Volkswagen Transporter T4 2007 Instruction Manual

Body builder guidelines 2007
Body builder guidelines
Transporter T4

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 modifications to the vehicle.
Ensure that no modification adversely affects the functional reliability and safety of the running gear, the body or the
electric system. Modifications must only be performed by qualified specialists and in accordance with the generally
acknowledged rules of the automotive industry.
Prerequisites for modifications to used vehicles: The vehicle must be in a good overall condition, i.e. structural parts such
as longitudinal and cross members, pillars etc. must not be corroded to such an extent that structural stability might be
adversely affected.
Vehicles whose modifications might affect the validity of general certificate of roadworthiness must be presented to an
authorised testing centre for approval. It is recommended to clarify in advance with the relevant authority whether approval
is required.
When inquiring about planned modifications, please enclose two sets of design drawings of the complete scope of the
modification, including weights, centre of gravity and dimensions, which also clearly show how the body is attached to the
chassis. Please use the online contact form:
http://www.vwn-aufbaurichtlinien.de/de/kontaktformular
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.
The work safety regulations of the trade association and the EU machine directive apply.
When making modifications to vehicles, all corresponding and applicable legal regulations, rules, laws and directives must
be observed.
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
1

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 delivered after 01. January 2005 are covered by a 2-year warranty without mileage limitation for the
flawless condition of the product (Volkswagen warranty).
Defects of bodies, installations and conversions provided by third parties as well as defects of the vehicle caused by the
said bodies, installations or conversions are excluded from the Volkswagen warranty and also from the Volkswagen paint
and body warranty. This also applies to accessories which were not installed and/or supplied by the vehicle manufacturer.
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.
Due to the multitude of conversions and diversity of operating conditions, the information provided by Volkswagen AG is
subject to the reservation that modified vehicles are not tested by Volkswagen AG. Modifications may affect the properties
of the vehicle.
For reasons of liability, the body builders or fitters must provide the following information in writing to their
customers:
"Due to the modifications* to your Volkswagen Commercial Vehicles base vehicle, the properties of your base vehicle may
have changed.
Please understand that Volkswagen AG does not assume any liability for any negative effects resulting from the
modifications* to the vehicle."
* At this point, the term "modification" may be substituted by a more precise description of the work performed, e.g. by
"camping equipment installation", "wheelbase extension", "box body".
In individual cases, Volkswagen AG reserves the right to demand proof of the information being passed on to the
customer.
No general legal entitlement for the approval of a body modification exists, even if such approval was previously granted.
Bodies, installations or conversions complying with the present guidelines do not require additional approval by
Volkswagen AG to be presented at the authorised examining body.
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
2

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•
Disconnect battery(ies)•
Remove dirt, snow and moisture from vehicle (footwell)•
Close windows, doors, front lid, rear lid and sunroof•
Put manual gearbox into 1st gear or lever of automatic gearbox into park position. Do not engange reverse gear.
Do not apply the parking brake.
•
Remove the windscreen wiper bags and prop up the wiper arm using a foam pad, remove any loose protective
film. ("Aero wipers": remove and store in suitable location inside vehicle).
•
Check tyre pressures; increase to 4.5 bar for commercial vehicles, if required.•
Check vehicles weekly for contamination by aggressive media (e.g. bird droppings, industrial dusts) and clean, if required.
Check battery open-circuit voltage every three months. Open-circuit voltage means the voltage of the disconnected
battery after a minimum storage period of 12 hours. Recharge battery in due time before it reaches an open-circuit voltage
of 12.4 volt ('magic eye' changes from green to black). Batteries with an open-circuit voltage of less than 11.6 volt are in
state of exhaustive discharge and should be disposed of soon.
Batteries must be recharged only with current-controlled and voltage-limited chargers. A maximum charging voltage of
14.4 volt must not be exceeded.
It is recommended to check the tyre inflation pressure every three months and to increase it to 4.5 bars for commercial
vehicles, if required.
Reconnect battery negative lead(s) before recommissioning the vehicle.
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
3

