battery VOLKSWAGEN TRANSPORTER 1992 T4 / 4.G Owners Manual

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CONTENTS
DASHBOARD AND

CONTROLS

Layout
4
i\='-:ng
lamps 6

CONTROLS
AND

EQUIPMENT

•
e.s. Central locking system 7, 8
I:cs, Tailgate 9, 10
I'I
~g doors 11

..
-^ows, Mirrors 12, 13
Sea: belts 15 5re:y for children 18
-ead restraints 19

Seats
20 _:ariing/sleeping surface 26

__ggage
compartment cover 27 __cgage compartment/load surface ... 28
-edals, Brakes 29 Vanual gearbox 31
--tomatic gearbox 32
gnition
lock 36
Starting / Stopping the engine .... 37, 38 "struments 40

.'.
arning lamps 47
Switches 50
~yn signal and dip lever 52

3'uise
control system 53 .'.'indscreen wiper 54
-eating and ventilation 55

Air
conditioner 57
Recirculating air switch 61
Auxiliary heater 63
Additional
water heater 67
Sun roof, Sliding/tilting roof 70, 71
nterior lights, Sun visors 72, 73
Ashtray, Cigarette lighter 73
-oof
rack 75
DRIVING
TIPS

The first 1500 km - and afterwards ... 76 Driving safely 78
Driving economically and

ecologically
79
Trailer towing 81

GENERAL
MAINTENANCE
Filling the tank, Fuel 85, 86
Care of car, Maintenance 88, 93 Bonnet, Engine compartment 94, 95
Engine oil, Gearbox oil 96, 99

Air
cleaner 100 Power assisted steering 100

Cooling
system 101
Brake fluid 104
Battery 106
Windscreen washer system 108
Wheels 110
Arduous operating conditions 115
Winter driving 116
Accessories, modifications and
renewal of parts 117
Mobile
telephones and two way
radios 117

DO-IT-YOURSELF

First
aid kit, Warning triangle 118
Vehicle tools 118 Spare wheel/changing wheel ... 119, 120
Fuses
122

Changing
bulbs 124
Adjusting/masking headlights .. 128,129
Headlights 129
Installing radio 129
Emergency starting 130
Tow starting/towing 132
Lifting vehicle 134
TECHNICAL
DESCRIPTION

Engine 136
Emission control system 137
Activated charcoal filter '38 Power flow '39
Steering, Axles 139 Brakes, Body -139,
1
AC
Environment compatibility 140

TECHNICAL
DATA
Engine 141
Performance 142
Fuel consumption 143
Spark plugs 145
V-belts 145
Wheels,
Tyre
pressures 146, 147

Weights,
Trailer weights 148, 151 Dimensions 152
Capacities 153
Vehicle identification data 154

SPECIAL
INFORMATION

Adjusting the brake pressure regulator 155

ALPHABETICAL
INDEX

Alphabetical index 156

CHECKS
WHEN
FILLING

THE TANK
Overview 160
3
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CONTROLS AND
EQUIPMENT

Seat
stop
(3)*
the second battery* is located under the •ft seat. To get to the battery the seat can

:e
cashed forward past the normal stop:
• Dush seat fully forward
• Dul stop outwards and push seat
further
":~.vard.

Pivoting
seats*
me release mechanism of both seats is lo­ rded on each seat base at bottom
right.

Seats
are released by pulling up the lever.

E::^
seats are turned anti-clockwise so
:~at it might be necessary to push the seat
':".vard slightly or open the doors.

Attention

When
vehicle
is
moving
the
seats
must
be
facing
forward
and be

properly
secured.
Two-seater
passenger bench*

To
lower the backrest, press locking knob to
the rear.
When lowered, the backrest is locked. The locking knob must therefore be pressed
again to
lift
backrest up.

Attention
For
safety
reasons the
backrest

must
always
be locked
when
ve­

hicle
is in
motion.
Head
restraints

The head restraints should be ac _s:e; body
size
- see page 19.

Seat
heating*

Seat
cushion and backrest of
front
seats can
be heated electrically when ignition is on. Further details are given under "Switches",
page 51.
Armrests*
The armrests on the
front
seats can be hinged up if they are not required.
The angle of the armrests can be adjusted

as
required
with
a knurled knob, underneath
the armrest.

2!
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CONTROLS
AND EQUIPMENT
Notes on driving Starting

\
e
engine
can only be started when
selec-
pr
ever
is at
"N"
or
"P".
See
also
"Starting

Br:
re" on
page
37.

Selecting
a driving range When the vehicle is stationary and
the engine is running always de­
press
the foot brake when selecting
i gear.
When the vehicle is stationary do
•ot depress the accelerator when
•electing a gear. f the lever is moved accidentally nto "IM" when driving, release ac­
celerator and let the engine speed
trop to idling before selecting a for­
ward
gear again.

