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My 2.5 TDI (BNZ) is cranking very slow like the battery is almost flat. When I first turn the key, it sounds like it almost has enough speed to start but then slows rapidity to no cranking at all. The dash lights also drop out in the process.

Tried another battery from my 1.9 T5 but made no difference. Thought it was the loose or dirty grounds so I cleaned them all up but didn’t fix the problem. Also swapped out relay 109 and made sure all the fuses were okay, both under the battery and under dash.

Before buying another starter motor, I was wondering if I could first try jump starting the starter whilst still connected to the engine by attaching one jumper lead from battery positive to main starter bolt and a lead from negative battery terminal to ground near starter and turn the key? Just incase the cables are corroded inside and it isn’t the starter itself.

I did pull a few electrical fault codes recently but it was starting at the time. Wouldn’t idle properly, surging, knocking, couldn’t rev it past 1200rpm and was blowing a heap of white smoke, but it did start.


Chassis Type: 7J (7J - VW Transporter Single/Double Cab (2003 > 2010))
Scan: 01 02 03 08 09 0B 15 16 17 18 19 1C 22 37 45 46 47 56 6E 76
77 7D

VIN: WV3ZZZ7JZ7X023399 Mileage: 274510km-170572miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 070-906-016-BPC.clb
Part No SW: 070 997 016 M HW: 070 997 016 M
Component: R5 2,5L EDC 000SG 0860
Revision: --H05--- Serial number: VWZ7Z0G5243974
Coding: 0051172
Shop #: WSC 00199 551 00000
VCID: 2411EA7102CF00BB17A-5184

2 Faults Found:
001137 - Exhaust Pressure Sensor 1
P0471 - 000 - Implausible Signal
Freeze Frame:
Fault Status: 01110000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Speed: 0.0 km/h
(no units): 132.60
(no units): -5.10
(no units): 0.0
Temperature: 114.0°C
Temperature: 30.6°C

000260 - Mass Air Flow Sensor (G70)
P0104 - 000 - Intermittent - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 1
Fault Frequency: 8
Reset counter: 255
Mileage: 274515 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Speed: 0.0 km/h
Load: 100.0 %
Duty Cycle: 100.6 %
Bin. Bits: 00000100
Mass Air / Rev.: 525.0 mg/str
Mass Air / Rev.: 175.0 mg/str

Readiness: 1 2 0 0 0

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Address 03: ABS Brakes Labels:. 7H0-907-37x-ABS.clb
Part No SW: 7H0 907 379 P HW: 7H0 907 379 P
Component: (M)ABS MK25E 0103
Revision: 00H12001
Coding: 0000091
Shop #: WSC 35110 377 00190
VCID: 42DD4CE9F89B2E8B056-5160

1 Fault Found:
00668 - Supply Voltage Terminal 30
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 2
Fault Frequency: 1
Reset counter: 40
Mileage: 274515 km
Time Indication: 0

Freeze Frame:
Count: 0
Count: 6145
Count: 128
Count: 0


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Address 08: Auto HVAC Labels: Redir Fail!
Part No: 7H0 820 045 AM
Component: CLIMA/AC 0303
Shop #: WSC 00000 000 00000
VCID: 70B9D62186B7EC1BA32-5160

2 Faults Found:
00668 - Supply Voltage Terminal 30
001 - Upper Limit Exceeded - Intermittent
01299 - Diagnostic Interface for Data Bus (J533)
013 - Check DTC Memory - Intermittent

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Address 09: Cent. Elect. Labels:. 7H0-937-049.lbl
Part No: 7H0 937 049 T
Component: BORDNETZ SGVER 1.0 2001
Coding: 0000101
Shop #: WSC 35110 377 00190
VCID: 43D349EDE78127830E0-5160

4 Faults Found:
00991 - Interior Lights
012 - Electrical Fault in Circuit - Intermittent
01598 - Drive Battery Voltage
001 - Upper Limit Exceeded
01598 - Drive Battery Voltage
002 - Lower Limit Exceeded
00538 - Reference Voltage
014 - Defective

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Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 A
Component: 3H AIRBAG VW51 0010
Coding: 13128
Shop #: WSC 35110
VCID: 221DEC691DDB0E8B656-5160

