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BigBlue DIY build thread ......... 2.5 TDi 151bhp Long Nose MultiVan

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  • #16
    It's to stop water being sucked into the engine causing it to hydraulic, I think that's what they call it, means you can go through deep water without buggering up the engine basically.

    Sell my T4 ? I'd rather stick wasps up my butt !!!

    Comment


    • #17
      Yeah, won't be doing the snorkle think myself, not intending to do any 'real' off-roading ......... I just want the ground clearance. I've got loads of electrics under my van anyway.


      TURK
      Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
      And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
      The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

      Comment


      • #18
        Sorry to ask but why would you want to take such a nice van through deep water ?

        On the seventh day there was the t4

        Comment


        • #19
          Originally posted by Mark Wilkes View Post
          Sorry to ask but why would you want to take such a nice van through deep water ?

          On the seventh day there was the t4

          If you happen to be off-roading or off the beaten track ....... and you happen to run into a stream, you have no choice than to cross it. You simply can't turn back and go home Mark ! With that extra ground clearance there aren't too many places you can't go. And there's loads of dirt tracks around where I live with very little tarmac !



          TURK
          Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
          And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
          The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

          Comment


          • #20
            'How to remove the headlights and front bumper on a long nose T4'


            Hi all,




            As the 'World Wide Web' is millions of computers interconnected together offering us virtually billions of bits of information, you would of thought that somebody would of written an article of how to dismantle the front end of a VW T4 long nose version ! ........ After a few days of looking around, it was obvious that no such document existed. So I thought I would remedy that !


            The following article is for my 1998 2.5 TDi 151 MultiVan Long Nose version. There's a myriad of how to's for the short nose, but the long nose is entirely different. The first identifyer that this is a 151bhp is the red 'I' on the engine cover, the 102bhp versions have a Silver 'I' and the 88bhp have a blue 'I' >>







            First we remove the front grill, only two philips type screws here, and ......... >>







            And a cunningly disguised Allun bolt in the VW insignia >>







            The grill and the colour coded body panel come off as an entire unit >>







            To remove the indicators you have to access the clip from inside behind the headlight unit, once unclipped the indicator unit slides forward.
            No need to disconnect the indicator bulb, just remove the bulb holder from the indicator .......
            and remove that screw at the base of the headlight unit ( the one that I forgot to arrow ! I: ) >>







            To remove the front panel, only three screws here, one either end and one in the middle >>







            Ignore that little tab that's arrowed in red as that will release the plastic fitting inside the panel and make it's removal very awkward as I found out ! ........ you should now be able to slide that panel out. Do a little bit at each end in turn making sure that you support it's weight, as that panel is made of steel and not plastic like the other parts >>







            If you're just needing access to your headlight units that's all you need to remove, otherwise, continue with the removal of the bumper and the entire front end. Over here in France by law we have to have our registration plates riveted on, and not plastic screws like in the UK, it's just as well there aren't any bolts behind the number plate like on the short nose T4 >>







            Now remove the four flat head Torx bolts along the top on the bumper >>







            And then the two screws ( again Torx fittings ) under the wheel arch >>







            This section is where most people will have problems, as I did. Because these two screws are directly under the bumpers at either end, they screw into the bumper supports and are usually encrusted with rust which makes them very difficult to undo. I couldn't budge mine at all ! ....... luckily ( in way ) one of the supports was snapped ! and the other had come adrift ! >>







            The support that's come adrift ....... this did allow me to remove my front bumper however >>







            After you've 'untucked' the bumpers ends from the wheel arches you can move the bumper forward and off completely ........ but wait ! >>







            ........ Don't walk off with it just yet ! >>







            ....... I almost missed it myself ! The wire is connected to a temperature sensor in the front bumper. Unplug it, now you're safe to remove the bumper completely. Obviously if you have fog lights installed, you will need to unplug those also >>







            Now we can get back to inspecting things ......... I knew I was going to have some rust on the front cross member, but not to that extent ! Closer examination told me it was completely shot >>







            It will need replacing, but how on earth can a mere DIY'er work on something like this ! Hopefully that accumulated rust doesn't extend into the chassis posts, that would be disastrous ! >>







