VOLKSWAGEN TRANSPORTER 1990 T4 / 4.G Owners Manual

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DO-IT-YOURSELF-SERVICE

EMERGENCY
STARTING

Starting by
pushing
or towing

Vehicles
with
Automatic Transmission
cannot
be started by
pushing
or
towing.

Vehicles
with
Manual
Transmission
must
not
be started by
pushing
or
towing.

Damage to the catalytic converter and/or
other parts of the vehicle may result. Starting
with
jumper
cables

WARNING
•
Always shield your eyes and avoid
leaning over the battery whenever
pos­

sible.

•
Do not allow battery acid to contact

eyes
or
skin.
Flush any contacted area

with
water
immediately.

•
Improper use of booster battery to
start a vehicle may
cause
an
explosion.

•
Vehicles batteries generate explo­

sive
gases.
Keep sparks, flame and lighted cigarettes away from batteries.

•
Do not charge a frozen battery; allow
it to thaw out first. Gas trapped
in the ice may cause an explosion.

•
Do not try to jump start any vehicle

with
a low electrolyte level in the bat­ tery.

•
The voltage of the booster battery
must also have a 12-volt rating. The

capacity
(Ah) of the booster battery

should
not be lower than
that
of the
dis­

charged
battery. Use of batteries of dif­
ferent voltage or substantially different

Ah
rating may cause an explosion and
personal
injury.
•
Applying
a
higher
voltage
booster

battery
will
cause
expensive
damage
tc

sensitive
electronic
components,
such
as
relays,
radio,
etc...

•
Vehicle
with
discharged
battery: turn off

lights
and
accessories,
move
lever
to N or

P
(Automatic
transmission)
or into
Neutra

(Manual
transmission)
and set
parking

brake.

Always
heed WARNINGS on page 97.


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DO-IT-YOURSELF-SERVICE

A
-
Discharged battery
B
-
Booster battery

X
-
To bolt securing ground strap
to
body Use
of jumper cables
WARNING
•
To avoid serious personal
injury

and damage to the vehicle, heed all
warnings and instructions of the
jumper cable manufacturer. If in doubt, call for road service.

•
The jumper cables must be long
enough so
that
the vehicles do not

touch.

•
When connecting jumper cables,
make sure
that
they
cannot get caught
in any moving parts in the engine
com­

partment.

Improper
hook-up of jumper cables can
ruin the
alternator.

Always connect
POSITIVE (+) to POSITIVE (+), and

NEGATIVE
(-) to bolt securing ground
strap to body.

1. Connect clamp
of
plus-cable
to
positive

(+)
terminal
(1) of
discharged battery.

2.
Connect clamp
on
opposite
end of

cable
to
positive
(+)
terminal
(2) of
boos­
ter battery.
4.
Connect clamp
on
opposite
end of

cable
to a
bare metal part bolted directly
to

bolt securing ground strap
to
body
(4) of

vehicle
with
discharged battery. Connect
clamp
as far
away from battery
as
possi­
ble.

5.
Start
the
engine
of the
vehicle
with

the booster battery. Run
the
engine
at a
moderate
speed.

6. Start engine
with
discharged battery
in

the usual manner.
If
engine fails to start,
do
not continue
to
crank
but
contact nearest
workshop.
7. With engine running, remove jumper

cables
from both vehicles
in
exact reverse
order: Steps
4
through
1.
Always heed WARNINGS on page 97.
3.
Connect clamp
of
minus-cable
to
nega­

tive
(-)
terminal
(3) of
booster battery. 137


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EMERGENCY
TOWING
WITH
COMMERCIAL TOWTRUCK

The
following information is to be used by
commercial
tow truck operators who know how to operate their equipment safely.
General
hints

•
Whenever possible, tow
with
front

wheels
off ground.

•
Vehicle may be
lifted
in rear and moved
to position for
front
hook-up.

•
The
Vanagon
cannot be towed
with
con­

ventional sling-type equipment. Towing
with

this type of equipment will cause bumper
and
body panel damage.

Vanagon
with
Automatic
Transmission

Tow
with
dollies under rear wheels or on
flat
bed truck to avoid damage to auto­matic transmission.

WARNING
Never
allow
passengers to
ride
in a

towed
vehicle
for any reason.
Front
Hook-up

•
Attach wheel
lift
equipment to wheels.

•
Attach safety straps to wheels.
•
Attach safety chains to axle platform.

•
Towing clearance: 6-12 inches
between tires and ground.

•
Towing
Speed/Miles:
Automatic
Transmission
-30 mph/30 mi

Manual
Transmission
-
50 mph/50 mi.

