T4 Van: Common Problems & Solutions

Heute habe ich unseren T4 aus der Werkstatt geholt. Er ist jetzt 5 Jahre alt und hat 89tkm auf der Uhr. Completed:
* Bremsbeläge vorn + hinten (normaler Verschleiß, 1. S(cheiben noch O.K.) - (This part is unclear and cannot be accurately translated without more context.)
* Timing belt of the fuel injection pump and the camshaft (as a precaution, due to experience with ).
* V-ribbed belt replaced (porous).
* accompanying tension rollers replaced (as expected).
* Camshaft seal replaced (due to a slow leak).
* Water pump replaced (3 replacements total: 1 at 25,000 km; 2nd replacement at 64,000 km due to failure).
* Tires changed and replaced (due to a suspension that was incorrectly adjusted and is now damaged).
* Suspension adjusted (see above).
* Main wiring harness for the driver's door repaired (cable breaks).
* Muffler replaced (pipe on the muffler rusted).
* Mass airflow sensor replaced (3rd mass airflow sensor, 1st one failed after 63,000 km; 2nd one failed after 26,000 km).
* TÜV and AU inspection.
* 90,000 km service with mobility guarantee.

In addition, recently:
Crankshaft vibration dampers replaced (had fallen off).
* Auxiliary heater repaired (glow plug...).
* 3x tie rod end (front)

And the vehicle was purchased new from us, has been well-maintained, and has a complete service history.
That just can't be right; he's a complete waste of money.
LMM geht auf Garantie. The rest doesn't.
Okay, one tie rod end replacement is fine, but if the workshop is too incompetent to properly align the suspension afterward, and you end up ruining your tires, that's a different matter. We switched workshops because we couldn't reach an agreement. So, we had to replace everything again and pay for it ourselves. In my opinion, the third water pump is also not normal. The exhaust should also last longer. The mass airflow sensor (MAF) is a whole other issue. The crankshaft damper shouldn't fail either. The auxiliary heater and wiring harnesses should also last longer.
What experiences and opinions do you have? I'd be interested to hear them.
PS: The van cost 52,000 Deutsche Marks! Plus all the repairs...

Hi,
The exhaust noise is normal for a T4, at least it is for the 2.4d in my department.
"A water pump failure is unlikely. While they are supposedly prone to breaking, I've never experienced it with my 2.3, 2.0, or now my 2.5 TDI engines, so it can't be that bad. Or perhaps it was just a bad production batch (a "Lopez effect")."
Tracking/Tie rod: If you're not smart enough to do it yourself, you need to have the suspension adjusted, and if you're still not smart enough for that...

@davidshoes

As a long-time T4 driver, I can only tell you that the issues you listed are completely normal for a T4.

* Timing belt (worn and brittle).
* V-ribbed belt replaced (porous).
* accompanying tension rollers replaced.
* Camshaft seal replaced.
* Water pump replaced.
* Seal the oil pump.
* Replace the valve cover (the gasket is not sold separately).
* Timing belt replaced.

...and all of this at 46,000 km for €1300. And it wasn't really anything new, a repair that T4 drivers should expect. However, it's not usually common to have it happen at such short intervals.

This donkey prefers to eat money, but believe me, it's not different with many other products from VW.

Best regards, Peter.

I'm starting to think that cars that are driven hard actually last longer than cars that are always treated with kid gloves.
If you read this, it can make you feel dizzy.
My dad also has a T4 from his company, a 1995 model with a 102 hp TDI engine. The van is poorly maintained (and it shows), but he drives it once a week from Plauen to Munich (about 380 km each way) and back, plus deals with heavy traffic on construction sites. He drives it hard, with the speedometer often showing 175 km/h. However, the engine is fantastic. It has very low fuel consumption (6 liters) despite this driving style, and the acceleration is great. It's the long version of the T4, and the odometer now shows 260,000 km. The only significant repair in the last 3 years was a faulty NHG (negative ion generator).
Are we driving our (private) cars gently enough?

