VW Transporter T4 ( Diesel - 2000-2004) Workshop Manual , livre ebook

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285 pages

English

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Easy to follow step by step instructions & advice which enables the owner to carry out many jobs himself for the Mercedes-Benz Sprinter Van & Camper Diesel. Models covered: 208 CDI, 308 CDI, 211 CDI, 311 CDI, 411 CDI, 213 CDI, 313 CDI, 413 CDI, 216 CDI, 316 CDI, 416 CDI with the 2.2 & 2.7 litre CDI Diesel (types 611 DELA & 612 DELA) From 2000 to 2006 with the commom rail injection system. A total of 232 fully illustrated pages.

Informations

Publié par	Brooklands Books
Date de parution	14 octobre 2012
Nombre de lectures	0
EAN13	9781783180219
Langue	English
Poids de l'ouvrage	11 Mo

Informations légales : prix de location à la page 0,0900€. Cette information est donnée uniquement à titre indicatif conformément à la législation en vigueur.

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VOLKSWAGEN
TRANSPORTER T4
WORKSHOP MANUAL
DIESEL MODELS 2000-2004
1.9 Litre DIESEL (ABL)
2.4 Litre DIESEL (AJA and AAB)
2.5 TDI DIESEL
(ACV, AHY, AJT, AUF, AXG, AXL, AYC)
COVERING
VAN 800, 1000, 1200 - CARAVELLE CL AND GL
BUS, LONG SHORT WHEELBASE
Copyright Brooklands Books Ltd. 2005, 2008 and Peter Russek Publications Limited
This book has been compiled from text and illustrations supplied by Peter Russek Publications Limited and have been used with their kind permission.
Text and illustrations may not be reproduced, transmitted or copied by any means without the prior written permission of Brooklands Books Limited and Peter Russek Publications Limited.
Whilst every effort is made to ensure the accuracy of the particulars in this manual, neither the Publisher nor the Distributors nor the Dealer, by whom this manual is supplied shall under any circumstances be held liable for any inaccuracy or the consequences thereof.
VW98WH
Brooklands Books Ltd.
PO Box 146, Cobham, Surrey KT11 1LG, England
Tel. 01932 865051
Fax 01932 868803
CONTENTS Introduction Chapter 1 Engine Chapter 2 Clutch Chapter 3 Transmission and Final Drive Chapter 4 Drive Shafts Chapter 5 Steering Chapter 6 Front Suspension Chapter 7 Rear Suspension and Axle Chapter 8 Wheels and Tyres Chapter 9 Brakes Chapter 10 Electrical Chapter 11 Bodywork Fault Finding Section Wiring Diagram Index
ABOUT THIS BOOK
This Owners Edition - Workshop Manual covers the the Volkswagen Transporter range from the end of 1999 (model year 2000) until the end of production and fitted with following engines: 1.9, 2.4 and 2.5 litre diesel engines. It has been specially written for the practical owner who wants to maintain a vehicle in first-class condition and carry out the bulk of his or her own servicing and repairs. Comprehensive step-by-step instructions are provided for service and overhaul operations to guide the reader through what might otherwise be unfamiliar and complicated tasks. Numerous drawings are included to amplify the text.
With the aid of this manual, many aspects of service, overhaul and repair are within the scope of an owner with a reasonable degree of mechanical aptitude. Some operations however demand more skill. Other jobs require the use of special tools and in some cases testing facilities and techniques that are not generally available. Only you can judge whether a job is within your capabilities. We do however try to assist the reader to come to an informed decision. Whilst every effort has been made to ensure that the information provided is correct, it is obviously not possible to guarantee complete freedom from errors or omissions.
Information to be found in the driver s handbook is not necessarily duplicated here and it is not possible within this volume to cover every aspect to be found in the manufacturer s own workshop manual which is of much greater size and complexity. However, it should be consulted if more detailed information is needed.
Always remember that you are responsible for your own safety and that of others when working on a vehicle. Take particular care with safety-related systems like the brakes and steering, and seek professional advice if in any doubt. Never work under a vehicle unless it is properly supported (a single jack is not enough). Take care with power tools, also regard as potentially harmful fuel, lubricants, solvents and sealers which should always be and kept in labelled, sealed containers.
With care and common sense, the practical owner can make an excellent job of maintenance and overhaul. The benefits include money saved and the satisfaction of work well done. You will be adding to your knowledge, too: knowing more about the vehicle you own will help you to make logical decisions about what needs to be done, even if it does in some instances have to go into a professional repair shop.
The Volkswagen Transporter T4 is a vehicle that will respond to careful regular servicing and is built to a standard that will ensure a long life if this is remembered.
0. Introduction 0.0. General Information 0.1. Identification 0.2. Dimensions (typical) 0.3. Capacities 0.4. General Servicing Notes 0.5. Jacking up of the Vehicle 0.0. General Information
This Manual covers the models in the Volkswagen Transporter range from the end of 1999, generally referred to as Type T4 vehicles, with a choice of three diesel engines. The following engines are covered in this manual: The 1.9 litre diesel engine is a four-cylinder engine and has the type designation ABL , replacing the engine type 1X . The engine has a performance of 50 kW at 3700 rpm. Earlier engines of the same capacity were rated at 45 kW at the same speed. There is also a 55 kW diesel engine. Either a diesel or turbo diesel engine is fitted. The 2.4 litre diesel engine is a five-cylinder engine and has now the type designation AJA , replacing the previously used AAB engine. The engine has a performance of 55 kW at 3700 rpm ( AAB engine 57 kW at 3700 rpm.) The engine is of the conventional type with indirect diesel fuel injection. From approx. August 1995 a new engine with a capacity of 2.5 litres has been fitted to T4 models, but the engine types have been changed since introduction. The engine performance is given in Section 1.0. The latest engines have the code letters AXG , AXL and AYC . All engines operate with direct fuel injection (TDI engine). A catalytic converter, exhaust gas recirculation, a turbo charger and a charge air intercooler are used in these vehicles.
The front suspension consists of an upper and lower wishbones, torsion bars and a stabiliser bar (anti-roll bar), together with double-acting, hydraulic shock absorbers. Not all models have the stabiliser bar. The individual parts of the front suspension can be removed from the vehicle without dismantling the complete assembly. All parts of the front suspension are mounted to a strong crossmember, which can be removed as a complete unit in order to remove the individual units, if major repairs are necessary.
The rear suspension consists of suspension arms with coil springs and hydraulic shock absorbers and a stabiliser (antiroll) bar. The suspension arms are rubber-mounted on the chassis. The wheel hub carrier is bolted to the outside of the suspension arm. The connection to the rear drive shafts takes place at the inside of each rear wheel hub carrier.
A rack and pinion steering, fitted with servo-assistance, is used. Disc brakes at the front wheels and rear wheels are fitted and a brake servo unit as standard fitment, make up the brake system, but not all models have the same front disc brake assemblies. Two types of Lucas calipers or Teves/ATE calipers were used during production and irrespective of the models in question will be covered in the relevant section. ABS can now be fitted to the vehicle. The vacuum for the operation of the brake servo unit is supplied by a separate exhauster pump (vacuum pump).
A five-speed manual or an automatic transmission can be fitted to the vehicles covered in this manual.
With regards to the range of models covered in the manual it must be pointed out that not all of these will be available in any particular country and that the manufacturer reserves the right to make modifications to standard equipment, optional extras and trim as may be necessary for any territory.
Since the variations between certain models are only in fittings and trim it will be unnecessary in some parts of this manual to refer to individual model designations.

