differential VOLKSWAGEN TRANSPORTER 1990 T4 / 4.G Owners Manual

Downloaded from www.Manualslib.com manuals search engine
1
INSTRUMENT PANEL
Illustration instruments and controls
Warning and indicator light symbols
CONTROLS AND EQUIPMENT

Keys,
central locking system .... 7, 8
Doors 9
Rear lid 11
Windows, mirrors 12, 13 Safety belts, head restraints . . . .14,19
Seats 20 Luggage compartment, pedals . 28,29
Brakes, Transmission 29, 32 Differential lock 33
Automatic-transmission 35 Steering lock/ignition/starter switch . 38
Starting procedures 39 Instrument cluster 40
Warning/indicator lights 43 Switches 46 Emergency flasher 46
Light switch, turn signals .... 46,48
Cruise control 49
Windshield wipers 50 Ventilation/Heating 51
Air conditioning 54
Heater 57
Sliding roof 62
Roof-rack 68 VEHICLE OPERATION
Break-in period - and afterwards . . 69
Operate your vehicle safety 70
Operate your vehicle economically
and minimize pollution 72
Trailer towing 73 Driving with the all-wheel drive ... 75
VEHICLE CARE
Fuel tank, fuel supply 85,86
Vehicle care (exterior/interior) . . 90, 93 Maintenance, inspection intervals . . 95 Engine compartment lid,
engine compartment 97 Lubricants, engine oil 98,99
Engine oil filter 101
Transmission oil 102
Power steering 103
Cooling system 104 Brake fluid 108
Battery 109
Windshield washers/wipers . . . 112,113
Tires/wheels 114 Difficult operating conditions .... 120
Winter driving 121
Accessories 122
DO-IT-YOURSELF SERVICE
Jack and tools 123 Spare wheel 124
Changing a wheel 125 Fuses, bulbs 128, 130 Adjusting headlights
134

Installing,
replacing the radio . . . . 135
Emergency starting 136
Emergency towing 138
Lifting vehicle . . 140
TECHNICAL DESCRIPTION
Engine, transmission 142

Steering,
suspension, brakes,
body, chassis 143 Emission-control-system 144
TECHNICAL DATA
Engine, spark plugs .
V-belts capacities . . Dimensions
Weights
Vehicle identification 146
147
148
150 151
CONSUMER INFORMATION
Service manuals 152
GAS STATION INFORMATION
Location of servicing points 156
ALPHABETICAL INDEX 158


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS AND
EQUIPMENT

THE
DIFFERENTIAL
LOCK*
(SYNCRO)

When driving around a curve, the outside
.vheels
turn
more than the inside wheels.

A
gear set, part of the transmission, called :he differential, compensates for the differ­
ence.
If, however, one wheel gets on a slip­ pery surface and starts to spin, the
differential will not transmit power to the
ether wheel. The car will be stuck. The
dif­

ferential lock will allow power to be trans­
mitted
to both wheels to help get the vehi-
:!e
moving again. Because the differential
5
then unable to compensate for corner-
~.g, vehicle handling and maneuverability

.'.ill
be reduced. Therefore the differential zck may only be used under limited condi-

:ons.

WARNING
Locked
differential
cannot
compensate

for
cornering
and
therefore
increases

tire
wear,
reduces
vehicle
maneuvera­
bility,
driveability
and can
impair
vehi­
cle
handling
performance.
See
detailed
instructions
on
next
page.
Using the
differential
lock

Engage
or disengage the differential
with

the knob shown in the center of the instru­ ment panel.

WARNING

To
reduce
the
potential
for loss of
vehicle
control,
only
use the
rear

differential
lock
under
the specific and
limited
circumstances described on
the
next
page.
When
the
knob
is
pulled
or pushed.
engagement or disengagement is ony initiated. The actual locking of the differ­
ential can be delayed if the wheels are rotating at substantially different speeds.
When driving around a corner it could also happen
that
the lock will not engage or

disengage.

