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
9

Station wagon 0J2 2.920 2.600 1.400 1.330 1.6072) 1.035 572 993
Station wagon 0J3 2.920 2.700 1.400 1.490 1.6072) 1.035 572 1.093
Station wagon1) 0J2 2.920 2.520 1.330 1.230 1.6072) 1.035 572 913
Station wagon 0J2 3.320 2.600 1.480 1.330 1.6492) 1.050 599 951
Station wagon 0J3 3.320 2.700 1.480 1.490 1.6492) 1.050 599 1.051
High-space
station wagon 0J2 3.320 2.600 1.480 1.330 1.6992) 1.075 624 901
High-space
station wagon 0J3 3.320 2.700 1.480 1.490 1.6992) 1.075 624 1.001
Flatbed truck 0J2 2.920 2.525 1.250 1.410 1.530 1.030 500 995
Flatbed truck 0J3 2.920 2.785 1.330 1.490 1.530 1.030 500 1.255
Flatbed truck 0J2 3.320 2.575 1.330 1.410 1.580 1.055 525 995
Flatbed truck 0J3 3.320 2.785 1.400 1.490 1.580 1.055 525 1.205
Flatbed truck 0J5/1LE 3.320 2.890 1.510 1.490 1.580 1.055 525 1.310
Deep-loading
flatbed truck 0J2 3.320 2.575 1.330 1.410 1.580 1.060 520 995
Deep-loading
flatbed truck 0J3 3.320 2.785 1.400 1.490 1.580 1.060 520 1.205
Deep-loading
flatbed truck 0J5/1LE 3.320 2.890 1.510 1.490 1.580 1.060 520 1.310
Chassis with
driver™s cab 0J2 2.920 2.525 1.250 1.410 1.375 1.015 360 1.105
Chassis with
driver™s cab 0J3 2.920 2.785 1.330 1.490 1.375 1.015 360 1.410
Chassis with
driver™s cab 0J2 3.320 2.575 1.330 1.410 1.400 1.030 370 1.175
Chassis with
driver™s cab 0J3 3.320 2.785 1.400 1.490 1.400 1.030 370 1.385
Chassis with
driver™s cab* 0J4 2.920 3.255 1.480 1.800 1.375 1.015 360 1.880
Chassis with
driver™s cab* 0J4 3.320 3.255 1.480 1.800 1.400 1.030 370 1.855
Chassis with
driver™s cab 0J5/1LE 3.320 2.890 1.510 1.490 1.400 1.030 370 1.490
Double cab 0J2 3.320 2.575 1.400 1.490 1.650 1.085 565 925
Double cab 0J3 3.320 2.785 1.400 1.490 1.650 1.085 565 1.135
Double cab 0J5/1LE 3.320 2.890 1.510 1.490 1.650 1.085 565 1.240
Chassis with
Double cab 0J2 3.320 2.575 1.400 1.490 1.520 1.085 435 1.055
Chassis with
Double cab 0J3 3.320 2.785 1.400 1.490 1.520 1.085 435 1.265
Chassis with
Double cab 0J5/1LE 3.320 2.890 1.510 1.490 1.520 1.085 435 1.370
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.
New: Latest unladen weight including driver™s weight, but without seats in the passenger compartment!
* Only for camper vans and sales vehicles
Important notice: For vehicles with automatic gear, the unladen weight is increased by 30 kg (front axle +30 kg, rear axle
0 kg)
10

