Volkswagen Transporter 2004 Instruction sheet

The Transporter 2004
Self-study programme 310
Service.

2
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.
1967 The T2 continues the success of the Trans-
porter series further. Single piece winds-
creen and larger windows offer more
light and greater driving safety. Dimensi-
ons and load capacity increase. For the
first time, a side sliding door in installed.
1979 With a new body design, the T3 (T25)
offers more space, improved all-round
view and greater active and passive
safety. Load volume and payload capa-
city increase. A new front axle provides
improved road handling and safety.
1990 With the T4, a completely new vehicle
concept with front wheel drive and front
transverse mounted water-cooled engine
is introduced.
2003 The new Transporter is launched on the
market. The great variety ranges from
drop-side and panel van variants up to
the Multivan. It is again a trendsetter in its
class.
Important
Note
NEW
This self-study programme shows the design
and function of new developments!
The contents will not be updated.
For the latest testing, adjustment and repair
instructions, please refer to the relevant
service literature.
310_002

3
Contents
Brief overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Occupant safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Heating, air conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4
Brief overview
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The Transporter 2004
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.
–Reduced fuel consumption
–Extensive range of power units with
petrol and diesel engines
–6-speed manual or 6-speed automatic
gearboxes
–Joystick gear selection
–Improved crash safety
Highlights
–Extensive product range
–Two sliding door concept (sliding doors on
each side)
–Low profile roof rails
–Variable interior concept
–Improved devices for driving, comfort and
safety
–Decentralised onboard electrical system
–3zone Climatronic

5
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 11.9 m
Load rating 451 to 801 kg depending on equipment level
Maximum towing capacity 2500 kg
Maximum roof load capacity 100 kg
310_005
310_003
1626
4890
3000
1904
1626
1949
310_004
For data about other variants, please
refer to the latest sales literature.
Technical data (Multivan)

6
Body
The Transporter 2004 is produced in a wide
spectrum of designs:
–As a people carrier, the vehicle is available as
the Kombi, Shuttle, Multivan or RV.
–In the other versions, it serves mainly as a
means of goods transportation.
–Within the product range, models are
available as short and long wheelbase
versions.
Transporter 2004 model range
Panel van Kombi Shuttle Multivan
Wheelbase
3400 mm 3000 mm

7
310_007
–The vehicles vary in their payload capacity
due to different areas of application.
–At a later date, a four-wheel drive version
(4motion) will also be on offer.
The further contents of this publica-
tion are focused on the description of
the Multivan.
Recreation
vehicle
Drop-side with
cab
Chassis with
double cab
Drop-side with
double cab
Chassis with
cab

8
Basic body structure
A sturdy basic body structure is a prerequisite for
vehicle safety and comfort.
A body structure with a high level of rigidity and
high level of crash safety was attained by the use
of high tensile and reinforced panels, tailored
blanks, laser welding and one piece side panels.
Body
The high rigidity of the body is also a prerequi-
site for:
–High level of comfort in interior
–Tight shutlines for doors, bonnet and tailgate
–Perfect functioning of doors, bonnet and tail-
gate
–High durability
–High level of driving comfort
The extensive use of galvanised panels makes it
possible to offer a guarantee against rust perfo-
ration for 12 years.
Floor system
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Front cross panel member
Strut turret
Reinforced panels
High tensile panels
Tailored blank

9
Body
High tensile panels
Tailored blanks
Laser seam
C-pillar
reinforcement
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Sill/wheel housing
reinforcement
B-pillar
reinforcement
Hinge carrier
reinforcement
Guide rail
reinforcement
Laser seam

10
Body
Underbody covering
The underbody covering of the Multivan is made
up of the following parts:
–Underbody trim
–Heat shield
–Insulation tray
They meet high demands in terms of weight,
cdvalue, recycling, heat and noise insulation.
The quantity of PVC (polyvinylchloride) on the
underbody was reduced in favour of an under-
body trim made from polypropylene (with long
fibreglass elements).
Some of the heat shields of the exhaust system
also act as noise insulation thanks to their sand-
wich construction.
Heat shield
Underbody trim Insulation tray
Direction of
normal travel
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11
The double sided version is also referred to as a
two sliding door concept. On this version there is
no folding table on the left sidewall.
Sliding door
The Multivan has a sliding door on the front pas-
senger's side. A sliding door is also available on
the driver's side as an optional extra.
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Sliding door, left
–Operation of the electric sliding door is possi-
ble from the driver's seat via the switch in the
instrument panel, from inside and out via the
door handle or via the radio remote control.
The sliding door is a completely new develop-
ment and has the following features:
–The sliding door is operated manually.
It can also be equipped with an electric
power latching system.
–As an optional extra, the vehicle can be fitted
with an electric sliding door with integrated
electric power latching system.

