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Related Manuals for Volkswagen Transporter T4 2007
Summary of Contents for Volkswagen Transporter T4 2007
- Page 1 Body builder guidelines 2007 Body builder guidelines Transporter T4...
- Page 2 Please also provide information about the intended operating conditions of the vehicle. If bodies, installations or conversions comply with the present guidelines, no additional approval by Volkswagen AG is required for the presentation of the vehicle at the relevant authority examining roadworthiness.
- Page 3 The body builder or fitter is solely responsible for the design and assembly of bodies and the execution of conversions. All conversions must be documented by the body builder or fitter in the service schedule provided with every Volkswagen vehicle.
- Page 4 Extended storage times cannot always be avoided. The following measures are recommended to ensure that vehicle quality is not affected by long-term storage: At vehicle delivery: Fill tank • Do not park the vehicle under trees, poles; etc. • Open all ventilation flaps, set blower to maximum speed •...
- Page 5 Fitters of accessories and body builders must ensure that they comply with all applicable environmental rules and regulations, especially EU directive 2000/53/EC concerning end-of-life vehicles and EU directive 2003/11/EC relating to restrictions on the marketing and use of certain dangerous substances and preparations. The vehicle owner must keep all assembly documentation concerning the modification and hand them over together with the vehicle to the dismantler.
- Page 6 Maintenance instructions or service schedules outlining inspection and servicing work should be provided for the modifications performed by the body builder or accessories fitter. These instructions or schedules must include the maintenance and inspection intervals as well as the required operating fluids and materials and the spare parts. Parts and components with a limited service life which must be checked in regular intervals to ensure service reliability and timely replacement must be explicitly stated.
- Page 7 Body builders must ensure that the fitted components, conversions, bodies and modifications comply with applicable legal rules and regulations as well as all regulations regarding work safety and accident prevention. All safety rules and the information material provided by accident insurance providers must be observed. All technically feasible measures must be taken to prevent unsafe operation.
- Page 8 The conceptual advantages of the Volkswagen transporter Wheel bases 2,920 mm and 3,320 mm • Three net-load classes for front-wheel drive variants. For details see weight table, 2.1 Dimensions and Weight • Two net-load classes (PR-No. 0J2 and 0J3) for the syncro-variants (see weight table, 2.1 Dimensions and •...
- Page 9 Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines). Data status March 2009...
- Page 10 Dimensions and Weight Volkswagen AG provides vehicles with front-wheel drive, such as box-type delivery van, station wagon, flatbed truck, chassis with cab, double cab and chassis with double cab, in the following weight classes: reduced net load (PR-No. 0J1). Standard net-load (PR-No. 0J2), increased net load (PR-No. 0J3) and increased net load with a permitted total weight of 2,890 kg (PR-No.
- Page 11 Station wagon 2.920 2.600 1.400 1.330 1.607 1.035 Station wagon 2.920 2.700 1.400 1.490 1.607 1.035 1.093 Station wagon 2.920 2.520 1.330 1.230 1.607 1.035 Station wagon 3.320 2.600 1.480 1.330 1.649 1.050 Station wagon 3.320 2.700 1.480 1.490 1.649 1.050 1.051 High-space...
- Page 12 Petrol/diesel, 5 cylinders Name PR-No. Wheelbase Permitted Permitted Permitted Unladen of it: on of it: Net load total axle load axle load weight front weight front rear with driver axle rear axle Box-type 2.920 delivery van Box-type 2.920 2.650 1.400 1.410 1.655 1.105 550 995...
- Page 13 Chassis with driver™s cab Chassis with 2.920 2.800 1.400 1.490 1.450 1.090 360 1.350 driver™s cab Chassis with 3.320 2.650 1.400 1.410 1.475 1.105 370 1.175 driver™s cab Chassis with 3.320 2.800 1.480 1.490 1.475 1.105 370 1.325 driver™s cab Chassis with 2.920 3.300...
- Page 14 High-space box-type delivery van High-space box-type 3.320 2.800 1.510 1.490 1.785 1.195 1.015 delivery van High-space box-type 0J5/1LE 3.320 2.890 1.510 1.490 1.785 1.195 1.105 delivery van Station wagon 2.920 Station wagon 2.920 2.700 1.510 1.330 1.712 1.140 Station wagon 2.920 2.800 1.510...