            Knowing this might be an issue I had already done a little research, as I now know that a fix isn't possible a new one would be required, but I don't think that VW stock them anymore. The alternative is a cheaper ( but still very expensive ) part by 'Klokkerholm', Part No: 7D0 803 671/A ........ about €300 >>







            Anyway, onto my reason's for removing my van's front end and needing access to my headlight units. First test of my long nose quad headlight prototype.
            First, remove the four flat head Torx bolts, T28 I think they were >>







            It does help if you have the correct tools also T: >>







            Once all four bolts are undone, you can safely disconnect the plug that feeds the headlight bulbs ( top arrow ). Unlike the short nose version of the headlights, these headlight units don't plug directly into the bulbs, but go through a four pin connector block ( 3 pins for the H4 bulb and an extra one to feed the side light bulb ). Chances are if you have a Caravelle or a Multivan, it'll be equipped with 'headlight levelling motors' so just unplug that also ( bottom arrow ) >>







            The two connector blocks arrowed >>







            My OE headlight unit to the right ........ and my 'Prototyping' headlight unit to it's left, both made by Valeo but strangely enough, both are different !
            I've already marked out an area that needs to be cut out as it wasn't a direct fit to my van ! >>







            So it was back to the carpark for another fit ........ and it still didn't fit ! I've marked out where my next cut needs to be, so it'll be another trip back to my workshop. I think the reason why these don't fit a 'standard' Multivan is because I have an air-conditioning system, so I have an extra radiator in front of the regular radiator >>







            Prototype headlight assembly now seated correctly, but things are a little skewiff ! Bottom left hand corner is catching on a part of the radiator ( arrowed ) so has the effect of pushing the entire headlight mounting bracket over to the right. The good news is, there seems to be two parallel lines on the headlight assemblies that are dead plumb, so I can use those to align the headlight mounting brackets with >>







            I seem to have the 'Plane' ( where the headlight unit mounting points will be positioned ) pretty close for now >>







            It was a fun day and an interesting day ........ also an expensive one ! as I realise now this will cost me even more money. But what the hell, every hobby costs money ! >>









            Just a couple of tips before I leave you all ....... If you're ever stuck identifying part numbers, you could use the solution I use ........ The VW parts diagram you see further up the page came from this website > http://www.auto-parts.spb.ru/cat/au/...UYLuULOXumSQw=


            It's Russian ! ...... not a problem


            Install 'Google Chrome' web browser, as it has an online translator that is very very good, and set the browser to 'Always Translate', that way you'll get all the parts description in English with the part numbers !


            As I always say ........ 'Upstairs for thinking, downstairs for dancing' LOL:






            TURK
            Last edited by TURK; 8 July 2017, 08:45 AM.
            Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
            And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
            The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

            Comment


            • #21
              Originally posted by TURK View Post
              Thanks Danny.

              My idea of 'styling' is a 'minimalist' style, so, no stick on chrome bits or fancy paint jobs .......... try and keep the vehicle as is, and just improve it's performance and road handling. Side by side you can clearly see the original standard height of the T4. I also went from 18" alloys with low profile tyres ( 45 profile ) to 16" Borbets with 55 profile tyres, but kept the front lowered by -60 and the rear is now -40 on Vogtland shocks and springs. So by lowering and stiffening the suspension on decent sized rubber, you do get a stiffer ride but with a tad of softness ....... best combination I've found that's for sure. I found that running 18" on 40 profile tyres was a very harsh ride. And by lowering and stiffening the suspension you obviously reduce the amount of roll you tend to get on any van, as they're high sided vehicles. She's got a nice rake on her with the rear sitting up slightly higher like that, but I do have to put a full conversion in the rear yet, so the rear will come down a bit more >>




              Gives the van a very nice stance I think, not as clumsy looking as the original look >>




              My goal for 'BigBlue' will be something totally different however ........ Tried as much as I could, I couldn't get a decent second hand 'Synchro', so my basis for a 4 X 4 will have to be the biggest engined T4 they produced. A 4 X 4 wanna-be if you like ............. pretty much like this >>






              TURK
              Hey Turk what offset is on lulu's boots. The wheels and stance are spot on.


