FAQ VW Audi Skoda Seat
Volkswagen Transporter T5 / Volkswagen Transporter T5 (model code: 7HA, 7HB, 7HH, 7HJ) 2003 - 2009 Volkswagen Multivan T5 / Volkswagen Multivan T5 (model code: 7HF, 7HM, 7HN) 2003 - 2009 Volkswagen California T5 / Volkswagen California T5 ( model code: 7HC) 2004 - 2009
Volkswagen Transporter T5 / Volkswagen Transporter T5 (model code: 7EA, 7EH) 2010 - 2015 Volkswagen Caravelle T5 / Volkswagen Caravelle T5 (model code: 7EB, 7EJ) 2010 - 2015 Volkswagen Multivan T5 / Volkswagen Multivan T5 (model code: 7EM, 7EN ) 2010 - 2015 Volkswagen California T5 / Volkswagen California T5 (model code: 7EC, 7EF) 2010 - 2014
Quick transition to sections: Engines Cooling, heating and air conditioning systems Injection, ignition systems Fuel system Exhaust system Front and rear suspension Brake system Steering Gearboxes, clutch Body Electrical equipment General documentation
Engines
Replacing the timing belt on Volkswagen Transporter T5, AXA 2.0 l engine (rus.)
Photo report
Determination of turbine overflow using logs, TDI engines, etc. (rus.)
Photo report The most pressing problem in turbocharged engines is the occurrence of overblowing. This is especially true for diesel engines because... the formation of soot in the exhaust gases leads to its rapid accumulation inside the turbine and jamming of the geometry. First, let’s try to figure out how the inflation pressure is adjusted, and then we’ll look at what the overblowing looks like in the logs...
Loss of power during acceleration, underblowing of the turbine, description of problems, removal of logs and diagnostics (rus.)
If problems arise related to loss of power during acceleration, both constant and variable loss of traction while driving. Loss of traction in the “full throttle” mode or the engine goes into emergency mode (it moves, but does not pull or pulls weakly), read this entire text carefully, and 9 out of 10 that this will help you establish the exact cause of the problem...
Volkswagen T5 Multivan / Transporter: Engine repair, lubrication system, cooling system (rus.)
Engines considered: AHA, BDL, BDM, BKK, AXC, AXB, AXD, BLJ, AX.
Volkswagen Transporter / Multivan T5 GP 2010->: Diesel engines installed on the car (rus.)
Technical training.
2.0L TDI engines for T5 2010 (rus.)
Engine letters: CAAA, CAAB, CAAC, CCHA. Device and principle of operation. Self-education program manual. Contents: 2.0L TDI engine, Cylinder block, Cylinder head, EGR system, Crankcase ventilation system, Exhaust manifold module, Intake manifold, Oil filter module, Cooling system with ball valve thermostat, 2.0L TDI engine management system, Pre-heating system, Common rail injection system, 2.0l TDI engine with twin turbochargers, Engine features: Cylinder block, Oil filter module, Twin turbocharging module, Twin-turbocharged engine management system, Twin-turbocharged engine charging system (twin-turbocharged ), Control system diagram, Electrical diagram, Maintenance and repair, Equipment and special tools, Instructions for working with twin turbocharging.
2.0 L TDI engines for T5 2010 (rus.)
Device and principle of operation. Self-study program 455 VW/Audi. Letter designations: 1.6 l 77 kW TDI engine (CLHA), 2.0 l 110 kW TDI engine (CRBC) As of the new T5 model 2010, Volkswagen Commercial Vehicles is switching to new injection technology in its engines: replacing good The proven 1.9L and 2.5L engines with pump injectors are being replaced by a new generation of 2.0L with CommonRail injection system. The new generation of engines ensures compliance with the stricter emission standards to be introduced in the future. Other important goals during their development were reducing fuel consumption and reducing operating costs. This self-study program covers the design and operation of new generation engines. Contents: Introduction, General description and technical specifications of 2.0L TDI engines, 2.0L TDI engine, Cylinder block, Cylinder head, EGR system, Crankcase ventilation system, Exhaust manifold module, Intake manifold, Oil filter module, Cooling system with thermostat with ball valve, 2.0L TDI engine management system, Engine management system, Pre-glow system, Common rail injection system, 2.0L TDI engine with two turbochargers, Engine design features, Cylinder block, Oil filter module, Twin turbocharging module, Twin-turbocharged engine control system, Twin-turbocharged (twin-turbocharged) engine supercharging system, Control system diagram, Electrical diagram, Maintenance and repair, Equipment and special tools, Guidelines for working on twin-turbocharged engines.
