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Self-study programme 310
The Transporter 2004


   Summary of Contents for Volkswagen Transporter 2004

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    Service. Self-study programme 310 The Transporter 2004...

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    1950 In March 1950, series production of the first VW Transporter starts at a rate of 10 vehicles per day. For engine and axles, standard parts from the VW Beetle are used. The vehicle is characterised by a self-supporting body on a ladder frame chassis and it is driven by a rear engine with rear wheel drive.

  • Page 3: Table Of Contents

    Contents Brief overview ........4 Body .

  • Page 4: Brief Overview

    It started with an idea in 1947 by the Dutch importer, Ben Pons, to construct a small Transporter. This was realised with the first "Bulli" in 1950 and continually improved upon. The Transporter 2004 is now availa- ble in a wide range of variants.

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    Technical data (Multivan) 310_003 3000 4890 310_005 310_004 1626 1626 1904 For data about other variants, please refer to the latest sales literature. Measurements and weights charts Unladen weight 2109 to 2474 kg depending on equipment level Gross weight 2850 to 3000 kg depending on equipment level Wheelbase 3000 mm Turning circle diameter...

  • Page 6: Body

    Transporter 2004 model range Panel van Kombi Shuttle Multivan The Transporter 2004 is produced in a wide spectrum of designs: – As a people carrier, the vehicle is available as – Within the product range, models are the Kombi, Shuttle, Multivan or RV.

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    Recreation Drop-side with Chassis with Drop-side with Chassis with vehicle double cab double cab 310_007 – The vehicles vary in their payload capacity The further contents of this publica- due to different areas of application. tion are focused on the description of the Multivan.

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    Body Basic body structure A sturdy basic body structure is a prerequisite for The high rigidity of the body is also a prerequi- vehicle safety and comfort. site for: A body structure with a high level of rigidity and – High level of comfort in interior high level of crash safety was attained by the use –...

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    Body Laser seam 310_011 Guide rail reinforcement C-pillar reinforcement B-pillar reinforcement Hinge carrier reinforcement Sill/wheel housing reinforcement Laser seam Tailored blanks High tensile panels...

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    Body Underbody covering The underbody covering of the Multivan is made The quantity of PVC (polyvinylchloride) on the up of the following parts: underbody was reduced in favour of an under- body trim made from polypropylene (with long – Underbody trim fibreglass elements).

  • Page 11: Sliding Door

    Sliding door The Multivan has a sliding door on the front pas- The double sided version is also referred to as a senger's side. A sliding door is also available on two sliding door concept. On this version there is the driver's side as an optional extra.

  • Page 12: Electric Sliding Door

    Body Electric sliding door The Transporter can be equipped as an option with an electric sliding door. The door is opened and closed by a cable system. The system consists of two cables, pulleys and a reel which has an electric motor flanged to it.

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    Function As the doors open and close under cable ten- By actuation of the sliding door motor, the door sion, two cables are necessary. One cable is is pulled open or closed via the relevant cable. responsible for pulling the door open and the The motor direction of rotation is determined by other is responsible for pulling the door closed.

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    You can find more details about the – Response of the active system in the door seal electric sliding door in self-study pro- results in the door being completely opened. gramme 311 "The Transporter 2004, Electrical system".

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    Sliding door electric power latching system To ease opening and closing of the sliding doors, an electric power latching system can be selected as an optional extra. Body The electric power latching system is installed in The power latching motor is connected directly to the C-pillar and consists of a power latching the eccentric bolt of the striker pin via a hollow motor and a striker pin.

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    310_119 Direction of rotation lock The function of the electric power latching system in the sliding door is described in detail in the multimedia program entitled "The Transporter 2004".

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    310_120 310_121 Worm gear The function of the electric power latching system in the tailgate is described in detail in the multimedia program entitled "The Transporter 2004". To open the tailgate in an emergency, please refer to the operating instructions.

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    Body Wing doors Exterior handle Commercial vehicles can be equipped with wing doors as an optional extra. The system is designed so that the left door has to be opened prior to the right door. The exterior handle of the left door is integrated in the light mounting.

