DIY repair of fv t4

Here are photo reports on repair and detailed documentation on cars:

Volkswagen Transporter T4 (model code: 70A, 70E, 70H, 70J, 70L, 70M) 1991 - 1996
Volkswagen Caravelle T4 / Volkswagen Caravelle T4 (model code: 70C, 70K) 1991 - 1996
Volkswagen Multivan T4 / Volkswagen Multivan T4 (model code: 70B) 1991 - 1996
Volkswagen Transporter T4 (model code: 7DA, 7DB, 7DE, 7DH, 7DJ) 1996 - 2003
Volkswagen Caravelle T4 1996 - 2003
Volkswagen Multivan T4 / Volkswagen Multivan T4 (model code: 7DC) 1996 - 2003

Cylinder head repair on Volkswagen Caravelle Т4 - ACV engine (AJT, AHY, AXG, AYC, AYY, AXL, AUF) (rus.) Detailed photo report.
The ACV engine was installed on the following vehicles: VW Transporter T4 (70), VW Transporter T4 (7D).

Replacing the drive belt on the AAA VR6 2.8 engine (rus.) Photo report
It's time for a little service. It is recommended to change the drive belt every 120 thousand, plus the fact that it is one for everything on this engine. Recently, the belt began to whistle, and why squeeze the maximum, in general, the replacement procedure is described in this report.

Determination of turbine overflow by logs, TDI engines, etc. (rus.) Photo report
The most pressing problem in turbocharged engines is the occurrence of an overflow. This is especially true for diesel engines. the formation of soot in the exhaust gases leads to its rapid accumulation inside the turbine and wedging of the geometry. First, let's try to figure out how the inflation pressure is regulated, and then let's look at what the blowout looks like in the logs.

Power loss during acceleration, turbine underflow, description of problems, removal of logs and diagnostics (rus.)
In case of problems associated with the loss of power during acceleration, both constant and variable loss of traction when driving. Loss of traction in "full throttle" mode or the transition of the engine to emergency mode (driving, but not pulling or pulling weakly) read this entire text carefully, and 9 out of 10 that this will help you establish the exact cause of the problem.

Technical characteristics and data for adjustments of vehicle systems:
engine and cooling system, ignition, fuel system, suspension, liquid volumes, etc.

Volkswagen T4 Caravelle / Transporter / Multivan since 1990: Lubrication system (rus.) Engines: AAC, AAF, ACU, AET, APL, AVT, AES, AMW, 1X, ABL, AJA, AAB, AJT, ACV, AUF, AXL, AYC, AHY, AXG.

Information on the repair of engines VAG / Engines repair
This engine repair information applies to all VAG vehicles. In order to quickly find the documentation for your engine, simply press Ctrl-F on the keyboard and type the letters of your engine. For example: 2E or BSE (English only!)

Cooling, heating, ventilation and air conditioning system
(Cooling, Heating, Air Conditioning and Climate Control Systems)

Volkswagen T4 Caravelle / Transporter / Multivan since 1990: Petrol injection system (rus.) Considered VW Digifant systems (engines: AAC, AAF, ACU); Bosch Motronic 3.8.1 / ME 7.1 (engines: AES, AMV); Simos 5S / 3.5 / 3.5 (engines: AET, APL, AVT)

Injection and ignition systems
This information on injection systems applies to all VW, Skoda, SEAT, Audi vehicles.
General information on ignition systems
Suitable for many cars VW, Skoda, SEAT, Audi

General information on fuel systems
Suitable for many cars VW, Skoda, SEAT, Audi

Disassembly of the inner and outer CV joints (rus.) Photo report.
When replacing the boot, if dirt has got into the grease, the CV joint must be disassembled, rinsed from the old grease, then assembled and filled with new grease. This work is not at all difficult, but it requires accuracy and attention.

General Suspension Information
Suitable for many cars VW, Skoda, SEAT, Audi

Airbag "spiral" repair, airbag slip ring restoration (rus.) Photo report
Let me disagree with the statements about the unrepairability of the “Airbag spiral”. As they say, “the collective farm was a success for me. "So we need: a soldering iron, a tester, a cross screwdriver, a thin slotted screwdriver, flux, tin, a skin or mini drill, accuracy, patience.