- Page 15 Chassis with 0J5/1LE 3.320 2.890 1.510 1.490 1.625 1.190 1.265 Double cab Chassis PR-No.1P4 is set deeper by 20 mm Unladen weight with trim panel in the passenger compartment/boot space. Trim panel controllable with PR-No. 5DA. Neu: Latest unladen weight including driver™s weight, but without seats in the passenger compartment! * Only for camper vans and sales vehicles Important notice: For vehicles with automatic gear, the unladen weight is increased by 30 kg (front axle +30 kg, rear axle 0 kg)
- Page 16 The weights must never exceed the permissible total weight • permitted front-axle weight • permitted rear-axle weight. • When projecting attachments/upgrades, it has to be ensured that a single-sided weight distribution is avoided - in particular if fixed attachments are to be installed. If it is not possible to adhere to this recommendation, the single-sided load may only result in a maximum difference between the wheel loads of 4%.
- Page 17 The chassis dimensions can be taken from the following drawings (see p. 20-23). Chassis drawings, on a scale of 1:20 and 1:10, are available to help you planning the attachment. If reinforced springs, enhanced springs are installed or if tyre sizes are used that are differing from the standard model, vehicle and frame heights (as measured from ground level) may change considerably.
- Page 18 Der Rahmen ist eine aus Blechpreßteilen bestehende Hohlprofilkonstruktion. Damit allen Gegebenheiten der Befestigung von Sonderaufbauten Rechnung getragen ist, sind konstruktiv folgende Vorkehrungen getroffen worden. Auf den Längsträgern sind Konsolen angeschweißt, die zur Befestigung der Sonder aufbauten dienen. Jede Konsole ist mit einer Bohrung von ø11 mm versehen.
- Page 19 Roof rack Roof loads raise the centre of mass of the vehicle and lead to a high dynamic axle-load shift and tilting of the vehicle on bumpy lanes and in bends. The road behaviour is considerably impaired. For this reason, roof loads should be avoided, if possible.
- Page 20 If rear luggage carriers for bicycles (max. 4 bicycles, equivalent to 75 kg) are mounted, it is required to relieve the tailboard. This is achieved by propping up the rear luggage carrier on the rear bumper. Afterwards, the hatchback lid hinges need only to carry the horizontal force component, thus preventing that the rear luggage carrier is tilting to the back.
- Page 21 Since calendar week 2/99, it is possible to supply the rear double-wing doors of box-type delivery vans and station wagons with both wheel bases, as well as with standard roof or standard high roof, with the above mentioned hinges ex works (PR-No.
- Page 22 If a vehicle is not operated for a longer period, the battery is gradually completely discharged by consuming devices (clock, tachograph, cigar lighter or radio), thus being constantly damaged. To avoid this damage, the line bundle is disconnected ex works using a plug-in connection which is reconnected when the vehicle is to be transferred, respectively by the delivery service.
- Page 23 Power output of the engine via V-belts At the engine, the output can be decreased by max. 10 kW via V-belts, if the available flange points are being used. The following power take-offs at the engine can be ordered ex factory if an air-conditioning system is available. However, a combination is not possible: Engines Installation...
- Page 24 - it is required to correct the regulation of the brake proportioning valve. The pressure check and regulation should be carried out at a Volkswagen dealer/workshop for utility vehicles. The regulation has to be performed in such a way that the balance beam is horizontal.
- Page 25 29±6/4 45±6/4 1000 53±8 1100 62±8 1200 69±10 1300 75±2 1400 82±10 1500 87±10 1600 97±122 1700 103±129 1800 108±135 For deviating axle loads, intermediate values are to be applied. For adjustment and function, refer to the operating instructions. Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines).
- Page 26 Connect the pressure gauge to the wheel cylinder (rear). Unscrew the bleeder valve for this. Operate the brake pedal with enough pressure to achieve the inlet pressure (see signboard of braking force regulator), then adjust the outlet pressure. After the check, bleed the brake system. Tighten the bleeder valve by MA=4,9+1Nm. With the specified axle loads, every pressure within the tolerance limits is permitted (e.
- Page 27 Possibility to increase the load up to a permitted total weight of 2,890 kg for vehicles with short and long front section, with both wheel bases, based on individual acceptance. 1. Preconditions: At vehicles with increased net load (PR-No. 0J3), it is required to convert the front-axle brake (standard: Ø 54 mm pin sliding calliper brake) to the Ø...
- Page 28 TDI engine, it is generally only possible to increase the load, if a calculation of weights is available for the upgraded special vehicle and if the brake calculation shows a positive result in the individual case.* Observe item 2.1! Import certificates can be obtained from: Volkswagen AG, Department NE-GG, Brieffach [pigeonhole] 1745, Postfach [P.O. box], 38436 Wolfsburg, Germany Fax +49-5361-972917 Time required for handling:approx.
- Page 29 The free space required for the wheels, including snow chains, must be considered. In the chassis drawings, the minimum distance between the top edge of the side rails and the wheel housings is indicated. Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines).
