Car engine repair VW Transporter T4
Engine design
5-cylinder petrol engine 1. Idle speed control valve; 2. Intake manifold; 3. Dipstick tube for checking the oil level; 4. Exhaust manifold; 5. Oil radiator; 6. Oil filter 7. Oil...
5-cylinder petrol engine 1. Idle speed control valve; 2. Intake manifold; 3. Dipstick tube for checking the oil level; 4. Exhaust manifold; 5. Oil radiator; 6. Oil filter 7. Oil...
General engine data
Engines on VW T4 minibuses The VW T4 has a transverse engine layout in the engine compartment. Engines are installed 4- and 5-cylinder, both petrol and diesel. The engines are...
Engines on VW T4 minibuses The VW T4 has a transverse engine layout in the engine compartment. Engines are installed 4- and 5-cylinder, both petrol and diesel. The engines are...
Removal and installation the engine
4-cylinder petrol engine The engine is removed downwards without the gearbox. An engine jack or factory car jack is required to remove the engine. To install the machine on...
4-cylinder petrol engine The engine is removed downwards without the gearbox. An engine jack or factory car jack is required to remove the engine. To install the machine on...
Removal the radiator
1. Unscrew the 4 mounting screws (indicated by arrows) on top of the radiator. 2. Pull the radiator by the locking handle (in the middle) first up, then forward. 3. If access to...
1. Unscrew the 4 mounting screws (indicated by arrows) on top of the radiator. 2. Pull the radiator by the locking handle (in the middle) first up, then forward. 3. If access to...
Removal and installation the engine mudguard
Removal 1. Place the machine on supports. 2. Unscrew the combination, hex bolts and hex nuts (indicated by arrows). 3. Release the locking lever. 4. Fold the mudguard down and...
Removal 1. Place the machine on supports. 2. Unscrew the combination, hex bolts and hex nuts (indicated by arrows). 3. Release the locking lever. 4. Fold the mudguard down and...
Toothed belt — design description
V-belt drive and toothed belt drive of a 4-cylinder gasoline engine 1. Bolt, 10 Nm; 2. Lower timing belt cover; 3. Bolt, 20 Nm; 4. Upper timing belt cover; 5. Remote part; 6....
V-belt drive and toothed belt drive of a 4-cylinder gasoline engine 1. Bolt, 10 Nm; 2. Lower timing belt cover; 3. Bolt, 20 Nm; 4. Upper timing belt cover; 5. Remote part; 6....
Timing Belt Adjustment (4-Cylinder Petrol)
Adjusting the timing belt tension Weakening 1. Remove the upper timing belt cover. 2. Install a nut tool, such as HA2ET 2587, on the tension roller. 3. Loosen the tension roller...
Adjusting the timing belt tension Weakening 1. Remove the upper timing belt cover. 2. Install a nut tool, such as HA2ET 2587, on the tension roller. 3. Loosen the tension roller...
Timing Belt Adjustment (4-Cylinder Diesel)
Adjusting the timing belt tension Checking the tension 1. Remove the upper timing belt cover. 2. Loosen the spring by turning the handle of the VW 210 control device. 3. Install...
Adjusting the timing belt tension Checking the tension 1. Remove the upper timing belt cover. 2. Loosen the spring by turning the handle of the VW 210 control device. 3. Install...
Timing Belt Adjustment (5-Cylinder Petrol)
Weakening 1. Remove the upper timing belt guard. 2. Loosen the 3 screws securing the water pump. Fold the shelf to the right with a crowbar and loosen the toothed belt. Tension...
Weakening 1. Remove the upper timing belt guard. 2. Loosen the 3 screws securing the water pump. Fold the shelf to the right with a crowbar and loosen the toothed belt. Tension...
Timing Belt Adjustment (Diesel 5-Cylinder)
Examination 1. Remove the upper timing belt cover. 2. Loosen the generator mounting bolts and tension eye by one turn. 3. Unscrew the water pump tensioning eye and push the...
Examination 1. Remove the upper timing belt cover. 2. Loosen the generator mounting bolts and tension eye by one turn. 3. Unscrew the water pump tensioning eye and push the...
Removal and installation the timing belt (petrol 4-cylinder)
Removal 1. Remove the V-belt (see subsection 2.12.1 ). 2. Set the crankshaft to the TDC position for cylinder 1 and do not change the position further. Setting the engine to TDC...
Removal 1. Remove the V-belt (see subsection 2.12.1 ). 2. Set the crankshaft to the TDC position for cylinder 1 and do not change the position further. Setting the engine to TDC...