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 2.920 2.650 1.400 1.410 1.655 1.105 550 995
Box-type
delivery van 0J3 2.920 2.800 1.480 1.490 1.655 1.105 550 1.145
Box-type
delivery van1) 0J2 2.920 2.600 1.400 1.230 1.655 1.105 550 945
Box-type
delivery van 0J2 3.320 2.700 1.480 1.410 1.705 1.140 565 995
Box-type
delivery van 0J3 3.320 2.800 1.480 1.490 1.705 1.140 565 1.095
Box-type
delivery van 0J5/1LE 3.320 2.890 1.510 1.490 1.705 1.140 565 1.185
High-space
box-type
delivery van
0J2 3.320 2.700 1.480 1.410 1.755 1.165 590 945
High-space
box-type
delivery van
0J3 3.320 2.800 1.480 1.490 1.755 1.165 590 1.045
High-space
box-type
delivery van
0J5/1LE 3.320 2.890 1.510 1.490 1.755 1.165 590 1.135
Station wagon 0J1 2.920 - - - - - - -
Station wagon 0J2 2.920 2.700 1.480 1.330 1.682 1.110 572 1.018
Station wagon 0J3 2.920 2.800 1.480 1.490 1.682 1.110 572 1.118
Station wagon1) 0J2 2.920 2.620 1.400 1.230 1.682 1.110 572 938
Station wagon 0J2 3.320 2.700 1.570 1.330 1.724 1.125 599 976
Station wagon 0J3 3.320 2.800 1.570 1.490 1.724 1.125 599 1.076
Station wagon 0J5/1LE 3.320 2.890 1.570 1.490 1.724 1.125 599 1.166
High-space
station wagon 0J2 3.320 2.700 1.570 1.330 1.724 1.150 624 926
High-space
station wagon 0J3 3.320 2.800 1.570 1.490 1.724 1.150 624 1.026
High-space
station wagon 0J5/1LE 3.320 2.890 1.570 1.490 1.724 1.150 624 1.116
Flatbed truck 0J2 2.920 2.600 1.330 1.410 1.605 1.105 500 995
Flatbed truck 0J3 2.920 2.800 1.400 1.490 1.605 1.105 500 1.195
Flatbed truck 0J2 3.320 2.650 1.400 1.410 1.655 1.130 525 995
Flatbed truck 0J3 3.320 2.800 1.480 1.490 1.655 1.130 525 1.145
Flatbed truck 0J5/1LE 3.320 2.890 1.510 1.490 1.655 1.130 525 1.235/1.214
Deep-loading
flatbed truck 0J2 3.320 2.650 1.400 1.410 1.655 1.135 520 995
Deep-loading
flatbed truck 0J3 3.320 2.800 1.480 1.490 1.655 1.135 520 1.145
Deep-loading
flatbed truck 0J5/1LE 3.320 2.890 1.510 1.490 1.655 1.135 520 1.235/1.214
0J2 2.920 2.600 1.330 1.410 1.450 1.090 360 1.150
11

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 1.570 1.800 1.450 1.090 360 1.850
Chassis with
driver™s cab* 0J4 3.320 3.300 1.570 1.800 1.475 1.105 370 1.825
Chassis with
driver™s cab 0J5/1LE 3.320 2.890 1.510 1.490 1.475 1.105 370 1.415
Double cab 0J2 3.320 2.650 1.480 1.490 1.725 1.160 565 925
Double cab 0J3 3.320 2.800 1.480 1.490 1.725 1.160 565 1.075
Double cab 0J5/1LE 3.320 2.890 1.510 1.490 1.725 1.160 565 1.165
Chassis with
Double cab 0J2 3.320 2.650 1.480 1.490 1.595 1.160 435 1.055
Chassis with
Double cab 0J3 3.320 2.800 1.480 1.490 1.595 1.160 435 1.205
Chassis with
Double cab 0J5/1LE 3.320 2.890 1.510 1.490 1.595 1.160 435 1.295
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.
New: Latest unladen weight including driver™s weight, but without seats in the passenger compartment!
Important notice: For vehicles with automatic gear, the unladen weight is increased by 30 kg (front axle +30 kg, rear axle
0 kg)
5 cylinders, TDI/VR 6 petrol engine
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 2.920 2.680 1.430 1.410 1.685 1.135 550 995
Box-type
delivery van 0J3 2.920 2.800 1.510 1.490 1.685 1.135 550 1.115
Box-type
delivery van1) 0J2 2.920 2.630 1.430 1.230 1.685 1.135 550 945
Box-type
delivery van 0J2 3.320 2.730 1.510 1.410 1.735 1.170 565 995
Box-type
delivery van 0J3 3.320 2.800 1.510 1.490 1.735 1.170 565 1.065
Box-type
delivery van 0J5/1LE 3.320 2.890 1.510 1.490 1.735 1.170 565 1.155
0J2 3.320 2.730 1.510 1.410 1.785 1.195 590 945
12