Information on the repair of gearboxes VAG / Transmission repair
This gearbox repair information applies to all VAG vehicles.

Repair of the Bosch starter No. 0 001 108 094 (1.4 kW), replacement of components (rus.) Photo report
Once I heard how my starter began to "idle" shriek. I purchased the bushings for replacement.After reading the forum, I saw that many describe the procedure for removing the starter, so I decided not to repeat myself. But some of the nuances directly related to the disassembly of the starter and the further replacement of parts are not reflected in such detail, I hope this report will correct this.

Replacing bearings in alternators Bosch 90A and 65A (rus.) Photo report
The 90A VAG generator number 026 903 015B, Bosch number 0 120 469 729 was installed on many cars, the grinding and rumble when the generator is running indicate that its bearings need to be changed.

Replacing the slip rings of the Bosch 65 Amp generator (rus.) Photo report
The consequences of worn slip rings - there will be no normal charging of the battery and the brushes of even a new relay-regulator will wear off faster. How to replace them in this report.

Volkswagen T4 Caravelle / Transporter / Multivan from 09/1990, petrol / diesel. Repair and maintenance (rus.) The book contains information necessary for the repair of all components and assemblies of a car: engine, fuel system, exhaust system, clutch, gearbox, steering, braking system, tires and tires, bodywork, electrical equipment, accessories. Recommendations for car care are given. The manuals are intended for professionals and car enthusiasts and include over 400 illustrations, fault tables, colored wiring diagrams. Petrol engines: 2.0 l / 62 kW (84 hp), with 9/90 2.5 l / 81 kW (110 hp), 12/90 - 7/96 2.5 l / 85 kW (115 HP), from 8/96 2.8 l / 103 kW (140 HP), from 1/96 - 5/00 2.8 l / 150 kW (204 HP) , from 5/00 Diesel engines: 1.9 l / 45 kW (60 HP), 9/90 - 7/96 1.9 l / 50 kW (68 HP), from 10/92 2 , 4 l / 55 kW (75 hp), from 4/97 2.4 l / 57 kW (78 hp), 9/90 - 3/97 2.5 l / 65 kW (88 hp) .s.), from 4/98 2.5 l / 75 kW (102 HP), from 8/95 2.5 l / 111 kW (150 HP), from 4/98. 350 pages. 72 MB.

If you did not find information on your car, look at the cars built on the platform of your car.
With a high degree of probability, the information on repair and maintenance will be suitable for your car as well.

All documentation in English is marked (eng.), In German - (ger.)
For everyone who has a Volkswagen, hands and the desire to do something with them.
For all who has Volkswagen, hands and desire to do something by them.

Volkswagen T4 minibuses were produced from 1990 to 2003. Due to its reliability, ease of use and a wide range of model range, the car has become extremely popular both in Europe and among motorists from the CIS. Along with a huge number of advantages, the Volkswagen T4 has some disadvantages and weaknesses that the future buyer should be aware of and pay attention to when buying.

In general, the Techik's body is very durable, made of galvanized metal. However, this material is susceptible to prolonged exposure to moisture. Significant amounts of rust on the body are rare. But a rusty bottom is a very common phenomenon. Corrosion often affects the underside of doors, sills, gutters and rear fenders. Particularly vulnerable are cars that have been operating for a long time in conditions of poor-quality roads, a large amount of reagents on the roads in winter and a humid climate. How to check? To check the condition of the car body, it is necessary to carry out a thorough visual inspection on the overpass. It is necessary to expose the surface of the body, especially the underside, to light mechanical stress with your hands, especially at the seams. And it is important to remember that this model (T4) is no longer produced and therefore practically all cars have problems with paintwork.

Both diesel and gasoline engines have vulnerabilities. Diesel engines are characterized by periodic breakdowns of the high-pressure fuel pump and the glow plug control system. Turbocharger breakdowns are not uncommon for turbo diesel engines. In gasoline engines, the most common malfunctions of auxiliary electrical equipment: starter, generator, ignition coil and others.

First of all, to check the engine, it is necessary to measure the compression in the cylinders using a special device. The main "symptoms" of a problem engine are as follows:

1. the car does not start well or does not start at all;
2. exhaust gases are blue or white;
3. oil on the dipstick with foam or white or light blue splashes;
4. the coolant in the expansion tank is dirty brown;
5. third-party noise when the motor is running;
6. poor cravings.

