0. Introduction

This Manual covers the models in the Volkswagen Transporter range from the end of 1999, generally referred to as Type T4 vehicles, with a choice of three diesel engines. The following engines are covered in this manual:

• The 1.9 litre diesel engine is a four-cylinder engine and has the type designation “ABL”, replacing the engine type “1X”. The engine has a performance of 50 kW at 3700 rpm. Earlier engines of the same capacity were rated at 45 kW at the same speed. There is also a 55 kW diesel engine. Either a diesel or turbo diesel engine is fitted.
• The 2.4 litre diesel engine is a five-cylinder engine and has now the type designation “AJA”, replacing the previously used “AAB” engine. The engine has a performance of 55 kW at 3700 rpm (“AAB” engine 57 kW at 3700 rpm.) The engine is of the conventional type with indirect diesel fuel injection.
• From approx. August 1995 a new engine with a capacity of 2.5 litres has been fitted to T4 models, but the engine types have been changed since introduction. The engine performance is given in Section 1.0. The latest engines have the code letters “AXG”, “AXL” and “AYC”. All engines operate with direct fuel injection (TDI engine). A catalytic converter, exhaust gas recirculation, a turbo charger and a charge air intercooler are used in these vehicles.

The front suspension consists of an upper and lower wishbones, torsion bars and a stabiliser bar (anti-roll bar), together with double-acting, hydraulic shock absorbers. Not all models have the stabiliser bar. The individual parts of the front suspension can be removed from the vehicle without dismantling the complete assembly. All parts of the front suspension are mounted to a strong crossmember, which can be removed as a complete unit in order to remove the individual units, if major repairs are necessary.

The rear suspension consists of suspension arms with coil springs and hydraulic shock absorbers and a stabiliser (antiroll) bar. The suspension arms are rubber-mounted on the chassis. The wheel hub carrier is bolted to the outside of the suspension arm. The connection to the rear drive shafts takes place at the inside of each rear wheel hub carrier.

A rack and pinion steering, fitted with servo-assistance, is used. Disc brakes at the front wheels and rear wheels are fitted and a brake servo unit as standard fitment, make up the brake system, but not all models have the same front disc brake assemblies. Two types of Lucas calipers or Teves/ATE calipers were used during production and irrespective of the models in question will be covered in the relevant section. ABS can now be fitted to the vehicle. The vacuum for the operation of the brake servo unit is supplied by a separate exhauster pump (vacuum pump).

A five-speed manual or an automatic transmission can be fitted to the vehicles covered in this manual.

With regards to the range of models covered in the manual it must be pointed out that not all of these will be available in any particular country and that the manufacturer reserves the right to make modifications to standard equipment, optional extras and trim as may be necessary for any territory.

Since the variations between certain models are only in fittings and trim it will be unnecessary in some parts of this manual to refer to individual model designations.

The type identification plate can be found near the front door pillar, close to the door striker plate, at the position shown in Fig. 0.1. The chassis number is stamped into the right-hand side, below the windscreen, and is visible from the outside of the vehicle (arrow, Fig. 0.2). The chassis number can have the following appearance:

WVW2 ZZZ 370 Z Y H 00001

which relates to the following data:

• The first three letters with the “2” refer to the code letters of the manufacturer.
• The next three letters are filler letters.
• The number “370” refers to the model designation.
• The single “Z” is a filler letter.
• The letter “Y” refers to the model year, in this case given for a 2000 model. After “Y” you will find “1”, “2” or “3” (2001, 2002, 2003), referring to subsequent model years.
• The “H” refers to the manufacturing plant in Germany.
• The last numbers are the actual serial number of the vehicle.

The engine number of a 1.9 litre diesel engine is stamped into the cylinder block between the injection pump and the vacuum pump, at the position shown in Fig. 0.3. The engine code of the two five-cylinder engines can be found next to the injection pump on the left-hand side of the cylinder block, at the position shown in Fig. 0.4. The engine code and engine serial number are quoted. A sticker with the engine code and the engine number is attached to the upper timing belt cover.

These numbers are the essential information needed whenever spares or replacement parts are required. The vehicle manufacturer operates a policy of constant improvement and updating and it is only by quoting the vehicle and engine numbers that your dealer can provide you with the correct spares and replacements. The engine code is also included in the details of the vehicle data plate.

Note: If ever in the life of your T4 a replacement cylinder block is fitted, make sure that the original engine number has been transferred to the new cylinder block. This is (a) a legal requirement and (b) will avoid complications whenever you want to sell, part exchange or use the vehicle abroad.

The transmission and the automatic transmission are also identified by a number. As not all transmissions, i.e. gearboxes have the same reduction ratio for the final drive, it will be necessary to refer to these identification numbers (further details in Section 3) when for example a secondhand transmission is fitted. Each transmission has a code and is allocated to a particular engine within the vehicle range.

Section “Brakes” will refer to details where to find the code for the fitted front brake calipers, without the need to remove the front wheels to check their construction.