VW T4 transporter workshop manual First Edition Books

VW T4 transporter workshop manual

Introduced in 1990, the T4 is initial Volkswagen van having a front-mounted, water-cooled motor. Area of the success of the T4 was their flexibility.Wheelbase Two standard wheelbases were readily available; "brief" and "long".Body sort Van Panel Van - with no

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nine liter (1896 cubic centimetre ) 4 piston and 2.4 liter (2370 cubic centimetre ) two point five liter (2461 cubic centimetre ) 5 piston * DOES NOT cover petrol motor models all-wheel-drive 'Syncro' models interior features specific to Westfalia Caravelle or Multivan or specialist bodywork/camper conversions. * DOES NOT cover Transporter 'T5' range introduced July 2003. Contents: * Safety First! * Roadside repairs * Weekly checks * Routine maintenance and servicing * 4 - piston motor in-vehicle repair procedures * 5 - piston motor in-vehicle repair procedures * motor removal and overhaul procedures * Cooling heating and ventilation systems * Fuel and exhaust systems * Emission control systems * Starting and charging systems * friction clutch * Manual transmission * Auto gearbox * Driveshafts * Braking system * Suspension and steering * Bodywork and fittings * Body wirings * electrical schematics * Reference find out more.....

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four-stroke diesel workshop manual. motors Covered: 2.0-liter 4-cylinder type AAC Digifant Electronic Fuel Injection petrol 2.5-liter 5-cylinder type AAF Digifant Electronic Fuel Injection petrol one point nine-liter 4-cylinder type 1X four-stroke diesel 2.4-liter 5-cylinder type AAB four-stroke diesel gearboxs covered: four geared manual 5-speed manual Covers: Manual Gearbox only. Short and Long Wheelbase. Van. Caravelle. Bus. 2.0 and 2.5-liter Petrol. one point nine and 2.4-liter four-stroke diesel. Four Cylinder Petrol motors. Five Cylinder Petrol motors. Fuel Injection System - Four Cylinder. Fuel Injection System - Five Cylinder. four-stroke diesel motors. four-stroke diesel Injection System. Contents: General Information. Four Cylinder Petrol motors. Five Cylinder Petrol motors. Ignition System. Lubrication System - Petrol motors. Cooling System. Motor Ignition System Digifant System Digifant System Connections for Self Diagnosis Digifant System Fuel Supply Lambda Control Instrument Panel Oil Pressure and Coolant Monitoring Instrument Panel Revolution CounterFuel Supply Warning Lights Instrument Panel Speed Sensor Time Clock Radio Cigar further data

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recirculation turbo and a charge air intercooler Models Covered: ● Van 800 Van 1 000 Van 1 200 ● Caravelle CL and GL ● Bus (long and short wheelbase) Index: ● Engine ● Clutch ● Transmission and Final Drive ● tail shafts ● Steering ● Front springs and shock absorbers ● Rear springs and shock absorbers ● Wheels and rubber tyres ● Brakes ● Electrical System ● vehicle body Wiring Diagram - one point nine liter four-stroke diesel Engine: ● Engine Type ABL Alternator Battery Starter Motor ● Ignition / Starter Switch ● Control Unit for Glow Time and Exhaust Gas Return System (EGR) ● Glow Plugs and Coolant Run-On ● Dash Panel Insert Oil Pressure and Coolant Monitor Fuel Guage Glow Time Warning Lamp Wiring Diagram - two point four liter Natural Aspirating four-stroke diesel Motor Plugs and Coolant Run-On ● Dash Panel Insert Oil Pressure and Coolant Monitor Fuel Guage Glow Time Warning Lamp Wiring Diagram - two point four liter Natural Aspirating four-stroke diesel Motor - Engine Code AAB: ● Alternator Starter Motor Continued Coolant Circulation ● Pre-Glow click