Removal and installation the timing belt (diesel 4-cylinder)
Adjusting ruler and mandrel for checking the camshaft Usually, the valve timing adjustment is performed after repairs in which the toothed belt was removed. If the valve timing...
Adjusting ruler and mandrel for checking the camshaft Usually, the valve timing adjustment is performed after repairs in which the toothed belt was removed. If the valve timing...
Removal and installation the timing belt (petrol 5-cylinder)
Removal 1. Place the machine on supports. 2. Remove the lower engine compartment cover. 3. Remove the car from the supports. 4. Remove the V-belt. 5. Set the crankshaft to the TDC...
Removal 1. Place the machine on supports. 2. Remove the lower engine compartment cover. 3. Remove the car from the supports. 4. Remove the V-belt. 5. Set the crankshaft to the TDC...
Removal and installation the timing belt (5-cylinder diesel)
Removal 1. Place the machine on supports. 2. Remove the lower engine compartment cover. 3. Fold the radiator and lock support forward. 4. Remove the alternator and power steering...
Removal 1. Place the machine on supports. 2. Remove the lower engine compartment cover. 3. Fold the radiator and lock support forward. 4. Remove the alternator and power steering...
Cylinder head — design description
Cylinder head of a 4-cylinder petrol engine 1. Upper timing belt cover; 2. Fastening bolt, 80 Nm; 3. Camshaft gear; 4. Bolt, 40 Nm; 5. Lower timing belt cover; 6. Spring washer;...
Cylinder head of a 4-cylinder petrol engine 1. Upper timing belt cover; 2. Fastening bolt, 80 Nm; 3. Camshaft gear; 4. Bolt, 40 Nm; 5. Lower timing belt cover; 6. Spring washer;...
Removal and installation the cylinder head (petrol 4-cylinder)
Cylinder Head Bolt Tightening Sequence Cylinder Block Gasket Marks Removal and installation of the cylinder head is performed on a cold engine. The exhaust manifold is not...
Cylinder Head Bolt Tightening Sequence Cylinder Block Gasket Marks Removal and installation of the cylinder head is performed on a cold engine. The exhaust manifold is not...
Removal and installation the cylinder head (diesel 4-cylinder)
Removal 1. Disconnect the electrical wiring from the fuel switch and glow plugs. 2. Clean the feed pipes at the points of connection with the pump and nozzles with a cold cleaning...
Removal 1. Disconnect the electrical wiring from the fuel switch and glow plugs. 2. Clean the feed pipes at the points of connection with the pump and nozzles with a cold cleaning...
Removal and installation the cylinder head (petrol 5-cylinder)
Cylinder Head Bolt Tightening Sequence Remove the cylinder head only when the engine is cool (room temperature). The exhaust and intake manifolds are not removed. The cylinder...
Cylinder Head Bolt Tightening Sequence Remove the cylinder head only when the engine is cool (room temperature). The exhaust and intake manifolds are not removed. The cylinder...
Removal and installation the cylinder head (diesel 5-cylinder)
Removal 1. Remove the brake booster vacuum hose from the vacuum pump on the side of the cylinder head. 2. Remove the coolant hose from the connecting pipe on the cylinder head...
Removal 1. Remove the brake booster vacuum hose from the vacuum pump on the side of the cylinder head. 2. Remove the coolant hose from the connecting pipe on the cylinder head...
Removal and installation the camshaft
Camshaft and valve train of a 4-cylinder petrol engine 1. Main bearing caps; 2. Nut, 20 Nm; 3. Key (working without tightening); 4. Camshaft; 5. Cone valve crackers; 6. Outer and...
Camshaft and valve train of a 4-cylinder petrol engine 1. Main bearing caps; 2. Nut, 20 Nm; 3. Key (working without tightening); 4. Camshaft; 5. Cone valve crackers; 6. Outer and...
Hydraulic disc tappets
All VW T4 engines are equipped with hydraulic plate tappets, which reduce valve train noise and, in addition, do not require valve clearance adjustment as part of maintenance....
All VW T4 engines are equipped with hydraulic plate tappets, which reduce valve train noise and, in addition, do not require valve clearance adjustment as part of maintenance....
Replacing the valve stem seals
Spark plug 1. Ground electrode; 2. Ceramic insulator; 3. Central electrode; 4. Glass mass; 5. Connecting finger Increased oil consumption may be caused by worn out oil seals. Oil...