4-cylinder diesel engine AXB AXC BRR BRS (eng.)
Workshop Manual.
VW Transporter 2004 ➤ Repair manual for diesel engines with letter designation: AXB, AXC, BRR, BRS
. Edition 04.2013 These engines were installed on the following cars: Volkswagen Transporter T5 / Volkswagen Transporter T5 (model code: 7HA, 7HB, 7HH, 7HJ, 7JD, 7JE, 7JL, 7JZ) Volkswagen California T5 / Volkswagen California T5 (model code: 7HC) Volkswagen Multivan T5 / Volkswagen Multivan T5 (model code: 7HF, 7HM, 7HN) Contents (repair groups): 00 - Technical data, 10 - Removing and installing engine, 13 - Crankshaft group, 15 - Cylinder head, valve gear, 17 - Lubrication, 19 — Cooling, 20 — Fuel supply system, 21 — Turbocharging/supercharging, 23 — Mixture preparation — injection, 26 — Exhaust system, 28 — Glow plug system. 165 pages. 5 Mb.
Information on VAG engine repair / Engines repair
This engine repair information applies to all VAG vehicles. To quickly find documentation for your engine, simply press Ctrl-F on your keyboard and type the letters of your engine. For example: 2E or BSE (English only!)
specifications
In the domestic market, the minivan is equipped with a total of seven different engines, as well as mechanical or proprietary robotic variable gearboxes with two clutches. The drive, by default, is front-wheel drive, however, for an additional fee, you can order a version with the 4MOTION system, which is based on a Haldex multi-plate clutch.
Diesel Volkswagen Multivans will receive an inline two-liter turbocharged four with a Common Rail system. Depending on the version, it produces 102-204 horsepower and 250-450 Nm of torque. Acceleration to hundreds will be 9.9-17.9 seconds, and the maximum speed will be 157-203 kilometers per hour. Fuel consumption, with a calm driving style, ranges from 6 to 8.8 liters of diesel fuel per hundred kilometers in a mixed driving cycle.
Gasoline engines are also available in the form of two-liter turbocharged fours with direct fuel injection. They develop 150-204 horsepower and 280-350 Nm of torque. Acceleration to a hundred kilometers per hour will take 9.5-12.5 seconds, and the speed ceiling is at around 182-202 kilometers per hour. Fuel consumption will be 9-9.2 liters of gasoline per hundred in the combined cycle.
Fuel System
VW Transporter T5 — Fuel supply system, engines petrol (eng.)
Repair Manual Volkswagen Transporter from 2004, Volkswagen Transporter from 2010. Edition 09.2018 Repair manual for the fuel system of Volkswagen Transporter T5 gasoline two-liter engines with the letter designation: AXA, BDL, BKK, CJKA, CJKB.
VW Transporter T5 — Fuel supply system, diesel engines (eng.)
Repair Manual Volkswagen Transporter from 2004, Volkswagen Transporter from 2010. Edition 09.2018 Repair manual for the fuel system of Volkswagen Transporter T5 diesel engines of 1.9, 2.0 and 2.5 liters with letter designations: AXB, AXC, BRR, BRS, AXD, AXE, BLJ, BNZ, BPC, CAAA, CAAB, CAAC, CAAE, CCHA, CCHB, CFCA, CAAD.
General information on fuel systems
Suitable for many VW, Skoda, SEAT, Audi cars
Prone to defects
Regardless of the chosen body style, a thorough check of the vehicle, especially the engine, is necessary. The T5 has 4-, 5-cylinder and comfort-oriented 6-cylinder engines. The minibus inherited all power units from passenger cars, but with minor modifications. The heavy weight of the van, frequent loads, rough handling and significant mileage inevitably leave an indelible mark on the condition of the power units.
