VW T4 workshop manual volkswagen Workshop Manuals

VW T4 workshop manual volkswagen

The Transporter T4 was shipped to the united states from 1992 until 2003 in moniker Eurovan. In america, the brief wheelbase Eurovan 5-cylinder passenger brands are only sold for design seasons 1993. VW imported the quick wheelbase Eurovan 5-cylinder gas engine passenger

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identification and interchange section tells what parts can be swapped where and specifies the best 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 here

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other VW repair manuals here Volkswagen Transporter T4 four-stroke diesel Covers Covers all T4 four-stroke diesel motor car from 2000 to the end of 2004. Models Covered: Vans - 800 1 000 and 1 200 - 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 / 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 come here

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as Westfalia camper) models sold in the USA and Canada. motors and gearboxs covered. 2.8 Liter VR6 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 details

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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 come here

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"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 Plugs and Coolant Run-On ● Dash Panel Insert Oil Pressure and Coolant Monitor Fuel Guage Glow Peter Russek Publications Limited (UK). Over 200 illustrations.Published by Brooklands Books and compiled from text and illustrations supplied by Peter Russek Publications Limited (UK). Information on Repair and Service Manuals Note that repair manuals are normally produced for models sold in a click here

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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 Contacts Wiring Diagram - Headlamps (Long Front End) Side Lights Wiring Diagram - Headlamp Range Warning Lamp and Sender Unit Wiring Diagram - Dash Panel Insert Sender Unit Continued Wiring Diagram - 1.8 liter Carburettor Engine - Automatic Choke Intake Manifold Pre Heating Over 300 illustrations. here

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Electronic Fuel Injection petrol 2.5-liter 5-cylinder type AAF Digifant Electronic Fuel Injection petrol one point nine-liter 4-cylinder type 1X four-stroke diesel 2.4-liter 5-cylinder type AAB 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. Motor Ignition System Digifant System Digifant System Connections for Self Diagnosis Digifant System Fuel Supply Lambda Control Instrument Panel Oil Pressure and Coolant Monitoring Instrument Panel Revolution CounterFuel Supply Warning Lights Instrument Panel Speed Sensor Time Clock Radio Cigar more advice

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volume contains detailed step-by-step instructions for converting a VW Transporter van or bus to a 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 on

The Transporter T4 was shipped to the united states from 1992 until 2003 in moniker Eurovan.

In america, the brief wheelbase Eurovan 5-cylinder passenger brands are only sold for design seasons 1993. Smaller compared to a standard American distribution van, but larger than an United states or Japanese passenger minivan, Volkswagen played up their dimensions using the slogan, "EuroVan: you'll find nothing mini about it". VW just brought in them into US for starters season because product sales in the US were unsatisfactory, but sales carried on in Canada and Mexico. VW reintroduced the Eurovan passenger designs in the US for model seasons 1999 with a VR6 engine as standard, and discontinued it once again with globally T4s after 2003. The manual transmission was not offered in united states because of the VR6 engine.

VW imported the quick wheelbase Eurovan 5-cylinder gas engine passenger models to Canada from 1991 to 1996. The 77 hp 2,4L diesel system is optional in Canada between 1993 to 1996. The long wheelbase variation was also available in 1992 best as a 10 seaters CL or GL design trim. Combi and crewcab pick-up models had been furthermore obtainable in 1992. A panel version had been marketed from 1993 to 1997.

The Eurovan Camper by Winnebago was introduced in the usa and Canada in 1995 using the five-cylinder system, and had been enhanced into VR6 for the 1997-2003 designs. These were only available on the longer 3,320 mm wheelbase T4. These tiny pop music top camper vans tend to be unique in North America and also have created a cult after.

Winnebago furthermore built three tiny lessons C motorhomes using the forward taxi associated with the T4/Eurovan known as the Rialta, Vista, and Sunstar. The Rialta ended up being obtainable in 1995-1996 with all the five-cylinder engine, in 1997-2001 aided by the AES form of the VR6, plus in 2002-2005 because of the AXK engine. The Vista and Sunstar were best produced in 2002-2004, all making use of the AXK engine.