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volumes of this Volkswagen Official Factory Repair Manual present the service and repair information for Volkswagen EuroVan EuroVan MultiVan (including Weekender) and EuroVan CV Camper (commonly known as Westfalia camper) models sold in the USA and Canada. motors and gearboxs covered. 2.8 Liter VR6 gasoline (motor code AES) 2.5 Liter 5-piston gasoline (motor code AAF ACU) 2.5 Liter TDI four-stroke diesel (motor code ACV) two point four Liter four-stroke diesel (motor code AAB) 02B and 02G 5-speed manual gearboxs 098 and 01P four geared automatic gearboxs. For the professional automotive technician this manual includes the specifications and procedures that were available in an authorized Volkswagen dealer service department as this manual went to press. Two volume set click to go

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other VW repair manuals here Volkswagen Transporter T4 four-stroke diesel Covers Covers all T4 four-stroke diesel motor car from 2000 to the end of 2004. Models Covered: Vans - 800 1 000 and 1 200 - Caravelle CL and GL - Bus (long and short wheelbase). motors Covered: one point nineL 4 piston four-stroke diesel (ABL) 2.4L 5 piston four-stroke diesel (AJA AAB) two point fiveL 5 piston TDI four-stroke diesel (ACV AHY AJT AUF AXG AXL AYC) Contents: motor Clutch gearbox Final Drive tail shafts Steering Front Suspension Rear Suspension Axle Wheels rubber tyres braking system Electrical vehicle body Fault Finding electrical schematics: Wiring Diagram - Battery X Contact Relief Relay Ignition Switch Fuses Wiring Diagram - Heater Blower Blower Switch Two Way Valve and Switch for Fresh Air and Recirculating Air Flap Glovebox Light Wiring Diagram - Immobiliser Cable Distributer Lamp Wiring Diagram - Dash Panel Insert Brake Pad Wear Indication Wiring Diagram - Dash Panel Insert Handbrake Warning Light Brake Fluid Warning Switch Brake Warning Light Speedometer Wiring Diagram - Dash Panel Insert Radio Connection Wiring Diagram - Interior Lights Door Contact Swithches Wiring click on

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Engines friction clutch Transmission and Final Drive Drive Shafts Steering Front Suspension Rear Suspension and Rear Axle Wheels and Tyres braking system Electrical System Five Cylinder Petrol Engines Bodywork Fault Finding electrical schematics: Wiring Diagram - Battery X Contact Relief Valve II Wiring Diagram - Ignition / Starter Switch Immobiliser Wiring Diagram - Fresh Air Blower Fresh Air Blower Switch Glove Compartment Lamp Wiring Diagram - Dash Panel Insert Oil Pressure and Coolant Warning / Gauge Fuel Gauge Wiring Diagram - Dash Panel Insert Revolution Counter Distance Recorder Turn Signal Warning Lights Wiring Diagram - Dash Panel Insert Clock Handbrake Warning Light Wiring Diagram - Self Diagnosis Junction Box Radio Connection Wiring Diagram - Interior Lights Door Contacts Wiring Diagram - Headlamps (Long Front End) Side Lights Wiring Diagram - Headlamp Range Heated Windscreen Washer Jets Wiring Diagram - Automotive alternator Stater Motor Ignition Switch Wiring Diagram - Digifant Control Unit Injection Valves Lamdba Probe Coolant Shortage Warning Sender Wiring Diagram - Oil Pressure Switch Fuel Gauge Sender Speedometer Sender Io; Pressure Warning full details

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chassis from '61-'83: Beetle Ghia Bus Squareback 411/412 and Porsche 914. Includes comprehensive chapters on how to: * Troubleshoot engine and decide to rebuild. * Remove disassemble inspect and assemble engine. * Recondition cylinder heads and crankcase internals. Invaluable parts identification and interchange section tells what parts can be swapped where and specifies the best parts for durability or performance. Concise text and 500 photos drawings and charts lead you through each rebuilding step. Finish with an engine ready for thousands of miles of service! Models covered: * Beetle and Karmann Ghia (Type 1) * Bus and Transporter (Types 2 4) * Fastback Squareback Notchback (Type 3) * 411/412 and Porsche 914 Engines covered include 36 HP 40 HP 1300 1500 1600 1700 1800 and 2000. Contents: * Time to Rebuild? * Engine Removal * Parts Identification Interchange * Teardown * Crankcase Cylinder Reconditioning * Cylinder Head Reconditioning * Engine Assembly * Engine Installation Break-in Tuneup * Index additional info.....

