Category Archives: T4

Always trying to stay ahead of the curve, the T4 used all the automotive design enhancements that had occurred in the last 10 years. The very essence of Volkswagen usability.

The spare parts list

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Compiled by Ian Crawford

Accelerator Cable
Allen Key
Aluminium Tube (to fit INSIDE fuel hose if leaking).
Battery Earth Strap
Battery Tester (6 x LED’s)
Brake and Clutch Fluid
Brake pedal Return Spring
Bulbs (Various)
Cable Ties
Carburettor Return Spring
Clutch Cable
Coil
Condenser for Distributor
CV Axle Boot Cap and Grease
Distilled Water
Distributor cap + (rotor arms x 2)
Distributor Contact Points
Dynamo Carbon Brushes
Fan belts x 2
Feeler Gauges
Fuel Hose & Clips Fuses (Various)
Hacksaw Blades
Handbrake cable (2 x needed)
Insulation Tape x 4
Magnetic Dish Holder
Magnifying Glass
Multi-Meter + spare PP3 battery
Pill Pot containing
a) Matches,
b) Lighter,
c) Flints,
d) Water Purifying Tablets,
e) Sweeteners,
f) Sewing Kit,
g) Safety Pins,
h) Buttons
Plastic Wire Ties
Rocker Cover Gaskets x2
Shorting Links + Micro Switch & Croc Clips
Spark Plugs
Stanley Knives
Starting Relay + Fuse Tools (various)
Tyre Pressure Gauge
Tyre Valve Cores
Vaseline
Voltage Regulator
Walking Boot Laces (waxed)
Wine corks

Website Manager Nick agrees with most of these. However a wine cork is not something he has ever needed.

The engine battery

Prompted by a member called Robert who was asking, sharing in case it helps anyone else.

Robert had an issue with his starter battery and wanted to replace it but of course is space constrained in an older vehicle. His 72Ah battery was the right size, but how many Amp Hours do you need?

A standard 1.6 litre air cooled engine requires a starter motor such as the Power Lite one from JK. That one is a 1.4 kilowatt starter. Converting kilowatts to amps you need to change 1.4KW to 1,400 watts and then divide it by the voltage, in our case 12 volts.

1,400 / 12 = Around 120 amps.

For two litre engines, you will need a little more. For a customised engine, who knows?!

If you look at The battery charge quick reference guide you know that you do not wish to flatten the battery completely as that will break it. Ideally avoid going more than 30% depleted.

If you know that you never use more than a minute on the starter motor to get the engine into life, that is 1/60th of an hour. Running that 120 amp starter motor for an hour would be 120 amp hours, so 1/60th of that is 2 amp hours.

As long as you have no current leaks and are not sitting in your vehicle draining the battery with a stereo, a fridge, lighting or other circuits on the starter motor, as you can see, a minute to start the engine on a 1.6 litre air cooled engine will drain 2 amp hours out of your battery. Even the smallest and cheapest car batteries will cope with that, but for peace of mind, don’t buy the cheapest battery in the shop!

Improving fuel economy

Following on from last week’s article, this week we are talking about improving fuel economy.

Now that you know how to calculate fuel economy, let’s look at ways to improve it!

Improvements before you start the engine

  • Remove anything in the vehicle that is not required. Lighter vehicles use less fuel. Take it out!
  • Pump up the tyres to the manufacturers recommended pressure. Soft tyres create friction and use more fuel.
  • Ensure that the engine is well maintained and running well. Properly adjusted points / electronic ignition uses the fuel better and wastes less, good carb adjustment uses optimal amounts of fuel. It all adds up!
  • Similarly the drive train / brakes / hubs / wheels can create friction and drag slowing down the vehicle taking fuel to overcome it.
  • Remove the top box or roof rack if you do not need it. Aerodynamics makes a big difference even to a vehicle shaped like a loaf of bread!