Under
such conditions slow down and
drive in a straight-ahead direction so
that

the lock may engage or disengage.
The
warning
light
above the knob indi­
cates
the operational condition of the lock:
• The
light
comes on only when the lock

has
engaged properly.
• The
light
goes out again once the knob

has
been pushed in and the lock has actu­
ally disengaged. If the warning
light
does not
light
up, after selecting the differential
lock, and after an extended drive, the elec­
trical system and the lock should be

checked
by your VW dealer.
e applicable


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS
AND
EQUIPMENT

WARNING
Never
lock the differential when...
•
driving on paved roads. When the

differential
is locked, the rigid connec­
tion between the rear wheels has
a
rub­
bing
effect on the tire when cornering.

This
leads to increased tires wear and
also
to "jerking motion" when the
vehicle is being steered. The differ­

ential
lock*
for the rear axle must only be used when the vehicle is stuck or is in immediate danger of becoming

stuck;

•
one wheel is spinning. First bring
the spinning wheel to a
standstill,
and only then engage the
differential.
This
prevents damage to the drive train or
uncontrollable acceleration leading to
loss
of control and personal
injury.

See
"Driving Tips" on pages
79-84
also.
•
The vehicle is being towed - see page

139
also.

•
Testing the vehicle on a dynamome-
*where applicable 1) further information is given on page 84.



www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
VEHICLE OPERATION

Advantages off the all-wheel drive

The Vanagon/Transporter Syncro
all-
wheel drive system
has the
following
ad­

vantages over
a
two-wheel drive vehicle:
Driving Power
Driving Power
is
greatly increased
by the

continual all-wheel drive especially
on
snow
and
slippery surfaces, when starting
off from
a
standstill,
and
when driving
on
rough roads.
Within reason, your Vanagon/Transporter Syncro
can go
places where other
vehi­

cles
may
likely
get
stuck.
It is
easier
to
stop
on slippery hills
and get
going again.
Moving Force
As
the
driving force applied
to the
road goes
to
four wheels instead
of two, the

amount
of
slip
is
considerably reduced.
This improves
the
traction between tire and road surface
and
thereby,
the
drive-
ability
on
slippery road surfaces. On vehicles with two-wheel drive,
the
driv­
ing wheels
can
spin
on
slippery surfaces
if

too much acceleration
is
applied. This
greatly reduces tire grip
and can
result
in
loss
of
vehicle control.
By distributing
the
driving forces
to
four
in­

stead
of two
wheels,
the
wheels
of the
Va­ nagon/Transporter Syncro
are
less likely
to spin under
the
same conditions.
Snow tires
With
the
all-wheel drive system
the
Vana­ gon/Transporter Syncro
is
good
for
winter
driving even with standard tires. However,
we recommend
the use of all
season tires
or radial snow tires (M
+
S) with
or
without

studs*,
on all
wheels,
for
better driving,
cornering
and
braking,
in
winter weather.
Details under "Snow tires"
on
page
118

also apply.
Snow chains
Snow chains can improve both road traction
and braking when driving
in
severe winter
weather. Therefore,
use
snow chains
on

your all-wheel drive vehicle when required. For additional information,
see
page
119.
Operation
In contrast
to
conventional all-wheel drive
systems that require transmissions
to be

manually engaged when needed,
the Va­
nagon/Transporter Syncro all-wheel drive
system
is
always engaged. Only
the

amount
of
power being transmitted
to the

front
and
rear wheels changes automati­ cally
as the
road surface demands.
The

Syncro driver
is
therefore able
to
fully
con­

centrate
on the
road and traffic conditions.
The differential lock*
for the
rear axle must only
be
used when
the
vehicle
is
stuck
or
in immediate danger
of
becoming stuck. For further information
on the
differential
lock,
see
page
33.

78 "Check with your local Motor Vehicle Bureau
for

possible restrictions.
'where applicable


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
-
VEHICLE
OPERATION

Driving on dry roads

Attention

"his
is an
all-wheel drive multipurpose
rassenger
vehicle which
will
handle
and

maneuver
differently
from
an ordinary
pas­

senger
car in driving conditions which may

occur
on
streets
and
highways
and off-

'oad.
As
with
other vehicles
of
this type,
if

you make sharp turns
or
abrupt maneu­

vers,
the
vehicle
may
roll over
or
may
go
kit
of
control and
crash.
You should read
:he driving guidelines
and
instructions
in

the Owner's
Manual.
The
driver
and all
oassengers
should wear safety belts
at all

times.

