My 1996 Surf was suffering from the usual rusted through rear bumper. I could’ve got a stock replacement from Roughtrax, but I fancied having a go at making something like Bandit Runner’s. Fortunately, Bandit (aka Jeremy) offers customised plans for his bumpers. Jeremy was great to work with, and before long I had the plans. The bulk of the bumper is made from 3mm steel, but the main cross beam called for some 6mm angle.

Error code 5 relates to a pair of resistors on the side of the injection pump, at least on the 2.4TD engine. These resistors are installed when the pump is calibrated and fine tune the timing and fuelling. I measured both resistors. The grey one was 0.622kΩ while the beige one was open circuit. The insides are potted in epoxy, so I dug out the trusty Dremel and went in.