  • Page 19: Sun Blind

    Sun blind Sun blind hook On the sliding door windows and also rear win- dows, sun blinds can be pulled up from the side panel trim and hooked in place at the top of the window. The sun blinds considerably reduce sunlight from entering the interior and thereby reduce the build up of heat.

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    Body C-profile rail in roof of Multivan The C-profile rails can be found on the left and right along the roof and are so-called because of the shape of the profile. They allow accessories to be attached. The roof carrier required for this is inserted in the C-profile of the rail at the rear end and pushed into the desired position.

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    Seats in the Multivan The interior of the Multivan is distinguished by its variable seating arrangement and sturdy workmanship. Driver and front passenger seat The driver and front passenger seats are height Under the seat frames, a second battery (driver adjustable single seats with armrests.

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    Body Single seats in passenger compartment Single seats are installed in the passenger com- The backrests of the single seats can be folded partment that can be rotated by up to 180°. They down completely and placed in the table posi- are available either for the 1st or 2nd seat row in tion.

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    Seat guide in floor A rail system in the floor of the vehicle allows the seat to be adjusted in the longitudinal plane. It consists of guide rail and cover strip. The seat is equipped with four rollers. It is moved on 2 rails.

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    Body 3-seater fully reclining bench seat In addition to the single seats in the passenger For reasons of safety, longitudinal movement of compartment, there is also a 3-seater fully rec- the 3-seater fully reclining bench seat is only lining bench seat. This is also equipped with possible in the passenger compartment when the three-point seatbelts, head restraints and Isofix backrest is placed in the forward table position.

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    Bench seat guide in floor The 3-seater fully reclining bench seat is also incorporated in the rail system. The bench seat is equipped with 8 rollers. It is moved on 4 rails. 2 rollers run along the cover strip on each rail. Adjustment of the seat by means of rollers and blocks is the same as that on single seats.

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    Body Commercial vehicle seats The commercial vehicle range also features a Driver/front passenger seat (height adjustable) wide variety of seats. Driver/front passenger seat (fixed) Side airbag 310_097 Longitudinal 310_096 Height adjustment adjustment Longitudinal Side storage adjustment compartment Front passenger double bench seat For information about the various seat configurations in commercial vehicles, please refer to the multime-...

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    2-seater bench seat Easy entry seat Lever for tilting seat forwards 310_099 Seat mounting in passenger compartment 310_100 3-seater bench seat 310_102 On commercial vehicles, mounting of the seats in the passenger compartment is via quick release catches in the body floor. Each type of seat is equipped with 4 mountings.

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    Compartment A compartment, a drawer and a bottle storage facility are integrated in the table base. 310_015 Drawer For details of the table functions, please also refer to the multimedia program entitled "The Transporter 2004".

  • Page 29: Dash Panel

    Dash panel The dash panel has been completely redesigned and there are different types for the Multivan and com- mercial vehicles. This affects the exterior design, the materials used and also the extent and finish of equipment components. Front passenger Compartments airbag Commercial vehicle dash panel:...

  • Page 30: Occupant Safety

    Occupant safety Occupant safety Occupant safety is guaranteed by the airbag Curtain airbag system with two full size airbags on the driver's Front passenger Curtain airbag and front passenger's side, side and curtain air- Front passenger bags, seatbelts, belt tensioners and child res- traint system (Isofix).

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    Curtain airbag module Curtain airbag Three-point seatbelt, integrated in seat Passenger compartment curtain airbag crash sensor, at bottom of C-pillar 310_047 Three-point seatbelt with rack- type seat belt tensioner, attached to body Module for driver side airbag Driver side airbag Cab curtain airbag crash sensor, at bottom of B-pillar Driver...

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    Occupant safety Rack-type seat belt tensioner In the new Transporter, a rack-type seat belt ten- Rest position sioner is installed on the driver and front passen- Damping element ger side instead of the familiar ball-type belt Sprocket 1 tensioner. Pinion Sprocket 2 Roller Task...

  • Page 33: Power Units

    Power units Engine and gearbox combinations The range of power units covers two petrol and There are two manual gearboxes and there is four diesel engines with unit injectors. The engi- one automatic. At a later stage, 4motion all- nes are installed transversally. wheel drive will be offered.