The 4-cylinder diesel engine with pump injectors has become quite widespread. But such a motor is too weak. Most often, the cylinder head and pump injectors are annoying here. After restyling in 2009, VW abandoned its use.
Five-cylinder diesel engine with 130 and 174 hp. used until the 2010 model year. Instead of a timing belt, a more reliable scheme is used here with the camshafts driven through gears. Preference should be given to a stronger version of the motor.
The 5-cylinder unit is not without its shortcomings. Starter malfunctions, wear of the dual-mass flywheel and injectors, flying pipes, failure of the pump (from 6,000 rubles), turbocharger (from 36,000 rubles) and cracks in the exhaust manifold (typical for the 174-horsepower modification until 2006). An inexplicably high oil level is caused by fuel entering the lubrication system through a tandem pump (from 18,000 rubles) or leaky injector seals. The most unpleasant surprise is the shedding of plasma spraying from the cylinder walls. To overhaul the 2.5 TDI R5 you will need at least 100,000 rubles. The condition of the diesel particulate filter installed since January 2006 should also be checked.
With high mileage, development or cracks may form in the wells of the pump injectors. In this case, you will have to change the block head (from 59,000 rubles) or line the wells (about 17,000 rubles). The problem is typical for diesel engines of 1.9 and 2.5 liters.
In the case of the 2.5 TDI (AXE and AXD), after 200-300 thousand km, premature wear of the camshaft, its bearings and hydraulic compensators occurs (from 500 rubles apiece, 10 compensators in total). The BPC version after 2007 was freed from problems with the camshaft and spraying in the cylinders. True, the exhaust manifold studs sometimes fail here, which is why a burning smell appears in the cabin.
After 100-150 thousand km, the overrunning clutch of the air conditioning compressor or generator fails. It is replaced assembled with a pulley (2-4 thousand rubles). And due to a failed air quality sensor (4,000 rubles), the radiator fans can thresh without stopping. Less commonly, the cause is a faulty fan control unit (10,000 rubles).
Front and rear suspension
Volkswagen T5 Multivan / Transporter / Caravelle / California 2003->: Chassis - Front axle, rear axle (rus.)
4MOTION all-wheel drive with Haldex clutch model year 2004 (rus.)
Design and principle of operation. Self-education program manual 333 VW/Audi. Contents: Quick Facts, 4MOTION All-Wheel Drive, Haldex Clutch, Rear Axle, Differential Lock, Maintenance.
Volkswagen Transporter / Multivan T5 GP 2010->: Chassis (rus.)
Brake system and steering. Technical training.
General information on suspension
Suitable for many VW, Skoda, SEAT, Audi cars
dimensions
Volkswagen Multivan is a minivan with seven seats. Its overall dimensions are: length 4904 mm, width 1904 mm, height 1970 mm, and wheelbase 3000 mm. Ground clearance is quite respectable and amounts to 193 millimeters. This landing allows you to storm medium-sized curbs and, thanks to the long strokes, maintains a smooth ride, even when driving on a rough paved road. The suspension itself has a completely independent layout. The front axle has McPherson struts and the rear axle has a multi-link design. The chassis is equipped with steel coil springs, telescopic shock absorbers and anti-roll bars.
By default, Multivan can carry up to seven passengers. Two people in the front and middle rows and three in the back. It is worth noting that thanks to the rail system, you can transform the interior to suit your needs or completely dismantle the seats for transporting large cargo.
Brake system (ABS, EDS, ESP / Brake system)
Volkswagen Transporter / Multivan T5 GP 2010->: Chassis (rus.)
Brake system and steering. Technical training.
ESP repair - soldering of the lateral acceleration sensor G200 (rus.)
Photo report ESP unit number 1J0 907 657 A / acceleration sensor 1J0 907 651A installed on cars: VW Golf 4 / Bora (1J), VW New Beetle (1C, 9C), VW Lupo (6X, 6E), VW Polo 3 (6N) , VW Sharan (7M), VW Transporter T5 (7H), Skoda Octavia (1U), Audi A2 (8Z), Audi A3 (8L), Audi TT (8N), SEAT Alhambra (7V), SEAT Ibiza / Cordoba (6K ), SEAT Leon / Toledo (1M). It is likely that this information will also apply to other cars.