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volume contains detailed step-by-step instructions for converting a VW Transporter van or bus to a Camper. It gives advice on how to choose the best van for your needs and prepare it - how to plan the layout and choose fittings how to fit an elevating roof how to cut panels and fit utilities. Integracar tries to have a sizeable array of owners guides. However owners manuals can sometimes be manufactured for very different nations and the motor motor car designed for those nations. For this reason not all workshop manuals may be applicable for your individual car. If you have important questions whether or not a selected maintenance manual is best suited for your car do not hesitate to make contact with us hereHow to Convert Volkswagen Bus or Van to Camper by Lindsay Porter considerably more details

Introduced in 1990, the T4 is initial Volkswagen van having a front-mounted, water-cooled motor. Prompted by the popularity of similar moves with their passenger cars, Volkswagen had toyed into the belated 1970s using the notion of replacing their air-cooled, rear-engined T2 vans with a front-engined, water-cooled build. The causes for deciding in 1980 to alternatively establish a brand new rear-engined T3 become not clear. Therefore, the development of a front-engined design had been delayed before arrival associated with T4. After a run of nearly 14 years, T4 manufacturing stopped in 2003, rendering it second simply to the T1 for length of manufacturing in its home market.

Area of the success of the T4 was their flexibility. It was available in most types and models as standard and formed the foundation of numerous expert automobiles, from buses to campervans to ambulances.
Wheelbase

Two standard wheelbases were readily available; "brief" and "long".
Body sort
Van

Panel Van - with no microsoft windows behind the b-pillar; single row of chairs
Kombi or Half-Panel - with further microsoft windows amongst the b and c-pillars; 2 rows of seats
Caravelle or Multivan - with windows over-all; 3 rows of seating

Pickup

Single cab - based on a SWB chassis
Double taxi - considering a LWB chassis

Roofs

Panel vans had been available with two various roofing heights; standard and high-top. High-tops are only manufactured from the LWB framework, although campervan sales frequently have pop-top or high-tops put into both SWB and LWB chassis.
Doorways

Vans has often one, roof-hinged "tailgate" or two "barn" doors at backside and often just one or twin sliding doors.
Longer and short-nose

There was one big renovation into the T4, in 1996, when a re-shaped, longer front end ended up being introduced. It was had a need to fit the six-cylinder VR6 motor to the T4's motor bay. In the beginning, best Caravelles and Multivans were offered utilizing the extended nostrils, as these had been the only products available utilizing the VR6 engine.

The commercial variants continued to be produced with the reduced nostrils until 1999. But campers alongside specialist cars created between 1994 and 1999 could have either the quick or the long nostrils, based which design was made use of as the base automobile. In keeping with the kind 2's naming meeting, the short and long-nose models are also informally called T4a and T4b, correspondingly.

a locking differential, differential lock, diff lock or locker try a variation on the standard automotive differential. a securing differential may provide increased grip when compared with a typical, or "open" differential by restricting all the two tires on an axle on same rotational speeds without regard to offered traction or differences in opposition seen at each and every wheel.

a securing differential is designed to conquer the main restriction of a typical open differential by really "locking" both tires on an axle collectively as though on a common shaft. This forces both rims to make together, no matter what the grip available to either wheel individually.

If the differential try unlocked, it allows each wheel to rotate at different speeds, thus avoiding tire scuffing. An open differential continually supplies the exact same torque to each regarding the two rims, thereon axle. So even though the wheels can turn at various speeds, they apply the exact same rotational energy, even when a person is totally fixed, and the other whirling..

By comparison, a secured differential forces both left and right wheels for a passing fancy axle to rotate at the same rate under most circumstances, without reference to tractional distinctions seen at either wheel. Consequently, each wheel can put on as much rotational energy since the grip under it will allow, therefore the torques for each side-shaft may be unequal.. Exceptions apply to automated lockers, talked about below.

a locked differential provides a substantial traction advantage over an available differential, but only once the grip under each wheel differs significantly.

Most of the earlier remarks connect with central differentials in addition to to those in each axle: full-time four-wheel-drive automobiles have three differentials, one in each axle, and a main any between your front side and rear axles.