Automatic transmissions are especially problematic. In them, torque converters regularly fail. But there are many problems in mechanical engineering. Bearings and gears wear out rather quickly. As a result, gear shifting becomes difficult. By the way, the gearbox is considered one of the problem areas of the Volkswagen Transporter 4. When checking, you first need to check the quantity and quality of oil in the gearbox. It should be clean, level. Next, you should shift the gears, on the spot and while the car is moving. In a serviceable car, gears are switched easily, smoothly, without third-party noise, tapping. The gears do not "pop out".

The Volkswagen T4 suspension is strong enough. Its condition depends on the operating conditions of the vehicle and the quality of the roads. In the front torsion bar suspension, the upper ball bearings fail - 50 t.km., the stabilizer bushings - 30 t.km., the silent blocks of the lower arms will last a little more than 60 t.km .. Rear spring suspension - shock absorbers move away 120 t.km ... without a fanatical load. When checking, you should start with a visual inspection. Defective parts very often have oil drips. All rubber components must be intact, free from defects and cracks. A faulty suspension creates characteristic noises while driving.

Breakage of side door rollers is a fairly common problem and one can say Volkswagen T4 disease. At the initial stage of the malfunction, the side doors close poorly, not always the first time. Over time, the door simply cannot be closed. In good condition, it should close easily and immediately. Therefore, when buying, you need to pay attention to this and open and close the door several times.

• Expensive spare parts;
• The gear lever is far away;
• Weak insulation;
• Vibration of window frames;
• Bad optics;
• Crickets in a torpedo;
• Weak and long warm-up of the passenger compartment in the winter.

Based on the foregoing, we can conclude that, in general, the car at one time occupied a worthy place among its competitors, but due to the age parameters of these cars, it should be understood that the body is quite corroded. Therefore, when choosing a car, you need to make the right choice, conclusion and think over all the pros and cons. After all, there are many alternatives to these cars in the car market.

The Volkswagen T4 is considered to be very reliable. He selflessly resists the influence of time. But is he as good today as he used to be? What malfunctions are hidden in its design?

Model history

The Volkswagen T series has a very long tradition. The first such car was created in the late 40s of the twentieth century. It received the designation Typ 2 (T1). The successor to the T2 appeared in the second half of the 60s and stayed on the assembly line for about 10 years. In 1979, the time came for the next generation - T3, which existed until 1992. In South Africa, its production continued for another 12 years.

In the early 90s, the design and construction of the T3 was already heavily outdated, and Volkswagen released the T4. The new generation was innovative not only in terms of style, but also in terms of powertrain. It was in this model that the Germans decided to abandon the rear-wheel drive, replacing it with the front one. Those interested could purchase the all-wheel drive version of the Syncro 4 × 4 for a surcharge. The location of the engine has also changed: it has been moved from the back of the car to the front.

The minibus was offered in four basic versions - Transporter, Carravella, California and Multivan. The Transporter is a utilitarian basic van. The rest of the versions are luxury passenger models.

In the fall of 1995, the Volkswagen Transporter received a new diesel engine, and the Carravelle and Multivan versions underwent a slight facelift. The most notable differences are the new radiator grille, headlights and hood, giving the van a more aggressive look. There is a new steering wheel inside and there have been a few minor changes to the dashboard. Gradually updates appeared in other versions as well.Volkswagen T4 was assembled until 2003 in Germany, Taiwan and Indonesia.

Minibuses do not usually have a very wide range of powertrains. But Volkswagen did not stint, offering a large selection of engines. The most popular are, of course, diesel units. Not surprisingly, gasoline-powered vans under the hood consume too much fuel, and low fuel consumption is very important for users of this type of vehicle.

Diesel engines, like the car, come from the 90s. The higher the power, the better the dynamics, but also the more frequent service visits. The weaker R4s have more difficulty overclocking the Transporter. Until recently, these motors were considered very reliable, but today, due to giant runs, they are increasingly starting to crumble. 1.9 D and 2.5 TDI (150 hp) may require overhaul after 300-350 thousand km. The rest of the diesel engines easily nurture 450-500 thousand km.