12
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. The door is connected to the cable system by
means of a hinge joint.
Body
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Reel on sliding door motor
Design of cable system
Pulley
Cable to close
sliding door
Pulley
Cable attachment points
Hinge joint
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310_123
Cable to open
sliding door
Reel on sliding
door motor

13
Function
As the doors open and close under cable ten-
sion, two cables are necessary. One cable is
responsible for pulling the door open and the
other is responsible for pulling the door closed.
One end of the cable is attached to the motor
pulley. The cable is reeled around the pulley
here. The other end of the cable is attached to
the hinge joint.
By actuation of the sliding door motor, the door
is pulled open or closed via the relevant cable.
The motor direction of rotation is determined by
the sliding door control unit.
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Reel on sliding
door motor
Cable attachment points
Close
Pulley
Open
Hinge joint on sliding door with
cable attachment points
Pulley
If the electric sliding door operation fails, the door can still be opened and closed using
manual force.

14
Body
Actuation of electric sliding door
Signals are transferred between the sliding door
components and the sliding door control unit via
a sliding door coil and sliding door reader coil
on the upper sliding door guide. Electric opera-
tion is via the operating buttons on the interior,
the door handles or radio remote control.
310_136
Sliding door coil
You can find more details about the
electric sliding door in self-study pro-
gramme 311 "The Transporter 2004,
Electrical system".
Sliding door rollback function
Two systems of protection are used:
–The passive system reacts to any drop in the
speed of the sliding door motor. The result is
that the door will stop moving or rollback to
the open position.
–Response of the active system in the door seal
results in the door being completely opened.
310_137
Sensor for
rollback function
Locking unit for
central locking
Sliding door motor
Overview of components
Electric power
latching motor
Sender unit for
electric sliding door
Sliding door
control unit
Contact strip

15
Body
The electric power latching system is installed in
the C-pillar and consists of a power latching
motor and a striker pin.
The power latching motor is connected directly to
the eccentric bolt of the striker pin via a hollow
shaft with inner splines.
310_087
Striker pin
Hollow shaft with inner splines
Electric power
latching motor
Direction of
normal travel
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.

16
Function
When the hollow shaft turns on the power
latching motor, this movement is transferred to
the eccentric bolt.
Rest position
When the door is unlocked or opened, the
eccentric pin is in the rest position.
Body
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310_119
Locking
When the sliding door is placed in the prelock
position, the power latching motor is actuated
after locking. The hollow shaft of the power
latching motor turns the eccentric pin. The rota-
tion of the pin pulls the door into the end position
where it is held.
The function of the electric power latching system in the sliding door is described in
detail in the multimedia program entitled "The Transporter 2004".
Striker pin
Eccentric pin
Direction of
rotation lock

17
Tailgate
The tailgate is installed as standard in Multivan
and light commercial vehicles with enclosed
body.
As an optional extra, the tailgate can also be
installed with an electric power latching system.
Tailgate electric power latching system
The electric power latching system eases closing
of the tailgate and contributes towards comfort.
Function
The drive unit consists of an electric motor,
mechanical drive system and a striker wedge.
When the tailgate lock engages in the prelock
position, the electric motor is actuated and the
tailgate is pulled into the fully locked position.
Striker wedge
310_094
310_085
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.
310_120
Striker wedge in "prelock position"
Cam adjuster
Worm gear
Drive unit
Striker wedge
Striker wedge in "end position"
Electric motor
310_121
Tail gate lock
Prelock position
End position
Tail gate lock

18
Body
Wing doors
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.
The doors can be opened up to an angle of 90°.
As an option, an opening angle of 250° is possi-
ble.
310_078
Door holder with
cover cap
Opening lever on wing doors
The right door has an opening lever, which is
integrated in the body contour.
Wing door holder
The door holder allows the doors to be opened
and held in the following positions:
90° - Via the holder/unlocking mechanism on
the door (beneath cover cap)
250° - By pressing cover cap, striker wedge is
moved and striker pin released. The wing door
can now be fully opened to the magnetic door
holder on the body.
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Opening lever
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Magnetic door holder
Exterior handle
Door holder
Wing door
Striker wedge Striker wedge
actuation
310_132
Striker pin

19
Sun blind
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.
Sliding window
In the sliding door, there is a sliding window,
which closes flush with the outer body.
To open, the handle of the sliding window is pul-
led inwards and the window can then be pushed
back.
The sliding window can be placed in several
positions thanks to a multi-holed locking rail.
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310_075
Sun blind hook
Sun blind
Sliding window
Locking rail
Handle

20
Commercially available roof attachments, such
as
–roof box,
–ski holder,
–load carrier,
–bike rack or similar
can be attached to the rails.
The roof can withstand a maximum of 100 kg.
Body
The commercial vehicle variants feature 4 mounting plates in the roof instead of the
C-profile rails. These mounting plates are closed with sealing bolts. Retrofitting of
C-profile rails is possible as the bodywork is made ready for this purpose.
C-profile rails Insertion and
removal point
C-profile rail
310_012
Speed nut
Body panel
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. The recesses are protec-
ted by cover caps.
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