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VW T4 workshop manual volkswagen

Introduced in 1990, the T4 ended up being initial Volkswagen van having a front-mounted, water-cooled system. Area of the success of the T4 is their usefulness.Wheelbase Two standard wheelbases were offered; "brief" and "long".Human anatomy types Van Panel Van -

Introduced in 1990, the T4 ended up being initial Volkswagen van having a front-mounted, water-cooled system. Encouraged by the success of close techniques making use of their passenger automobiles, Volkswagen have toyed within the late 1970s aided by the notion of changing their particular air-cooled, rear-engined T2 vans with a front-engined, water-cooled design. The reasons for deciding in 1980 to rather present a new rear-engined T3 were uncertain. Therefore, the development of a front-engined layout was delayed before the arrival regarding the T4. After a run of almost 14 ages, T4 production ceased in 2003, which makes it 2nd only to the T1 for length of manufacturing with its real estate market.

Area of the success of the T4 is their usefulness. It had been obtainable in numerous kinds and models as standard and created the basis of numerous professional cars, from buses to campervans to ambulances.
Wheelbase

Two standard wheelbases were offered; "brief" and "long".
Human anatomy types
Van

Panel Van - with no house windows behind the b-pillar; single-row of seats
Kombi or Half-Panel - with further windows between the b and c-pillars; 2 rows of seats
Caravelle or Multivan - with microsoft windows all-round; 3 rows of seats

Pickup

Single cab - based on a SWB framework
Dual taxi - based on a LWB framework

Roofs

Panel vans had been available with two various roof heights; standard and high-top. High-tops had been only made regarding LWB framework, although campervan conversion rates usually have pop-top or high-tops included with both SWB and LWB framework.
Doors

Vans need both just one, roof-hinged "tailgate" or two "barn" doors within rear and either one or twin sliding doors.
Long and short-nose

There was clearly one big facelift on T4, in 1996, whenever a re-shaped, much longer forward end was introduced. It was needed to fit the six-cylinder VR6 system in to the T4's engine bay. At first, just Caravelles and Multivans were available utilizing the extended nostrils, because these had been the sole designs available with the VR6 motor.

The commercial alternatives stayed produced using the smaller nose until 1999. But campers along with other specialist automobiles created between 1994 and 1999 could have both the brief and/or long nostrils, based on which model had been put as base vehicle. Commensurate with the kind 2's naming convention, the quick and long-nose variations may informally called T4a and T4b, correspondingly.
Four-wheel Drive

The T4 has also been readily available with a permanent 4WD system that uses a Viscous coupling unit as a centre differential to manage the circulation of torque into the back axle. These versions are known as "syncro" and were available with the 2.4D, 2.5Tdi and 2.5 petrol engines on all system kinds and both wheelbases. Some syncro versions likewise have a mechanically securing rear differential. Because the rear differential precludes the placement of the spare wheel inside normal put underneath the human body, syncro vans either shop it in the human anatomy or on an external, hinged bracket.
Campervans
The T4 are a really well-known base for building a little to medium sized camper and day-vans, both as self-build tasks as well as for expert conversions. Volkswagen by themselves in addition offered campervan versions of T4, made by and named after their particular contractor, Westfalia-Werke.

Petrol motors
Model Engine ID rule system setup system displacement DIN rated motive energy @ rpm Torque @ rpm Years
1.8 PD inline-4 SOHC 8v 1,781 cc 67 PS @ 4,000 140 N·m @ 2,200 1990–1992
2.0 AAC inline-4 SOHC 8v 1,968 cc 84 PS @ 4,300 159 N·m @ 2,200 1990–2003
2.5 AAF; ACU inline-5 SOHC 10v 2,461 cc 112 PS @ 4,500 190 N·m @ 2,200 1990–1997
2.5 AET; APL; AVT inline-5 SOHC 10v 2,461 cc 115 PS @ 4,500 200 N·m @ 2,200 1997–2003
2.8 VR6 AES VR6 DOHC 12v 2,792 cc 140 PS @ 4,500 240 N·m @ 3,000 1996–2000
2.8 V6 AMV, AXK VR6 DOHC 24v 2,792 cc 204 PS @ 6,200 245 N·m @ 2,500 2000–2003
Diesel motors