138


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GAS
STATION
INFORMATION!

• Attach safety chains on axle platform -
not
around
brake
lines.
Towing clearance: four inches between
tires and road.
Towing speed/distance:
Automatic Transmission - 30 mph/ 30 miles (48 kmh/48 km).

Manual
Transmission - 50 mph/50 miles
(80 kmh/80 km).

|
B25-586

Rear
Hook-up
• Attach wheel
lift
equipment to wheels.
• Attach safety straps to wheels.
• Attach safety chains to trailing arms.
• Towing clearance: 6-12 inches
between tires and ground.
• Towing Speed/Miles: Automatic Transmission -30 mph/30 mi

Manual
Transmission -
50 mph/50 mi.
Vanagon
Syncro

Front
and
Rear
Hook-up

The Vanagon Syncro cannot be towed
with
conventional sling-type towing equip­ment nor
with
wheel
lift
equipment or
wheel dollies to avoid damage to the all-
wheel drive system. Use flat-bed tow truck
only.
139


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DO-IT-YOURSELF-SERVICE

LIFTING
VEHICLE

The vehicle should
never
be lifted or
jacked
up from underneath the engine
oil
pan, the transmission housing, or the

front
or rear axle.
This
could lead to serious damage.
The same lifting points as illustrated for the hoist also apply when using a floor jack. To
avoid damage to the underbody or chassis

frame,
it is necessary to insert a rubber pad between the floor jack and the lift

points.

Lifting
with workshop hoist
and with floor jack

Make
sure there is sufficient clearance
between pads and vehicle before driving
vehicle on to hoist.
WARNING
When removing components such as engine block, transmission housing,

fuel
tank, wheels,
front
or rear axle, anchor vehicle to hoist or add corre­
sponding weights to maintain the cen­
ter of
gravity.
Otherwise the vehicle
might tilt or slip off the hoist, causing
serious damage or personal
injury.
•
To reduce the risk of serious perso­

nal
injury
and vehicle damage, lift
vehicle only at the special workshop hoist and floor jack lift points illustra­

ted.
Failure to lift vehicle at these points could cause the vehicle to tilt or
fall

from a lift when, for example,
heavy
components such as the engine block
or transmission are removed result­
ing
in a change in vehicle weight and

balance.

•
If you must lift
your
vehicle with a
floor jack to work underneath, be sure
the vehicle is safely supported on
stands
intended for this purpose.
Lifting
points

Front

At the
front
jacking point.
Rear

At rear cross member.
The vehicle must be lifted only at the lift
points illustrated.

Lifting
with vehicle jack Refer to the "Changing a wheel" on page

125.

140


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TECHNICAL DESCRIPTION


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I TECHNICAL
DESCRIPTION

ENGINE
MANUAL
TRANSMISSION

AUTOMATIC
TRANSMISSION

• Four stroke gasoline engine in rear.
• Four cylinder horizontally opposed.
• Crankshaft
with
four main bearings.
• Liquid cooling system, thermostatically
controlled.
• Thermoswitch operated electric fan. • Pressure oil feed
with
gear - type
pump and
full
flow
filter.

• Self-adjusting hydraulic valve filters.
• AFC (Airflow controlled) fuel injection.
•
Paper
element air cleaner.
• Exhaust emission control system
with

activated charcoal
filter
in the fuel system.
• Breakerless electronic ignition. • Single plate, dry clutch.
• Synchronized four speed transmission

and'
differential in one housing
with
com­

mon lubrication.
•
Rear
wheel drive,
with
two constant
velocity joints per drive shaft.
Syncro • Hydraulically operated single plate

clutch.

• Baulk synchronised 4-speed manual
transmission
with
additional Low-speed
traction gear (4+L transmission).
• Permanent four-wheel drive through

viscous
coupling.
• Manually operated differential lock for
rear final drive available as optional extra. • Hydrodynamic torque converter an:
planetary gearing
with
three forward an:
one reverse gear.
• Final drive in separate housing.
•
Rear
wheel drive,
with
two constar:
velocity joints per drive shaft.