Do
not
engage
the
differential lock on nor­
mal
dry
roads
as it
will
not
provide any ad­
vantage. Under these circumstances,
an
engaged differential lock
will
impair the ve-
nicle's
maneuverability and
will
cause
ex­

cessive
tire
wear.
Driving on wet, slippery roads

Due
to the
all-wheel drive,
the
engine
power
is
transmitted evenly
to a
moder­
ately slippery road surface.
On
wet surface

As
with
any
other vehicle, excessive driv­ ing speed on very wet roads can cause hy­
droplaning
and
loss
of
vehicle control.
Therefore, slow down.
The
differential lock* must
not be
engaged.

Important
instructions
on
the
differential

locks
are to be found on page
33/34.

On
slippery surfaces

On
slippery surfaces the rear axle differen­

tial
lock may only be engaged when
start­
ing
from
a
standstill
or at
very low
speeds.

When
the
road surface has improved
the
lock should
be
disengaged again. On
snow covered surfaces

On
a
snow covered road, maintain traction by making gradual changes
in
speed
or
di­
rection. Avoid sudden maneuvers. Be alert
to problems other drivers around you may be having which could create
a
hazardous
situation
for
you.
In heavy snow, maintaining reasonable
momentum
is
important
for
safe vehicle
operation. Try
to
keep moving
by
using
the
L-gear and
a
steady accelerator pedal
at

low
speed.

WARNING
•
Always
maintain
a safe driving

speed,
especially
when
road and

weather
conditions are poor.

•
Excessive
driving speed on very wet
roads can cause hydroplaning and

loss
of vehicle control.

•
Always avoid forceful and
abrupt

braking action.
You
could block all four
wheels simultaneously and lose
con­

trol
of the vehicle.

•
The braking capability of your Vana-
gon/Transporter Syncro is
greatly
de­
pendent on the
traction
of your tires.

'where applicable 79


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
VEHICLE
OPERATION

WARNING continued
•
The permanently engaged allwheel-
drive
will
provide
good
performance on relatively wet or slippery
roads.
Be
sure
to use these features and advantages
wisely. Do not let the excellent traction
which your VW
SYNCRO
offers lead

you
to underestimate the difficulties
and risks involved in negotiating wet or
slippery
roads. Always drive defen­

sively
and adapt vehicle operation and
driving speed to road and
traffic
condi­

tions.
Driving Off-Road
WARNING
The Vanagon/Transporter
Syncro
is not an off-road or all
terrain
vehicle. Use of
this or any other vehicle under off-road
conditions
requires special skills and knowledge. The off-road operation of
this or any other
vehicle
can
lead
to per­
sonal
injury.

•
Driver and all
passengers
must
wear

safety belts at all times.

•
Keep your thumbs and fingers on
the outside of the steering wheel.
Potholes
or rocks can
jerk
the
wheel

from your grip; it really hurts if a spoke
catches
you on the way around.

Off-Road
Driving
Driving off-road places extra demands
on

your vehicle and on you, the driver.
If
under

exceptional
circumstances
you
judge
it

safe
and
appropriate
to
leave
the
paved highway,
first
make sure
that
your vehicle

is
in top
mechanical condition. Make cer­

tain
that
all
vehicle systems
are
function­ ing normally,
in
particular,
for
example,

that
the engine, especially the cooling
sys­

tem,
is
operating properly and
that
trans­
mission,
brakes and steering are function­ ing normally. Tires must have adequate

tread,
be
free
of
damage
and be
adequately inflated.

Before
driving over
difficult
terrain, such as

mud,
sand,
water, snow
or
steep
slopes,

we recommend engaging
the
differentia lock*
at low
speed.
Important
information
regarding
the
differential lock
is on
page

33/34.

Whenever
you
operate your
car you
should
be
well
and fit, but
your physical

and
mental condition
are
especially
im­

portant
when driving
off
the road.

As
a
general rule
you
should
go
only where others have gone before.

