heating VOLKSWAGEN TRANSPORTER 1990 T4 / 4.G Owners Manual

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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


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CONTROLS
AND
EQUIPMENT

WARNING continned •
The
engine compartment
of any

motor vehicle
is a
potentially hazard­
ous
area.
Before you check anything in the engine compartment, stop
the

engine and
let it
cool down. Always
exercise extreme caution when work­
ing
one the
engine. Heed
all of the

WARNINGS on page
97.

Reduce the risk
of
scalding from
hot

coolant by following these steps.
• If the coolant reservoir cap must be
removed, wait until
the
engine
has

cooled down.
• Protect face, hands
and
arms
by

covering
the cap
with
a
large, thick
rag
to
protect against escaping fluid
and
steam.

• Carefully and slowly
turn
cap
one

turn
to
allow excess pressure
to es­
cape before completely removing

cap.

•
To
help avoid being burned,
do not

spill
antifreeze
or
coolant
on the ex­

haust system
or hot
engine parts.
Under
some conditions, the ethylene
glycol
in
engine coolant
is
combusti­
ble.
If a
visual check shows that coolant level
and V-belt
are
normal,
but the
warning light continues to
flash,
contact
your
near­
est dealer
to
have
the
cause located
and

corrected.
For more details see "Cooling system"
on

page 104.

If the
coolant gauge needle nears
the

upper end
of
the scale and the engine ap­
pears
to be
overheating,
turn
off the air

conditioner.
Do
not
install accessories
(fog
lights
or
in­
sect screens,
for
example)
on top of the

front
bumper.
They
may
restrict engine
cooling.
5
-
Fuel gauge
The needle
in
the fuel gauge will indicate the fuel level
in the
tank shortly after
the
ignition is switched on.
The fuel tank capacity is
16
gal/60
(syncro
18.5/70)
liters.
When
the
needle reaches the
red
area
at
the bottom there
is a
reserve
of
about 2.6 U.S. gal.
or
10 liters
of
fuel left in the tank.
Time to refuel.


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CONTROLS AND
EQUIPMENT

-Rear
window Trm defogger* I I1*

__e
rear window defogger works only
with

re ignition on.

_-e
rear window defogger - together :i the flow through ventilation - will
••= o to keep the inside of the rear window
: ear of condensation and frost.

~~e
rear window defogger is not designed

Of
melting snow. Therefore, always re-
_:ve heavy snow and ice accumulations
refore driving off.

Zepress
the switch to
turn
on the rear * ndow defogger.
~ie control
light
in the switch will
light
• to remind you
that
the defogger is
switched on. After the rear window has

ceen
cleared, switch off the rear window :efogger to avoid unnecessary drain
:i the battery.
By saving electricity, you save fuel. See

aso
page 72.
Vhen
the rear window defogger is
i.vitched on, the outside mirrors
with

;!ectric remote control* are electrically
bated at the same time (see page 13).
Electrically
heated seat*
With ignition on, the backrest and seat
cushion
of the driver's seat can be heated
electrically.
The heating element can be regulated and turned on and off
with
the thumbwheel switch behind the steering wheel.
where applicable


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EMULATION/HEATING

CONTROLS
AND EQUIPMENT
I
perating
Controls

_evers
A and C - Air
distribution

.ever A at
right
- windshield (1) and side
A'ndow
(2)
outlets
open,
•ver C at
left
-
footwell
outlets
under
:ashboard (4) and
footwell
outlets
in
:=ssenger compartment* open.

_ever
B -
Temperature
control

•
increase heat - slide lever to
right.
~3
decrease heat - slide lever to
left.
Lever
D -
Roof
outlets
in
passenger

compartment*

To increase outside air
flow
- slide lever to
left.

To decrease outside air
flow
- slide lever to
right.

Fan
control
switch
E
The air column can be regulated
with
three
fan speed settings. Air
outlets/vents

Heater or outside air
flow
from
outlets
1, 2, 3, 4 and
footwell
outlets
in passenger
compartment*, according to control lever positions.
Outside air
flow
from
roof
outlets
in
pas­

senger compartment*.
The side dashboard
outlets
3 are indi­ vidually adjustable -
side lever down -
vent
open side lever up
-vent
closed.

Adjust air
flow
direction sideways or up and down
with
center lever.

WARNINGS
see
next
page.

'where
applicable
51


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CONTROLS
AND EQUIPMENT

WARNING
• Good
visibility
comes
with
windows

free
of
fog,
condensation and
frost.

• For clear
visibility
and safe
driving
it
is
extremely
important
that
you
thor­

oughly
familiarize
yourself
with
and fol­ low the
operating
instructions
pertain­

ing to the proper use and
function
of
the
ventilation/heating
and defogging/
defrosting
system in
this
manual. If in

doubt,
consult your Volkswagen
dealer.