Indirect injections

Model system ID code motor setup system displacement DIN ranked motive energy @ rpm Torque @ rpm many years
1.9 D 1X inline-4 SOHC 8v 1,896 cc 61 PS @ 3,700 127 N·m @ 1,700 1990–1995
1.9 TD ABL inline 4 SOHC 8v 1,896 cc 68 PS @ 3,700 140 N·m @ 2,000-3,000 1993–2003
2.4 D AJA inline-5 SOHC 10v 2,370 cc 75 PS @ 3,700 160 N·m @ 1,900-2,900 1997–2003
2.4 D AAB inline-5 SOHC 10v 2,370 cc 78 PS @ 3,700 164 N·m @ 1,800 1990–1998

Turbocharged Direct Injections

Design motor ID code system configuration Engine displacement DIN ranked motive energy @ rpm Torque @ rpm Compression Ratio Years
2.5 TDI AJT; AYY inline-5 SOHC 10v 2,461 cc 88 PS @ 3,700 195 N·m @ 2,000-2,600 19,5 1998–2003
2.5 TDI ACV; AUF; AYC; AXL inline-5 SOHC 10v 2,461 cc 102 PS @ 3,500 250 N·m @ 1,900-2,300 19,5 1995–2003
2.5 TDI AHY; AXG inline-5 SOHC 10v 2,461 cc 151 PS @ 4,000 295 N·m @ 1,900-3000 19,0 1998–2003

The Transporter T4 had been shipped to united states from 1992 until 2003 underneath the moniker Eurovan.

In america, the brief wheelbase Eurovan 5-cylinder traveler brands had been just offered for model 12 months 1993. Smaller than a regular American delivery van, but bigger than an United states or Japanese passenger minivan, Volkswagen played up their dimensions using the motto, "EuroVan: there is nothing mini about this". VW best imported them on people for one seasons because selling in the US had been unsatisfactory, but marketing proceeded in Canada and Mexico. VW reintroduced the Eurovan passenger models in the US for model year 1999 with a VR6 engine as standard, and stopped it once more with globally T4s after 2003. The manual transmission had not been available in united states utilizing the VR6 motor.

VW brought in the short wheelbase Eurovan 5-cylinder petrol system traveler designs to Canada from 1991 to 1996. The 77 hp 2,4L diesel motor is recommended in Canada between 1993 and 1996. The lengthy wheelbase variation was also available in 1992 only as a 10 seaters CL or GL model trim. Combi and crewcab pick-up versions had been in addition obtainable in 1992. A panel version had been offered from 1993 to 1997.

The Eurovan Camper by Winnebago is launched in the usa and Canada in 1995 because of the five-cylinder system, and ended up being upgraded towards the VR6 for the 1997-2003 models. These were just available on the extended 3,320 mm wheelbase T4. These smaller pop music top camper vans tend to be special in united states and also have created a cult after.

Winnebago furthermore built three little lessons C motorhomes using forward cab regarding the T4/Eurovan known as the Rialta, Vista, and Sunstar. The Rialta is obtainable in 1995-1996 because of the five-cylinder system, in 1997-2001 with all the AES version of the VR6, and in 2002-2005 with the AXK engine. The Vista and Sunstar are best stated in 2002-2004, all utilising the AXK motor.

Inside U.S., the brands are:

the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, when the 2nd row of chairs deal with a corner consequently they are removable, the next row converts into a bed, a foldable dining table within the passenger area, drapes, and a fluorescent lamp above table.
the Eurovan MV Weekender, an MV plus a Westfalia transformation that adds a pop-top roofing, an extra overhead bed, bug displays for negative microsoft windows and back hatch, complete group of curtains, additional power, fluorescent interior lighting and under seat thermoelectric cooler.
the Eurovan Camper, the lengthy wheelbase commercial van converted by Winnebago sectors to include a pop-top roofing, two two-person bedrooms, sitting for four, a single cubic base ice box that operates on propane, DC, or AC, a propane furnace, a dresser, cupboards, sink with cold-water and a grey water tank, a two-burner propane kitchen stove, two two-person dinette tables, mentor power, residence illumination, therefore the two front container chairs meant to swivel around to handle the dinette/kitchen room. The 2000 EVC are 17 feet very long.
Whenever production of the Volkswagen T4 were only available in August 1990, also referred to as a Eurovan in america, it absolutely was an enormous step of faith that followers regarding the rear engined Transporters would accept it. After a slow begin the T4 is actually a rather popular model with VW lovers, tradesmen using them as a works van, motorhome proprietors and folks hunting for a really multipurpose leisure car.

