VW T4 Transporter

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    parts for durability or performance. Concise text and 500 photos drawings and charts lead you through each rebuilding step. Finish with an engine ready for thousands of miles of service! Models covered: * Beetle and Karmann Ghia (Type 1) * Bus and Transporter (Types 2 4) * Fastback Squareback Notchback (Type 3) * 411/412 and Porsche 914 Engines covered include 36 HP 40 HP 1300 1500 1600 1700 1800 and 2000. Contents: * Time to Rebuild? * Engine Removal * Parts Identification Interchange * Teardown * Crankcase Cylinder Reconditioning * Cylinder Head Reconditioning * Engine Assembly * Engine Installation Break-in Tuneup * Index details
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    gasoline (motor code AES) 2.5 Liter 5-piston gasoline (motor code AAF ACU) 2.5 Liter TDI four-stroke diesel (motor code ACV) two point four Liter four-stroke diesel (motor code AAB) 02B and 02G 5-speed manual gearboxs 098 and 01P four geared automatic gearboxs. For the professional automotive technician this manual includes the specifications and procedures that were available in an authorized Volkswagen dealer service department as this manual went to press. Two volume set find out more…..
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    nine liter (1896 cubic centimetre ) 4 piston and 2.4 liter (2370 cubic centimetre ) two point five liter (2461 cubic centimetre ) 5 piston * DOES NOT cover petrol motor models all-wheel-drive ‘Syncro’ models interior features specific to Westfalia Caravelle or Multivan or specialist bodywork/camper conversions. * DOES NOT cover Transporter ‘T5’ range introduced July 2003. Contents: * Safety First! * Roadside repairs * Weekly checks * Routine maintenance and servicing * 4 – piston motor in-vehicle repair procedures * 5 – piston motor in-vehicle repair procedures * motor removal and overhaul procedures * Cooling heating and ventilation systems * Fuel and exhaust systems * Emission control systems * Starting and charging systems * friction clutch * Manual transmission * Auto gearbox * Driveshafts * Braking system * Suspension and steering * Bodywork and fittings * Body wirings * electrical schematics * Reference more information…..
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    and short wheelbase) Note: Does Not Cover Four Wheel Drive Models Contents: Four Cylinder Petrol Engines friction clutch Transmission and Final Drive Drive Shafts Steering Front Suspension Rear Suspension and Rear Axle Wheels and Tyres braking system Electrical System Five Cylinder Petrol Engines Bodywork Fault Finding electrical schematics: Wiring Diagram – Battery X Contact Relief Valve II Wiring Diagram – Ignition / Starter Switch Immobiliser Wiring Diagram – Fresh Air Blower Fresh Air Blower Switch Glove Compartment Lamp Wiring Diagram – Dash Panel Insert Oil Pressure and Coolant Warning / Gauge Fuel Gauge Wiring Diagram – Dash Panel Insert Revolution Counter Distance Recorder Turn Signal Warning Lights Wiring Diagram – Dash Panel Insert Clock Handbrake Warning Light Wiring Diagram – Self Diagnosis Junction Box Radio Connection Wiring Diagram – Interior Lights Door Diagram – Windscree Wipe / Wash System Wiring Diagram – Rear Window Wipe / Wash System (Tailgate) Heated Windscreen Washer Jets Wiring Diagram – Automotive alternator Stater Motor Ignition Switch Wiring Diagram – Digifant Control Unit Injection Valves Lamdba Probe Coolant Shortage Warning Sender click here