•
Maximum
heating
output
and
fast

defrosting
can be
obtained
only
after

the
engine
has reached
operating
tem­
perature.
Defogging and
defrosting
wind­
shield and side
windows

• Slide all control levers to the extreme
right and
turn
fan control switch E to speed
setting 2.
• The fan control switch for the
secon­

dary heat exchanger should be
OFF.

Warming
up vehicle
interior
quickly • Slide levers
A,
B and D to extreme right.
• Slide lever C to extreme left.
• Open air outlets 3.
• Turn fan control switch E to speed
setting 2.

Warming
up vehicle
interior
normally

Once
the windshield and side windows

are
clear and the vehicle interior is warm,
you may want to set the controls as fol­
lows:

• Slide lever A to the left.
• Slide lever B to desired temperature

setting.
• Slide lever C toward center.
• Turn fan control switch E to speed
setting 1.
Outside air
ventilation

With lever B at extreme left, outside air is emitted from all open outlets.

Hints
• All operating controls, except fan
con­

trol
switch E and fan control switch for the
secondary
heat exchanger can be ad­
justed to any intermediate position.
• Stale air is drawn out of the vehicle
interior through vents on the inside
front

door
panels. The vents can be opened or
closed
by sliding the lever forward or
rearward.

52


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CONTROLS
AND EQUIPMENT
AIR
CONDITIONER*

WARNING
• Good
visibility
comes
with
windows

free
of fog, condensation and
frost.

• For clear
visibility
and safe
driving
it
is
extremely
important
that
you
thor­

oughly
familiarize
yourself
with
and fol­ low the
operating
instructions
pertain­

ing to the proper use and
function
of
the
ventilation/heating,
defogging/de-

frosting
and air conditioning system in

this
manual. If in
doubt,
consult your
Volkswagen
dealer.

The
air conditioning unit is installed under
the roof of the driver's cab. Ten air outlets permit interior cooling throughout the

vehicle.

Two
climate control switches are located
on the instrument panel.

The
unit operates on the air recirculation
principle.
Air is sucked in through the two
large
air intake grilles at the rear portion of
the unit.

Because
the air conditioner is not nor­mally used at low ambient temperatures it

is
designed to operate only when outside
temperature is above 41° F or + 5° C.
When
the air conditioner is on, tempera­
ture as well as humidity inside the vehicle

is
controlled. During high outside humidi­
ty you can prevent windshield and win­

dows
from fogging by setting the controls
accordingly.

Maximum
cooling is maintained with

standard
heating/ventilation controls
turned off and the windows
closed.

However,
when the vehicle interior is very
hot from standing in the sun, open a win­
dow for a few minutes to permit hot air to

escape.
• iHBll
1
m
Air
outlets/Vents

1 - These air vents can be adjusted or
closed
completely.
• Tilt air vent housing to direct air
flow up or down.
• Turn thumb wheel to direct air
flow sideways.
• To open outlets, position thumb

wheel
in center of vents.
• To close air outlets,
turn
thumb

wheel
to extreme right or left.

2
- These air vents can be adjusted but not
closed.

• Direct air flow by swiveling the
vent housing.
54 * where applicable


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CONTROLS AND EQUIPMENT
lie heater has a safety switch which is lo- :ated under the dash on the left near the
steering column. If the heater does not
start, or starts and then stops again, wait
3 minutes and then operate the red lever
on the safety switch.
[f the heater still does not work or if the
safety switch stops it again, there is a de-
:ect in the heater which can only be re- :aired by a Volkswagen workshop. Fuses
The auxiliary heater is equipped with two
fuses,
one 16 amp fuse for the entire heater and one 8 amp fuse for the over­
heating switch. Both fuses are located in a
fuse holder behind the fuse panel on the left side under the dashboard. When the
fuse for the overheating switch is blown,
the fan is working however no heat is

delivered.

If the replacement fuse blows again, have
the heater checked by your Volkswagen dealer.
59


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I
CONTROLS AND EQUIPMENT
AUXILIARY HEATER* (Syncro models only)
The auxiliary heater* heats the coolant in the heating circuit and supplies the heat exchanger in the normal heating system
and the additional heat exchanger* for the
passenger compartment heating with heated coolant.
The system is switched off and on or the
switch-
on time preselected by means of a
switch and indicator unit located on the left under the instrument panel.
Air distribution and regulation is done with the controls of the normal heating and
ven­

tilation system (see "Ventilation/Heating"
on page 51).
The auxiliary heater can be used with vehicle stationary or when it is moving.
When vehicle is stationary, the heater only runs for a maximum of 30 minutes in order
to avoid draining the battery. It also switches off automatically when a coolant
temperature of 80° C (175° F) is reached.
When the coolant temperature drops below 70° C (158° F) the heater is auto­matically switched on again. The heater runs on fuel from the vehicle
tank and uses up to half a litre (one quart) per hour. Controls
A - Buttons for setting time and
preselected time
B - Indicator lamp for preselected time
C - Preselected time D - Display
E - Actual time
F - Heater on/off
G - Warning lamp (Heater on)
60 "where applicable