T4 was an entirely new-model utilizing latest tactics, numerous extracted from the Golf and Passat range. Becoming front engined, front wheel drive and having a monocoque building, smashed the majority of their hyperlinks to 50 several years of heritage.
T4 design alternatives

Built in the devoted Transporter factory in Hanover, Germany, it had been available in SWB or LWB. The number is comprised of:
● Panel Van
● Eurovan
● Kombi
● Caravelle
● Solitary Taxi Pickup
● Dual Cab Pickup
● Syncro
Camper and commercial conversion rates

Once again, much like its predecessors, it became a strong preferred utilizing the car transformation organizations. It is often made as refrigerated automobiles, authorities and ambulances, taxis, impairment cars with wheel chair ramps etcetera. It even became the somewhat special Razor Back, that was built as a brewery shipments car with reducing flooring to load/unload drums of beer.

Progressively VW T4 vans are increasingly being converted into campers and day vans. You can find progressively more garages speciliaisng in T4 camper sales, such as for example Vanworx, but the majority of holders prefer to select a DIY conversion system.
Manufacturing history and technical modifications

1990 to 1995 couple of model changes. The product range ended up being provided with either petrol and diesel motors.

1996 biggest model revamp. Changes include back disc brake system, one piece back bumper and 2.5 litre TDi system.

The Caravelle VR6 had been launched necessitating an extended nose to allow for the new system. The extended nostrils was used on the Caravelles after that, as well as the quick nostrils T4 is employed for the lesser brands.

2003 summertime saw the end of T4 manufacturing in Hanover, to help make way for it’s more recent cousin, the T5.
T4 system data

The system amounts try stamped regarding the front of the motor block. On Petrol motor the amount is situated below two for the spark plugs. The motor quantity can be revealed on the timing belt cover as well as on the ID dish in the home pillar. On the Diesel motor the amount is located amongst the shot pump and vacuum cleaner pump. And is additionally shown on timing buckle cover and on the ID dish regarding the door pillar.
Rule Dimensions BHP Records
AAB 2400cc 78 bhp Diesel
AAC 2000cc 84 bhp Petrol
AAF 2500cc 110 bhp Petrol
ABL 1900cc 68 bhp TDi
ACU 2500cc 110 bhp Petrol
ACV 2500cc 102 bhp TDi
AEN 2500cc 110 bhp Petrol
AES 2800cc 140 bhp VR6
AET 2500cc 115 bhp Petrol
AEU 2500cc 110 bhp Petrol
AHY 2500cc 151 bhp TDi
AJA 2400cc 75 bhp Diesel
AJT 2500cc 88 bhp Diesel
AMV 2800cc 204 bhp VR6
APL 2500cc 115 bhp Petrol
AUF 2500cc 102 bhp TDi
AVT 2500cc 114 bhp TDi
AYC 2500cc 102 bhp TDi
T4 chassis data

The chassis amounts, or VIN, is available on the top of this dashboard and is most useful seen from external.

This instance chassis amounts, WV2ZZZ70Z2H131652, belongs to a kind 4 VW Caravelle/Multivan built-in 2002 in Hanover. It had been number 131652 from the production line.

Analysing the framework number will expose important info concerning the van...
WV ‘Manufacturer’
2 ‘Type of vehicle’ - 1 = Panel van, 2 = screen van, 3 = framework taxi
ZZZ ‘Filler code’
70 ‘VW Transporter’
Z ‘Filler code’
2 ‘Year of manufacture’
H ‘Built in Hanover’
131652 ‘Production range number’
tenth digit Design season Develop day
M 1991 first Aug 90 > 31st Jul 91
Letter 1992 1st Aug 91 > 31st Jul 92
P 1993 1st Aug 92 > 31st Jul 93
R 1994 1st Aug 93 > 31st Jul 94
S 1995 1st Aug 94 > 31st Jul 95
T 1996 1st Aug 95 > 31st Jul 96
V 1997 1st Aug 96 > 31st Jul 97
W 1998 1st Aug 97 > 31st Jul 98
X 1999 1st Aug 98 > 31st Jul 99
Y 2000 first Aug 99 > 31st Jul 00
1 2001 1st Aug 00 > 31st Jul 01
2 2002 1st Aug 01 > 31st Jul 02
3 2003 1st Aug 02 > 31st Jul 03

VW T4 campervans remain a top favourite for many different applications, from light commercial to minibuses and camping. Creation of the T4, which sported a revolutionary front-mounted water-cooled system, were only available in 1990 and proceeded for 13 years until 2003.

Volkswagen was toying with all the concept of front-engined campervans because the ‘70s as they have enjoyed triumph with regards to passenger cars, nevertheless the van was delayed until the release of VW T4 campervans.

It really is this style of campervan that officially launched the ‘Transporter’ name as its predecessors are only colloquially referred to as Transporter campervans; the VW T4 could be the original car to use title.

