VOLKSWAGEN TRANSPORTER 1990 T4 / 4.G Owners Manual

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DO-IT-YOURSELF-SERVICE

Step
3
•
Loosen
wheel
nuts or bolts counter­

clockwise
about one turn with the lug

wrench.
Do not yet remove the nuts or
bolts.

To
loosen
- turn
counterclockwise

To
tighten - turn
clockwise

Step
4

There
are two jack ports on
each
side
under
the car
body
for front and
rear
wheel

changing
- see right illustration. [
B25-3)9|

WARNING
•
Mounting the jack at any other place
may damage the car or may result in
personal
injuries.

•
Provide a firm a base for the jack on
the ground. If
necessary,
use a board.

•
Securely
insert the jack into the jack

port
closest
to the
wheel
to be
changed.

•
Before
inserting jack,
clear
jack port.

•
Place
jack as straight as
possible,
as

shown.
Step
5
Never jack the vehicle up by the bu~
per or body.

Do
not raise the vehicle until you are

sure
the jack is securely engaged.

Passengers
must not remain in the
vehicle when jacked up.

•
Make sure
that
passengers
wait
in z
safe place away from the vehicle arc

well
away from the roadway and traffic

•
To raise the
vehicle,
turn the
har:T

clockwise.

Only
raise
the
vehicle
as
much
as
needed
to
change
a
wheel.

Step
6
WARNING Before installing the spare wheel, acc-
mulated road
dirt
must be remove:
from the inside and outside of the
wheel nut/bolt holes to assure a secure mount on front hub or rear drum.

126


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• Fully unscrew wheel nuts or bolts and

dace
them into the hub cap. Take the top
nut or bolt off last.
Place
the spare wheel against the wheel hub and slightly rotate
:he wheel until a bolt hole in the wheel is in ine
with
a threaded stud in the wheel hub.

Reinstall
nuts or bolts and tighten them

crosswise
by hand before jacking the car

down.

Step
7 • To
lower
the vehicle,
turn
the handle

counterclockwise.
Step
8
• Then go crosswise from one nut or bolt
to another tightening them firmly
with
the lug wrench.
• Correct
tightness
of the
wheel
nuts
is

important.

• Correctly tightened nuts or bolts should

have
a torque of 130 ft lb/180 Nm. This
tor­

que can be obtained
with
the lug wrench by any person of average strength. If in
doubt about the correct tightness of the
wheel nuts, have them checked
with
a
tor­

que wrench by your dealer or at service
station.
Step
9
• To install the hub cap, place it around
the lower part of the wheel center. With a

firm
blow of your hand on the upper part,
the hub cap will snap into place. Make sure it is firmly seated.

Step
10 • Fully lower the vehicle and remove
jack.
• Correct the air pressure of the
tire
you

have
just
put on. For correct
tire
inflation

pressures,
see the sticker on the
left
door-
jamb.
• Store the jack and tools under the
driver's seat.
• Store damaged
tire
in spare wheel
metal plate under
front
of vehicle.
• Engage lock for metal plate and firmly

secure
plate
with
bolt.
• Have
flat
tire
repaired and replaced
promptly.
127


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FUSES

A
failure in the electrical system may be
caused
by a burned fuse.

Fuses
are arranged in one centralized

unit.
The
unit
is located on the
left
side under the dashboard behind a cover.

Removing
cover:

Detach cover at
front,
swing downwards
and take it off.

Installing
cover:

Hang
cover in the eyes of fuse box
bracket, swing it upwards and press it

firmly
into
position.
Replacing
a
fuse

Before
replacing
a fuse,
turn
off all
lights

and accessories and
remove
the
ignition
key to
avoid
damaging
the
electrical

system.
• Consult the fuse listing on the following
page to
find
out which fuse belongs to the
component
that
has failed.
• Remove blown fuse
with
the plastic clip
located on cover in
front
of fuse box.
Three spare fuses can be attached to the
bottom
of the fuse panel. It is good plan­ning to keep a supply of spare fuses on

hand.
They are available at your Volks­
wagen dealer.
• Replace the blown fuse which can be
recognised by the
burnt
metal strip,
with
a
fuse of equal ampere rating. If a
fuse
blows
repeatedly,
do not
keep
or

replacing
it. The cause of the
short
cir­

cuit
or
overload
must
be found. On nc

account
should fuses be
patched
up

with
tin
foil
or
wire
as
this
may cause serious
damage
elsewhere
in the
electrj

cal
circuit
or cause a
fire.