Fig. 0.1. - The location of the type identification plate on the passenger side of the vehicle.

Fig. 0.2. - The location of the vehicle identification number at the bottom of the windscreen. 0.1. Identification
The type identification plate can be found near the front door pillar, close to the door striker plate, at the position shown in Fig. 0.1. The chassis number is stamped into the right-hand side, below the windscreen, and is visible from the outside of the vehicle (arrow, Fig. 0.2). The chassis number can have the following appearance:
WVW2 ZZZ 370 Z Y H 00001
which relates to the following data: The first three letters with the 2 refer to the code letters of the manufacturer. The next three letters are filler letters. The number 370 refers to the model designation. The single Z is a filler letter. The letter Y refers to the model year, in this case given for a 2000 model. After Y you will find 1 , 2 or 3 (2001, 2002, 2003), referring to subsequent model years. The H refers to the manufacturing plant in Germany. The last numbers are the actual serial number of the vehicle.

Fig. 0.3. - The location of the engine number on the 1.9 litre diesel engine.
The engine number of a 1.9 litre diesel engine is stamped into the cylinder block between the injection pump and the vacuum pump, at the position shown in Fig. 0.3. The engine code of the two five-cylinder engines can be found next to the injection pump on the left-hand side of the cylinder block, at the position shown in Fig. 0.4. The engine code and engine serial number are quoted. A sticker with the engine code and the engine number is attached to the upper timing belt cover.

Fig. 0.4. - The position of the engine number on the five-cylinder diesel engine.
These numbers are the essential information needed whenever spares or replacement parts are required. The vehicle manufacturer operates a policy of constant improvement and updating and it is only by quoting the vehicle and engine numbers that your dealer can provide you with the correct spares and replacements. The engine code is also included in the details of the vehicle data plate.
Note: If ever in the life of your T4 a replacement cylinder block is fitted, make sure that the original engine number has been transferred to the new cylinder block. This is (a) a legal requirement and (b) will avoid complications whenever you want to sell, part exchange or use the v