Since the car is already very many years old, malfunctions can catch any of the modifications. Old diesel engines primarily suffer from fuel leaks and failure of the injection pump. In addition, it is not only the glow plugs that often fail, but the glow control system itself. In younger TDIs, the turbocharger, flow meter and fuel injection system fail.

If you do not have the desire to spend a lot of money on repairs in a car service, then you should pay attention to gasoline engines. Their resource is over 500-700 thousand km. They break down much less often, but the savings on repairs simply burn out along with the fuel while traveling. Regardless of the version of the gasoline engine chosen, you should not expect that the fuel consumption in the city will be less than 10 liters per 100 km. The most powerful V6 easily burns more than 15 l / 100 km there.

Unfortunately, gasoline units are not completely free from technical faults. Most often this applies to auxiliary equipment: a generator, a starter, ignition coils and all kinds of sensors, including lambda probes. There is also oil leakage. In severely neglected instances, it may be necessary to overhaul the engine.

The most capricious is the gasoline AAS (2.0 / 84 hp). It's all about the Digifant injection control system. She sometimes starts to play the fool: then suddenly the fuel consumption increases, then there are interruptions in the operation of the engine at an air temperature of about zero. A way out was found - replacing the injector with a VAZ "January". The cost of such an alteration is about 30,000 rubles.

Transmission

The Volkswagen T4 has broken with tradition forever: rear-wheel drive and an engine located behind the rear axle. The minibus has become front-wheel drive with a motor in the front. The power take-off from the engine takes place using a 5-speed mechanics or a 4-speed automatic.

In the all-wheel drive version of the Syncro 4 × 4, the distribution of torque between the axles is carried out through a viscous clutch, which, when the front wheels slip, connects the rear ones. The presence of Syncro will require additional operating costs: an outboard bearing and elastic couplings of the propeller shaft, gearbox oil seals or a buzzing rear gearbox.

Some owners are keen to turn regular versions into four-wheel drive. Fortunately, such modernization is quite possible and can be successfully solved in specialized services.

Typical problems and malfunctions

If you purchase a Volkswagen T4 of the first years of production, then a thorough inspection of the body for corrosion is necessary. Rust often appears on the tailgate, rear fenders, bonnet, windshield frame and vertical seam on the left side of the body, as well as on the sliding door area. The younger the specimen, the lower the risk of the onset of "rotting".

Another weak point of the German delivery vehicle is leaks in the power steering system. Many cars relatively often require replacement of steering rods, repair of the power steering pump and steering rack.

The most quickly in the suspension are the struts and stabilizer bushings. Ball joints, silent blocks of levers and shock absorbers serve more than 100-150 thousand km.Russian roads contribute to the rapid wear and tear of wheel bearings. After all, nothing lasts forever!

Do not differ in excessive endurance and gearboxes. In the case of automatic machines, after 200-250 thousand km, the torque converter, hydraulic lock clutch, valves in the valve body and solenoids fail. For repairs, you will need at least 50,000 rubles. The manual transmission clutch (15-25 thousand rubles) will last 250-350 thousand km. In the mechanics itself, the gears of the 5th gear, bearings and synchronizers wear out.

The vacuum brake booster pump is another weak spot. In cars without ABS, the brake force regulator stops working with age. In addition, Volkswagen T4 owners periodically complain about the loss of tightness in the cooling system. When inspecting the car, it is also necessary to check the ease of movement of the sliding doors. If difficulties arise, the rollers may need to be replaced. In a German van, there are problems with the mechanism for opening doors and windows.

The Volkswagen T4 is often viewed by drivers as a sturdy workhorse. Any repairs can be postponed until later, as the German minibus will endure everything! Unfortunately, the consequences of this approach often fall on the shoulders of the next owner, when, after the purchase, you have to overhaul the engine and suspension.

Years go by, and the van, despite its former solidity, today is no longer so perfect and can often break down. After the purchase, one way or another, something will still have to be repaired. Prices for used copies range from 200 to 600 thousand rubles. As a rule, most of them are already on the verge of exhaustion.

What's useful in the Volkswagen T4? Huge trunk, ergonomic interior, economical diesel engines and relatively rich equipment of the top versions. The biggest advantage is the good availability of a wide range of spare parts and a variety of body options.

