My 2001 VW T4 2.5 diesel caravelle. was running perfect then the following morning refused to even attempt to fire .

Holding the relay 109 allowed it to fire up immediately ( as normal) but releasing the manually operated 109 relay arm the motor immediately cuts out.

replacing the 109 relay with a two terminal "yellow" one from a bmw .. cured the starting problem .

Now after one hours driving the glo plug dash warning light flashes continuously.
the local garage replaced four of the five glo plugs . but after a similat journey time the dash light comes on and contiues flashing ... Durr, My brain hurts. what can I do to make my T4.2.5 tdi VW caravelle better again .. I have ordered a T4 workshop manual DVD and intend to get to the bottom of the problem .

Dastardly2010., December 2010

the main relay somtimes get dry or cracked solder joints i had a starting problem, auto electrician removed my relay opened it up and re soldered joints not had a problem since using a bmw relay may be your problem with ya glow plugs or warning light try putting a vw one back in

porkpie, March 2013

two VW specialist diagnostic garages in then UK failed to be any assistance .. one UK VW Garage. diagnosed a faulty ign. switch .. and brake light switch ... £ 145 Pounds. The service engineer told me that the mechanic had "adjusted the brake light switch . My nightmare was just beguinning. The steering wheel was now compressing the steering column controls and making them unusable and the horn no longer worked. As my Caravelle was now undrivable I requested the tools to investigate the stiff steering and jammed column stalks. Fuse 13 resurrected the horn .and with the steering wheel nut only finger tight .. I was able to use my Beloved VW Caravelle over the Xmas break . This Midlands VW garage offered to PUT RIGHT at no cost to me their earlier cock up.. Now everything is working 90%... the indicator cancelling is no longer cancelling to the left. and the fusebox lid is held in place with a bodged up cable tie after the mechanic broke the lug off the fusebox lid ..I was extremely fortunate not to have an accident due to the broken fusebox lid falling down over the brake peddal.
As I had now lost faith in This VW garage . I took their service managers advice and booked My caravelle in to a VW Van centre.
The service manager booked it in for an early first job start on Thursday ..I elected to leave my Caravelle with them on the Wednesday afternoon to avoid any possible delays on my part.The weather and travelling conditions were not good and more snow was forecast.
With no phone call from the VW Van centre .. I phoned first thing on Friday only to be told that the work hadn,t even been started ... Needless to say I collected my VW and scarpered PDQ back to Portugal. Where the Local VW garage in Evora did a diagnostic whilst I stood watching . The nice Portuguese speaking storesman supplied a new replacement brake switch The mechanic took around 20 seconds to fit it and promptly reset the ecu to get rid of the flashing warning light on the dash.Pointing out that the diagnostics had highlighted a problem with an oil sensor in the sump.. I had noticed the Yellow oilcan sign had been indicating briefly when Starting the engine . As my Caravelle is due an oil and Filter service I have ordered the sensor and will happily entrust my Beloved Caravelle to this "Proper" VW garage in Evora Portugal. Oh I forgot to mention the cost for theis diagnostic and Brakelight switch replacement .. Zero. They only charged for the brakelight switch €10 euros plus iva (vat).

Dastardly2010., January 2011