Volkswagen Transporter repair manual

Introduced in 1990, the T4 ended up being initial in a distinct Volkswagen Transporters having a front-mounted, water-cooled motor. Prompted because of the success of similar techniques with their passenger cars, Volkswagen have toyed in belated 1970s with all the concept of replacing their particular air-cooled, rear-engined kind 2 vans with a front-engined, water-cooled design. The causes for deciding in 1980 to rather establish a unique rear-engined Type 2/Vanagon are ambiguous. Hence, the development of a front-engined layout is delayed through to the arrival of T4

After a manufacturing run of almost 14 ages, T4 manufacturing stopped in 2003, which makes it second only to the T1 for amount of manufacturing in its real estate market.
The T4 had been manufactured in five basic human body kinds: Panel Van, Kombi Van or Half-Panel, Multivan, Westfalia and often an individual or double taxi — with a pick-up design platform behind it.

These people were two standard wheelbases available; "brief" and "long" and many different different roofing heights, including a pop-top roofing for campers.
Long and short-nose

There was clearly one major facelift to the T4, in 1996, when a re-shaped, longer front end was introduced. This is necessary to fit the six-cylinder VR6 engine to the T4's system bay. At first, just Caravelles and Multivans were available aided by the extended nostrils, as these are the actual only real products readily available using the VR6 engine.

The commercial variants stayed created using smaller nostrils until 1999. However, campers along with other professional automobiles created between 1994 and 1999 could have often the brief and/or longer nose, dependent on which model had been put because the base automobile. In keeping with the kind 2's naming meeting, the quick and long-nose variations may also be informally known as T4a and T4b, correspondingly.
The Transporter T4 was exported to united states from 1992 until 2003 under the moniker Eurovan. In the US, the brief wheelbase Eurovan 5-cylinder traveler systems had been just marketed for design seasons 1993. Smaller compared to a typical United states shipping van, but bigger than an American or Japanese traveler minivan, Volkswagen played up its dimensions using slogan, "EuroVan: There's nothing mini about any of it". VW best brought in them towards the US for starters seasons because selling in america had been disappointing, but sales carried on in Canada and Mexico. VW imported the brief wheelbase Eurovan 5-cylinder fuel system traveler models to Canada from 1991 to 1996. The 77 hp 2,4L diesel system ended up being optional in Canada between 1993 to 1996. The longer wheelbase variation has also been available in 1992 just as a 10 seaters CL or GL design trim. Combi and crewcab pick-up models were furthermore available in 1992. A panel variation was offered from 1993 to 1997. VW reintroduced the Eurovan traveler products in the usa for model seasons 1999 with a VR6 engine as standard, and stopped it again with global T4s after 2003. The handbook transmission had not been available in the united states utilizing the VR6 system.

The Eurovan Camper by Winnebago was introduced in the US and Canada in 1995 using five-cylinder system, and is upgraded to the VR6 for 1997-2003 models. These were just on the extended 3,320 mm wheelbase T4. These small pop top camper vans tend to be unique in the united states and have developed a cult following.

Winnebago additionally built three tiny course C motorhomes utilizing the forward taxi of this T4/Eurovan called the Rialta, Vista, and Sunstar. The Rialta had been available in 1995-1996 aided by the five-cylinder system, in 1997-2001 with the AES type of the VR6, and in 2002-2005 because of the AXK motor. The Vista and Sunstar had been only produced in 2002-2004, all utilising the AXK system.

Into the U.S., the models were:

the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, when the second row of seating face the trunk and detachable, the next line converts into a sleep, a foldable table when you look at the passenger area, window treatments, and a fluorescent lamp above dining table.
the Eurovan MV Weekender, an MV plus a Westfalia conversion that adds a pop-top roofing, an extra overhead bed, bug screens for negative microsoft windows and rear hatch, full set of curtains, auxiliary battery pack, fluorescent internal lighting and under seat thermoelectric cooler.
the Eurovan Camper, which is the long wheelbase commercial van converted by Winnebago companies to include a pop-top roofing, two two-person beds, seating for four, a one cubic leg refrigerator that works on propane, DC, or AC, a propane furnace, a dresser, cupboards, sink with chilled water and a grey liquids container, a two-burner propane kitchen stove, two two-person dinette tables, coach battery pack, home lighting, and the two forward container seats built to swivel around to handle the dinette/kitchen location. The 2000 EVC try 17 ft very long

Design system ID code system configuration system displacement DIN ranked motive power @ rpm Torque @ rpm many 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 system ID code motor setup Engine 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 Shot

Design system ID rule Engine setup motor displacement DIN rated motive energy @ rpm Torque @ rpm Compression Ratio many 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 1998–2003

The Volkswagen kind 2 is the third generation regarding the Volkswagen Transporter and was advertised under different nameplates global – including because the Transporter or Caravelle in European countries, Microbus in South Africa, and as the Vanagon in North and south usa.