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 1.140 572 988
Station wagon 0J3 2.920 2.800 1.510 1.490 1.712 1.140 572 1.088
Station wagon1) 0J2 2.920 2.620 1.430 1.230 1.712 1.140 572 908
Station wagon 0J2 3.320 2.700 1.600 1.330 1.754 1.155 599 946
Station wagon 0J3 3.320 2.800 1.600 1.490 1.754 1.155 599 1.046
Station wagon 0J5/1LE 3.320 2.890 1.600 1.490 1.754 1.155 599 1.136
High-space
station wagon 0J2 3.320 2.700 1.600 1.330 1.754 1.180 624 896
High-space
station wagon 0J3 3.320 2.800 1.600 1.490 1.754 1.180 624 996
High-space
station wagon 0J5/1LE 3.320 2.890 1.600 1.490 1.754 1.180 624 1.086
Flatbed truck 0J2 2.920 2.630 1.360 1.410 1.804 1.135 500 995
Flatbed truck 0J3 2.920 2.800 1.430 1.490 1.804 1.135 500 1.165
Flatbed truck 0J2 3.320 2.680 1.430 1.410 1.635 1.160 525 995
Flatbed truck 0J3 3.320 2.800 1.510 1.490 1.635 1.160 525 1.115
Flatbed truck 0J5/1LE 3.320 2.890 1.510 1.490 1.635 1.160 525 1.205
Deep-loading
flatbed truck 0J2 3.320 2.680 1.430 1.410 1.685 1.165 520 995
Deep-loading
flatbed truck 0J3 3.320 2.800 1.510 1.490 1.685 1.165 520 1.115
Deep-loading
flatbed truck 0J5/1LE 3.320 2.890 1.510 1.490 1.685 1.165 520 1.205
Chassis with
driver™s cab 0J2 2.920 2.630 1.360 1.410 1.685 1.120 360 1.150
Chassis with
driver™s cab 0J3 2.920 2.800 1.430 1.490 1.685 1.120 360 1.320
Chassis with
driver™s cab 0J2 3.320 2.680 1.430 1.410 1.505 1.135 370 1.175
Chassis with
driver™s cab 0J3 3.320 2.800 1.510 1.490 1.505 1.135 370 1.295
Chassis with
driver™s cab 0J5/1LE 3.320 2.890 1.510 1.490 1.505 1.135 370 1.385
Chassis with
driver™s cab* 0J4 2.920 3.300 1.600 1.800 1.480 1.120 360 1.820
Chassis with
driver™s cab* 0J4 3.320 3.300 1.600 1.800 1.505 1.135 370 1.795
Double cab 0J2 3.320 2.680 1.510 1.490 1.755 1.190 565 925
Double cab 0J3 3.320 2.800 1.510 1.490 1.755 1.190 565 1.045
Double cab 0J5/1LE 3.320 2.890 1.510 1.490 1.755 1.190 565 1.135
Chassis with
Double cab 0J2 3.320 2.680 1.510 1.490 1.625 1.190 435 1.055
Chassis with
Double cab 0J3 3.320 2.800 1.510 1.490 1.625 1.190 435 1.175
13

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 without seats in the passenger compartment!
* Only for camper vans and sales vehicles
Important notice: For vehicles with automatic gear, the unladen weight is increased by 30 kg (front axle +30 kg, rear axle
0 kg)
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
14

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 not possible to adhere to this recommendation, the single-sided
load may only result in a maximum difference between the wheel loads of 4%.
Example:
Permitted axle load 1.430 kg
Theoretical wheel load left/right 715 kg/715
kg
4% of this wheel load 29 kg
Permitted wheel load distribution
left/right
686 kg/744
kg
To ensure a sufficient manoeuvrability and a satisfying driving behaviour of the vehicle in all loading states, the minimum
front-axle load must be 965 kg.
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
15