Volkswagen Transporter T5 / Multivan 2003- : Brake system (rus.)
Repair and maintenance in color photos. Design features, checking and adjusting the brake system, checking the tightness of the hydraulic brake system, checking the degree of wear of brake pads and discs, checking the parking brake, checking the operation of the vacuum brake booster, bleeding the hydraulic brake system, replacing brake fluid in the hydraulic brake, master brake cylinder, replacement master brake cylinder reservoir, replacement of the master brake cylinder, vacuum brake booster, replacement of the vacuum booster, replacement of hydraulic brake hoses and tubes, replacement of brake hoses and tubes, removal and installation of the brake pedal, front wheel brakes, replacement of front wheel brake pads, replacing the front wheel brake caliper, replacing the front wheel brake disc, rear wheel brakes, replacing the rear wheel brake pads, replacing the rear wheel brake caliper, replacing the rear wheel brake disc, parking brake, adjusting the parking brake drive , replacement of the brake pads of the parking brake drive in version 1, replacement of the brake pads of the parking brake drive in version 2, replacement of the parking brake drive cables, replacement of the parking brake drive lever.
General information on brake systems, ABS, EDS, ESP, etc.
Suitable for many VW, Skoda, SEAT, Audi cars
Steering
Volkswagen Transporter / Multivan T5 GP 2010->: Chassis (rus.)
Brake system and steering. Technical training.
Replacing the steering column switch on a VW Multivan T5. Steering wheel. Airbag. Dismantling (rus.)
Photo report
Airbag ring and steering column switch VW Multivan T5 Comfortline. Device (rus.)
Photo report
General information on steering
Suitable for many VW, Skoda, SEAT, Audi cars
Transmission, clutch
Elimination of backlash in the input shaft of 6-speed gearboxes 02N, 02M, 02Q, 02Z and 0A5 (rus.)
Photo report Signs of play: Poor clutch operation, difficulty disengaging first gear and reverse gear. In some cases, the clutch pedal does not return. Mostly the problem occurs after people drive with a rattling flywheel...
7-speed dual clutch transmission 0BT T5, modification 2010 (rus.)
Device and principle of operation. Self-education program manual. Contents: Introduction, Gearbox selector, Gearbox design: Multi-disc clutch, Gearbox shafts, Force closure of secondary shaft gears, Parking lock, Power flow distribution, Reverse gear. Mechatronic unit, Electro-hydraulic control unit, Transmission hydraulic circuit, Transmission control system, Maintenance.
Volkswagen Transporter / Multivan T5 GP 2010->: 7-speed gearbox DSG 0BT (DQ 500) (rus.)
Technical training.
Volkswagen Transporter / Multivan T5 GP 2010->: 4MOTION - all-wheel drive system (rus.)
Technical training.
5-speed manual gearbox 0A4, Workshop Manual (eng.)
Repair manual for manual transmission 0A4.
Edition 04.2010 Five-speed gearbox 0A4
with gearbox letters:
FNE, FNC, GQQ, GTB, HGR, HDR, HJK, HNV, JCT, JCR, JCU, JCX, JCV, JQP, JVF, KBL, KBL, KBM, KCD, KCL, KJF, KQM, KPF, LHW, LEA, LHP, LLL, LUB, MDM, MDZ
installed on cars: Volkswagen Transporter T5 / Volkswagen Transporter T5 (7HA, 7HB, 7HH, 7HJ) 2003 - 2009 Contents (repair groups): 00 — Technical data, 30 — Clutch, 34 — Controls, housing, 35 — Gears, shafts, 39 — Final drive — differential. 319 pages. 7 Mb.
Information on repair of VAG gearboxes / Transmission repair
This transmission repair information applies to all VAG vehicles.
Transmission
A manual transmission can become noisy after 150-250 thousand km - the bearings wear out prematurely. In addition, sometimes the shaft moves along the axis, or synchronizers fail. The cost of the bulkhead is approximately 40-50 thousand rubles. The service life of the clutch largely depends on operating conditions and driving style, but the average resource, as a rule, exceeds 200-300 thousand km. The cost of a new set is about 10,000 rubles.