VW T4 campervans stayed fairly similar within the whole 13 many years of production, with just one major change in 1994 if the front end is re-shaped. The move ended up being needed so that you can fit the bigger six-cylinder VR6 motor into the bay.

The 2 various models of VW T4 campervans were called T4a and T4b by super- lovers, maintaining in traditional with the Type 2.

You can find a huge quantity of machines to choose from because the re-model: the T4a are powered by four machines in a choice of petrol or diesel, however the T4b in addition spotted the five-cylinder TDI motor.

We have written this guidelines as an aid to whoever was thinking about buying a Volkswagen T4 Transporter camper van. Clearly you will find different design variants with respect to the seasons plus various transformation firms such as Autohomes, Autosleeper, Bilbos, Carthago, Danbury, Dehler, Fischer, Holdsworth, Karmann, Leisuredrive, Reimo and Westfalia so a number of the facts will connect with some campers and not to other people. A few of the information pointed out are general and would connect with any vehicle but i'll you will need to highlight issues that become certain to VW T4 Transporters. In addition whenever examining a bus be practical as you cant anticipate an inexpensive van to-be no cost of faults. The notion of this guide is the fact that it helps you will be making the best choice highlighting any problems that exist so you know exactly what you are actually purchasing. You'll choose if the camper will probably be worth the price tag and if you're able to point out any trouble toward vendor it could present a basis for price negotiation. Some of the info is centered on my very own private opinion and you will not concur so please email me personally and let me know. I am in addition hoping subscribers will e-mail myself with any useful pointers that I can increase the web site the good thing about rest.

When planning thought a van at the minimum attempt to bring somebody with you that knows about general mechanics and bodywork. Preferably take anyone who has experience of Volkswagen campers. In the event that you don’t discover any person see if you can find any VW people Clubs within locality and get if someone in club will come with you, because it really helps you to have a moment opinion especially if they know about VW campers.

When planning to look at a coach try to go on a dry time. On a wet day it is extremely very easy to miss blemishes in paintwork and little corrosion bubbles. Also if underside of van are damp it could mask dilemmas such as for example leakages from braking techniques either from braking system pipelines, contacts or from braking system cylinders. These leaks is apparent as damp patches on brake drums or on to the floor under the van. Also if brake fluid or oils was dripping underneath the van it may not become as obvious if the path below are damp.

If you do not posses welding techniques i recommend that you purchase the best van you really can afford having to pay particular awareness of the bodywork. If you need to pay a garage for welding and respray jobs it could total up to a ton of cash. Usually the preliminary estimate find yourself being a starting point as it is most probably more trouble is discovered as soon as services commences. Technical dilemmas are simpler much less expensive to fix and that can sometimes be performed yourself with the aid of the correct workshop manual. Once you get stuck there are many forums where you are able to publish concerns and obtain responses from other Volkswagen lovers.

Ask owner regarding the coach if he's got any provider record, expenses for efforts done, past MOT’s or just about any other records. Usually the even more record that can be found the greater the possibility it is a van since it is an indicator the last owners need looked after it.

Items which you will discover beneficial to accept a viewing incorporate a torch, a mat to lie in, a magnet and slim cloth, smaller step ladder and a cloth or tissues to wipe oil etc.

The T4 Camper you will be viewing will be any such thing between 8 and twenty years older so you should be aware of areas to check for corrosion. Rust proofing is a lot enhanced compared to earlier in the day Splitscreen, bay-window and T25 / T3 / Vanagon models but on an automobile this years you are able so it could have some rust issues.

Just because a bus possess a nice shiny respray does not mean that it has-been restored properly and so sometimes it really is more straightforward to buy a coach withn’t become resprayed in order to see any difficulties before you buy they.

If purchasing a restored van inquire the owner if he's got photographs showing the van before and throughout the repair. People and garages restoring vans bring images to enable you to see the work was performed correcly utilizing new panels and minimal human anatomy filler. In addition in the event that van ended up being restored by a garage inquire owner when you can see any receipts to confirm exactly what was finished. In the event that seller won't have photographs and receipts you run the possibility that after a few months ownership you are going to begin to read rust bubbles coming through that good paintwork in which rust has-been patched and disguised with extra body filler. If you believe that any location has been loaded exceedingly after that an easy test is need a magnet and check if it sticks toward region. Placed a thin cloth such as for example a handkerchief involving the magnet and also the bodywork. Inquire the vendor before achieving this as he might be focused on his paintwork however if he claims no then it is quite likely he could be worried about what you might find. In the event that coach happens to be loaded it can typically become spotted by standing at each and every part of the bus going straight back somewhat and looking down the whole amount of the van. If you see ripples into the paintwork then there is a good chance there is filler below.

