1. Vw T4 Transporter

VW OWNERS EDITION VOLKSWAGEN TRANSPORTER T4 WORKSHOP MANUAL (Powered by 1.9, 2.4 & 2.5 TDIdiesel engines) Diesel models - years 2000-2004 COVERING VAN 800, 1000, 1200- CARAVELLE CL AND GL BUS, LONG & SHORT WHEELBASE. VW OWNERS EDITION VOLKSWAGEN TRANSPORTER T4 WORKSHOP MANUAL (Powered by 1.9, 2.4 & 2.5 TDIdiesel engines) Diesel models - years 2000-2004 COVERING VAN 800, 1000, 1200- CARAVELLE CL AND GL.

Vw T4 Transporter

• 2

  List of Workshop Manual Repair Groups
• 3

  Contents
• 5

  Electrical Check
• 5

  Checking of Wiring and Components With Test Box Y.A.G 1598
• 5

  Idling Speed Stabilisation (2E4 Carburetor)
• 6

  Test Table
• 7

  Air Cleaner and Vacuum Connections
• 7

  34 PICT Carburetor
• 8

  2E3 and 2E4 Carburetor
• 9

  Checking Intake Air Preheating
• 9

  Checking Control Box/vacuum Unit
• 9

  Checking Temperature Regulator
• 10

  Removing and Installing Carburetor and Intake Manifold
• 12

  Removing and Installing 34 PICT Carburetor
• 12

  Checking Intake Manifold Preheater
• 12

  Removing and Installing Intake Manifold Preheater
• 13

  Servicing 34 PICT Carburetor
• 14

  Top Part of Carburetor
• 15

  Bottom Part of Carburetor
• 16

  Carburetor Adjustment Data
• 17

  Jets and Settings
• 17

  Adjusting Idling Speed
• 17

  Checking and Adjustment Conditions
• 17

  Checking and Adjusting Idling Speed and CO Content
• 18

  Test Specification
• 18

  Setting
• 19

  Checking and Adjusting Amount Injected By Accelerator Pump
• 19

  Adjusting Choke Waive Gap
• 19

  Checking and Adjusting Cold Idle Speed
• 20

  Checking and Adjusting Throttle Damper and Delay Valve
• 20

  Servicing 2E3 and 2E4 Carburetor
• 23

  Servicing Components of Idling Speed Stabilisation System
• 27

  Jets at Top in Top Part of Carburetor
• 27

  Jets at Bottom in Top Part of Carburetor
• 28

  Installing Injection Tube
• 28

  Adjusting Choke Cover
• 28

  Fuel Reservoir
• 29

  Adjusting Idle Speed
• 29

  Checking and Adjusting Idle Speed and CO Content
• 30

  2E4 Carburetor Only
• 31

  2E3 Carburetor
• 31

  2E4 Carburetor
• 32

  Checking and Adjusting Pull-down Unit
• 32

  Checking Operation
• 32

  Checking Pull-down Unit for Leaks
• 32

  Checking and Adjusting Choke Valve Gap
• 33

  Checking Operation of Throttle Valve, Stage II
• 33

  Checking Vacuum Unit for Leaks
• 33

  Checking Operation of Vacuum Unit
• 33

  Checking Vacuum for Vacuum Unit, Stage II
• 34

  Checking and Adjusting Accelerator Pump Injection Rate
• 35

  Checking Part-load Duct Heating
• 35

  Basic Adjustment of Throttle Valve, Stage II
• 36

  Basic Adjustment of Throttle Valve, Stage I (2E4 Carburetor Only)
• 37

  Checking Throttle Valve Positioner (2E4 Carburetor Only)
• 39

  Repairing TCI-H Ignition System
• 42

  Safety Precautions for TCI-H Ignition System
• 42

  Adjustment Data
• 43

  Spark Plugs
• 43

  Ignition Timing Mark
• 43

  Distributor Data
• 44

  Removing and Installing Distributor Drive Shaft
• 45

  Removing and Installing Rotor Plate
• 45

  Checking and Adjusting Ignition Timing
• 45

  Engine Code Letters DF
• 46

  Engine Code Letters DG, SP
• 46

  Checking Distributor
• 46

  Checking Centrifugal Advance With TDC Sender
• 47

  Checking Centrifugal Advance With Stroboscopic Lamp
• 48

  Checking Vacuum Advance Angle
• 48

  Checking With TDC Sender
• 49

  Checking With Stroboscopic Lamp
• 49

  Checking Vacuum Retard Angle
• 50

  Checking TCI-H Ignition System
• 50

  Checking With TCI Tester V.A.G 1451
• 50

  Checking With Digital Multimeter V.A.G 1315 A/ Hand Multimeter V.A.G 1526 and Auxiliary Cables From V.A.G 1594
• 50