The T4 was also offered with a permanent 4WD system that utilizes a Viscous coupling product as a centre differential to regulate the distribution of torque to your rear axle. These products are called "syncro" and had been offered using 2.4D, 2.5Tdi and 2.5 petrol machines on all human anatomy sort and both wheelbases. Some syncro products also have a mechanically securing rear differential. Because the backside differential precludes the keeping the extra wheel when you look at the normal destination underneath the system, syncro vans either store they inside human body or on an external, hinged bracket.
Westfalia is the designation of numerous specifically converted Volkswagen camper vans. Its called after Westfalia-Werke, the specialist that built the vans, which will be based when you look at the city of Rheda-Wiedenbrück, found in the Westphalia area of Germany.

Westfalia-Werke furthermore converted non-Volkswagen vans, and produced trailers also services and products, however they had been best known due to their Volkswagen camper sales. Westfalia started converting Volkswagen buses in 1951. Their popular "pop-top" bundle is added later, and became preferred from the second-generation VW coach from 1968 to 1979, its successor the Vanagon, the Sven Hedin and Florida conversion rates on the Volkswagen LT, after which the T4 EuroVan, that has been stopped in 2003. This build furthermore motivated numerous imitators, with lots of other businesses globally offering pop-top van sales. Consequently, not all the pop-top Volkswagens were Westfalia conversions, although in the usa, the Westfalia transformation was the most typical. Conversely, not totally all Volkswagen Westfalia sales had pop-tops or preparing business. Volkswagen supplied a "Weekender" package in 1970s with a Westfalia inside, but no pop-top. Later, some Vanagon conversion rates are offered with a pop-top and interior table, but lacked preparing business and alternatively included a luggable 12 volt refrigerator.

In 1999, DaimlerChrysler purchased a 49% stake in Westfalia-Werke's van conversion division, plus in 2001 soaked up the residual 51per cent. Naturally, since DaimlerChrysler is a Volkswagen competitor, this spelled the end of the Volkswagen-Westfalia partnership. While Volkswagen still provides pop-top camper conversions in European countries, they today have another supplier doing the sales. Meanwhile, Westfalia today makes high-roof — as opposed to pop-top — factory camper conversion rates for Mercedes vans, distributed in the usa by Airstream and badged as Dodge Sprinters. Additionally they create automotive accessories to BMW, including truck hitches.

In 2008, a control buyout taken place and Westfalia Van Conversion is currently an independent entity. It still converts some vehicles for biggest automobile brands to offer through their own communities, including the Ford Nugget, additionally markets conversions through its very own community of leisure vehicle dealers. These models include the Ford-based Big Nugget, Volkswagen-based Sven Hedin while the Michelangelo. The Michelangelo vehicle uses a Fiat Scudo chassis and is made to be a major competitor towards Volkswagen Ca.

The Transporter T4 had been exported to North America from 1992 until 2003 under the moniker Eurovan.

In the US, the quick wheelbase Eurovan 5-cylinder traveler products were only sold for design season 1993. Smaller than a standard US shipping van, but larger than an American or Japanese passenger minivan, Volkswagen played up their size with all the motto, "EuroVan: there is nothing mini about any of it". VW best brought in them into people for example 12 months because purchases in the US were unsatisfactory, but business carried on in Canada and Mexico. VW reintroduced the Eurovan passenger versions in america for design 12 months 1999 with a VR6 motor as standard, and discontinued they once more with globally T4s after 2003. The handbook transmission had not been available in North America using the VR6 engine.

VW imported the quick wheelbase Eurovan 5-cylinder fuel system traveler models to Canada from 1991 to 1996. The 77 hp 2,4L diesel engine ended up being recommended in Canada between 1993 and 1996. The long wheelbase version was also available in 1992 only as a 10 seaters CL or GL design trim. Combi and crewcab pick-up models are furthermore available in 1992. A panel version was sold from 1993 to 1997.

The Eurovan Camper by Winnebago is introduced in the usa and Canada in 1995 using the five-cylinder system, and is upgraded towards the VR6 when it comes to 1997-2003 designs. They were best on the longer 3,320 mm wheelbase T4. These small pop music top camper vans are unique in the united states but developed a cult following.

