Volkswagen Transporter T5 2003 - 2015 Workshop Manual. EWD

Manual for the repair, operation and maintenance of Volkswagen T5 Multivan / Transporter / Caravelle / California since 2003, equipped with gasoline engines with a working volume of 2.0, 3.2 liters. and diesel engines with a working volume of 1.9, 2.5 liters. Error codes, troubleshooting.

The book contains the information necessary for the repair of all components and assemblies of the VW T5 Multivan / Transporter / Caravelle / California: engine, fuel system, exhaust gas system, clutch, gearbox, steering, brake system, tires and tires, bodywork, electrical equipment, accessories. Separate sections of the manual include operating instructions, recommendations for maintenance and color wiring diagrams (electrical equipment diagrams) of the car.

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• Transporter T5 (7HA, 7HB, 7HH, 7HJ) 2003 - 2009
• Multivan T5 (7HF, 7HM, 7HN) 2003 - 2009
• California T5 (7HC) 2004 - 2009
• Transporter T5 (7EA, 7EH) 2010 - 2015
• Caravelle T5 (7EB, 7EJ) 2010 - 2015
• Multivan T5 (7EM, 7EN) 2010 - 2015
• California T5 (7EC, 7EF) 2010 - 2014

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7-speed dual clutch gearbox 0BT 2010+ Repair Manual

LZZ, MAA, MXZ, MYA, NEY, NEX, NHX, NZR, NZQ, NKD, NYB, NYC.

5-speed manual gearbox 0A4, Workshop Manual

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

Volkswagen Transporter T5 (7H) - Component Locations

VW Transporter T5 (7E) - Fitting Locations Fuse and Relay Wiring Diagrams

Volkswagen Transporter T5 (7H) - Wiring Diagrams

• 1.9L 63 kW  AXC
• 1.9L 77 kW -  AXB
• 2.5L 96 kW - AXD
• 2.5L 128 kW - AXE
• 2.0L 85 kW - AXA
• 3.2L 173 kW - BDL
• 3.2L 173 kW - BKK
• 3.2L 173 kW - BDM
• 2.5L 96 kW - BNZ
• 2.5L 128 kW - BPC
• 1.9L 75 kW - BRS
• 1.9L 62 kW - BRR

VW Transporter T5 (7E) - Current Flow Diagram Wiring Diagrams

• 2.0l diesel engine CAAA, CAAB, CAAC, CAAE, CCHA, CCHB
• 2.0l diesel engine CFCA
• 2.0l petrol engine AXA
• 2.0l petrol engine CJKA,CJKB

Body

In terms of resistance to corrosion damage, the situation with WV T5 is ambiguous. On the one hand, the car does not rust quickly, but its bottom has a lot of grooves without any protection from dirt or chemicals in winter. As a result, it is this element that is most susceptible to corrosion damage, and when buying a car, an inspection of the condition of the bottom should become a prerequisite.

If we talk about painting the body, then there are certain problems here, on some vans, damage becomes noticeable after three to four years of operation. For example, the movement of door handles suggests damage to the paint around them, up to chipping. The most experienced car owners protect the space around the handles with armored film. The solution is not complicated, but at the same time effective.

Headlights

The front headlight of the Volkswagen T5 is very weak, the power of the headlights is not enough for reliable illumination, even replacing the lamps with more powerful samples does not give almost any improvement. Over time, the situation only worsens, as the cloudy shades absorb some of the generated light. In addition, spraying flies on the reflectors.

Rear license plate light

The tightness of the shades is very weak, so water, penetrating inside, leads to a short circuit. There are two options here, someone changes the shades, buying Chinese counterparts, someone is trying to improve the tightness through additional protective equipment.

sliding door

An impressive sliding door ensures the convenience of boarding / disembarking passengers, loading cargo, but at the same time, the guides quickly fail. As a result, any bumps in the road end with a characteristic roar. You can change the rollers, as well as the bracket supporting them, using analog kits, to save money.

Another source of noise is a worn lock bracket that does not fix the canvas in one position. The solution to the problem is to change the bracket.

front doors

Sagging hinges on the sashes cause the paint to peel off under the plastic upholstery panels. Handles on the inside are prone to breaking off the lining, and their repair is most often carried out with electrical tape. This happens when you try to open the handles with several fingers, and not with five fingers in coverage.

Water penetration into the cabin

In the cabin, rust can appear on the second-row seat mounts. Water enters the cabin through the vents in the middle part of the side glazing. It gets on the floor, accumulates under the carpet, becoming a source of corrosion. Water penetrates inside through the window seals, which lose their elasticity. In any case, when moisture appears in the cabin, it is necessary to pay attention to the seals.

Electrical system

The presence of microswitches in the locks is highly doubtful. The failure of any of them leads to the appearance of a signal on the dashboard and the light in the cabin, as if the door was not closed. Possible chaotic switching on / off of the light on the bumps. It is expensive to buy replacement originals, and Chinese samples are not able to last even a year. Some "masters" solve the problem using improvised means.

Diesel

Initially, fifth-generation cars became owners of 1.9 TDI and 2.5 TDI diesel engines, with four and five cylinders, respectively. In compliance with Euro-4 standards, such engines received a particulate filter.

There are plenty of variations of the 1.9-liter diesel:

• 1.9 TDI (AXC) 85 HP
• 1.9 TDI (BRR) 84 HP
• 1.9 TDI (BRS) 102 HP
• 1.9 TDI (AXB) 105 HP

• 2.5 TDI (AXD) 131 HP
• 2.5 TDI (BNZ) 131 HP
• 2.5 TDI (AXE) 174 HP
• 2.5 TDI (BPC) 174 HP

Petrol engines

Gasoline versions of the VW T5 are much less common, however, the engines used on them look quite decent, yielding to diesels only in fuel consumption.

• 2.0 MPI (AXA) 115 hp

This old motor due to the maximum simplicity of design has practically no problems in operation. It is only necessary to control the operation of sensors and ignition, and periodically change the timing belt. For those who do not want to face the need for expensive diesel repairs, but do not drive very much, this is a great alternative.

• 3.2 MPI (BDL) 231 hp
• 3.2 MPI (BKK, CFLA) 235 HP

These motors are very rare, but the most powerful. Such six-cylinder engines are capable of moving up to 500 thousand kilometers, but changing the timing belt will cost a pretty penny, and consumption figures at the level of 15-18 liters, depending on the operating mode, can be disheartening.

• 2.0 TSI (CJKB) 150 hp
• 2.0 TSI (CJKA) 204 HP