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VEHICLE
CARE

COOLING
SYSTEM
The cooling system
is
sealed and gener­ ally requires little attention.
The cooling system has been filled at the factory with
a
permanent coolant which
does not need to be changed. The coolant

consists
of a
mixture
of
water
and the
manufacturer's coolant additive
G 11 —

antifreeze
on
glycol basis with anticorro-
sion additives (40% for USA
models;
50%
for Canadian models).
This
mixture
assures
the
necessary frost protection
and protects
the
entire cooling system
against corrosion and
scaling,
and raises
the boiling point of the coolant.
Do
not
reduce
the
concentration
of the

coolant
in the
summer
by
adding plain
water.
The coolant additive proportion
must
be at least
40%
but not more than

60%,
to
maintain the antifreeze protection
and the cooling efficiency. For year round driving, antifreeze is added
at the factory for temperatures down to:

-13°
F/-25°C(USA)

-40°
F/-40°
C
(Canada)

Only
use
quality phosphate-free
anti­

freeze containing ethylene glycol. Such antifreeze
is
available at
your
Volkswagen

dealer.

WARNING Antifreeze is poisonous. Always store antifreeze in its original container and

well
out of the reach of children. If you drain
the
coolant,
it must
be
caught
and

safely stored. Drained coolant should normally not be reused. Always des-

pose
of used coolant observing all en­
vironmental regulations.
Coolant losses
Coolant losses may indicate
a
leak in
the

cooling
system.
In
this
case,
the
cooling
system should
be
inspected immediately by
your
Volkswagen dealer.
It is not
suffi­

cient merely to add coolant.

In a
sealed system, losses can only occur
if
the
boiling point
of the
coolant
is ex­

ceeded as
a
result of overheating.
Overheating can occur
if:

•
the
flow
of air to the
radiator
is

obstructed
by
leaves, dust, insects
or by

additional
lights installed
in
front
of the
radiator grille;

•
the boiling point of the coolant has been
reduced
due to an
incorrect mixture
of

coolant and water;

•
the
radiator fan
is not
working
- see

"Radiator
fan",
or;

•
the vehicle is being driven up
a
long
hill
j

in
a
low gear with engine speed
very
high
and
at
very
high ambient temperature
-

see
"Radiator fan".

If
the cause for the overheating cannot
be

determined
and
corrected, contact
your

Volkswagen dealer immediately, other-
I
wise serious engine damage could result.

104
Always
heed
WARNING on page
97.


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VEHICLE CARE
Adding
coolant

Turn
off the
engine
and allow it to cool
down.

WARNING
Reduce the
risk
of scalding
from
hot

coolant
by
following
these
steps.
• If the cap
from
the expansion
tank

must
be
removed
wait
until
the
engine

has cooled down. The cooling system
is
under
pressure.
•
Protect
face, hands and
arms
by
covering the cap
with
a
large,
thick
rag
to
protect
against
escaping
fluid
and steam.
•
Carefully
and
slowly
turn
cap one

turn
to
allow
excess pressure to es­ cape
before
completely
removing
cap.

Top
up coolant in refill tank. Only when
cooling
system was drained or a lot of
cool­
ant needs to be added, also
fill
expansion
tank.

To
maintain the anti-corrosion properties of the coolant, the antifreeze concentra­
tion should not be reduced, even during
the warm
season.
Increasing
the
antifreeze
in the
coolant

to
more
than
60% is not
only
unecono­ mical, it is also
detrimental
to
engine

cooling.

Only
use quality phosphate-free anti­

freeze
containing ethylene glycol. Such antifreeze is available at your Volkswagen

dealer.

Antifreeze,
other
than
specified by Volks­
wagen,
may cause corrosion of the cool­ ing system,
leading
to
engine
over­

heating
and
damage.

Only
for topping-up coolant, a small amount of antifreeze containing ethylene

glycol
and phosphates may be
used,
if rec­
ommended antifreeze is not available.
• After adding coolant, run the engine at
idle speed for a few seconds.
• Wait for the radiator fan to switch on

and
off again.
• Check coolant level. Add more coolant
if necessary.

Do
not overfill the system.
Excess
coolant will be forced out through
the pressure relief valve in the reservoir
when the engine becomes hot.
Screw cap on
again
tightly.
Radiator
fan

The
electric radiator fan (located in
fror:
r the car behind grille) is controlled by !':
moswitches
from the coolant and enc
TE

compartment temperature.

After
turning
off the
engine,
the
radiate

fan can
continue
to run (up to 10 r>
nutes).
It may also suddenly
start
to rx

again
even
with
the
ignition
switched
c*

Notes
• If the radiator fan does not come c
when the coolant temperature is very high

check
the fuse and replace it if necessar, - see page 129.
• The speed of the radiator fan does nc

depend
on the engine
speed,
therefore
cooling
effect cannot be increased b.
downshifting. As long as the engine runs smoothly and driving an uphill road does
not considerably reduce
speed,
there is n:
need
to downshift.

Always
heed
WARNINGS
on
page
97.


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