•
Attention
•
When the engine is running it
is
necessary to hold the vehicle

with
the foot brake in all gears.
Because
with
an automatic gear­
box the transfer of power is not
fully interrupted even at idling

speed
- and the vehicle tends to
"creep".
When the vehicle is stationary
and a gear is engaged, the

throttle
must not be opened inad­

vertently
on any account (for in­

stance
by hand from the engine
compartment). Otherwise the ve­hicle
will
move immediately -
even if the handbrake has been
fully applied.
Before working on the vehicle

with
the engine running, apply
the handbrake and put the selec­
tor lever in "P".
Moving off

Select
driving
range
(R, D, 3, 2, 1).
Wait

until
the gearbox has
shifted
and the

power
flow
is made to the
driving

wheels
(light
selection
jerk
perceptible).

Then
one can accelerate.

Stopping

To
stop
vehicle
temporarily
such
as at traffic
lights,
it is only
necessary
to
apply
the

brakes.
It is not
necessary
to
move
selector

lever
to
"N".
The
engine
should
however

only
be running at idling
speed.
Parking

On
level
ground all you
need
do is
engage

the
parking
lock.
On a gradient the
hand­
brake
should
be
applied
firmly first
and
then

the
parking
lock
engaged.
This
will
ensure

that the
locking
mechanism
is not too
heav­
ily
loaded
and
makes
the
lock
easier
to
dis­

engage.

Tow starting
On
vehicles
with
automatic
gearbox
the en­

gine
cannot
be started by towing or
pushing

the
vehicle.
See
page
133.

When
the battery is flat, the
engine
can be
started
from the battery of another
vehicle

by
using
jumper
cables.
See
"Emergency

starting",
page
130.
Towing If the
vehicle
has to be towed at any time,

you
must
read
the instructions in the
sec­

tion
"Towing/tow
starting on
page
132.
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CONTROLS
AND EQUIPMENT
Ignition
lock

Petrol
engines
1 -
Ignition
off/engine
stationary

-
Steering
can be
locked
2
-
Ignition
on
3
-
Starting
engine
Diesel
engines

1 -
Fuel supply
cut
off/engine
sta­
tionary
-
Steering can
be
locked
2
-
Glow
and
drive
position
No
other current consumers should
be

switched
on together with the glow plugs
-

this avoids draining the battery
unnecessar­
ily.
3
-
Starting
engine
For
all
vehicles:

Position
1:

To
lock
the
steering
wheel
withdraw
key
and turn wheel until you hear the locking
pin engage.

Attention
Do
not
withdraw
key
from
lock
until
vehicle
is
stationary!
The

steering lock could
be
uninten­

tionally
engaged.
Position
2: If
the key is difficult to turn in the lock or
can­

not be turned to this position at
all,
the steer­
ing wheel must be rocked
to
and fro slightly
to release the locking pin.
Position
3:
In this position
the
headlights
and
other

heavy
current consumers are switched
off.

Before
the starter can be operated again the

key
must be turned back
to
position 1. The
non-repeat
mechanism
in the
ignition lock

prevents
the
starter from being operated

when
engine
is
running, as this could
dam­

age
the starter.

36
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CONTROLS AND EQUIPMENT

Starting
the
engine

General
hints
Attention

When
starting
the
engine
in con­

fined
spaces
there
is a
danger
of poisoning.
• Before starting, move gear lever to neu- ml
(with
automatic gearbox, selector lever -
"P"
or "N" position) and apply handbrake
I 'mly.
• On vehicles
with
a manual gearbox de-
:"9ss
the clutch pedal when operating

=:arter
so
that
starter only has to
turn
en­
gine.

• As soon as engine starts, release the gnition key so
that
starter can disengage.
• After starting a cold engine it may sound
_oisy
for a moment or two because the oil pressure has to build up in the hydraulic
tappets
first.
This is normal and no cause for
a
arm. Do not
warm
engine
up by run-
W>
ning
it
with
vehicle
stationary.
Drive
off
straight
away.

Do
not overrev or use
full
throttle
until the
engine has reached the normal operating
Temperature. • On vehicles
with
a
catalytic
con­

verter
the
engine
must
not be

started
by
towing
the
vehicle
in ex­

cess
of 50 m.
Otherwise
unburnt

fuel
can pass
into
the
converter
and
lead
to
damage.

•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see
page
130.
Petrol
engines

These
engines are equipped
with
a cer: ~-
jection system
that
automatically s^c; es the correct fuel/air mixture at ail anc e~:
temperatures.

When
engine is cold or at
operating

temperature
do not accelerate before or
during the starting procedure.
Applicable to all engines:
If the engine does not start at once, stop

using
the starter after 10
sees,
wait about
half a minute and then try again. If the engine still does not start, the electric
fuel pump fuse may have blown - see page
122.