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. This ensures that modified vehicles are processed in compliance with environmental rules
and regulations at the end of their lifecycle.
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
4

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.
This should be supported by a repair manual including tightening torques, settings and tolerances as well as other
relevant specifications. Special tools, including their source of supply, must also be stated.
The manual must also state which type of work must be performed only by the body builders and accessories fitters or
their authorised workshops.
If the body builders or accessory fitter's scope of supply includes electric, electronic or mechatronic, hydraulic or
pneumatic systems, circuit diagrams and diagnosis routines or similar documentation facilitating a systematic search for
faults must be provided.
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
5

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.
Country-specific laws, directives and approval regulations must be observed.
The body builder or device or equipment manufacturer is responsible for the compliance with these laws, rules and
regulations.
For further information about commercial freight traffic in the Federal Republic of Germany please contact:
Berufsgenossenschaft für Fahrzeughaltung
Fachausschuss "Verkehr"
Sachgebiet "Fahrzeuge"
Ottenser Hauptstraße 54
22765 Hamburg, Germany
Homepage: www.bg-verkehr.de
E-Mail: [email protected]@bgf.de
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 September 2010
6

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
Weight)
•
Chassis for sales cars and mobile homes with a permitted total weight of 3,300 kg (details 2.1 Dimensions and
Weight).
•
Large proportion of usable floor area•
Hatch clearance width between the wheel housings: 122 cm; pallet dimensions•
Low, plane loading floor with a height of 52 cm•
Stable frame and smooth upper belt for easy attachment mounting•
Independent suspension, at the front and back•
Powerful and economical engine program•
cw peak value of 0.36 for box-type delivery van and station wagon•
High vehicle safety•
Trailing load up to 2,000 kg•
Syncro offer for all models with standard net-load (PR-No. 0J2) and increased net load (PR-No. 0J3)•
Little maintenance efforts•
7

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

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. 0J5). syncro vehicles are only available with standard net-load (PR-No. 0J2) and increased net load
(PR-No. 0J3).
Note:
There are also chassis with increased net load (PR.-No. 0J4) available (only for sales cars and mobile homes). Permitted
total weight 3,300 kg - only in front-wheel drive version!
Permitted Weight, Unladen Weight
The weight specifications in the technical data refer to the standard base vehicle equipment. According to DIN 70020,
weight tolerances of +5% are permitted in production and are to be considered, where appropriate.
If extras are installed, the permitted unloaded weight increases. The final unladen weight of the entire vehicle is to be
determined using a scale.
Petrol/diesel, 4 cylinders
Petrol/diesel, 5 cylinders
5 cylinders, TDI/VR 6 petrol engine
Petrol/diesel, 4 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 2.380 1.250 1.230 1.580 1.030 550 800
Box-type
delivery van 0J2 2.920 2.575 1.330 1.410 1.580 1.030 550 995
Box-type
delivery van 0J3 2.920 2.785 1.400 1.490 1.580 1.030 550 1.205
Box-type
delivery van1) 0J2 2.920 2.525 1.330 1.230 1.580 1.030 550 945
Box-type
delivery van 0J2 3.320 2.625 1.400 1.410 1.630 1.065 565 995
Box-type
delivery van 0J3 3.320 2.800 1.480 1.490 1.630 1.065 565 1.170
Box-type
delivery van 0J5/1LE 3.320 2.890 1.510 1.490 1.630 1.065 565 1.260
High-space
box-type
delivery van
0J2 3.320 2.625 1.400 1.410 1.680 1.090 590 945
High-space
box-type
delivery van
0J3 3.320 2.800 1.480 1.490 1.680 1.090 590 1.120
High-space
box-type
delivery van
0J5/1LE 3.320 2.890 1.510 1.490 1.630 1.065 565 1.210
Station wagon 0J1 2.920 2.430 1.330 1.230 1.6072) 1.035 572 823
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