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    four-stroke diesel one point nineL 4 piston 1X ● four-stroke diesel two point fourL 5 piston “AAB” ● four-stroke diesel two point fiveL TDI 5 piston “ACV” fitted with a catcon exhaust gas recirculation turbo and a charge air intercooler Models Covered: ● Van 800 Van 1 000 Van 1 200 ● Caravelle CL and GL ● Bus (long and short wheelbase) Index: ● Engine ● Clutch ● Transmission and Final Drive ● tail shafts ● Steering ● Front springs and shock absorbers ● Rear springs and shock absorbers ● Wheels and rubber tyres ● Brakes ● Electrical System ● vehicle body Wiring Diagram – one point nine liter four-stroke diesel Engine: ● Engine Type ABL Alternator Battery Starter Motor ● Ignition / Starter Switch ● Control Unit for Glow Time and Exhaust Gas Return System (EGR) ● Glow ● Self Diagnosis Junction Box Radio Connection ● Interior Lights Door Contacts ● Headlamps (Long Front End) Side Lamps ● Headlamps Range Control Hazard Warning Lights ● Turn Signal Switch Headlamp Dipped Beam / Flasher Switch Parking Light Switch ● Flasher Lamps here
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    four-stroke diesel gearboxs covered: four geared manual 5-speed manual Covers: Manual Gearbox only. Short and Long Wheelbase. Van. Caravelle. Bus. 2.0 and 2.5-liter Petrol. one point nine and 2.4-liter four-stroke diesel. Four Cylinder Petrol motors. Five Cylinder Petrol motors. Fuel Injection System – Four Cylinder. Fuel Injection System – Five Cylinder. four-stroke diesel motors. four-stroke diesel Injection System. Contents: General Information. Four Cylinder Petrol motors. Five Cylinder Petrol motors. Ignition System. Lubrication System – Petrol motors. Cooling System. Fuel Injection System – Four Cylinder. Fuel Injection System – Five Cylinder . Exhaust System. friction clutch. Manual gearbox. Drive Shafts. Power – Assisted Steering. Front Suspension. Rear Axle and Rear Suspension. Brake System. Electrical Equipment. four-stroke diesel motors. motor Axle and Rear Suspension. Brake System. Electrical Equipment. four-stroke diesel motors. motor Lubrication – four-stroke diesel motors. motor Cooling System – four-stroke diesel motors. four-stroke diesel Injection System. four-stroke diesel motors – Tightening Torques. Body Work. click here…..
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    200 – Caravelle CL and GL – Bus (long and short wheelbase). motors Covered: one point nineL 4 piston four-stroke diesel (ABL) 2.4L 5 piston four-stroke diesel (AJA AAB) two point fiveL 5 piston TDI four-stroke diesel (ACV AHY AJT AUF AXG AXL AYC) Contents: motor Clutch gearbox Final Drive tail shafts Steering Front Suspension Rear Suspension Axle Wheels rubber tyres braking system Electrical vehicle body Fault Finding electrical schematics: Wiring Diagram – Battery X Contact Relief Relay Ignition Switch Fuses Wiring Diagram – Heater Blower Blower Switch Two Way Valve and Switch for Fresh Air and Recirculating Air Flap Glovebox Light Wiring Diagram – Immobiliser Cable Distributer for Data Bus Self Diagnosis Connection Wiring Diagram – Dash Panel Insert Oil Pressure and Coolant Temperature Warning Fuel Gauge Revolution Counter Wiring Diagram – Dash Panel Insert Multi-Function / Flasher Switch Side Light Switch Wiring Diagram – Cigarette Lighter Brake Light Switch Reversing Light Wiring Diagram – Left Hand Rear Turn Signal Light Left Hand Tail Light Left Hand Reversing Light Left Hand Brake Light Rear Fog Light Raised Brake Light Wiring Diagram – Right Hand Rear Turn more tips
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    Camper. It gives advice on how to choose the best van for your needs and prepare it – how to plan the layout and choose fittings how to fit an elevating roof how to cut panels and fit utilities. Integracar tries to have a sizeable array of owners guides. However owners manuals can sometimes be manufactured for very different nations and the motor motor car designed for those nations. For this reason not all workshop manuals may be applicable for your individual car. If you have important questions whether or not a selected maintenance manual is best suited for your car do not hesitate to make contact with us hereHow to Convert Volkswagen Bus or Van to Camper by Lindsay Porter click here