Into the U.S., the brands were:

the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, when the second row of chairs face the rear and they are detachable, the next row converts into a sleep, a folding dining table when you look at the traveler region, window curtains, and a fluorescent lamp above dining table.
the Eurovan MV Weekender, an MV plus a Westfalia conversion that adds a pop-top roofing, a second expense sleep, bug displays for side windows and rear hatch, full set of curtains, auxiliary battery pack, fluorescent inside lights and under chair thermoelectric cooler.
the Eurovan Camper, which is the lengthy wheelbase commercial van converted by Winnebago companies to include a pop-top roof, two two-person bedrooms, sitting for four, a single cubic foot refrigerator that operates on propane, DC, or AC, a propane furnace, a wardrobe, cabinets, sink with cold water and a grey liquids container, a two-burner propane stove, two two-person dinette tables, coach battery, household lighting effects, and two front bucket chairs made to swivel around to manage the dinette/kitchen room. The 2000 EVC was 17 foot very long
Introduced in 1990, the T4 was the initial Volkswagen van to possess a front-mounted, water-cooled engine. Prompted by the success of similar moves using their passenger vehicles, Volkswagen have toyed in belated 1970s utilizing the concept of replacing their air-cooled, rear-engined T2 vans with a front-engined, water-cooled build. The reasons for determining in 1980 to rather establish an innovative new rear-engined T3 were unclear. Therefore, the development of a front-engined layout had been delayed through to the arrival associated with the T4. After a run of almost 14 years, T4 manufacturing stopped in 2003, which makes it second only to the T1 for length of production with its market.
LWB short-nosed Panel Van
SWB short-nosed Kombi van
SWB long-nosed Multivan
LWB short-nosed Dual cab Pickup

Area of the popularity of the T4 ended up being its flexibility. It absolutely was available in numerous kinds and sizes as standard and created the foundation of several specialist cars, from buses to campervans to ambulances.

Two standard wheelbases had been available; "brief" and "long".
Human anatomy sort

Panel Van - without any windows behind the b-pillar; single row of chairs
Kombi or Half-Panel - with additional microsoft windows amongst the b and c-pillars; 2 rows of seats
Caravelle or Multivan - with microsoft windows at all times; 3 rows of chairs


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


Panel vans had been offered with two different roofing levels; standard and high-top. High-tops were just made regarding the LWB framework, although campervan sales often have pop-top or high-tops put into both SWB and LWB framework.

Vans need both an individual, roof-hinged "tailgate" or two "barn" doors at back and often an individual or twin sliding doors.
Long and short-nose

There is one significant renovation towards the T4, in 1996, when a re-shaped, longer front end ended up being launched. It was necessary to compliment the six-cylinder VR6 motor in to the T4's motor bay. In the beginning, just Caravelles and Multivans are available using longer nostrils, because these were the only designs available using VR6 motor.

The commercial alternatives always been produced with all the smaller nostrils until 1999. But campers and other professional motors created between 1994 and 1999 could have often the brief and/or longer nostrils, depending on which model was used because the base car. In keeping with the sort 2's naming convention, the brief and long-nose models may also be informally generally T4a and T4b, respectively.
Four-wheel Drive

The T4 has also been readily available with a permanent 4WD program that utilizes a Viscous coupling product as a center differential to regulate the distribution of torque into back axle. These models are called "syncro" and had been readily available with the 2.4D, 2.5Tdi and 2.5 petrol motors on all body kinds and both wheelbases. Some syncro versions have a mechanically securing back differential. Because the backside differential precludes the keeping the spare wheel in usual put under the human body, syncro vans either shop they within the system or on an external, hinged bracket.

The T4 is an extremely popular base for design a small to medium sized camper and day-vans, both as self-build works and professional conversions. Volkswagen by themselves furthermore marketed campervan versions regarding the T4, produced by and named after their particular specialist, Westfalia-Werke.
Petrol machines
Model Engine ID code system configuration Engine 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 engines

Indirect shot

Design motor ID code Engine configuration motor displacement DIN rated motive energy @ rpm Torque @ rpm ages
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 Injection

Model motor ID code motor setup Engine displacement DIN rated motive power @ 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
Fans' teams

Due largely to their versatility, also popularity as a campervan, the Volkswagen Transporter has actually a thorough appropriate among fans. Group meetings take place frequently throughout every season in countries across European countries and there are numerous websites forums aimed at T4 owners and fans.

In May 2010, the German fans of the T4 held a party of the twentieth anniversary of the creation of the first T4. A few hundred T4s took part with vans from as far afield as Russia, France, Spain, central European countries and also the Nordic countries.

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