  Checking TCI-H Switch Unit
• 52

  Checking Hall Sender
• 52

  Checking DIS Switch Unit (Engine Code Letters DF)
• 53

  Repairing Breaker-triggered Ignition System
• 55

  Adjustment Data
• 57

  Installing Distributor
• 58

  Adjusting Ignition Timing
• 58

  With TDC Sender
• 58

  With Stroboscopic Lamp

• 3

  Index
• 4

  Instrument Panel
• 6

  Operation
• 6

  Keys
• 7

  Central Locking System
• 8

  Cab Doors
• 8

  Sliding Doors
• 8

  Child-proof Catch On Sliding Door
• 9

  Tailgage
• 9

  Engine Compartment Cover
• 10

  Windows
• 10

  Vent Wings
• 10

  Sliding Windows
• 10

  Door Windows
• 11

  Mirrors
• 11

  Normal Exterior Mirror
• 11

  Electrically Adjustable Mirrors
• 11

  Anti-dazzle Interior Mirror
• 12

  Seat Belts
• 12

  Safety for Children
• 13

  Belt Height Adjustment
• 13

  Three-point Inertia Reel Belts
• 13

  Putting Belt On
• 13

  Taking Belt Off
• 14

  Head Restraints/Adjusting Height/Removing and Installing
• 14

  Lap Belt
• 14

  Two-point Inertia Reel Belts
• 15

  Seats in Cab
• 15

  Individual Driver's and Front Passenger Seats
• 15

  To Move Seats Back or Forward/adjust Backrest Rake/Armrest
• 15

  To Take Seat Out
• 16

  Seats in Passenger Compartment
• 16

  Removing and Installing Centre Bench Seat/Head Restraints
• 16

  Swiveling Seats/Seat Heating
• 16

  Two Seater Bench/To Remove
• 17

  Individual Seats in Passenger Compartment
• 17

  Cenre Seats/Turning
• 17

  Adjusting Backrest Angle
• 17

  Removing
• 18

  Rear Seats
• 18

  Mechanical Adjustment
• 18

  Adjusting Seat Angle/hight
• 18

  To Adjust Backrest Angle
• 19

  Electrical Adjustment
• 19

  Adjusting Seat Angle/seat Height/backrest Angle
• 20

  Rear Seat/Fully Reclining Seat Bench
• 20

  To Convert Reclining Seat Bench
• 20

  Returning Seat Bench to Original Position
• 21

  Luggage Compartment/Load Surface
• 21

  Roof Rack
• 21

  To Enlarge Luggage Space
• 22

  Cover
• 22

  Dropsides
• 22

  Handbrake
• 23

  Manual Gearbox
• 23

  4 Speed Gearbox/Engaging Reverse
• 23

  5 Speed Gearbox/To Engage 1St Gear/reverse Gear
• 23

  4+G Gearbox (4 WD Vehicles)/Engaging Crawler Gear
• 24

  Differential Locks
• 24

  Limited Slip Differential (Rear Wheel Drive)
• 24

  Driving Tips
• 24

  Gear Oil
• 25

  Selectable Differential Locks
• 25

  Engaging the Differential Locks
• 27

  Selectable Four-wheel Drive
• 28

  Automatic Gearbox
• 28

  Selector Lever Positions
• 28

  Kick-down Device
• 29

  Notes On Driving
• 29

  Starting/Stopping
• 29

  Parking
• 29

  Emergency Starting/Towing
• 30

  Steering Lock/Ignition Switch
• 31

  Starting the Engine
• 31

  Starting 44 and 57 KW Carburetor Engines
• 31

  Starting a Cold/warm/hot Engine
• 32

  Fuel Injection Engines
• 32

  Diesel Engines
• 32

  Glow Plugs
• 33

  Stopping Engine
• 34

  Warning Lamps