The Volkswagen Transporter (T4), promoted in united states because the Volkswagen Eurovan, try a van made by the German manufacturer Volkswagen Commercial motors between 1990 and 2003, succeeding the Volkswagen Type 2 (T3) and superseded because of the Volkswagen Transporter (T5).

Part of the popularity of the T4 had been their flexibility. It had been obtainable in most types and models as standard and created the cornerstone of numerous specialist cars, from buses to campervans to ambulances.

Two standard wheelbases were readily available; “quick” (2920mm) and “long” (3320mm).
System sort

Panel Van – without any windows behind the b-pillar; single row of seating
Kombi or Half-Panel – with additional windows involving the b and c-pillars; 2 rows of chairs
Caravelle or Multivan – with microsoft windows at all times; 3 rows of chairs (Known as the Eurovan within the US)


Solitary cab – predicated on a SWB framework
Double cab – considering a LWB framework (aka Doka, through the German: Doppelkabine)


Panel vans are available with two different roofing levels; traditional (1940mm) and high-top (2430mm). High-tops had been just produced from the LWB chassis, although campervan conversion rates usually have pop-top or (usually fibreglass) high-tops included with both SWB and LWB framework.

Vans have actually both an individual, roof-hinged “tailgate” or two “barn” doorways within rear and often a single (traveler part) or twin (both side) sliding doors.
Extended and short-nose

There was clearly one biggest renovation into T4, in 1996, when a re-shaped, longer front end ended up being launched. This is necessary to compliment the six-cylinder VR6 engine to the T4’s system bay. In the beginning, only Caravelles and Multivans were available because of the extended nostrils, because these were truly the only designs available using the VR6 system.

The commercial alternatives always been created using the shorter nostrils until 1999. But campers alongside expert cars created between 1994 and 1999 could have either the quick or perhaps the lengthy nose, based which model was put as base automobile. Consistent with the nature 2’s naming meeting, the quick and long-nose models are informally generally T4a and T4b, correspondingly.
Four-wheel Drive (Syncro)

The T4 was also offered with a permanent 4WD program that makes use of a Viscous coupling device as a center differential to regulate the circulation of torque into the rear axle. These versions are known as “syncro” and are readily available because of the 2.4D, 2.5Tdi and 2.5 petrol machines on all human anatomy kinds and both wheelbases. Some syncro products supply a mechanically securing back differential. Since the rear differential precludes the placement of the spare wheel when you look at the typical destination beneath the human anatomy, syncro vans either store they inside system or on an external, hinged bracket.

The T4 was a very preferred base for design a little to medium sized camper and day-vans, both as self-build jobs as well as expert conversions. Volkswagen themselves furthermore sold campervan versions regarding the T4, made by and named after their specialist, Westfalia-Werke.

Introduced in 1990, the T4 is the initial Volkswagen van to possess a front-mounted, water-cooled motor. Encouraged by the popularity of close moves due to their passenger vehicles, Volkswagen have toyed when you look at the belated 1970s using notion of replacing their particular air-cooled, rear-engined T2 vans with a front-engined, water-cooled design. The reasons for deciding in 1980 to as an alternative present a new rear-engined T3 is confusing. Hence, the introduction of a front-engined design had been delayed before the arrival associated with T4. After a run of nearly 14 ages, T4 manufacturing ceased in 2003, which makes it 2nd and then the T1 for duration of manufacturing in its home market.

Petrol motors
Design motor ID rule motor setup Engine displacement DIN ranked motive energy @ rpm Torque @ rpm Years
1.8 PD inline-4 SOHC 8v 1,781 cc (108.7 cu in) 67 PS (49 kW; 66 bhp) @ 4,000 140 N*m (103 lbf*ft) @ 2,200 1990–1992
2.0 AAC inline-4 SOHC 8v 1,968 cc (120.1 cu in) 84 PS (62 kW; 83 bhp) @ 4,300 159 N*m (117 lbf*ft) @ 2,200 1990–2003
2.5 AAF; ACU inline-5 SOHC 10v 2,461 cc (150.2 cu in) 112 PS (82 kW; 110 bhp) @ 4,500 190 N*m (140 lbf*ft) @ 2,200 1990–1997
2.5 AET; APL; AVT inline-5 SOHC 10v 2,461 cc (150.2 cu in) 115 PS (85 kW; 113 bhp) @ 4,500 200 N*m (148 lbf*ft) @ 2,200 1997–2003
2.8 VR6 AES VR6 DOHC 12v 2,792 cc (170.4 cu in) 140 PS (103 kW; 138 bhp) @ 4,500 240 N*m (177 lbf*ft) @ 3,000 1996–2000
2.8 V6 AMV, AXK VR6 DOHC 24v 2,792 cc (170.4 cu in) 204 PS (150 kW; 201 bhp) @ 6,200 245 N*m (181 lbf*ft) @ 2,500 2000–2003
Diesel motors