'I sometimes feel that way too. When you consider that the fuel injectors in my TDI are probably due for replacement soon, and taxis often drive these for 300,000 - 400,000 km. Perhaps we also pay too much attention to what the engines and their components are doing, and therefore notice problems early on.'

Best regards, WarLord.

I think 6 liters per 100 kilometers for a T4 with that driving style is just a rumor!

Sure, here is the translation of the text from German to English:

'MFG' is an abbreviation for 'mit freundlichen Grüßen,' which means 'best regards' or 'sincerely.' It is commonly used in German-language emails and letters.

Okay, so if a T4 uses 6 liters of fuel at 175 km/h... I WANT one of those! My Golf can easily be driven with 5 liters or less... although it's 100 km/h slower (?).

Are we driving our (private) cars gently enough?

Hello,

"There's probably something to that. A car that is warmed up every day (which takes more than 20km for a diesel engine) will certainly wear out more slowly per kilometer driven compared to a car used mostly for short trips in cold conditions. Minor corrosion damage caused by prolonged standstill on seals and bearings also contributes. Sales cars or taxis often reach twice the mileage with fewer problems."

Best regards,
Christian.

Hello!

6 liters for a T4? That would be the what-numbered wonder of the world???

No, no, 12 liters at a brisk pace is absolutely normal. As a long-time T4 driver and forum member in a T4 forum, I can confidently and firmly state that a fuel consumption of 6 liters is only possible at a maximum cruising speed of no more than 90 km/h. Given the aerodynamics of a boxy vehicle, one cannot expect reasonable fuel consumption at high speeds.

Greetings, Peter.

Therefore, I think it's a rumor that a T4 would use 6 liters with that driving style!

MFG

Seriously, no joke. I didn't believe it either, but it's true. There are always three of them inside... Despite its size, the bus apparently isn't that heavy, considering it has absolutely no equipment.
I would also like to have that engine. When driving at full throttle on the highway, my 1Z consumes 8-9 liters or more...

Hello!

The T4 van, in its panel van configuration, weighs between 1700 and 1800 kilograms when empty and has a Cd (drag coefficient) value equivalent to a closed garage door. Today, I drove 90 km/h on a country road, maintaining a constant speed, and achieved a fuel consumption of 6.5 liters. On the highway, at a speed of 170 km/h, the current fuel consumption is around 13 liters. I'm really sorry, but 6 liters is not possible; you've likely been given incorrect information, or there's been a calculation error.

Best regards from Graz, Peter.

I wouldn't believe it myself... Hmm, how can I prove it? Roughly, how much fits into the ventilation tank (it doesn't even have one of those nozzles in the intake manifold yet)? They fill the car up completely at the construction site in Munich using canisters (!), until you can see the diesel (the car is parked at an angle). Then they drive off, and the fuel gauge still shows full. I've actually seen this with my own eyes... (okay, maybe they're not always driving 170 km/h, it's just Friday afternoon traffic on the A9). And it's not one of the newer T4s, but one with the rectangular headlights and I think it has 102 horsepower).

Hello!

"When I fill up the tank and wait for the nozzle to unlock, with a little skill and patience, I can usually squeeze in an extra 10 liters. Officially, the T4 has a 75-liter tank, give or take a couple of liters. My personal record was 91 liters, which I managed to get in there. This was with the tank not completely empty (it hadn't yet shown the reserve light). So, in total, there were definitely over 100 liters in the tank (this also happened with my old 2.4 T4). That allows me to drive from Klagenfurt to Graz (145 km) without the fuel gauge moving even a millimeter, which is obvious. You can easily get six liters per 100 km. Your people should go to a gas station, fill the tank completely, and then drive a bit. Afterwards, they should fill it up again at the same pump and see how much goes in. Then they will realize that they are dealing with a real gas guzzler."

Best regards, Peter.

The T4 has an 80-liter tank .