An automatic transmission was offered in conjunction with the diesel R5 or petrol V6. The Aisin machine gun is quite durable. Restoration repairs are usually necessary no earlier than 250-300 thousand km, which will require about 80-100 thousand rubles.
The robotic gearbox appeared after restyling. Owners with DSG7 begin to contact services after 100-150 thousand km. Reflashing and adaptation often helps.
After 150-250 thousand km, the splines of the right intermediate drive shaft wear out. The original wash shaft is available for 30,000 rubles, the price tag for analogues starts at 5,000 rubles.
The model range also includes vehicles equipped with the 4MOTION all-wheel drive system. The rear wheels are engaged when the front wheels slip. There is no possibility of forced blocking. The Haldex coupling is responsible for traction distribution. The system is quite reliable. The clutch fails only after long runs as a result of wear on the electric pump brushes. The cost of a new pump is about 23,000 rubles. The driveshaft outboard bearing (3-4 thousand rubles for an analogue) is sold after 200-300 thousand km.
Body
Volkswagen T5 Multivan / Transporter / Caravelle / California 2003->: Exterior body (rus.)
Volkswagen Transporter / Multivan T5 GP 2010->: Body (rus.)
Technical training.
Replacing the driver's seat cushion, VW Multivan T5 (Multivan T5) (rus.)
Photo report
Repair of the interior table (central) on the VW Multivan T5 (Multivan T5) (rus.)
Photo report
Replacing the small items drawer on the VW Multivan T5 (Multivan T5) (rus.)
Photo report
Installing and connecting a tow bar on a VW T5 Transporter (rus.)
Photo report
DIY accessories for VW Multivan T5 (Multivan T5) (rus.)
Photo report
VW Transporter T5 – General body repairs, interior (eng.)
Repair Manual Volkswagen Transporter from 2010. Volkswagen Transporter from 2004. Volkswagen Business since 2011. Volkswagen Multivan from 2004. Detailed instructions for repairing the interior of Volkswagen Transporter T5 from 2004/2010. Revision 09.2018 The documentation covers: 68 - Interior equipment, 69 - Passenger protection, airbags, seat belts, 70 - Interior trim, 72 - Seat frames, 74 - Seat - upholstery, covers. Contents (repair groups): 00 - Technical data, 68 - Interior equipment, 69 - Passenger protection, 70 - Trim, insulation, 72 - Seat frames, 74 - Seat - padding, covers. 606 pages.
General information on the body, tires and wheels
Suitable for many VW, Skoda, SEAT, Audi cars
Electrical equipment
Replacing the Bosch 140A generator charging relay, VAG number: 06F 903 023 F (rus.)
Photo report
Generator repair - no charging, generator lamp blinking (rus.)
Photo report
Replacing a generator pulley with a freewheel (rus.)
Photo report
Installing parking sensors on a VW Transporter T5 (rus.)
Photo report
Installation of an on-board voltage indicator on a Multivan T5 Comfortline (rus.)
Photo report
Replacing the cigarette lighter and ashtray lamp on a VW Multivan T5 (Multivan T5) (rus.)
Photo report
Repair of the interior lighting switch on a VW Multivan T5 (Multivan T5) (rus. )
Photo report
Repair of seat heating on VW Multivan T5 (rus.)
Photo report
Repair of ESP control keys and central locking on VW Multivan T5 (rus.)
Photo report
Dashboard VW Multivan T5. Construction, dismantling, disassembly. (rus.)
Photo report
Front electric motor of 3-zone climate control (stove) on VW Multivan T5.
Dismantling (rus.) Photo report
Volkswagen T5 Multivan / Transporter / Caravelle / California 2003->: Electrical diagrams (rus.)
Volkswagen Transporter T5 / Multivan 2003- : Electrical equipment (rus.)