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    Power units 2.0ltr./85 kW petrol engine The engine, used widely in the Group, was adap- ted for installation in the Transporter, e.g. in the location of the dipstick and design of oil sump. Technical properties – Jets for piston cooling –...

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    3.2ltr./173 kW V6 petrol engine The engine is a further development of the 2.8ltr. V6 engine from Volkswagen. Technical properties – Continually variable inlet and exhaust cams- hafts via fluted variator – Optimised inlet and exhaust ports – Larger inlet and exhaust valves –...

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    Power units 1.9ltr./63 kW diesel engine with unit injector system This engine is very similar to the 74 kW variant installed in cars. Constructional alterations were necessary for installation in commercial vehicles. Technical properties – Vertical oil filter module – VTG turbocharger –...

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    1.9ltr./77 kW diesel engine with unit injector system This engine is very similar to the 74 kW variant installed in cars. Constructional alterations were necessary for installation in commercial vehicles. Technical properties – Vertical oil filter module – VTG turbocharger –...

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    Power units 2.5ltr./96 kW diesel engine with unit injector system Technical properties – Aluminium cylinder block – Cylinder head with cross flow principle – Timing and ancillary drive system via spur gears – Vertical oil filter module – Exhaust gas recirculation on automatic gearbox with additional cooler –...

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    2.5ltr./128 kW diesel engine with unit injector system This engine is very similar to the 96 kW variant. The differences in power are achieved by the fol- lowing changes. Technical properties – More powerful VTG turbocharger – Adapted dual mass flywheel 310_033 Additional detailed information about the engine can be found in self-study...

  • Page 40: Power Transmission

    Power transmission Manual gearbox Two manual gearboxes are installed in the Trans- The gearboxes differ in construction, maximum porter 2004, the 02Z and the 0A5. They are torque and number of gears. designed for transverse installation in the vehicle. 02Z gearbox The gearbox is a further development of the 02J The speed signal is transmitted from the ABS type.

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    0A5 gearbox The gearbox was developed for use with 5-cylin- The compact gearbox is suitable for transverse der engines and for the V6 engine and is a com- installation thanks to the 4-shaft design. pletely new development. It features 6 gears and can transmit a maximum of 500 Nm torque.

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    Power transmission Pull ring Gear selector mechanism - mechanical gear- The gear selector mechanism for mechanical gearboxes is cable operated. Unlike the previous model, the gear selector mechanism is housed in the dash panel and features a joystick. The procedure of pushing down on the gear lever to engage reverse, common in many Group vehicles, now involves pulling a ring upwards on the lever to engage the gear.

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    Automatic gearbox 09K The newly developed gearbox is installed in con- junction with the 3.2ltr. V6 and 2.5ltr. TDI engines and features 6 gears. It can transmit a maximum 400 Nm of torque. Gear selection is via Tiptronic. 310_044 Automatic gear selector mechanism The Tiptronic is designed as a gate selector Tiptronic type and is installed in the same posi- tion as the mechanical gear selector mechanism.

  • Page 44: Running Gear

    4 engine and gearbox mounting points (engine and gearbox mounting on body side pendulum support on subframe side) Front and rear anti-roll bars For details about the anti-roll bar, please also refer to the multimedia program entitled "The Transporter 2004".

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    Conti Teves MK 25, ABS with EDL, TCS and EBD, ESP with brake assist system Ventilated brake discs at front and rear Active wheel speed senders 310_048 Handbrake lever on driver's seat console Special running gear packages are also available for different applications with adapted spring/shock response (e.g.

  • Page 46: Front Axle

    Running gear Front axle The front axle is a new development. Technical features are: – 4 engine and gearbox mountings with two – Anti-roll bar above each coupling rod, con- engine and gearbox mountings on the body nected to suspension strut. and two pendulum supports on the subframe.

  • Page 47: Rear Axle

    Rear axle The well proven semi-trailing arm rear axle with independent suspension from the previous model was further developed in detail and refined. Technical features are: – Cast semi-trailing arms house wheel bearings. Wheel bearings are same as those used in front axle.

  • Page 48: Steering Column

    Running gear Steering column The safety steering column features three angle In order to balance the elastic movements of the points with two simple universal joints and one subframe, which is joined to the body, the bottom double universal joint. Unlike the fixed steering part of the steering column is telescopic.