Spark plug 1. Ground electrode; 2. Ceramic insulator; 3. Central electrode; 4. Glass mass; 5. Connecting finger Increased oil consumption may be caused by worn out oil seals. Oil...
Removal and installation valves
Rack for valve drive parts Removal 1. Remove the cylinder head. Attention! If the valve drive parts are to be installed again, they must be installed in the old places. In order...
Rack for valve drive parts Removal 1. Remove the cylinder head. Attention! If the valve drive parts are to be installed again, they must be installed in the old places. In order...
Checking the valve guides
When carrying out repair work on an engine with leaky valves, it is not enough to treat or replace the valves. It is imperative to check the wear of the valve guide rods. This is...
When carrying out repair work on an engine with leaky valves, it is not enough to treat or replace the valves. It is imperative to check the wear of the valve guide rods. This is...
Finishing the valve seat in the cylinder head
Valve seats with signs of wear and burning can be finished as long as the maximum permissible finishing dimension is maintained. If the adjustment size is exceeded, the hydraulic...
Valve seats with signs of wear and burning can be finished as long as the maximum permissible finishing dimension is maintained. If the adjustment size is exceeded, the hydraulic...
Lapping of valve seats
With perfectly machined valve seat rings and new valves, lapping of the valve seats in the cylinder head is not required. 1. Valves may be lapped only with fine-grained grinding...
With perfectly machined valve seat rings and new valves, lapping of the valve seats in the cylinder head is not required. 1. Valves may be lapped only with fine-grained grinding...
Checking the compression in the cylinders
Compression testing allows you to draw conclusions about the engine condition. Based on the results of the test, you can determine the degree of wear of the valves or pistons...
Compression testing allows you to draw conclusions about the engine condition. Based on the results of the test, you can determine the degree of wear of the valves or pistons...
V-belt for alternator or alternator and water pump
Please note: Depending on the equipment and for easier access, it may sometimes be necessary to tilt the radiator forward (see subsection 2.2 ). Replacement and tensioning 1....
Please note: Depending on the equipment and for easier access, it may sometimes be necessary to tilt the radiator forward (see subsection 2.2 ). Replacement and tensioning 1....
Power steering pump V-belt
The V-belt is tensioned correctly if it deflects approximately 5 mm when pressed with your thumb between the two belt pulleys. The V-belt is tensioned by adding or removing...
The V-belt is tensioned correctly if it deflects approximately 5 mm when pressed with your thumb between the two belt pulleys. The V-belt is tensioned by adding or removing...
Removal, installation and tensioning the V-belt
Since September 1992, some 4-cylinder engines have been equipped with toothed V-belts instead of V-belts. Checking and adjusting V-belts is not required as the spring-loaded...
Since September 1992, some 4-cylinder engines have been equipped with toothed V-belts instead of V-belts. Checking and adjusting V-belts is not required as the spring-loaded...
Engine fault diagnostics
If the engine does not start, you should look for the cause, systematically narrowing the search circle. In order for the engine to start at all, two basic conditions must be met....
If the engine does not start, you should look for the cause, systematically narrowing the search circle. In order for the engine to start at all, two basic conditions must be met....
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Transporter T4
Transporter T3
- General information
- User manual
- Maintenance
- Power unit
- Engine repair
- Ignition system
- Lubrication system
- Cooling system
- Fuel system (petrol)
- Fuel system (diesel)
- Injection system (petrol)
- Exhaust system
- Transmission
- Clutch
- Car gearbox
- Chassis
- Car suspension
- Steering
- Brake system
- Wheels and tires
- Body
- Exterior
- Interior
- Doors and windows
- Heating system
- Electrical equipment
- Equipment and devices
- Lighting and signaling
- Power devices
- Electrical circuits
- General information
- Maintenance
- Petrol engines
- Engine repair
- Lubrication system
- Cooling system
- Power and exhaust system
- Carburetor 34 PICT
- Carburetors 2E3 and 2E4
- Fuel injection system
- Ignition system
- Diesel engines
- Engine repair
- Lubrication system
- Cooling system
- Power and exhaust system
- Transmission
- Clutch
- Car gearbox
- Chassis
- Front suspension
- Rear suspension
- Steering
- Brake system
- Body
- Body and interior elements
- Doors, locks and windows
- Electrical equipment
- Lighting system
- Equipment and devices
- Power devices (diesel)
- Power devices (petrol)
- Wiring diagrams (diesel)
- Wiring diagrams (petrol)