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 model,
vehicle and frame heights (as measured from ground level) may change considerably. In this case, it is necessary to
consider this equipment during projecting.
Important note
The minimum distance between cab and attachment must be at least 30 mm.•
The rear overhang of the attachments must not exceed 40% of the wheel base.•
The maximum permitted overhang (rear) of 40% of the wheel base, results in the following max. external attachment
lengths for chassis. These values must not be exceeded:
Wheelbase
Standard attachment
length, interior
max. external attachment
length, 40% overhang
Chassis with
driver™s cab
2.920 mm 2.505 mm 2.686 mm
Chassis with
driver™s cab
3.320 mm 2.905 mm 3.246 mm
Chassis with
double cab
3.320 mm 2.140 mm 2.476 mm
Attachment width:
The exterior width of the driver™s cab is 1,840 mm. If the standard exterior mirrors are used, the attachment width must
not exceed 2,200 mm.
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
16

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 aufbauten dienen. Jede Konsole ist
mit einer Bohrung von ø11 mm versehen.
Die Befestigung zwischen Aufbau und Fahrzeugrahmen sollte immer über alle Konsolen erfolgen. Die Schraubverbindung
zu den Konsolen muß kraftschlüssig ausgeführt werden.
Der Spalt zwischen den Konsolen über dem Fahrgestellrahmen muß nicht ausgefüttert werden.
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
17

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 least 2 base carriers are required which are to be mounted in the pillar area, if possible.
Roof loads (only for standard vehicles):
Vehicles with high-space roof 100 kg
Vehicles with standard roof 100 kg
Double cab 75 kg
Driver™s cab 50 kg
Pop-up top 50 kg
Rear luggage carriers/rear ladders
The rear luggage carrier or the rear ladder must be executed in such a way, that, after having been mounted, no vertical
static or dynamic loads are working on the tailboard or rear double-wing doors. In combination with the currently available
hatchback lid hinges, rear luggage carriers (for max. 4 bicycles, equivalent to a weight of 75 kg) must not be propped up
on the rear bumpers. Since the beginning of the great product upgrading (January 1996), rear luggage carriers may no
longer be propped up on the rear bumpers.
Load of tailboards/rear double-wing doors
Since the beginning of series production of the T4 (1990), the tailboard is provided with the shown hatchback lid hinge
(figure 1).
18

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 preventing that the rear luggage carrier is tilting to the
back. Since the currently available hatchback lid hinges (figure 2) are being used, it is no longer necessary to relieve the
tailboard by propping it up on the rear bumper. However, this option is still possible. Since the great product upgrading
(January 1996), new bumpers are in use which may no longer be used for supporting the rear luggage carriers, due to
their construction, but which is, however, no longer necessary. A fatigue loading of the rear bumpers may lead to
permanent bumper distortions!
Fig. 1
Fig. 2
Note: With the introduction of the currently available hatchback lid-hinge version, the air gap between roof and opened
tailboard was considerably reduced. To prevent the top holding clamps of the rear luggage carrier from pressing onto the
roof if the tailboard is being opened, it is required that they can be mounted directly next to the hatchback lid hinges!
Depending on the equipment scope of the tailboards (i. e. weight), appropriately strong gas springs are used. Within the
scope of a subsequent retrofitting, the tailboard weight may increase, so that the tailboards then no longer can be opened
up to the top limit-stop. The following table will help you to select appropriate gas springs.
Drawing No.: Ejection
force in N
F1
Insertion
force in N
F4 max
Friction
in N
FRmax
Ejection
speed in m/s
vs8
Identification
(print)
Statically measured force at +20°C
701 829 331 Q 710±30 960 80 0,15...0,4 1 bar
701 829 331 R 770±30 1030 80 0,15...0,4 2 bars
701 829 331 S 830±30 1120 80 0,15...0,4 3 bars
701 829 331
AB 910±30 1200 80 0,15...0,4 4 bars
As before, rear double-wing doors may carry no additional loads!
250° hinges for the rear double-wing doors
19