When
the engine is
very
hot it may be
necessary
to accelerate slightly after the
engine has started.
37
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CONTROLS AND EQUIPMENT

Diesel
engines

Glow plug system

The
engine is
fitted
with
a glow plug
sys­
tem.
The required glow plug warm-up time
is
indicated by a lamp which is controlled by
the coolant temperature - see page 49.
Cold
starting
aid

To
assist cold starting, there is a device (cold starting aid)
fitted
in the injection
pump.

The
cold starting aid is actuated when the knob on the
left
of the steering column is

fully
pulled out.
Starting
a cold
engine

• At ambient temperatures down to -15
degrees
C, pull the cold start knob our

fully
before operating the starter.
At lower temperatures, the knob should not
be
pulled out
until
engine
is
firing
reg­
ularly
- the engine will then start more
readily.
• Turn the key in the ignition lock to
posi­
tion 2 (see page 36) - the glow plug warning lamp comes on. It goes out when the igni­
tion temperature is reached (see page 49).

While
the
glow
plugs are
working
do not
switch
on any
other
heavy
cur­

rent
consumers because
this
would

place an unnecessary load on the

battery.

• When the warning lamp goes out, start the engine immediately.

Do
not depress the accelerator while start­

ing.

If the engine only fires irregularly, continue
to operate the starter a few seconds longer (30 seconds at maximum) until the engine runs under its own power.
If the engine does not start, switch the glow
plugs on again and try starting it again as de­

scribed.
If the engine still does not start the
fuse for the glow plugs may have blown -
page123.
•
Push
the cold start aid knob in fully as

soon
as the engine has reached its normal
operating temperature.

Starting
a
warm
engine

The
glow plug lamp does not come on - the engine can be started straight away. Do not pull the cold start aid knob and do not press
the accelerator pedal.
38
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CONTROLS AND EQUIPMENT
call up the data the memories are se-
r ::ed by means of the switch A in the wiper
- Single journey memory
'- - Total journey memory

_~e
"allowing data can be obtained from the ~ r~iories:
• Driving time • -verage fuel consumption
• Distance driven
• -verage speed
E-asing the
memories
:~ the ignition switched on, both mem-
: es can be erased separately in each
: :ch position by pressing switch A : --sed the appropriate detent position to 0
::; tion for longer than one
second.

" :~.e battery is disconnected for any rea-
::" the stored information is automatically

Ksed.
The displays

When
the ignition is switched on
"MF11"
or
"MFI 2" appears in the display according to
which memory is switched on.
No symbol -
Time

The
time is shown even when the ignition is switched off.

The
time can be set
with
the buttons (h and min) on the lower
left
of instrument cluster
- see "Digital
Clock"
page 41.
—'— -
Driving
time

In
switch
position 1 the driving time
which has elapsed since ignition was
switched on or the memory cancelled is indicated - see previous page also "Single
journey memory".
In
switch
position 2 the total driving
time for all individual journeys is indicated -
see
previous page also "Total journey mem­
ory".

The
maximum time in both switch positions
is
99 hours 59 minutes. When this figure is

exceeded
the indication starts at zero again. MPG
(1/100
km) -
Average

fuel
consumption

The
average consumption is indicated not
the actual consumption at the time of read­
ing.

The
average fuel consumption is indicated,
after switching on the ignition or erasing the memory being
used,
after a distance of
about 100 metres. Up to this point a dash

appears
instead of a figure. When vehicle is moving the indicated value is up-dated
every 5
seconds.

In
switch
position 1 the average
con­

sumption for the single journey is indicated.
In
switch
position 2 the average
con­

sumption indicated is
that
obtained during

all
single journeys - see "Total journey memory" on previous page
also.

Note

The
amount of fuel used is not indicated.

43
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CONTROLS
AND
EQUIPMENT

6-Alternator
Q

~ne warning lamp comes on when the
igni-

I
on
is
switched on and must go out when

She
engine
is
started.
i the warning lamp comes on when driving,

stop,
switch
engine
off
and
check
the
alternator V-belt.
f the V-belt
is
broken or loose do not
drive

on with
a
vehicle which
has a 4 cylinder
engine
because the coolant pump
is
then
no
longer being driven. The V-belt must
be

tensioned
or
renewed.
ehicles with
a 5
cylinder engine
can
nor­
mally
be
driven to the nearest Volkswagen
dealer when
the
V-belt
is
broken
or
loose oecause
the
coolant pump
is
driven separ­
ately but then the battery will discharge
con­

tinuously
and all
non-essential electrical consumers should
be
switched
off.

f the warning lamp comes on although
the

belt
is
not broken, one can normally drive on

to
the nearest Volkswagen dealer (all engine

types)
but the
battery will then discharge
continuously
- see
previous paragraph.
7-Glow
plugs
W

(Diesel engines only)

When
the engine
is cold
the warning lamp comes on when key
is
turned to Drive
posi­

tion
(ignition on).

