Over 250,000 miles on the clock and still earning its keep. This 2004 VW T5 1.9 TDI was being converted into a camper, but the owner had noticed it struggling as the extra weight was added. A visit to PP Tuning for a Pendle Performance remap revealed a problem that needed sorting first.
A 104bhp Engine Producing Just 81bhp
This T5 has the 104bhp 1.9 TDI engine and five-speed manual gearbox. Before remapping, Jason carried out the usual health checks and data logging to see how the engine was performing.
The initial figures weren’t encouraging. Just 81bhp and 201Nm of torque, well below what this engine should be producing.
Further checks revealed the problem. The throttle damper was restricting throttle operation to just 72%, leaving the driver without the full response of the accelerator.
Fixing the Problem Before Remapping
Jason sorted the throttle damper issue, restoring 100% throttle operation before proceeding with the Pendle Performance remap.
There’s a good reason for carrying out these checks. Remapping an engine that’s already underperforming can mask problems that really ought to be fixed first.
It’s something PP Tuning regularly encounters when working on older Transporters, including this previous VW T5 1.9 TDI camper remapping job.
VW T5 Remapping Results
With the throttle problem corrected and the remap completed, the final rolling road figures were:
- Power: 81bhp to 134bhp (+53bhp)
- Torque: 201Nm to 300Nm (+99Nm)
- Throttle operation: Restored from 72% to 100%
Volkswagen T5
1.9 TDI 104The final data logging also showed that everything was working as it should.
Of course, the improvement came from a combination of fixing the throttle problem and remapping the engine. Without the initial checks, that fault could easily have gone unnoticed.
More Pulling Power for the Camper
With 300Nm of torque now available, this T5 should be much better suited to carrying the additional weight of its camper conversion, particularly on hills and when accelerating.
It’s covered more than a quarter of a million miles already, and the owner clearly has plans to make plenty more use of it.
If your VW Transporter or camper feels short of power, PP Tuning can check its condition and advise whether remapping would be worthwhile.
Get in touch with PP Tuning to discuss your vehicle.
VW T5 Remapping, Engine Health Checks and High-Mileage Campers
Can you remap a VW T5 with over 250,000 miles?
Yes, a high-mileage VW T5 can still be suitable for engine remapping, provided the engine and supporting components are in good condition. PP Tuning recently remapped a 2004 VW T5 1.9 TDI with over 250,000 miles, achieving 134bhp and 300Nm of torque after identifying and correcting an existing throttle fault.
How much power can a VW T5 1.9 TDI gain from remapping?
The improvement depends on the engine’s condition, original power output and individual tuning requirements. This 104bhp VW T5 initially produced just 81bhp because of a throttle restriction. After repairing the fault and completing a Pendle Performance remap, it achieved 134bhp and 300Nm of torque. The overall gain includes both the repair and remapping.
Why are engine health checks important before remapping?
Pre-remapping diagnostics and data logging help identify mechanical or electronic problems that could affect engine performance. On this VW T5, the checks revealed a throttle damper issue restricting throttle operation to 72%. Correcting the problem before remapping allowed PP Tuning to tune an engine that was operating properly.
Will remapping help a VW T5 camper cope with extra weight?
Remapping can improve the available torque and make a VW T5 camper easier to drive when carrying additional weight, particularly on hills and during acceleration. This 1.9 TDI achieved 300Nm after its throttle repair and remap. The extra pulling power can improve drivability, but it does not increase the vehicle’s legal weight limits or towing capacity.
Can remapping fix an underperforming diesel engine?
Remapping cannot repair mechanical faults or faulty engine components. If a diesel engine is producing less power than expected, the cause should be investigated before tuning. PP Tuning uses diagnostics, performance testing and data logging to identify potential problems and assess whether the vehicle is suitable for a Pendle Performance remap.