              Sent from my iPhone using Just T4s

              Comment


              • #22
                Thank you that makes sense now, we only have tarmac around us and I forget that some people have countryside that they can enjoy to the full.

                On the seventh day there was the t4

                Comment


                • #23
                  Great post on the front end removal mate, should help a load of people out, it's always nice to have something to follow if you're not to sure 👍

                  Sell my T4 ? I'd rather stick wasps up my butt !!!

                  Comment


                  • #24
                    Nice to see you here Turk! I was following your headlight thread on the firum pre hack but haven't been back since.

                    Sent from my GT-I9301I using Just T4s

                    Comment


                    • #25
                      Originally posted by Stuart Lugg View Post
                      Nice to see you here Turk! I was following your headlight thread on the firum pre hack but haven't been back since.


                      Yeah, you're 'FamilyLugg' aren't you, how's it going mate ? ......... you're on my 'Pre-Order List' if I remember rightly what van you got now ? I've started work on the long nose version if you're interested.
                      Your not the only one that didn't go back ........ I know many that couldn't be arsed anymore !




                      TURK
                      Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                      And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                      The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                      Comment


                      • #26
                        Originally posted by chally69 View Post
                        Hey Turk what offset is on lulu's boots. The wheels and stance are spot on.


                        Hang on mate ........ let me get my calipers out !




                        TURK
                        Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                        And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                        The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                        Comment


                        • #27
                          I am/was FamilyLugg. Sadly my Mrs and I have split up. She still has the long nose 'velle. I'm running a swb short nose at present but have a lwb project van awaiting a petrol engine transplant. This one will be really special once it's done.

                          Sent from my GT-I9301I using Just T4s

                          Comment


                          • #28
                            Sorry to hear about your marital status mate .......

                            When ever you're ready mate with your van conversion, they'll always be a set of quad headlights for you.
                            Your van will probably be ready before my lights at this rate !



                            TURK
                            Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                            And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                            The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                            Comment


                            • #29
                              Originally posted by chally69 View Post
                              Hey Turk what offset is on lulu's boots. The wheels and stance are spot on.

                              Originally posted by TURK View Post
                              Hang on mate ........ let me get my calipers out !
                              Sorry Chally, that was just me way of saying I'll have to check it out, as nobody really remembers their ET !




                              Borbet A's 16" staggered fitment - Borbet had actually ceased making these for a long time, but due to high demand they began producing them again. I did have a mare trying to get hold of a set, took a fair bit of time but managed to source these originals in very very good condition >>







                              The 9J rears have a 9cm dish ...... more than enough
                              Did I happen to mention that these were second hand !? ...... I almost wet myself when I unpacked em !!! >>







                              A 9J is actually 24.5 cm wide, that's a huge alloy ! I can't begin to imagine what a 10J must look like >>







                              Offset ( ET ) for staggered fitment:

                              Front 7.5J x 16 ET 30
                              Rear 9J x 16 ET 15


                              Tyre sizes the were recommended to me that would be an ideal fit:

                              Front 215/55/16 97W XL
                              Rear 225/55/16 99W XL


                              So the tyres I went for in the end were:

                              Continental Premium 215/55/16 97W XL
                              Continental Premium 225/55/16 97W XL



                              Staggered is the way to go. Gives the van a nice poise, and not forget nice plump tyres ! Makes for a very comfortable cushiony ride








                              TURK
                              Last edited by TURK; 20 May 2017, 05:11 AM.
                              Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                              And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                              The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                              Comment


                              • #30
                                Sorry, forgot to mention ........ plus it may help others who don't know what an 'ET' is or what is meant by 'Offset'.

                                Offset is basically how much your wheels stick out from the side of your vehicle. Too much rubber poking out is deemed as a 'Protrusion' and thus not road legal.


                                Handy online Offset Calculator ( screenshot below ) and the link > http://www.1010tires.com/Tools/Wheel-Offset-Calculator >>








                                TURK
                                Yeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
                                And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
                                The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064

                                Comment

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