Winnebago also built three small Class C motorhomes because of the forward cab regarding the T4/Eurovan labeled as the Rialta, Vista, and Sunstar. The Rialta ended up being for sale in 1995-1996 using the five-cylinder system, in 1997-2001 with all the AES form of the VR6, as well as in 2002-2005 using the AXK motor. The Vista and Sunstar were only produced in 2002-2004, all making use of the AXK engine.

In U.S., the systems are:

the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, when the second line of seats face the rear as they are removable, the next line converts into a bed, a foldable dining table within the traveler location, window curtains, and a fluorescent lamp above dining table.
the Eurovan MV Weekender, an MV plus a Westfalia transformation that adds a pop-top roof, a moment overhead sleep, bug displays for negative house windows and back hatch, full collection of curtains, additional power, fluorescent internal lights and under chair thermoelectric cooler.
the Eurovan Camper, the long wheelbase commercial van converted by Winnebago sectors to include a pop-top roofing, two two-person beds, sitting for four, a one cubic foot refrigerator that runs on propane, DC, or AC, a propane furnace, a cabinet, cupboards, sink with chilled water and a grey liquid container, a two-burner propane kitchen stove, two two-person dinette tables, mentor power, house illumination, additionally the two front container seats designed to swivel around to face the dinette/kitchen region. The 2000 EVC was 17 foot very long.

The first mutterings about a kind 25 substitution began in 1982, at comparable time due to the fact water-cooled Type 25 replaced the air-cooled version, with all the very first model moving aside a-year later on. Shock scary, VW had eventually chosen a completely latest front-engine, front-wheel-drive configuration for new model.

Early drawings appeared as if a Renault Espace, with a large amount of curved cup area, however the in-house stylists sooner or later decided for something which took their cues from the Mk2 Golf. Wise move, considering that the T4 will not day, plus the initial people nevertheless look contemporary.

The last styling option gained endorsement by VW’s board and had been placed before a person center where they attained an 80 per cent endorsement rating. The largest improvement within the kind 25, it was verified, was at regards to practicality.

Surprisingly, deciding on its British-designed cockpit claimed a Design Council honor, those active in the consumer study saw only a marginal enhancement in motorist convenience throughout the elderly vehicle. Though in the event that you’ve previously driven a late ’80’s / very early ’90’s water-cooled means 25 your’ll see they do feeling remarkably sumptious and civilised for a rear-engined VW.

1st production T4 eventually broke address in January 1990. Yes, it had been a large departure from the kind 25, which the VW purists struggled to deal with, nonetheless it quickly established itself a reputation to be a challenging, trustworthy and user-friendly workhorse.

Built at VW’s devoted Transporter factory in Hanover, it comes down in SWB or LWB structure as well as in numerous different roofing levels, because of the number including a Panel Van, Eurovan, Kombi, Caravelle, Single and Double Cab Pick-Up and Syncro. You may also get one that’s already been changed into a Camper, the Westfalia Ca being the name that gains continued kudos in VW circles.

a facelift in 1996 introduced a longer, re-shaped nostrils to accommodate the optional VR6 swelling. When this occurs ‘short noses’ are referred to as T4a, ‘long noses’ as T4b.

The T4 was replaced in 2003 by the T5, though numerous however believe the 4th generation Transporter to be the better option.
Machines and ’boxes

Petrol engine choices included a 1.8, 2.0, 2.5 five cylinder and the 2.8 VR6, which was furthermore for sale in 201bhp 24-valve guise from 2000. The latter were lovely, but dehydrated, until you have one which’s have a well executed LPG conversion. When it comes to diesels, there is a 1.9D, 1.9TD additionally the 2.4D, alongside range-topping 2.5 five-cylinder products that at first created 88bhp, rising to 102bhp from 1995 and a stonking 151bhp from 1998, but only on German Vans.