• 34

  Engine Oil Pressure Warning Lamp
• 34

  Generator Warning Lamp
• 35

  Coolant Temperature/level Warning Lamp
• 35

  Glow Plugs Warning Lamp
• 35

  Turn Signals Lamp/High Beams Lamp
• 35

  Brake System/Differential Locks/selectable Four Wheel Drive Warning Lamps
• 36

  Instruments
• 36

  Speedometer
• 36

  Rev Counter
• 36

  Clock
• 37

  Coolant Temperature Gauge
• 37

  Fuel Gauge
• 38

  Switches
• 38

  Lighting Switch/Emergency Lights
• 38

  Heated Rear Window
• 38

  For Lights/rear Fog Light
• 39

  Knurled Disc for Seat Heating
• 40

  Turn Signal and Dip Lever
• 40

  To Signal a Lane Change
• 40

  To Dip Headlight
• 40

  Headlight Flasher/Parking Lights
• 41

  Windscreen Wiper and Washer System
• 41

  Headlight Washer System
• 42

  Heating and Ventilation
• 42

  Air Vents
• 43

  Heating Interior Normally
• 43

  Defrosting/demisting Windscreen and Side Windows
• 43

  Heating Interior As Quickly As Possible
• 44

  Additional Heat Exchange for the Passenger Compartment
• 45

  Auxiliary Air Heater
• 45

  Heating With Engine nor Running
• 46

  Heating When Driving
• 46

  Heating System Maintenance
• 48

  Auxiliary Water Heater
• 49

  Setting the Auxiliary Water Heater Time
• 49

  To Switch Heater On or Off
• 49

  Preselecting Starting Time for Heater
• 49

  Switching Preselected Time Off
• 50

  Sliding Roof
• 50

  Sun Roof
• 51

  Interior Lights
• 51

  Step Illumination/Table Light
• 51

  Reading Lamps
• 51

  Interior Light in Front of Passenger Seat/Boot Lights
• 52

  Sun Visors
• 52

  Illuminated Make-up Mirror
• 53

  Ashtrays
• 53

  Cigarette Lighter/socket
• 53

  Glove Box
• 54

  Curtains
• 54

  Extending Table
• 55

  The First 1500 Km - and Afterwards
• 55

  From 1000 - 1500 Km
• 55

  After the Running-in Period
• 56

  Driving Safety
• 57

  Driving Economically and Environment-conscious
• 59

  Trailer Towing
• 60

  Driving a Four-wheel Drive Vehicle
• 61

  Advantages of Four-wheel Drive
• 62

  Driving On Dry/wet, Slippery Roads
• 63

  Driving Cross Country
• 64

  Note for Vehicle With Differential Locks
• 64

  Output Testing
• 64

  Brake Test Stand
• 65

  Operating Instructions
• 65

  Fuel
• 65

  Petrol Engines
• 65

  Vehicles Without/with Catalyst
• 66

  Fuel Additives
• 66

  Diesel Engines/Diesel Fuel to DIN 51601 CN Not Lower Than 45
• 67

  Filling Tank
• 67

  Note for Vehicles With Diesel Engine
• 67

  Bleeding the Fuel System
• 67

  Note for Vehicles With Factory Fitted Catalyst
• 68

  What to Do When Wrong Fuel Has Been Put Into Tank
• 69

  Lubricants
• 70

  Engine Oil
• 70

  Checking Oil Level
• 70

  Topping Up/changing Engine Oil
• 71

  Gearbox Oil
• 71

  Checking Oil Level/Changing Oil
• 72

  Power Assisted Steering
• 73

  Cooling System
• 73

  Checking Coolant Level
• 74

  Coolant Losses
• 74

