other ( I already know I hate foot operated park brakes for vehicles with manual gearboxes).

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Post Options Post Options   Thanks (0) Thanks(0)   Quote The Transporter Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 15 at 20:42
Greg, I'll keep you informed about my Transit... 1000 miles so far and the doors still haven't fallen off. If it gets to 2000 miles without the window falling out, then it is one up on my T5
2004 174bhp AXE engine..... Belligerence has been confirmed.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Alonline Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jun 15 at 00:55
Remember Kev the Gas and I spoke too soon post!

Now Gregg the fact you have though about it lighting will strike!

Wonder should I open a VW parts export to AU land?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gregozedobe Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jun 15 at 02:19
After last night I have completely lost faith in my local dealer.  Had my Skoda in for a cambelt change and waterpump etc, plus seatbelts stalk. $AU 1535.00 later went to collect car, they couldn't find key or car. After 1/2 hour of further waiting they found car (out the back paddock), but the key was nowhere to be seen.  I got sick of waiting so used my spare keys to get home. I'm so glad I'm such a "be-prepared" boy scout Wink 

I'm still waiting to hear about the key they lost.

Maybe I'll ditch VW altogether and buy a new Mazda MPS 3 when they come out later this year/early next year to complement a new Vito 119 CDI  Evil Smile


Edited by gregozedobe - 17 Jun 15 at 02:30
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