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

VW T5 2.5 TDI Hydraulic Lifter Set: 10 FAI BFS101S

We supply 10 brand new FAI BFS101S black hardened hydraulic lifters for VW T5 2.5 TDI five-cylinder PD engines. You recieve all ten valve lifters for one compatible engine with each lifter individually sealed. These parts are also known as hydraulic tappets or camshaft followers.

The set is for VW Transporter T5, Caravelle, Multivan and California models with the engine codes listed below. BFS101S identifies one individual FAI lifter. This listing supplies ten.

Lifter specification

• 10 × FAI BFS101S hydraulic bucket tappets
• Black finish with a heat-treated oil-based coating
• Two internal springs
• 35 mm diameter and 26 mm height
• For inlet and exhaust valves
• For the 2461 cc five-cylinder 2.5 TDI PD engine with ten valves

VW T5 engine codes and years

The dates below cover the relevant T5 applications. Availability varies by body style and market so check the engine code before ordering. Registration year alone doesnt confirm fitment.

Compatible T5 models

• Transporter T5 panel van: 7HA / 7HH / 7EA / 7EH. AXD, AXE, BNZ and BPC applications within the 2003–2009 range.
• Transporter T5 Kombi, Shuttle and Caravelle passenger versions: 7HB / 7HJ / 7EB / 7EJ. AXD, AXE, BLJ, BNZ and BPC where fitted within the 2003–2009 range.
• Transporter T5 chassis cab, dropside and double cab: 7JD / 7JE / 7JL / 7JY / 7JZ and related 7F variants. AXD, AXE, BNZ and BPC applications within the 2003–2009 range.
• Multivan T5: 7HM / 7HN / 7HF / 7EF / 7EM / 7EN. AXD, AXE, BLJ, BNZ and BPC where fitted within the 2003–2009 range.
• California T5 camper: 7EC / 7EF / 7EG / 7HF / 7HC. Listed catalogue applications include May 2007 to November 2009 with AXD, AXE, BLJ, BNZ and BPC where fitted. Earlier vehicles need checking by engine code and VIN.

Suitable for front-wheel-drive and 4Motion versions with a compatible engine. If you are unsure of the egnine code check the vehicle data sticker or have it confirmed from the VIN. The model name or power output alone isnt enough.

OE references and cross references

• Supplied part: 10 × FAI BFS101S
• Relevant VAG PD lifter reference: 038 109 309 C / 038109309C
• Earlier related VAG references: 038 109 309 A / 038109309A and 038 109 309 B / 038109309B
• Related aftermarket references: INA 420 0209 10 / 420020910 and AE FOL175

These references help identify the application. Confirm the correct replacement specification for your engine rather than chosing by dimensions alone. The parts supplied are FAI BFS101S lifters.

Check the injectors when replacing worn lifters

A worn camshaft or damaged lifter can be the result of a problem elsewhere in the engine. On a T5 PD engine movement of the injector body can wear its bore in the cylinder head. Wear around the body and sealing area can damage the seals or prevent them from sealing properly. Diesel can then leak into the engine oil.

Fuel dilution reduces the oil's viscosity and weakens the protective oil film. This can accelerate wear on the camshaft lobes and hydraulic lifter faces. Replacing the worn parts without checking for injector leakage may leave the cause in place.

We recommend replacing the seal sets on all five PD injectors whenever you replace the hydraulic lifters or camshaft. Have the injector bodies, seal grooves and cylinder-head bores inspected at the same time. New seals alone may not give a lasting repair if the body or bore is badly worn. Correct any leakage and replace contaminated engine oil and the filter.

A rising oil level deserves investigation even if the engine still runs normally. In this T5 2.5 TDI oil-pressure discussion an owner reported recurring diesel contamination after a tandem pump replacement. Other members suggested checking the injector seals and bores. Its an example of why replacing one suspected part doesnt always resolve the problem. Injector leakage is one possible cause of wear so the oil supply, oil specification and instalation also need checking.

Injector body and cylinder-head wear

These photos from our PD camshaft listing show areas to inspect during the repair. They illustrate wear on used PD engine parts and arent photographs of the new lifters supplied.

BFS101S and uncoated lifters

FAI specifies a heat-treated oil-based coating and two internal springs for BFS101S. Its uncoated BFS66S lifter uses one spring. FAI states that BFS101S can replace BFS66S but BFS66S cannot replace BFS101S. These differences are explained in FAI technical bulletin TB0075.

A lifter with matching dimensions may still have the wrong specification. BFS101S shouldnt be confused with FAI BFS318S which uses a diamond-like carbon coating. This listing supplies BFS101S.

Black hardened lifters still need clean oil and a healthy oil supply. Their coating cannot compensate for fuel-contaminated oil or worn injector bores. Not every original T5 lifter was uncoated so this set shouldnt be described as an upgrade over every factory-fitted lifter.

Before fitting

• Inspect the camshaft lobes and lifter bores. Dont fit new lifters against a damaged camshaft.
• Replace all five injector seal sets as recommended above 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. Matching the viscosity grade alone isnt enough.
• Follow the vehicle repair procedure for lifter preparation, camshaft installation and injector adjustment. Check the required steps seperately rather than assuming the new lifters are ready for immediate engine start-up.

FAI specifies these components for standard unmodified vehicles and requires installation by a qualified technician. Fitting instructions arent supplied with the lifters.