Always
obey applicable
Federal,
State
and
local regulations
and
above
all re­

spect
and protect the environment. Do
not

scar
the
land, avoid unnecessary wheel
spinning and other driving behavior which

will
create
ruts
and destroy vegetation.
Be

careful when parking and when standing

with
a hot
engine. The catalytic converter

with
which your vehicle
is
equipped devel­

ops
very high temperatures which can set
dry grass and brush
on
fire. Respect
the

wildlife, leave animals
to
themselves
and

do not destroy their areas
of
refuge. Above
all,
be
considerate and operate your vehi­

cle
sensibly and safely. Nature
is a
natural
resource
which belongs
to
all
of
us.
'where applicable


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
VEHICLE OPERATION
After driving over
difficult
terrain,
espe­
cially through water or mud, the following
is
important:
• Disengage the differential lock*.
• After long drives through deep mud, the
brakes must be checked and cleaned if
they are
dirty.
This will prevent damage to
the brakes and premature wear.
• After driving through deep water, take
out oil dipstick and check to see whether
there are drops of water on the dipstick or if the oil level has risen. In
that
case,
the oil
must be changed immediately.
• If during an off-road drive the vehicle

has
become stuck (dug its way
into
the
ground) or the underside was stuck by
rocks
or similar, check undercarriage,
brake lines and oil pan for damage. • The engine compartment and vehicle
underbody must be cleaned if they are
very
dirty
so
that
the function of all mova­ ble and electrical/electronic parts is main­
tained.
•
Clean
heavy soil from wheels and tires,

check
tires for damage or foreign objects in treads.
•
Clean
turn
signals, lights and license
plate.
• Dry brake system by driving a short dis­
tance
with
brake pedal slightly depressed.

This
will help regaining normal braking ac­
tion
and help prevent the possibility of the
vehicle pulling to one side while braking.
Performance
testing

If the
Vanagon/Transporter
Syncro re­

quires
testing
on a
dynamometer
(en­

gine
output
analysis and
brake
test)
the

transaxle
drive
shaft
must
be discon­ nected.
The
differential
lock
must
not be en­ gaged.
84 "where applicable


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
[
VEHICLE
CARE

LUBRICANTS I
Climate Tropical
40'
30-
20- 10-
0-

10'

20

30'
Single grade oil
Multi grade oil
Gasoline Engines
|B25-565/21

Engine
Your engine was factory filled with an all- season high quality engine oil. If you need
to add oil between oil changes use any high quality petroleum or synthetic based
oil with correct specifications.
The following term must appear on the oil container singly or in combination with
other designations: "API Service SF or
SG".

Engine oils are graded according to their
viscosity. The proper grade to be used in your engine depends on existing climatic
or seasonal conditions. Refer to the temperature chart when
selecting engine oil. As temperature ranges of the different oil grades overlap,
brief variations in outside temperatures
are no cause for alarm. It is also permissi­ ble to mix oil of different viscosities if you
find it necessary to add oil.
When using SAE 10 W or SAE 5 W-20 or SAE 5 W-30 engine oil, avoid high speed
long distance driving if outside tempera­
ture rises above the indicated limits.
Engine Oil Identification Symbol
Select an oil for your vehicle which
con­

forms to the standards of the American Pe­
troleum Institute (API). A symbol has been added to the top of some oil containers to help in selecting the correct oil.
-l -l
/ / SAE '. j -2
t—i iow-3o jji -3

1B25-
532
98 (1) The top portion indicates the oil quality
by API designations.
(2) The center portion shows the SAE oil
viscosity grade.
(3) The lower portion indicates that the oil
has fuel saving capabilities. Transmission
Manual transmission: Hypoid oil SAE 80 (Mil-L-2105 or

API/GL4).

Automatic transmission:
ATF Dexron® or Dexron II® for torque cor
verter and hypoid oil SAE 90 (Mil-L-2105
E

orAPI/GL5) for final drive.
Front axle differential (Syncro only)
Hypoid oil SAE 80 (Mil-L 2105 B M
API/GL 4) or synthetic transmission oi
G50,
SAE75W-90.
The lubricant used does not have to be
changed.

Should the need arise to add oil, it shoulc
only be done with the necessary workshop equipment.
Power steering
ATF Dexron®
Lubricant additives
Volkswagen does not recommend the use of oil additives. It may adversely af­
fect your warranty.


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
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.


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans

Downloaded from www.Manualslib.com manuals search engine
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


www.westfaliaT3.info - a useful website for owners and enthusiasts of VW Westfalia T25 / T3 Campervans