Indirect shot

Design system ID signal Engine setup system displacement DIN ranked motive power @ rpm Torque @ rpm Years
1.9 D 1X inline-4 SOHC 8v 1,896 cc (115.7 cu in) 61 PS (45 kW; 60 bhp) @ 3,700 127 N*m (94 lbf*ft) @ 1,700 1990–1995
1.9 TD ABL inline 4 SOHC 8v 1,896 cc (115.7 cu in) 68 PS (50 kW; 67 bhp) @ 3,700 140 N*m (103 lbf*ft) @ 2,000-3,000 1993–2003
2.4 D AJA inline-5 SOHC 10v 2,370 cc (144.6 cu in) 75 PS (55 kW; 74 bhp) @ 3,700 160 N*m (118 lbf*ft) @ 1,900-2,900 1997–2003
2.4 D AAB inline-5 SOHC 10v 2,370 cc (144.6 cu in) 78 PS (57 kW; 77 bhp) @ 3,700 164 N*m (121 lbf*ft) @ 1,800 1990–1998

Turbocharged Direct Shot

Design system ID code system configuration motor displacement DIN rated motive power @ rpm Torque @ rpm Compression Ratio Years
2.5 TDI AJT; AYY inline-5 SOHC 10v 2,461 cc (150.2 cu in) 88 PS (65 kW; 87 bhp) @ 3,700 195 N*m (144 lbf*ft) @ 2,000-2,600 19,5 1998–2003
2.5 TDI ACV; AUF; AYC; AXL inline-5 SOHC 10v 2,461 cc (150.2 cu in) 102 PS (75 kW; 101 bhp) @ 3,500 250 N*m (184 lbf*ft) @ 1,900-2,300 19,5 1995–2003
2.5 TDI AHY; AXG inline-5 SOHC 10v 2,461 cc (150.2 cu in) 151 PS (111 kW; 149 bhp) @ 4,000 295 N*m (218 lbf*ft) @ 1,900-3000 19,0 1998–2003

The Transporter T4 is shipped to North America from 1992 until 2003 underneath the moniker Eurovan.

In america, the quick wheelbase Eurovan 5-cylinder passenger versions (CL, GL, GLS, and MV) are best sold for design season 1993. Smaller than a regular US delivery van, but bigger than an American or Japanese traveler minivan, Volkswagen played up their size with all the motto, “EuroVan: you’ll find nothing mini about it”. VW best brought in all of them towards people for example season because purchases in america had been unsatisfactory, but deals continued in Canada and Mexico. VW reintroduced the Eurovan traveler models in the usa for model season 1999 with a VR6 motor as standard, and discontinued they again with global T4s after 2003. The handbook transmission wasn’t offered in North America with the VR6 engine.

VW brought in the quick wheelbase Eurovan 5-cylinder gas engine passenger products (CL, GL, GLS, MV Weekender and Westfalia Camperised) to Canada from 1991 to 1996. The 77 hp 2,4L diesel system ended up being recommended in Canada between 1993 to 1996. The long wheelbase variation has also been being offered in 1992 only as a 10 seaters CL or GL design trim. Combi and crewcab pick-up versions (marketed as Transporter) were also for sale in 1992. A panel version (longer wb just) ended up being marketed from 1993 to 1997.

The Eurovan Camper by Winnebago ended up being launched in the US and Canada in 1995 utilizing the five-cylinder system, and ended up being enhanced into the VR6 when it comes to 1997-2003 versions. They certainly were best on the extended 3,320 mm (131 in) wheelbase T4. These small pop top camper vans tend to be special in the united states and have now developed a cult following.

Winnebago in addition built three smaller lessons C motorhomes utilizing the forward cab for the T4/Eurovan called the Rialta, Vista, and Sunstar(Itasca labeled). The Rialta was available in 1995-1996 using five-cylinder engine, in 1997-2001 using AES version of the VR6, plus in 2002-2005 using AXK system. The Vista and Sunstar had been only manufactured in 2002-2004, all utilising the AXK system.