Repair and maintenance in color photos. Design features, diagnostics of electrical equipment faults, location of fuses and relays, removal and installation of mounting blocks in the cabin, battery, generator, starter, ignition switch, replacement of the ignition switch contact group, diesel engine control system, replacement of glow plugs for a car with a diesel engine, control system gasoline engine, lighting, light and sound alarms, checking and adjusting headlights, replacing lamps, headlights, fog lights, replacing side turn signal lights, replacing rear lights, replacing additional brake lights, removing and installing sound signals, replacing steering columns switches, removal and installation of electric motors for radiator fans of the engine cooling system, electric heating of the tailgate glass, instrument cluster, removal and installation of the car radio, replacement of sensors and switches, replacement of the brake light switch, replacement of the warning lamp sensor for emergency oil pressure drop, checking and replacement of the pointer sensor fuel level, checking and replacing the reverse light switch, replacing contact switches.
Transporter 2004 model. Electrical equipment (rus.)
Design and operation of components. Self-education program manual. CAN data bus, Location of electrical components, On-board power supply control unit, Control unit with display in the instrument cluster, Electric speedograph, Central control unit for the convenience system, Security alarm, Electric sliding door, Multifunction steering wheel, Cruise control, Radio, Loud voice communication DVE, Amplifiers, Antennas, Air conditioning, Maintenance.
Volkswagen Transporter T5 (7H) - Component Locations (eng.)
Component Locations Location of all electronic components, fuses and relays, ground connections, connector installation locations. The nominal value of fuses and what they are responsible for. Pinout of connectors. 243 pages! 3 Mb.
Volkswagen Transporter T5 (7H) - Wiring Diagrams (eng.)
Complete electrical circuits for Volkswagen Transporter T5 (7H) from 2003. 1.9L 63 kW — Turbodiesel engine (unit injectors), engine code AXC 1.9L 77 kW — Turbodiesel engine (unit injectors), engine code AXB 2.5L 96 kW — Turbodiesel engine (unit injectors), engine code AXD 2.5L 128 kW — Turbodiesel engine (unit injectors), engine code AX 2.0L 85 kW - Motronic, engine code AXA 3.2L 173 kW - engine (Motronic), engine code BDL 3.2L 173 kW - engine (Motronic), engine code BKK 3.2L 173 kW — engine (Motronic), engine code BDM 2.5L 96 kW — Turbodiesel engine, engine code BNZ 2.5L 128 kW — Turbodiesel engine, engine code BPC 1.9L 75 kW — Turbodiesel engine, engine code BRS 1.9L 62 kW — Turbodiesel engine, engine code BRR 6-speed automatic gearbox (09K) Auxiliary coolant heater Thermo Top Z / CB, Thermo Top Z / CD Anti-lock brake system (ABS) with electronic differential lock (EDL) and traction control system (TCS) and electronic stabilization program (ESP) and much more. 2616 pages! 62 Mb.
Volkswagen Transporter / Multivan T5 GP 2010->: Electrical and comfort electronics (rus.)
Technical training.
Navigation system Volkswagen RNS 310 and RNS 315 (rus.)
Operating manual in Russian. Option codes: RNS 310 - 7T2 and RNS 315 - 7UC. These navigation systems RNS 310 and RNS 315 were installed in Volkswagen Amarok, VW Caddy, VW Golf, VW Golf Plus, VW Jetta, VW Passat, VW Polo, VW Tiguan, VW Touran, VW Transporter/Caravelle, etc.
General information on electrical equipment
Suitable for many VW, Skoda, SEAT, Audi cars
Radios and radio navigation systems for Volkswagen, Audi, Skoda, Seat
Documentation for car radios and navigation Volkswagen, Audi, Skoda, Seat
Gasoline engines
If you are afraid of problems with diesel engines, then you can pay attention to gasoline modifications. The 2-liter naturally aspirated AXA is considered the most reliable and unpretentious. However, some of its owners have to deal with replacing stuck rings after 500-600 thousand km.
Turbo engines with 150 and 204 hp. found their use since the 2012 and 2103 model years, respectively.
Problems with starting and interruptions in the operation of the VR6 with a working volume of 3.2 liters may arise due to a rupture of the membrane of the crankcase ventilation valve (1,200 rubles). But replacing a stretched timing chain will cost much more. The disease occurs after 200,000 km, and to eliminate it you will need about 100,000 rubles - the engine has to be removed.
