VW T5 2.5 TDI Hydraulic Lifter Set – 10x FAI BFS101S

VW T5 2.5 TDI Hydraulic Lifter Set – 10 FAI BFS101S

This listing is for 10 brand new FAI BFS101S black hardened hydraulic lifters for VW T5 2.5 TDI five-cylinder PD engines. These parts are also known as hydraulic tappets or camshaft followers. The set contains all ten valve lifters for one compatible engine.

Suitable applications include the VW Transporter T5, Caravelle, Multivan and California with the engine codes listed below. BFS101S is the FAI part number for each individual lifter. You receive ten lifters in this listing sealed individually. 

Set contents and specification

• Quantity: 10 hydraulic lifters
• Manufacturer: FAI
• Part number: BFS101S
• Type: Black hardened hydraulic bucket tappet
• Surface treatment: Heat-treated oil-based coating
• Internal design: Two springs
• Diameter: 35 mm
• Height: 26 mm
• Fitting position: Inlet and exhaust valves
• Engine: 2461 cc 2.5 TDI PD – five cylinders and ten valves

VW T5 Engine Codes and Years

This ten-piece set is for the following 2.5 TDI PD engine codes. Dates cover the relevant VW T5 application range. Availability varies by body style and market.

• AXD: 2.5 TDI – 96 kW / 130 PS – 2003–2009.
• AXE: 2.5 TDI – 128 kW / 174 PS – 2003–2009.
• BLJ: 2.5 TDI – 120 kW / 163 PS – 2003–2009. Selected passenger models and markets.
• BNZ: 2.5 TDI – 96 kW / 130 PS – 2006–2009.
• BPC: 2.5 TDI – 128 kW / 174 PS – 2006–2009.

Compatible T5 models

• Transporter T5 panel van (7HA / 7HH / 7EA / 7EH): 2003–2009 – AXD / AXE / BNZ / BPC.
• Transporter T5 Kombi, Shuttle and Caravelle passenger versions (7HB / 7HJ / 7EB / 7EJ): 2003–2009 T5 application range – AXD / AXE / BLJ / BNZ / BPC where fitted.
• Transporter T5 chassis cab, dropside and double cab (7JD / 7JE / 7JL / 7JY / 7JZ and related 7F variants): 2003–2009 – AXD / AXE / BNZ / BPC.
• Multivan T5 (7HM / 7HN / 7HF / 7EF / 7EM / 7EN): 2003–2009 – AXD / AXE / BLJ / BNZ / BPC.
• California T5 camper (7EC / 7EF / 7EG / 7HF / 7HC): FAI catalogue applications from May 2007 to November 2009 – AXD / AXE / BLJ / BNZ / BPC where fitted. Please check your logbook/V5C for your engine code.

Suitable for front-wheel-drive and 4Motion versions where the listed engine is fitted. Check the engine code before ordering. The registration year alone does not confirm fitment.

Lifter OE Part Numbers and Cross References

• Supplied part: 10 × FAI BFS101S.
• Relevant VAG PD lifter OE reference: 038 109 309 C / 038109309C.
• Earlier related VAG lifter references: 038 109 309 A / 038109309A and 038 109 309 B / 038109309B. Confirm the correct replacement specification for the engine.
• FAI-listed cross references: INA 420 0209 10 / 420020910 and AE FOL175.

The VAG reference is linked through FAI's cross-reference to INA 420 0209 10. These numbers help identify the application. The set supplied contains FAI BFS101S lifters.

Why Injector Sealing Matters When Replacing T5 Lifters

A worn camshaft or damaged lifter can be the result of a problem elsewhere in the engine. On a T5 PD engine the injector body can move and wear against its bore in the cylinder head. Wear around the injector body and its seating area can damage the seals or prevent them from sealing properly. Diesel can then leak into the engine oil. This fuel dilution reduces the oil's viscosity and weakens the protective oil film. The camshaft lobes and hydraulic lifter faces can suffer accelerated wear as a result. Replacing those worn parts without checking the injectors may leave the cause of the damage in place.

We recommend replacing the seal sets on all five PD injectors every time you replace the hydraulic lifters or carry out a camshaft replacement. At the same time have the injector bodies, seal grooves and cylinder-head bores checked for wear. New seals alone may not provide a lasting repair if the injector body or bore is badly worn. Correct any leakage and change the contaminated engine oil and filter as part of the repair. Injector leakage is one possible cause of camshaft and lifter wear. Oil supply, oil specification and installation must also be checked.

Examples of injector and cylinder-head wear

These photos from our PD camshaft listing show the areas that need inspection. They illustrate PD engine wear and are not photographs of the new lifters supplied.

Why choose black hardened lifters instead of basic uncoated lifters?

The correct surface treatment matters at the contact between the camshaft and lifter. FAI BFS101S uses a heat-treated oil-based coating and two internal springs. The basic uncoated FAI BFS66S uses one spring. FAI states that BFS66S must not be used in place of BFS101S. When repairing a PD engine that requires this coated specification, matching the dimensions alone is not enough. Choose the correct black hardened lifter and deal with any injector leakage at the same time.

Hardened black lifters still need clean oil and a healthy oil supply. Their coating cannot make fuel-contaminated oil safe or compensate for damaged injector bores. Not every original T5 lifter was uncoated. Always use the correct replacement specification for the engine.

Before fitting the new hydraulic lifters

• Inspect the camshaft lobes and lifter bores. New lifters should not be fitted against a damaged camshaft.
• Replace all five injector seal sets and inspect the injector bodies and cylinder-head bores.
• Investigate a rising oil level or signs of diesel contamination before returning the engine to service.
• Check the oil supply and use oil with the correct VW approval for the specific engine. A matching viscosity grade alone is not enough.
• Follow the vehicle repair procedure for lifter preparation, camshaft installation and injector adjustment.

Professional installation is required. FAI specifies these parts for standard engine applications.