When you look at the U.S., the products were:

the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, in which the 2nd line of chairs face the rear and are usually removable, the 3rd line converts into a bed, a folding table inside passenger area, window treatments, and a fluorescent lamp above table.
the Eurovan MV Weekender, an MV plus a Westfalia transformation that adds a pop-top roof, an additional overhead bed, bug screens for negative house windows and back hatch, complete collection of curtains, auxiliary battery, fluorescent inside lights and under chair thermoelectric cooler.
the Eurovan Camper, the lengthy wheelbase commercial van transformed by Winnebago Industries to add a pop-top roof, two two-person bedrooms, sitting for four (plus optional single or two-person center seating), a single cubic leg refrigerator that operates on propane, DC, or AC, a propane furnace, a wardrobe, cabinets, sink with chilled water and a gray liquid container, a two-burner propane kitchen stove, two two-person dinette tables, mentor electric battery, house illumination, and also the two front bucket seating designed to swivel around to face the dinette/kitchen room. The 2000 EVC are 17 ft long (5,189 mm.)

The existing search Volkswagen Transporter was launched in 1993 and contains enjoyed a great selling record currently. 1997 has actually seen the introduction of some adjustment and modifications through the entire Transporter number of commercial cars which will verify their position among the market leaders in its lessons.

Volkswagen provides both Transporter (commercial van) additionally the Caravelle (staff mover) in a variety of various versions. The Transporter will come in four human body types, the brief and long wheelbase van, framework cab and double taxi framework. Two petrol motors, one diesel system, guide and automatic transmissions and an option associated with Synchro (four-wheel drive) go with the Transporter number. The Caravelle has sitting capacity for eight persons and is offered only with a 2.5 litre petrol motor although a range of manual or automatic transmissions is present.

The Multivan utilizes both Caravelle additionally the Transporter ideas while the foundation for producing an automobile to execute multipurpose jobs. Regarding one-hand, the Multivan was a real group mover for the reason that it offers seating for seven grownups and ample space for storing because of their luggage. The trunk bench seat can fold level to make a double bed or as an alternative the rear seats can be eliminated completely to provide the same space of a Transporter van (up to 6.3 cubic metres of room within the long wheelbase design).

A corner chair transformation the Multivan is carried out in your area by dominant Sydney formulated business Trakka, an expert in camper conversions. A typical Trakka Multivan transformation include the inclusion of centre and back house windows, a good rear flooring with heavy weight plastic cover, hardboard part linings and a removable three individual back bench seat that will additionally be creased to form a double sleep. The improvements completed are fully certified to make sure compliance try maintained with all appropriate Australian Design formula.

Budget permitting, there was a wide range of additional equipment and trim standards being offered. The van evaluated because of this report, aided by the Trakka Multivan Deluxe conversion retails for $53,990 plus on path outlay.

The most significant adjustment to have already been incorporated to the 1997 Transporter range comprise the fitment of a motorist’s side airbag together with inclusion of four wheel disc brakes. These inclusions tend to be standard gear on all designs and help to narrow the gap which has usually been around between the security features available in traveler automobiles and light commercial motors.

One of the best strengths associated with the Multivan is the exceptional amount of space being offered. Lots of head and leg room is present for both front side and back chair occcupants, besides a more than large quantity of baggage ability. A notable exclusion, but could be the bulbous front-wheel arch intrusion which necessitates an awkward activity to operate the accelerator pedal.

A commanding view of this road forward can be obtained when seated into the driver’s chair, along with the expansive regions of cup, big side mirrors together with higher seating position. Flaccid cushions and minimal part bolsters create a comfy albeit relatively unsupportive ride.

The Multivan drives and manages quite nicely for this lessons of car when you come to be accustomed to the obvious human anatomy roll practiced whenever cornering. Performanceis not outstanding, nevertheless the system brings sensibly better from reasonable system rates when unladen, assisted by the four rate vibrant move regimen automated gearbox with ‘fuzzy logic’ computer system control.

Volkswagen Transporter (T4) – Wikipedia, the free encyclopedia

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