If possible try to see the below of a VW bus utilizing garage ramps so your van can be increased to an appropriate position. If seller cannot create these services perhaps you might have a word with a nearby garage and gives to pay for your a little cost if he'll enable you to make use of their ramps for 15 minutes approximately. Or else you will need to crawl underneath that isn’t also effortless especially if van is lowered.

As mentioned earlier in the day the rustproofing will be a lot best on VW T4’s than on older VW vans but have a good poke with a screwdriver around any suspect places. Be skeptical of any van which have freshly coated underseal since it might be hiding corrosion so check always they very carefully. Look at the framework, floors and sills. The sills would be the panels that operate horizontally over the bottom of each part. Check out the sills for rust and make certain they may not be filled with filler and painted with underseal. Occasionally patches happen welded to restore rusty areas. If any part of the internal or outer sill happens to be patch welded look at the quality of the welds also be sure the spot was welded to great material over-all.

The Volkswagen T4 Transporter is the first VW bus to truly have the system at the front end operating the front rims.

Firstly do a visual evaluation by having a good try the motor bay. Regarding VW T4 Transporter the bonnet release is inside the drivers taxi on the side wall surface just beneath the glove field. Search for oils leakages and check that most gasoline pipes come in good condition. Water level can be examined by considering markers on the clear round water top up tank over the engine. The oil level could be examined utilizing the dip stick as usual. Whenever motor was cool available water top up container and look for oils when you look at the water or a sludge deposit that looks like “mayonnaise” since this could be an indicator that the cylinder head gasket or cylinder mind need issues. Furthermore remove the oils filler limit and look the dip stick for the same sort of sludge. Observe that in the event that van has been doing many short journeys recently then there might be a tiny bit of the “mayonnaise” at the top of the oil filler throat as a result of condensation forming and mixing using oil. This might be okay providing it's just a small amount no “mayonnaise” is visible on dipstick or in water tank. It is brought on by condensation developing because of the lengthy period of the filler throat as soon as the engine is certainly not achieving full heat.

Pay attention for almost any hits coming from the system since these can be as a result of things severe such as used larger end bearings or worn crankshaft. See you to definitely sit-in the van and increase the revs regarding the motor and look that there's no black colored smoke coming from the fatigue. On a diesel you may get a puff of smoke on start yet not when run. Check the engine try running well just as if its run unevenly maybe it's operating on best 3 cylinders. If you should be uncertain carefully pull a plug lead off within spark plug end utilizing the motor working and you ought to hear the motor note change and it surely will begin running somewhat rough. Exchange that connect lead and pull associated with the next and so forth. If you pull of a plug lead as well as the engine note doesn’t change then your motor is certainly not firing thereon cylinder. There may be a number of possible known reasons for this however it will probably be an engine out task to correct.

The motors posses hydraulic tappets that can render an alarming clattering sounds if the van happens to be endured for a while. Simply because the oils empties through the tappets if the motor possessn’t already been begun for a while. Typically once the van possess run for a time the sounds should stop while the tappet fills with oil.

It is vital to be sure the van starts from cold and consistently operate efficiently without eliminating. Pay attention to the engine and also make certain it willn’t hunt whenever idling.

On diesels it is critical to check out the motor starts from cold which apart from that preliminary puff of smoke at start it cann’t consistently smoke cigarettes once run.

Check out the heat gauge functions and hits around halfway once engine is warm. If temp gauge browsing is very lower whenever motor is warm its likely a thermostat difficulties.

Obviously the greater amount of provider records information the seller gets the much better and also as with most cars in the event that you don’t have any evidence that the cam belt has been altered then it's a investments to get it finished. If the cam belt snaps it can cause bent valves and damaged pistons and cylinder head and will be very expensive to repair. It could be expensive to get the cam belt done this if it's been complete this is a significant plus point.

Whilst thinking about the cam belt pay attention away for a whirring sound coming from the left-hand region of the engine bay through the area of the devices and pulleys. Additionally go through the pulleys to test there's no wobbling. When there is a noise / wobble it might be anything simple such as the gear requires changing / tightening, water pump or something much more serious such as the additional pulley that works on the crankshaft. Its a metal / composite pulley that may perish over time and split up or the secret that keeps the base pulley regarding crankshaft becomes hurt and result in the pulley to operate loose . If it fails it will probably harm the engine in the same manner as though the cam gear snapped.