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Volkswagen Transporter T4 2007 Manuallines

Summary of Transporter T4 2007

  • Page 1

    Body builder guidelines 20 07 body builder guidelines transporter t4.

  • Page 2

    The body builder guidelines define the requirements for custom body builders and equipment fitters designing and mounting bodies or performing conversions to base vehicles of the volkswagen commercial vehicles brand. The body builder guidelines must be strictly adhered to when performing any modific...

  • Page 3

    The body builder's or fitter's warranty conditions apply to the body builder's or fitter's scope of supply. Therefore, warranty claims associated with complaints to this scope of supply cannot be made under the warranty conditions applicable to volkswagen commercial vehicles. Volkswagen vehicles del...

  • 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 • d...

  • 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 substan...

  • 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 ...

  • 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 provid...

  • 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 dimens...

  • 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 8.

  • 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), increas...

  • Page 11

    Station wagon 0j2 2.920 2.600 1.400 1.330 1.607 2) 1.035 572 993 station wagon 0j3 2.920 2.700 1.400 1.490 1.607 2) 1.035 572 1.093 station wagon 1) 0j2 2.920 2.520 1.330 1.230 1.607 2) 1.035 572 913 station wagon 0j2 3.320 2.600 1.480 1.330 1.649 2) 1.050 599 951 station wagon 0j3 3.320 2.700 1.480...

  • Page 12

    Petrol/diesel, 5 cylinders name pr-no. Wheelbase permitted total weight permitted axle load front permitted axle load rear unladen weight with driver of it: on front axle of it: on rear axle net load mm kg kg kg kg kg kg kg box-type delivery van 0j1 2.920 - - - - - - - box-type delivery van 0j2 2.92...

  • Page 13

    Chassis with driver™s cab chassis with driver™s cab 0j3 2.920 2.800 1.400 1.490 1.450 1.090 360 1.350 chassis with driver™s cab 0j2 3.320 2.650 1.400 1.410 1.475 1.105 370 1.175 chassis with driver™s cab 0j3 3.320 2.800 1.480 1.490 1.475 1.105 370 1.325 chassis with driver™s cab* 0j4 2.920 3.300 1.5...

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    High-space box-type delivery van high-space box-type delivery van 0j3 3.320 2.800 1.510 1.490 1.785 1.195 590 1.015 high-space box-type delivery van 0j5/1le 3.320 2.890 1.510 1.490 1.785 1.195 590 1.105 station wagon 0j1 2.920 - - - - - - - station wagon 0j2 2.920 2.700 1.510 1.330 1.712 1.140 572 9...

  • Page 15

    Chassis with double cab 0j5/1le 3.320 2.890 1.510 1.490 1.625 1.190 435 1.265 1) chassis pr-no.1p4 is set deeper by 20 mm 2) 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 with...

  • 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 no...

  • 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 mode...

  • 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 auf...

  • 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. Depending on load distribution, at ...

  • 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...

  • 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. 5v4). The double-wing doors can first be opened up t...

  • 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 reconne...

  • 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 ...

  • Page 24

    An operating permit is available for the brake system of the vehicles. This licensing becomes invalid if the brake system is modified. Load-related brake proportioning valve (only for front-wheel drive) the load-related brake proportioning valve is conceived for adjusting the brake pressure at the r...

  • Page 25

    800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 50 100 100 100 100 100 120 120 140 140 140 29±6/4 45±6/4 53±8 62±8 69±10 75±2 82±10 87±10 97±122 103±129 108±135 for deviating axle loads, intermediate values are to be applied. For adjustment and function, refer to the operating instructions. Not...

  • 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 bl...

  • 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 (stand...

  • Page 28

    Without special attachments. Wheel base 2920 mm these vehicles must have a minimum rear-axle load of 640 kg, to permit that they can also be driven without special attachment. In this context, it is not necessary to deal with the compliance with other possible regulations on driving. 1. No further b...

  • 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...

  • 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 al...

  • 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...

  • 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 ...

  • 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 app...

  • 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 33.

  • 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. Adjustment: a) d...

  • 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...

  • 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 ...

  • 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. 3. If the operators are procuring the jack themselv...

  • 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 permitt...

  • 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 39.

  • 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. Roof cut-outs betwe...

  • 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 - 41.

  • 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-...

  • 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 ma...

  • 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 45.

  • 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 retrofi...

  • 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/ca...

  • 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 in...

  • 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 ...

  • 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 connecti...

  • 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 in. • boreholes...

  • 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-...

  • 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.) 53.

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    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 54.

  • 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...

  • 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,...

  • Page 58

    Subframe the subframe must consist of steel. It is required for attachments whose lumped loads are guided into the chassis, e. G. For dump trucks and tractive units. The subframe is used to distribute the forces, which are induced punctiformly, uniformly over the entire chassis frame. For this purpo...

  • 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 58.

  • 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 w...

  • 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...

  • 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 dimensi...

  • Page 63

    Box-type delivery van, short wheelbase (a1m) box-type delivery van, long wheelbase (h1m) 62.

  • Page 64

    High-space box-type delivery van, long wheelbase (h1hdm) chassis with driver™s cab, short wheelbase (e1m) 63.

  • 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). Data status november 20...

  • Page 66

    Body builder guidlines 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...