VW T4 Transporter Diesel (90 - June 03) H to 03 Haynes Online Manual

Specifications
General

Engine type 5-cylinder, in-line, single overhead camshaft

Engine codes:
2.4 litre engines:
57 kW engines AAB
55 kW engines AJA
2.5 litre engines:
75 kW engines ACV, AUF, AYC, AXL
111 kW engines AHY, AXG
65 kW engines AJT, AYY
Capacity:
2.4 litre engines 2370 cc
2.5 litre engines 2461 cc
Bore:

2.4 litre engines 79.5 mm

2.5 litre engines 81.0 mm
Stroke 95.5 mm
Compression ratio:
2.4 litre engines 23.0 : 1
2.5 litre engines:
Engine code ACV (up to May 1999) 20.5 : 1
Engine code ACV (May 1999 onward) 19.5 : 1
Engine codes AHY, AJT 19.5 : 1
Engine codes AUF, AXG, AYC, AXL, AYY 19.0 : 1
Compression pressures – minimum:
2.4 litre engines 26 bar
2.5 litre engines 24 bar
Firing order 1-2-4-5-3 (No 1 cylinder at timing belt end)
Direction of crankshaft rotation Clockwise (seen from right-hand side of vehicle)
Auxiliary drivebelt tension (pre-February 1995 models):
Alternator V-belt adjustment arm nut:
New V-belt 8 Nm (6 lbf ft)
Used V-belt 4 Nm (3 lbf ft)
Timing belt tension (pre-february 1995 models) Scale reading of 12-13 units measured using
Volkswagen tool VW 210
Fuel injection pump drivebelt tension (2.4 litre engines) Scale reading of 12-13 units measured using
Volkswagen tool VW 210

Lubrication system

Oil pump type Mounted on front of cylinder block and driven directly
from crankshaft
Normal operating oil pressure 2.0 bars minimum (at 2000 rpm, oil temperature 80°C)

Nm lbf ft

Torque wrench
settings

Alternator mountings:
With auxiliary V-belt drive:
Adjustment arm nut locking 35 26
bolt
Adjustment arm-to-mounting 23 17
bracket bolt
Mounting bolts 35 26

With ribbed auxiliary belt drive:

Mounting bolts 25 18
Auxiliary drivebelt idler pulley 20 15
Auxiliary drivebelt tensioner 20 15
Big-end bearing caps bolts/nuts:*
Stage 1 30 22
Stage 2 Angle-tighten a further 90°
Camshaft bearing cap nuts 20 15
Camshaft cover nuts/bolts 10 7
Camshaft sprocket bolt (injection
pump drivebelt end):
2.4 litre engines 100 74
2.5 litre engines 160 118
Camshaft sprocket bolt (timing belt
end):
 Bolt strength classification 8.8 85 63
Bolt strength classification 10.9 100 74
Coolant pump bolts 20 15
Crankshaft oil seal housing 10 7
(flywheel/driveplate end)
Cylinder bore oil spray jet 10 7
Cylinder head bolts:*
Stage 1 40 30
Stage 2 60 44
Stage 3 Angle-tighten a further 90°
Stage 4 Angle-tighten a further 90°
Flywheel/driveplate bolts:*
Stage 1 60 44
Stage 2 Angle-tighten a further 90°
Fuel injection pump drivebelt idler 20 15
pulley nut

Fuel injection pump drivebelt 15 11

tensioner bolt
Fuel injection pump mounting 50 37
bracket to block
Main bearing cap bolts 65 48
Oil pressure relief valve to pump 40 30
body
Oil pump to block:
Long bolts 20 15
Short bolts 10 7
Oil pump pickup tube bolts 10 7
Roadwheel bolts:
Up to December 1995 160 118
January 1996 onward 180 133
Sump bolts 20 15
Timing belt idler pulley bolt 10 7

Timing belt tensioner bolt 20 15

Vibration damper-to-crankshaft
sprocket bolts:
Pre-February 1995 models 20 15
February 1995 models onward:
Stage 1 20 15
Stage 2 Angle-tighten a further 90°
Vibration damper central bolt:
Pre-February 1995 models 460 339
 February 1995 models onward:*
Stage 1 160 118
Stage 2 Angle-tighten a further 180°

*Use new nuts/bolts

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