- Page 30 If additional modules, units, etc. are to be attached to the chassis, it is required to fix them with brackets which are welded to the side rail in the neutral zone. If it cannot be avoided to screw them directly on the frame, it is required that the rails are executed as hollow profiles on which also distance bushes are to be welded.
- Page 31 Instructions on the attachment of a loading crane Since a power take-off from the transmission is not available, the crane can only be operated with an electrical pumping unit (reinforced battery and generator required) or a hydraulic pump (hydraulic pump required at the engine). When projecting the loading crane attachments, the required stability of the loading crane is to be considered.
- Page 32 Instructions on the attachment of a loading tailboard Before attaching a loading tailboard, it has to be checked (by means of a load-distribution calculation) whether the permitted rear-axle load and the minimum front-axle load are kept. It is not permitted to attach a loading tailboard to standard box-type delivery vans without the approval of the relevant manufacturer.
- Page 33 Only couplings which are approved by us may be used as trailer couplings. The following trailer couplings can be ordered ex works as special equipment: Spherical coupler - order code: 1D6: For trailing loads up to max. 2 000 kg during braking, with 12% angle of gradient. The permitted externally applied load is 100 kg.
- Page 34 Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines). Data status August 2007...
- Page 35 If the unladen weight of the vehicle at which an attachment was installed is considerably increased, compared to the base vehicle, it is required to adjust the standing height at the front axle. This is the only way to avoid an excessively high torque-rod load at the top limit-stop.
- Page 36 In motor vehicle power-supply circuits, the individual consuming devices cause electrical disturbance variables. Volkswagen AG checks whether electronic components (which are installed by the manufacturer) are electromagnetically compatible inside the vehicle. If electrical or electronic systems are to be upgraded or retrofitted, it is also required to check their electromagnetic compatibility.
- Page 37 a) With lifting platforms The vehicle may only be lifted at the location points provided for that purpose (see illustration). Only 2-pillar lifting platforms may be used. b) With a lifting jack (up to a permitted total weight of 2,800 kg) See operating instructions for procedure and location points for the jack at all vehicle versions.
- Page 38 If the loading is increased up to the permitted total weight of 2,890 kg, the permitted axle loads of PR.-No. 0J3 remain unchanged. Under these circumstances, the standard jack (considering the above mentioned boundary conditions) may also be used. If the operators are procuring the jack themselves, it is required to adhere to the following instructions on jack selection: a) The maximum permitted axle load for transporter chassis can be found under the specifications for the variant with a permitted total weight of 3,300 kg (applies only to sale cars and mobile homes!).
- Page 39 At the box-type delivery van/station wagon, attachment and base group form a self-supporting unit. Supporting parts of this self-supporting unit must not be removed without being replaced by another component. Baffles have no supporting function. Modifications, even the complete removal, are permitted. A.
- Page 40 Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines). Data status August 2007...
- Page 41 Roof cut-outs to prepare the subsequent attachment of vent roofs, pop-up tops and high roofs are currently not available ex works. B. Retrofitting of Roof Cut-Outs 1. It is possible to realise roof cut-outs between the bows and the lateral roof chassis. For details, see below. 2.
- Page 42 3. Large roof cut-outs for normal roof versions and both wheel bases to retrofit high roofs and pop-up tops. - Only for vehicles with max. sliding door -...
- Page 43 On the left-hand and right-hand side, the large roof cut-out is limited in the passenger compartment/boot space by the sheet edges of the lateral roof chassis (see sectional view A-A). In the rear area, the cutting edge runs along the edge of the D-cross-beam interior plate (see sectional view B-B).
- Page 44 C. Pop-Up Tops Subsequent mounting of a pop-up top with large roof cut-out (wheel base 2,920 mm) 1. For the above mentioned roof cut-out (see draft in section B3), a complete assembly set for reinforcing the roof frame (including installation instructions) is available from Westfalia company, Rheda-Wiedenbrück.A two-part base plate is also included in this supply scope.
- Page 45 C. High Roofs Subsequent installation of a high roof (Wheel bases 2.920 and 3.320 mm) 1. Preconditions a) The max. roof cut-outs may correspond only to those mentioned in section B3 of this construction guideline - the same applies to the California. (see draft in section B3) b)The base vehicles may only be provided with max.
- Page 46 Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines). Data status August 2007...
- Page 47 E. Retrofitting of Standard Seats in the Passenger Compartment/Boot Space The floor layout of the box-type delivery van and station wagon is identical and is suitable for the subsequent mounting of standard seats (wheel base 2,920 mm: 2 rows of seats/wheel base 3,320 mm: 3 rows of seats) The retrofitting of standard seats according to the requirements of the appropriate series type is only permitted with the upgrading equipment/accessories.