  • Page 49: Brake System

    Brake system For the braking system of the Transporter 2004, the MK 25 design from Conti Teves was installed. The system features anti-lock braking system (ABS), electronic differential lock (EDL), traction control (TCS) and electronic brake force distribu- tion (EBD) as standard.

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    Running gear Front brakes On the front axle, the Transporter 2004 features a 16“ brake system. The ventilated brake discs are Ø 308 x 29.5 mm in dimension. From 170 kW, a 17“ system is installed which is Ø 333 x 32.5 mm in dimension.

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    Pneumatic brake assist system The brake assist system is installed exclusively in conjunction with ESP. The role of the brake assist system is to support the driver in emergency braking situations. In addition to normal functioning of the brake servo, the version with brake assist system features a coil, a release switch and a travel sensor.

  • Page 52: Electrical System

    Electrical system The data bus network Description The control units of the Volkswagen Transporter are connected to each other via the CAN data bus network. The network makes it possible to exchange data J623 between the control units. Information is sent via the CAN data bus in digi-...

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    G24 Tachograph G85 Steering angle sender Climatronic/air conditioning operating and display unit E265 Rear Climatronic operating and display unit J104 ABS with EDL control unit J492 J217 J104 J136 Seat adjustment control unit with memory function J162 Heater control unit J217 Automatic gearbox control unit J234 Airbag control unit...

  • Page 54: Heating, Air Conditioning

    Heating, air conditioning Climate control In addition to the basic heating and ventilation The illustration shows the Multivan equipment, the Transporter also features an air with a Climatronic system. conditioning system. Two versions of air condi- tioning system are installed: –...

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    A/C headliner with air distribution Air conditioner for passenger compartment 310_116 Auxiliary heater Commercial vehicles with side win- dows also have the air channel, but there is no booster fan.

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    A/C headliner operating unit. Supplementary Auxiliary heater heater Air channel in door Vents in B-pillar Transition point to air channel 310_112 Booster fan For details about ventilation, please also refer to the multimedia program entitled "The Transporter 2004".

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    Air conditioner for passenger compartment Depending on the equipment level, the Transpor- A/C headliner To A/C headliner ter can be equipped with an air conditioning unit for the passenger compartment. On the Multi- van, this is a standard feature. In addition to air distribution in the bottom area, distribution is also channelled upwards to the A/C headliner.

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    Heating, air conditioning 3 zone Climatronic The air conditioning system can control tempera- Climatronic/air conditioning operating tures in three different zones. and display unit – At the front, individual temperatures for the driver and front passenger can be selected. The operating and display unit in the dash panel is used for the setting.

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    A/C headliner The A/C headliner has two air outlet points The vents have three functions: above each seat row in the passenger compart- ment. In the front outlet point, there are vents on – Closed with air outlet the left and right and a Climatronic operating –...

  • Page 60: Service

    Service New features of service Front end in service position Use of the guide rods for front end service position T10228 makes it possible to place the front end of the Transporter in a special service position. This creates space for service or repair work to be carried out. Front end 310_130 Guide rods for front end...

  • Page 61: Workshop Equipment

    Workshop equipment Designation VAS 6236 Straightening bracket set VAS 5007/20 Portal gauge supplement VAS 6248 Wing protector Special tools Designation T10220 Engine holder for assembly stand (5-cylinder TDI) T10221 Water pump spur gear puller (5-cylinder TDI) T10222 Water pump puller (5-cylinder TDI) 10-222A23 Support device adapter 10-222A24...

  • Page 62

    Service Diagnosis For the new Transporter, you have the vehicle diagnosis, testing and information system VAS 5051 and vehicle diagnosis and service information system VAS 5052 at your disposal. 310_110 310_109 You can choose the following modes of opera- Despite this, you also have the opportunity of tion on the vehicle diagnosis, testing and infor- creating your own test chart.

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    For internal use only © VOLKSWAGEN AG, Wolfsburg All rights and the right to make technical alterations reserved 000.2811.31.20 Technical status 03/03 This paper was manufactured from pulp that was bleached without the use of chlorine.

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