1 Fault Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 7Hx-920-xxx-17.lbl
Part No: 7H0 920 851 R
Component: KOMBI+WEGFAHRSP VDO V02
Coding: 02703
Shop #: WSC 00001
VCID: 3A2D3409954B664B5D6-5160
WV3ZZZ7JZ7X023399 VWZ7Z0G5243974

2 Faults Found:
01316 - ABS Control Module
49-10 - No Communications - Intermittent
01336 - Company Data Bus for Comfort System
80-10 - Single-Wire Operation - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00022
Shop #: WSC 35110
VCID: 70B9D62183B7EC1BA32-5160

2 Faults Found:
01316 - ABS Control Module
49-10 - No Communications - Intermittent
01336 - Company Data Bus for Comfort System
80-10 - Single-Wire Operation - Intermittent

-------------------------------------------------------------------------------
Address 22: AWD Labels: 7H0-907-554.clb
Part No: 7H0 907 554 F
Component: HALDEX 4Motion 2110
Coding: 0000002
Shop #: WSC 35110 377 00190
VCID: 3333192DB72197039E0-5160

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 7H0-959-433.lbl
Part No: 7H0 959 433 B
Component: CX6 Komfortgerát 0004
Coding: 00031
Shop #: WSC 35110
VCID: 323D1C294D3B9E0B956-4B1E

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No SW: 7H0 035 152 C HW: 7H0 035 152 C
Component: Radio DE2 0004
Revision: 00004000 Serial number: VWZ4Z4F9230269
Coding: 0020200
Shop #: WSC 35110 377 00190
VCID: 221DEC6918DB0E8B656-5160

No fault code found.

End----(Elapsed Time: 05:05, VBatt start/end: 12.0V/12.0V. VIgn 12.
 

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Even though you tried a battery from another van I'd say yours is failing. It is certainly flat. At the end of your scan it shows the battery voltage which is 12v so flat. I'd take it off charge it up and get it tested.

You can feed the starter direct but you have to be careful not to short to earth in the awkard space around the starter otherwise you will get a large crackle! You wouldn't need to turn the key. You connect one big jump lead from battery to the starter and another and then short across to the small solonoid connection. But I would start with the battery charge and test. Have a good tug at the the big earth connection on the top starter bolt also. It may well be that the starter is drawing a high current and needs replacing as well. This can finish off a old battery.
 

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Discussion Starter #3
Even though you tried a battery from another van I'd say yours is failing. It is certainly flat. At the end of your scan it shows the battery voltage which is 12v so flat. I'd take it off charge it up and get it tested.

You can feed the starter direct but you have to be careful not to short to earth in the awkard space around the starter otherwise you will get a large crackle! You wouldn't need to turn the key. You connect one big jump lead from battery to the starter and another and then short across to the small solonoid connection. But I would start with the battery charge and test. Have a good tug at the the big earth connection on the top starter bolt also. It may well be that the starter is drawing a high current and needs replacing as well. This can finish off a old battery.
Thanks for the info mate. The battery I was using when I pulled the codes back in April was a different battery to the fully charged one I’m trying to start it with now. I switched the one I’m using now back in to my 1.9 T5 and started it straight away. That’s not to say that it isn’t on its way out too and won’t start the bigger 2.5 engine.I’ve never noticed the scan shows volts - so I’ll run another scan and see what it reads there. If the volts reading is correct I’ll give the leads some further investigation, as you advised.
 

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Discussion Starter #4
Even though you tried a battery from another van I'd say yours is failing. It is certainly flat. At the end of your scan it shows the battery voltage which is 12v so flat. I'd take it off charge it up and get it tested.

You can feed the starter direct but you have to be careful not to short to earth in the awkard space around the starter otherwise you will get a large crackle! You wouldn't need to turn the key. You connect one big jump lead from battery to the starter and another and then short across to the small solonoid connection. But I would start with the battery charge and test. Have a good tug at the the big earth connection on the top starter bolt also. It may well be that the starter is drawing a high current and needs replacing as well. This can finish off a old battery.
Once again you’re right! I took both batteries to my local auto parts store and they said both tested as “good” I wasn’t convinced - so I bought a load tester. One dropped to 600 cca and the other one was 400 cca. Both enough to start my 1.9 but obviously not the 2.5. I’ll be grabbing a new battery tomorrow, so I can get back to trying to sort out the other issues I’m facing. 🍻
 
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