- Page 48 1) In the passenger compartment of the station wagon All station wagons are prepared in such a way that their standard seat combinations can be easily retrofitted. Caravel, Multivan and California are constructed on basis of the station wagon car-body so that also in these cases the station wagon/Caravel standard seat combinations can be retrofitted according to the series requirements, provided that the necessary open space is available.
- Page 49 a) Base vehicle: Box-type delivery van, wheel base 2,920 mm, short front section, however not for TDI engines. b) Base vehicle: Box-type delivery van, wheel base 3,320 mm, short front section, also for TDI engines. Within the scope of usage as money and valuables transporters, it is possible to increase the load of vehicles with the above mentioned scope up to 2,890 kg, if the vehicle is provided ex works with 1) reinforced springs (Pr-No.
- Page 50 If chassis is transported on their own axles on public roads, it is mandatory to use transport equipment (wheel housings at the back and ballast weight, PR-No. 2 A1). The wheel housings are suitable for permanent usage. Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines).
- Page 51 Chassis Modifications a) with driver s cab The maximum permitted cut-out is limited by the C-pillars, the C-bow and the cab floor. If also the B-bow and parts of the roof are being removed, it is required to install a reinforcing frame according to drawing ENT-156011. (illustration 5.3) The connection between boot attachment and cab must be realised form-locking (i.
- Page 52 Additional fastening points for special attachments • The side rails are hollow profiles. If it is required to drill there, this may only be performed in the neutral zone (centre of side rail, but with sufficient distance to the flange). In addition, spacer bushings must then be welded Boreholes which are applied ex-works at the upper and lower belt of the side rails must not be drilled and/or •...
- Page 53 b) With double cab Cut-out at the rear wall The maximum permitted cut-out is limited by the B-pillars, the B-bow and the floor of the driver™s cab. Roof cut-outs between the bows are to be realised in compliance with the specifications for box-type delivery vans/station wagons (section 3.2 Roof cut-outs).
- Page 54 Modification of chassis with double cab pressure struts for the safety belts according to ENT-149 918. (Required for usage for the standard trailing link arms, if these must be removed for installing special attachment.)
- Page 55 Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines). Data status August 2007...
- Page 56 Weld work at the vehicle frame should remain limited to absolutely necessary exceptions. Before performing weld works at the vehicle, it is required to disconnect the car battery. If cables are damaged which are routed not openly with the battery being disconnected, short-circuits may lead to severe damages. When performing electric welding works, the earth terminal of the welding set must be directly connected to the vehicle part to be welded.
- Page 57 If a wheel-base extension is to be performed work should start with the long wheel base. • the frame should be disconnected approx. 480 mm behind the driver™s cab. • The max. permitted total weights, axle loads, rear overhangs (depending on the wheel base), etc. are to be observed. For this purpose, adhere to the sections "Dimensions and Weight".
- Page 58 General instructions on the modification of standard vehicles It is not permitted to modify spring characteristics, brake system and steering unit. Exceptions must be approved by Volkswagen AG before the modification is carried out. If noise-emitting parts (e. g. engine, tyres, exhaust system, etc.) are modified, it is required to perform noise measurements according to EC directives.
- Page 59 Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines). Data status August 2007...
- Page 60 Attachments with high centre of mass At vehicles with high attachments or with a raised overall centre of mass, the driving conditions are limited. Stabilizer bars are used to prevent excessive heeling of the vehicles. The following table shows which centre-of-mass height is permitted for vehicles with standard equipment. These heights must not be exceeded.
- Page 61 For all permitted weights, the centre-of-mass height, Y, must not be exceeded. All centre-of-mass heights indicated in the adjacent table always refer to the vehicle being loaded up to its respective permitted total weight. Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines).
- Page 62 The individual dimensional drawings are in formats JPG, DXF, IGES and DWG. All files are packed in a zip archive. The files can be unpacked using Winzip (PC) or ZipIt (MAC). Click on the link in question to save the selected file directly to your computer. You can then view and print out the dimension drawing using appropriate software (e.g.
- Page 63 Box-type delivery van, short wheelbase (A1m) Box-type delivery van, long wheelbase (H1m)
- Page 64 High-space box-type delivery van, long wheelbase (H1HDm) Chassis with driver™s cab, short wheelbase (E1m)
- Page 65 Chassis with driver™s cab, long wheelbase (L1m) Chassis with double cab, long wheelbase (M1m) Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body guidelines).
- Page 66 Transporter T4 Body builder guidelines Subject to modifications Edition November 2007 Internet: www.volkswagen-nutzfahrzeuge.de Consulting for body builders in Germany is available from the listed address. Volkswagen Commercial Vehicles Brieffach 2963 Postfach 21 05 80 D-30405 Hannover Fax. +49 511 798 8500...