  Topping Up Coolant
• 75

  Fan
• 75

  Driving in Winter
• 76

  Windscreen Washer System
• 76

  To Fill Container
• 76

  Adjusting Washer Jets
• 77

  Brake System
• 77

  Brake Servo
• 78

  Brake Fluid Reservoir
• 78

  Checking Fluid Level
• 78

  Brake Fluid
• 79

  Pedals
• 80

  Battery
• 80

  Checking Acid Level
• 80

  Winter Driving
• 81

  Wheels
• 81

  New Tyres
• 82

  Tyre Wear
• 82

  Inflation Pressure
• 82

  Incorrect Wheel Alignment
• 82

  Wear Indicators
• 83

  Changing Wheels Round
• 83

  Replacing Tyres
• 83

  Balancing Wheels
• 84

  Winter Tyres
• 84

  Snow Chains
• 86

  Difficult Operating Conditions, Driving Abroad
• 87

  Care and Maintenance
• 87

  Washing
• 87

  Waxing
• 87

  Polishing
• 88

  Touching Up Paint Damage
• 88

  Cleaning Windows
• 88

  Door, Lid and Window Weatherstrips
• 88

  Cleaning Plastic/Cleaning Cloth Upholstery
• 89

  Care of Chromed Parts
• 89

  Cleaning Seat Belts
• 89

  Alloy Wheels
• 90

  Cleaning and Anti-corrosion Treatment of Engine Compartment
• 90

  Undercoating
• 90

  Cavity Preservation
• 90

  Not for Vehicles With a Catalyst
• 91

  Maintenance
• 92

  Lifting Vehicle
• 92

  Vehicle Hoist
• 92

  Trolley Jack/Vehicle Jack
• 92

  Lifting Points for Hoist and Trolley Jack
• 93

  Do-it-yourself
• 93

  First Aid Kit, Warning Triangle
• 93

  Tools, Jack
• 94

  Spare Wheel
• 95

  Changing Wheels
• 96

  Fuses/Changing a Fuse
• 97

  Fuse Layout
• 98

  Changing Bulbs
• 98

  To Change a Headlight Bulb
• 99

  To Change a Side Light Bulb
• 100

  To Change Headlight Bulb (H3)/fog Lights (H3)/rear Lights/front Turn Signals
• 101

  To Change Number Plate Light
• 101

  To Change Reading Lamps
• 101

  Interior/table Light
• 101

  Interior Light in Front of Passenger Seat, Step Light, Boot Lighs
• 102

  Adjusting/masking Headlights
• 103

  Installing of Replacing a Radio Set
• 104

  Emergency Starting
• 105

  Towing
• 106

  Technical Description
• 106

  Petrol Engines/diesel Engines Features
• 106

  Power Transmission/Manual/automatic Gearbox
• 106

  Transporter/Caravelle Syncro
• 107

  Steering/Axles Info
• 107

  Brakes Info
• 107

  Body Info
• 108

  Emission Control System
• 109

  Vehicle With 'Emission Control Package'
• 109

  Vehicles Without Emission Control System
• 110

  Technical Data
• 110

  Engine Data
• 112

  Fuel Consumption
• 115

  Performance Data
• 115

  Maximum Speed
• 116

  Hill Climbing Ability
• 117

  Spark Plugs Data
• 117

  Vee Belts Data
• 118

  Wheels Data
• 118

  Tyre Pressures
• 119

  Weights (Kg)
• 121

  Weights (Four Wheel Drive)
• 122

  Trailer Weights
• 123

  Dimensions
• 125

  Capacities
• 126

  Identification Data
• 126

  Identification Plate
• 126

  Chassis Number
• 126

  The Vehicle Data Sticker
• 127

  Engine Number
• 128

  Alphabetical Index