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
310_042
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
310_013
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
310_011
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
310_014