Well, here's the long-awaited continuation of my story. I finished my story on the fact that they caught up with the body. The subsequent action we weld and clean it.

Then we begin to collect it quietly. For now, we put what is, to overtake it for painting.

Then we polish and paint it.

Then I go to a friend's store and order the missing parts.
1. Shock absorbers 2pcs. 30 $
2. Rear tailgate lock. 55 $
3. Front bumper $ 85.
4. Front turn signal $ 7.
5. Parking brake cables assembly $ 60.

After he drove him home after painting, he began to disassemble the entire interior in order to wash it. And give it back for further painting inside.

To date, this has become the case.

See guys for follow-up work. Thanks to all)

Cars change, friends and the forum remain. [my.housecope.com/wp-content/uploads/ext/1209]

Message artem_20 »25 Oct 2010, 09:05

Message sava6565 »04 Nov 2010, 19:14

Message sokot8 »05 Nov 2010, 11:27

Message AUREL 06 Dec 2010, 21:41

Message AUREL "07 Dec 2010, 21:36

Message SpiderBUS71 "Dec 15, 2010 03:21 am

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We communicate, share experience in the operation and maintenance of VW Transporter / Caravelle / Multivan, help other participants to understand the problems that have arisen.

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Current time: 10/17/18, 15:15

Sat »17.06.10, 21:52 Re: Self-capital AAB

ALEX69 »17.06.10, 22:03 Re: Independent capital AAB

Sat »06/22/10, 09:16 Re: T4 AAB Independent capital

Caesar "06/22/10, 09:31 AM Re: T4 AAB Independent capital

Sat "06/23/10, 00:03 Re: T4 AAB Independent capital

AN12 "06/23/10, 01:39 AM Re: T4 AAB Independent capital

Skit "06.09.10, 10:32 T4 ААВ" And again - the capital of the show "

Finally matured for the capital of his AAB.

Yesterday, the "heart" of my bead was removed, with a preliminary removal of the "scalp" (cylinder head). Now we have to check, remove, search for new spare parts, in general, the usual scheme. I will not rush, it is better not in a hurry, for myself, without kroilov, but if possible it will be budgetary.

Smoked for a long time

how he, the poor, withstood, God only knows, held back loans with all sorts of difficulties stemming from here .

The fact of the disappearance of the coolant, without visible external leaks, increases in the oil level, and the appearance of white smoke, apparently steam, to the existing blue-gray was prompted to radical actions.

When removing the valve cover, I discovered the presence of antifreeze in the cavity next to the hydrics of the second cylinder (see photo)

I could not fill it there, for sure.

How he got there is a question.
The revision of the cylinder head will show, but I think that the cylinder head will be new, and this one in stock, if everything is normal.
Piston for replacement, with a bore, unambiguously. I have not disassembled it further.

Here is not a big photo report.

ZY A start has been made, the end is not yet in sight, there is a lot of work and thoughts, and not only on the engine.

З.З.Ы. Thanks to an old friend, Haysovod and not only, for the given place in the box.

Belyash "06.09.10, 10:40 Re:" And again AAV "-" capital of the show "

Sinister "06.09.10, 10:46 Re:" And again AAV "-" capital of the show "

Andrey-master "06.09.10, 11:31 Re:" And again AAV "-" capital of the show "

Skit wrote: Finally matured for the capital of his AAB. :

The most important thing is not to be afraid "the eyes are afraid but the hands are doing"
When I got the capital for defective parts, pistons and liners.
Good luck

T3 Volkswagen Caravelle 1986
T4 1993 was, faithfully served.

MTS + 7911213085seven + 7921774695five
Do not be afraid to do what you do not yet know how, remember the ark was built by amateur professionals who built the Titanic

ins "06.09.10, 12:20 Re:" And again AAV "-" capital of the show "

mishanja "09.09.10, 10:43 Re:" And again AAV "-" capital of the show "

MAX 2 "09.09.10, 11:25 Re:" And again AAV "-" capital of the show "

Big "09.09.10, 11:52 Re:" And again AAV "-" capital of the show "

Caesar "09.09.10, 12:41 Re:" And again AAV "-" capital of the show "

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VW T4 1.9 TD overhaul, VW 1.9 TD engine repair

Repair of the Volkswagen T4 1.9D engine. Part 3.