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Buying a T4 TransporterIt goes without saying it’s the diesels that are more abundant and, of these, the 2.5TDi is the most desirable, supplying a lot of results or more to 42mpg. It’s relatively easy to transform the 88bhp product to 102bhp by installing a top-mount intercooler, and even 150bhp is at reach with a significant fatigue system, ECU re-map and well-considered uprated diesel injector nozzles. On disadvantage, it’s more complex and the engine’s monitored by an ECU, so it’s additional pricey to correct if it can establish problematic.

The 68bhp 1.9TD is also an excellent bet. Awarded, it’s perhaps not quick in standard type, but it’s fairly tuneable and don’t command as highest an amount whilst the 2.5. The non-turbo diesels feeling slow and, although you would the believe the 2.4 five-cylinder is pretty swift, be confident it’s perhaps not.

Being Volkswagens, all devices are trustworthy – provided they are taken care of – even though 2.4D have a bit of a track record of busting head gaskets, therefore watch for oil / liquids contamination and signs and symptoms of overheating.

Because TDi’s time belt pushes the water pump aswell, if the pump fails it takes out the belt at precisely the same time. One of the keys then when buying is always to make replacing the cambelt and water push 1st tasks you do to prevent the chance of bent valves and a snapped camshaft if they allows get. Check always for a legitimate and dependable service records to read whenever these products had been last changed.

Gearboxes were sturdy, but check for any that leap away from equipment or has dodgy synchromesh, which could feel difficulty on high milers. As the T4 has a hydraulic clutch, look for fluid leaks across the pedal package. Even though your’re straight down indeed there with all the burn, check there are no cracks into the pedal field it self where in actuality the clutch master cylinder supports since this is another T4 foible.



Fortunately, T4 rust proofing had been much more effective than on some of the early in the day brands, so really serious corrosion shouldn’t become a significant problem, and actions enhanced more still after the 1996 facelift. However, as old workhorses could be around 25 yrs old today, it’s worth inspecting very carefully the normal rust places, such as the area at the base of the windscreen, the wheelarches, reduced sills, the base of the sliding home inside and outside additionally the region around the gas filler. Though not one are too tough to repair, obtaining the essential panels welded in and coated using strive to an expert human anatomy store can quickly commence to ingest up money.

While really serious architectural rot was not likely, there’s no damage inspecting the internal wings, chassis and floorpan. Corrosion may take hold around the backside crossmember, simply above where the rear springs find.

Check always all home seals become sound and watertight, especially round the base associated with tailgate. The sliding mechanism for the side door is smooth as well as. In the event that top railway is used, the door can drop out, so lift the entranceway up and down to check for play. It will furthermore sit flush when closed but, if it cann’t, there's some adjustment to get it installing precisely.

In the bottom end, around £3,000 will bring you when driving of an early on 2.4D or 1.9TD Panel Van, while £5,000 could be the beginning price for a half-decent 2.5TDi. Camper conversion rates from loves of Autosleeper begin at £10,000, while very nice conversions from Reimo or Westfalia with a 2.5TDi will make up to £12-£15k.

As constantly, best T4s were people which haven’t become fiddled with. So you’re finding a self-employed plumbing professional or electrician’s vehicle that’s already been cleaned to their drive at weekends and dropped in at a local VW expert or main dealer for regular servicing bang on whenever services booklet demands. Avoid the ratty, rotten people which have already been decreased and usually tinkered with unless you know it’s become performed correcly in accordance with top quality components.

Of course, everyone else wants the eager 2.5TDi, but you will see reduced to cover and, due to its extra difficulty, if things fail it'll be more expensive to fix. With that in mind, the 1.9TD could very well be an improved wager, because of the additional incentive it's also run using veg / bio fuel, which could feel considered.

Pick wisely and enjoy the T4 experience to the full. Whichever you choose, you’ll become joining an enormous clan of others which have complete exactly that while havingn’t checked back once again since.

There’s no genuine issues to avoid with regards to T4 anchors, so only do all the normal brake checks such as for example eyeballing the hydraulic pipes / hoses and making sure there’s no judder resulting from warped disks. If a Van draws to one side on a test drive, it might be one of the back calipers has actually seized. Replacements aren’t expensive. Neither, thankfully, are provider stuff like disks and shields.

Ensure that the handbrake is beneficial. The cable can adhere in its external sleeve if a Van happens to be kept located for a while.

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