Improvements once you are rolling

  • Drive safely and conservatively.
  • Stay within the speed limit.
  • Slower is better – every 10mph above 50mph will reduce your fuel economy by 10% on average. Enjoy the journey!
  • Find a route where there is constant speed – a few miles more around the outside of town with no slowing down is probably less fuel overall than going through the middle with the constant speed changes.
  • Accelerate smoothly without taking the engine to the red line.
  • Try not to accelerate up a hill if it is safe to do so.
  • Accelerate down a hill up to the speed limit if it is safe to do so. Remember being on a bicycle and how you used to get up speed downhill ahead of that big hill? That is the same principle of conserving energy!

Logging

  • Keep a diary of the fills. Monitor how things change through the seasons.
  • Observe any big changes and understand why – does one driver have a “heavier foot”? If so, is your biggest fuel saver asking them to be a passenger?!

If EVERYONE makes just a 1% change to their fuel needs, it will save 10 litres per person per year. 1% sounds like nothing but that is 3 billion litres per year in the US and 7 billion litres per year across Europe.

Helping yourself

If you are spending £1,000 per annum on fuel, a well thought out strategy and a £200 service can actually work out cheaper overall but reducing the fuel used / money spent. Drive sensibly, maintain the vehicle well. Not only are you saving fuel and helping the planet, but you are also keeping the vehicle in better shape, making it last longer and stay in better condition.

Fuel economy explained

You have a vehicle. It does not have “fuel economy”.

You have fuel. It ALSO does not have fuel economy.

Put the two together and you do have fuel economy.

Did you know that electric vehicles actually pre-date petrol / gasoline vehicles? The major downside even a century later is that electric power does not have the same energy density as a gallon of fuel. Your starter battery in your vehicle, whether it is a 2 seater light weight sports car or a large 4WD truck, will be somewhere between 20 to 50 pounds in weight / 10kg to 25kg.

Put that battery into an electric vehicle and even the most modern and lightweight electric vehicle will travel no more than about 6 miles. (Modern vehicles are approaching 150Wh per mile) and that is very optimistic. Take that same SPACE occupied by the battery and a petrol / gasoline engine will travel 40 miles / 60 kilometres conservatively. Take that same WEIGHT of the battery and you will travel far further. A starter battery of 50 pounds in weight (25kg) in a modern petrol car could travel more than 300 miles!

Due to this energy density, oil based vehicles, either petrol or diesel have dominated the market. They are however not overly efficient.

The above diagram of a passenger vehicle using the American EPA Urban cycle definitions shows that only 12% of the energy from the fuel ends up driving the wheels. A massive 62% of the energy is lost as heat.

Checking fuel economy

Fill up your tank as full as possible (initial fill). If you are using a classic vehicle, avoid supermarket fuel as some owners have found reduced fuel economy and other issues. Choose the RON fuel for your engine as applicable. Note the first odometer reading.

Drive normally and at a suitable point – ideally later in the tank not sooner to reduce the error margin, fill up again (second fill). Note the second odometer reading.

For those of you in America, you just filled up in gallons. For those in Europe, if you want to stay in litres then great. To convert to UK gallons, divide the number of litres by 4.56. So 45.6 litres is 10 UK gallons. Gallons are smaller in America!

(Second odometer reading) – (First odometer reading) is the distance travelled between fills. The fuel added in the second fill is how much fuel you needed to travel.

(Distance travelled between fills) / (Second fill) = Fuel economy.

Talking about a Volkswagen transporter, the older vehicles will be towards the 15 miles per UK gallon (12 miles per US gallon) or 1.6 miles per litre. More modern vehicles can get towards 50mpg (40mpg in the US or 11 miles per litre) and custom engines can make a big dent in this figure!

Some modern calculations are litres per 100 km / 60 miles. This is also valid but for this, the lower this number, the more efficient! MPG means a higher number is better.

Next week, we will be discussing improvements in fuel economy.