Larger and thicker than their predecessor, the T2, – in accordance with a far more squared and less curved styling – the T3 ended up being manufactured in Germany from 1979 until 1990. Creation of the 2WD proceeded until 1992 at Puch in Graz/Austria, where all 4WDs was indeed built. South African production of the T3 continuing, for that marketplace best, until 2002. The T3 had been the last generation of rear-engined Volkswagens
Following T2, the T2/3 - Transporter 2 Generation 3 - in the beginning featured air-cooled and afterwards water-cooled engines. Versions stated in Southern Africa from 1990 until 2002 showcased an Audi five-cylinder system.

Volkswagen sold the Westfalia camper variation throughout the T3 manufacturing, with features like a pop-up roof, ice box, sink, and stove.

Examples built between 1980 and 1985 showcased circular headlights and chrome-plated steel bumpers with plastic end-caps. Air-cooled brands lack the low barbecue grill above the radiator for the water-cooled models, except on versions with factory air conditioning. 1986 model year automobiles obtained changes like a tachometer, even more textile alternatives, redesigned air conditioning equipment, bigger water-cooled engine with a more higher level engine administration system, and redesigned transmissions like an optional syncro four-wheel drive. Exterior modifications feature rectangular headlights and various paint options. Alloy rims, larger and squarer synthetic bumpers with trim along the rocker panels had been recommended, and standard gear on Wolfsburg version vans. For 1990 and 1991 design many years, a "Carat" trim levels is available which included all available options.

All 1980 and some 1981 versions have eight welded-in metal slats within the engine air flow passages behind the rear microsoft windows. Later brands had black colored vinyl 16-slat covers that slotted in towards the top and screwed down in the bottom.

During the 1980s, the U.S. Army and environment energy in Germany utilized T3's as administrative vehicles. In military use, the vehicle's nomenclature is "lighter Truck, Commercial".

Porsche has created a version labeled as B32 in a limited edition. The van, on the basis of the luxurious Carat design, had been built with the 231 PS 3.2 liter Carrera system and ended up being originally developed to aid Porsche's testing tasks in Algeria. Ten of those are built, with offered by Porsche to unique customers. Porsche themselves also utilized the Porsche-engined bus to move team rapidly. Top speeds was around 135 miles per hour, although Porsche just advertised 116 mph to ensure that the data could possibly be replicated with nine men and women within the car along with the ac on full blast.

Oettinger has developed a six-cylinder version labeled as WBX6. The system is derived from the "Wasserboxer" motor and it has many common section along with it. The introduction of the system is initially developed to Oettinger by VW. Oettinger purchased the legal rights whenever VW do not make use of it.

Due to the system location, a T3 have almost equal 50/50 weight circulation fore-and-aft. The first air-cooled motors were significantly high priced to create along with some dependability issues; Volkswagen originally designed to exchange these with the Golf's inline-four system but the cost of reengineering both vehicle and motor made them choose updating the flat-four rather. An overhead-cam build had been mooted but declined as willingness to rev had been considered to be of less importance than low-end flexibility and low priced. The newest 1.9 "Wasserboxer" has also been initially considered for use in a few other Volkswagens such as the Gol, which nevertheless relied on old air-cooled flat-four during those times.

The U.S version 1.9 liter 1984 and perchance the 1985 water-cooled gasoline engines skilled big and repeated issues with mind gasket deterioration and troubles. Subsequent 2.1 liter machines were apparently redesigned to markedly lessen premature head gasket troubles.
Petrol/gasoline

There have been four general petrol motor variants between 1979 and 1991, with several sub-models. All were overhead-valve push-rod horizontally opposed four-cylinder engines. Offered system alternatives differed between regions. Aftermarket VW specialist Oettinger additionally offered the WBX6, a six-cylinder version.