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TECHNICAL
DESCRIPTION

FRONTWHEEL SUSPENSION
• Independent upper and lower control
arm
• Stabilizer
•
Coil
springs • Shock absorbers
Syncro • Independent wheel suspension by

means
of double wishbones
with
coil
springs and telescopic shock absorbers.
• Double
jointed
shafts
• Stabilizer bar
•
Viscous
coupling

Steering
•
Rack
and pinion
• Safety steering column REAR WHEEL SUSPENSION
• Independent semi-trailing arms
with

integrated axle support
•
Coil
springs
• Shock absorbers
Syncro • Independent wheel suspension by way
of diagonal arm axle
with
coil springs and

telescopic
dampers.
• Double
jointed
drive shafts
• Differential lock as optional extra.
BRAKES

• Hydraulic dual-circuit power-assisted
brake system
with
pressure regulator for rear wheel circuit. Front wheels
with
disc

brakes,
rear wheels
with
self-adjusting
drum brakes.
• Parking brake for rear wheels.
Body/Chassis • All steel unitized body
• Frame plates reinforced
with
side and

cross
members.

143


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TECHNICAL
DESCRIPTION

EMISSION
CONTROL SYSTEM
In the
interest
of
clean
air Pollution of our environment has become

a
problem
that
is of increasing concern to
all of us. We urge you to
join
us in our ef­

forts
for cleaner air in controlling the pollu­
tants emitted from the automobile.

You
can make a significant contribution to
keeping our air clean by:
• Always using lead free gasoline.
• Not
letting
your vehicle idle
unnecessa­

rily.
• Following the recommended preven­
tive maintenance schedule contained in
the maintenance booklet.
• Not removing or altering the emission
control system.
• Taking the precautions described
below to prevent damage to the emission
control system in your vehicle.

Volkswagen
warrants the Emission
Con­
trol
System in your new vehicle under the
terms and conditions set
forth
in the War­ ranty booklet.

Your
Volkswagen is equipped
with
such a
system,
which contains the following major components.
Catalytic
converter

The catalytic converter is an efficient
"clean-up"
device
built
into
the exhaust system of the vehicle. The catalytic conver­
ter burns the undesirable pollutants in the exhaust gas before it is released
into
the
atmosphere.
The
exclusive
use of
unleaded
fuel
is cri­
tically
important
for the
life
of the
cataly­

tic
converter
and
proper
functioning
of
the
engine.

The
catalytic
converter
will
be
perma­
nently
damaged
by
•
exceeding
the "max"
marking
when

adding
engine
oil (see
page
99)
• push or tow
starting
your
vehicle

•
misfiring
of the
engine

•
turning
off the
ignition
while
the

vehicle
is
moving
or
•
other
unusual
operating
conditions. Do not
continue
to
operate
your
vehicle

under
these
conditions, as
otherwise

fuel
can
reach
the
catalytic
converter.

This could
result
in
overheating
of the
converter,
requiring
its
replacement.

For
maintenance intervals refer to your
Maintenance booklet.

Oxygen
Sensor (OXS)
The oxygen sensor, installed in the exhaust manifold, continuously
senses

the oxygen content of the exhaust and

signals
the information to an electronic
control
unit.

Carbon
canister

The vehicle is equipped
with
a carbon canister to prevent fuel vapor from
esca­
ping
into
the atmosphere.
The vapor is passed
into
the carbon canister, where it is retained when the
engine is turned off. When the engine is running, a valve allows air
into
the canister,
and the fuel vapor is passed to the engine
for combustion.
The system does not require any main­
tenance.

144


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TECHNICAL
DESCRIPTION

To
assure
efficient
operation
of
the
Emis­
sion
Control
System:

•
Have
your
vehicle maintained pro­
perly and in accordance
with
the ser­
vice recommendations as described in
your
Maintenance booklet. Lack of
proper maintenance as
well
as im­
proper use of the vehicle
will
impair
the function of the emission control
system
and
could
lead
to
damage.

•
Do not alter or remove any compo­
nent of the Emission Control System

unless
approved
by
the
manufacturer.

•
Do not alter or remove any device,

such
as heat shields, switches, ignition
wires, valves, which are designed to protect
your
vehicle's emission control

system.

•
Do not continue to operate
your

vehicle if you detect engine misfire or
other
unusual
operating conditions. WARNING
Starting
Do
not leave engine idling unatten­

ded
after starting. If warning lights should come on to indicate improper

operation,
they would go unheeded. Extended idling also produces heat,
which could result in overheating
or other
damage
to
the
vehicle
or
other
property.

Parking
•
Do
not
park
or
operate
the
vehicle
in

areas
where the hot exhaust system
may
come in contact
with
dry grass,

brush,
fuel spill or other material,
which
can
cause
a
fire.
Undercoating

Do
not apply additional undercoating
or rustproofing on or
near
the
exhaust
manifold,
exhaust
pipes,
catalytic
con­

verter
or heat shields. During driving,
the substance used for undercoating
could
overheat
and
cause
a
fire.


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