VW T4 1990-2003 How to Remove Bumpers

The Volkswagen Transporter T4 is the fourth generation of the famous VW minibus family, produced from 1990 to 2003. This model marked the transition from rear-wheel drive (T1–T3) to front-wheel drive (T4 and later), which significantly influenced its design and consumer qualities.

Model Names and Codes

The official name is Volkswagen Transporter T4, but in different countries, it was known by other names:

• Volkswagen Caravelle – a passenger version (equivalent to the Multivan in later generations).
• Volkswagen Multivan (from 1995) – a premium modification with an upgraded interior.
• Volkswagen California – a camper version with a pop-up roof.

Body codes varied depending on the type:

• 70x – cargo van (e.g., 701 – base version).
• 7Dx – passenger version (7D1 – Caravelle).
• 7CM – Multivan.
• 7CU – California.

 

Production Years and Model Evolution

• 1990–1996 (first generation, T4a) – debut of the front-wheel-drive platform, angular design.
• 1996–2003 (second generation, T4b) – facelift: updated front end (new radiator grille, headlights), revised engines.

Production of the T4 ended in 2003, after which it was replaced by the T5.

 

Body Types and Modifications

• Panel Van – cargo version without side windows, with one or two doors.
• Kombi – passenger version with windows and additional seats.
• Caravelle – comfortable minibus with 7–9 seats and improved trim.
• Multivan – version with a folding table, leather seats, and other options.
• California – camper with a kitchen, sleeping areas, and a pop-up roof.
• Special versions – ambulances, motorhomes, double-cab trucks.

---

How to Remove the Front Bumper

Volkswagen T4 Transporter

1. In the wheel arches, unscrew two screws on each side that secure the edges.
2. Remove the license plate along with its frame.
3. Under the license plate, use a socket wrench to remove two bolts.
4. With an assistant, pull the front bumper forward off the guide elements in the fenders.
5. (If equipped) Disconnect the fog light connectors.

 

Volkswagen T4 Caravelle, Multivan

1. Open the hood.
2. Pull back the springs near the headlights and remove the turn signals.
3. Unscrew two screws on the front trim under the radiator grille.
4. Unscrew two screws under the turn signals, release the clips in the fenders, and remove the trim between the headlights and bumper.
5. Under the trim, unscrew four screws securing the top part of the front bumper.
6. (On both sides) In the wheel arches, unscrew two screws securing the sides.
7. With an assistant, pull the front bumper forward off the guide rails in the fenders (watch for wiring).
8. Disconnect the fog light connectors (if equipped).

---

How to Remove the Rear Bumper

There are two main methods for removing the rear bumper.

First Method (Removed with the Metal Reinforcement Bar)

The bumper is attached to the reinforcement bar with two upper and four lower TORX bolts. The lower bolts are easy to remove, but the upper ones are problematic as they are hidden under the body. Using a short or bent TORX bit may strip them, so it's better to remove the bumper together with the reinforcement bar.

1. In the wheel arches, unscrew one screw on each side securing the corners to the fenders and one screw on each side screwed upward from below.
2. Under the chassis, unscrew four bolts securing the reinforcement bar brackets to the body.
3. With an assistant, pull the rear bumper backward off the guide rails in the fenders (note: if there's a tow hitch, the assembly will be very heavy).

Second Method (Simpler, Without the Reinforcement Bar)

1. Open the trunk lid.
2. In the trunk opening, remove two plugs and unscrew the screws beneath them.
3. Remove two pins near the taillights.
4. Unscrew two screws (inserted from below) on the underside.
5. With an assistant, pull the bumper backward off the guide elements in the fenders.

---

Engines and Transmissions

The T4 was offered with a wide range of petrol and diesel engines:

Petrol:

• 2.0 L (84–115 HP)
• 2.5 L (110–150 HP)

Diesel:

• 1.9 TD (68–78 HP)
• 2.4 D (75 HP)
• 2.5 TDI (88–151 HP, the most powerful option)

Transmissions – 5-speed manual or 4-speed automatic.

 

Model Description

The T4 was known for its robust construction, spacious interior, and good load capacity (up to 1.4 tons). Thanks to front-wheel drive, it was more stable than the T3 but criticized for its less off-road-capable suspension.

In passenger versions, the interior was comfortable, with adjustable seats and plenty of space. The Multivan and California offered additional features like refrigerators, sliding roofs, and camping furniture.

 

Interesting Facts

• The last Transporter with an aluminum hood – early T4 models had aluminum hoods to reduce weight.
• Popular among emergency services – the T4 was used as an ambulance and police vehicle in Europe.
• Hybrid version – in 1992, VW introduced an experimental T4 with an electric motor and ICE, but it never entered mass production.
• Sport version – in 1994, a T4 Syncro concept with all-wheel drive and a turbo engine was created.
• Iconic camper – the California T4 remains one of the most sought-after campers on the used market.

 

The Legacy of the T4

Despite being replaced by the T5, the fourth generation remains popular among camper and commercial vehicle enthusiasts. Its reliability, repairability, and versatility have ensured its longevity on the roads.