Air-cooled
1.6 L air-cooled, solitary Solex 34 PICT-4 carburettor
2.0 L air-cooled, twin Solex 34 PDSIT-2/3 carburettor or gas injected flat-four within the 1980 to 1983½ brands
Water-cooled
1.9 litre motors:
1.9 L water-cooled system utilized for the 1983½ to 1985 designs, that used a gasoline injections program referred to as "Digijet"
1.9 L 8.6:1 compression ratio, 34-PICT carburetor
1.9 L 8.6:1 compression proportion, 2E3 or 2E4 carburetor
1.9 L 7.5:1 compression proportion, 34-PICT carburetor
1.9 L 8.6:1 compression ratio, Bosch Digijet electronic gas injections
2.1 Litre motors:
2.1 L Wasserboxer, put before the end of Vanagon importation into the people in 1991. This system put an even more advanced motor management system referred to as Bosch "Digifant we" which now digitally managed ignition timing in addition to fuel shipping.
2.1 L 9:1 compression proportion Wasserboxer
2.1 L 10:1 compression ratio, Digijet shot, just sold in europe not calling for catalytic converter.

The Wasserboxer showcased an aluminum situation, cylinder minds, and pistons, and a forged steel crankshaft. The Wasserboxer, as with every VW boxer machines has a gear-driven valvetrain. In addition it featured Heron, or "bowl-in-piston" type combustion chambers where in actuality the burning takes place inside the piston area, and never inside cylinder mind.

The change to water-cooling when it comes to boxer motors had been made mid-year in 1983. The earlier generation T2, at this time produced in Brazil, has been switched to water-cooled motors since 2005.

Oettinger WBX6
3.2 L VW-Oettinger Wasserboxer, gas inserted.
3.7 L VW-Oettinger Wasserboxer, fuel inserted.

The six-cylinder engine as found in the VW Oettinger WBX6 was created by VW along with Oettinger for usage into the T3. When VW abandoned the task Oettinger took the style, refined they and put it available on the market. As a result the six-cylinder shares numerous areas utilizing the four-cylinder Wasserboxer.
Diesel machines

In contrast to the conventional flat-four gasoline machines, all diesel system choices had been of an inline setup.

1.6 L commonly aspirated Diesel I4, available in the usa on 1982 models just.
1.6 L Turbocharged I4.
1.7 L Natural aspirated I4.

Creation of the T3 continuing in South Africa until Summer 2002, whenever, as a result of economies of scale, Volkswagen SA are obliged to cease manufacturing after components provide started initially to come to be a problem. The South African T3s article 1991 have a face-lift including changed front door sheet steel, bigger part house windows behind the B pillars and various backside grilles within the D pillars. The bodyshell are a genuine RHD build lacking the unused door track address regarding the offside and LHD wiper arm mount points as found on previous systems. On versions with 5-cylinder engines the boot floor grew up to accommodate the bigger engine and has smaller space places either region of the engine hatch. Inner changes add a completely padded dashboard featuring an inferior glove package and up-to-date vacuum-powered air flow settings operated by circular knobs in the place of slide levers, the fuse field was also relocated to the right hand region of the steering line. At the front end of the vehicle twin-headlamps in both circular and rectangular configurations were installed with the full width lower grille including the signal contacts, of altered from amber to smoked contacts from 1999 onwards, this grille and headlight fusion wasn't receive any place else on the planet. These later on South African T3s became referred to as gigantic Window T3s because of their larger part microsoft windows.

The 2.1 Wasserboxer motors are replaced with five-cylinder Audi motors within the "Microbus" and "Caravelle", while a VW 1.8 inline-four cylinder system was utilized in the "Kombi" and "Van" systems. The 5-cylinder T3's arrived on the scene initially with a 2.5 litre gas injected engine in 1991, but it was changed in 1995 with a 2.6 litre with an improved gas injection program, 5-speed transmission and two types of 15" alloy tires as standard along side bigger ventilated front disc brake system. A slightly lower spec 2.3 five cylinder fuel-injected model had been introduced together with the 2.6 but is loaded with a 4-speed transmission and customized wrap-around metal bumpers. Near the end of manufacturing, a premier of this range Caravelle 2.6i known as the "Exclusiv" included two rear facing seating in place of the centre bench chair, a fridge and a folding dining table in the rear of the vehicle and Carat 2 alloy rims. A Microbus 2.6i with close properties, however with Rhein alloy wheels had been referred to as "Activ". The past T3 from the production range in Uitenhage on Friday Summer 16, 2002 is a gold-coloured Microbus 2.6i which Volkswagen SA retained because of their AutoPavilion, Place of vehicles and Legends, which initially exposed its doorways in 2004. Regrettably this car had been later on written down in a transporter roll-over crash in November 2006, after returning from a display in Cape city. The Volkswagen Camper "Type 2" ended production in December 2013. After 64 years of production, the "Type 2" Camper can't create latest safety properties such atmosphere bags.