If
the warning lamp does not come
on,
there
is
a
defect in the glow plug system
-
call
in

expert assistance.

When
the
lamp goes out,
start
the engine
immediately
-
see page
38.

When
the
engine
is warm the
glow plug
lamp
does
not
come on -the engine can
be

started straight
away.
(®)
-
Anti-locking
Brake

System
(ABS)*

The operational readiness
of the
essential electrical components
of the ABS are

checked,
both before moving off and when

driving,
by an electronic monitoring system.
The warning lamp lights up when
the
igni­

tion
is
switched on and
it
must go out again, at the latest, after the engine
has
started.

If
the warning lamp does not go out
or if it

comes on when driving the system
is
not
in

order.
The
vehicle can then only
be
braked
with
the
normal system
-
that
is
without
ABS-.The vehicle must be taken to a Volks­
wagen Dealership
as
soon
as
possible.
Further details on ABS
is
given on page
30.

<]1i>
-
Trailer
turn
signals

The warning lamp
*
flashes when turn
sig­
nals are switched on when towing
a
trailer.

If a
turn signal fails on the trailer or vehicle,
the warning lamp does not flash.
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CONTROLS AND EQUIPMENT

Auxiliary
heater*
To
switch heater on
•
Press
rocker switch D on rent.
• Select desired heat
with
knee -
The
green heater in-operatior. =~~" _
comes
on.
Regulating
heat

The
heat is infinitely adjustable
with
:~e knob A.
After heater has been switched on it takes

a
little
time before heat can be
felt.

When
the set temperature is reached, the green in-operation lamp becomes darker.

The
temperature is then held fairly constant by the heater thermostatically.
w-^
=
jxiliary heater works independently of
me .ehicle heating. It is supplied
with
fuel
I: rr the vehicle tank.
He suxiliary heater can be used continu­

es
. when on the move or stationary.
|r~? current is supplied from a 2nd battery.

r~T
air flows from the outlets behind the p*.er's seat.
k- the summer the heater blower can be

(sed
to circulate the air in the vehicle with-
it.: heat.
5v. itching on and off and regulating the aux-
tey heater are done from the control panel
r the dash panel.
-
a
timer* is
fitted
(see page 65) the control

panel
is located on the roof cross member I the passenger compartment.
A
BCD

[J70~-T971

Control
elements

A
- Regulating heat output
B
- Overheating indicator (red)

C
- Heater in-operation lamp (green)
D
-
Rocker
switch for switching heater on
and
off and operating blower without heat.
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CONTROLS
AND
EQUIPVE\

Additional
water
heater*
E
additional water heater heats the
cool-

— ;he heater circuit and supplies the nor- • ^eating heat exchanger and the addi-

:~a
heat exchanger* for heating up the
rsaenger
compartment
with
heated
cool-
' ""e engine coolant circuit is not heated.
I current is supplied from a 2nd battery.

:ching
on and off and pre-selecting the
. :ch on/off times is effected via the timer,
- :h can be found in the instrument panel.

~a
air distribution and the air flow is ef-

:::ed
via the normal heating and ventila- : li aontrol elements (operating see page

a
additional water heater can be used

•en
stationary (short term operation) or -g the journey (continuous operation). If

.a;
when the vehicle is stationary the

•Her
runs for maximum 30 minutes,
;eoy
preserving the battery. Apart from
• 5 t switches off automatically, when a .: ant temperature of 92 degrees C is

Bcned.

"
an
the coolant temperature has dropped
-: .v 84 degrees C the heater switches on
The
additional water heater is supplied
with

fuel from the vehicle tank. It consumes up
to
1
litre
of fuel per hour. The heater output

is
approx. 7.0 kW.

Notes

• If the coolant temperature in the heater circuit reaches 55 degrees C, the fresh air
blower is automatically switched to stage 2.
• The additional water heater will only switch on when the temperature selector
lever
(see page 55, lever C) is pushed fully
to the
right.

• With the heater switched on the tem­ perature selector lever must not be pushed
to the
left.

• Regulating the heat output is not
poss­
ible
with
the temperature selector lever.
• When driving across country through mud or deep snow the heater exhaust pipe

can
become blocked. Therefore under

these
conditions check
that
the pipe is clear before switching on the heater.
Attention

The
heater
must
be s . ::'-
a
: : in confined spaces and when fil­

ling
the
tank.

•
Each
time the heater is sw :ce:
circu
at .-' pump and the comes::-blower continues to run for a v. K.e :: :::
down the heater
unit
quicker. Wher,-:. rg
the tank it is not necessary to vva :
end
of the run-on.
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