WARNING
Do not use a
fuse
of
higher
amperage,

because
this
could
damage
the
elec­

trical
part
and
fire
can
result.

128


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Fuse arrangement No. Component Amp. No. Component Amp.
From left to right: 1
Radiator fan 30 17 Windshield wiperengine 10
2 Brake lights 10
18 Brake warning light,
3 Interior lights, illuminated heated driver's seat,
Make-up mirror, clock,
ciga­
cruise control system 10
rette lighter, radio 15 19 Turn signals 10
4 Emergency flasher system 15 20 Number plate light,
5 Vacant headlight washer
10
6 Vacant 21 Low beam left
10
7 Tail and side light left 10
22 Low beam right 10
8 Tail and side light right
10
9 High beam right 10
10 High beam left
10 Additional fuses
11 Windshield wipers and washer
15 (in separate holders)
12 Cruise control system
Air conditioner, power above the fuse box:
windows, auxiliary heater, Instrument lightning
10
electric outside mirrors, Overheating fuse for auxiliary heater
10
auxiliary heat exchanger, Main fuse for auxiliary heater
20
rear window wiper 20 Central locking 20
13 Fresh air fan
20 Automatic fuse for window lifter
20
14 Rear window heating, heated
rear view mirror, light for Color codes
15
16 lighting switch
Back-up lights
Double tone horn 20
10
15 10 Amp. fuses - red
15 Amp. fuses - blue
15
16 lighting switch
Back-up lights
Double tone horn 20
10
15 20 Amp. fuses - yellow
30 Amp. fuses - green
The number on the face of the fuse is the amperage rating.


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REPLACING BULBS
Before starting to replace a bulb, switch off
the respective circuit.
Do not touch the glass part of the new bulb
with bare fingers. Finger prints left on the
glass evaporate when the bulb gets hot,
the vapor settles on the reflector surface and dims it.
Always use the same
type
of bulb. The designation is marked on the bulb.
It is advisable to always
carry
a box of
spare bulbs in the vehicle. Bulbs can be
obtained from any VW dealer.
It should contain, at least, the following
bulbs which are important for traffic safety:

12V/70/50W
- Headlight

12V/21
/5W -
Front
turn
signal and
front
side marker light

12V/21W
- Rear
turn
signal

12V/3W
- Rear side marker light

12V/21/5W
- Brake and tail lights
12V/4W
- Licence plate light Headlights
The outer units are for low and high beams and have two filaments. The auxiliary
driving lamps are for high beam only and have one filament.
Should it become necessary to replace a
headlight bulb, the air intake grille must be
removed first. • With a screwdriver loosen the five
quick-release screws along upper edge c
grille.
•
Pull
the grille slightly toward you.
•
Then
lift the grille out of its retainer.

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• Remove the four screws (arrows) and
take the headlight out. | B16-251

Outer
headlights
• Disconnect wire connector (1)
• Twist lock ring (2) counterclockwise,
pull bulb (3) out ot headlight housing and

discard.

• Install new bulb so
that
the locating lugs
on the headlight housing engage the
recesses
on the bulb.
• Reinstall lock ring so
that
its recesses

engage
the locating lugs on the headlight
housing.

• Twist lock ring clockwise until firmly

seated.

• Reconnect wire connector. Have head­
light beam alignment checked.
Auxiliary
driving
lamps

• Turn cap to
left
and take off.
• Pull wire connector off.
• Unhook spring clip holding bulb and
swing it away.
• Take bulb out and insert new bulb so

that
the locating lug on bulb plate engages
recess
in reflector.
• Swing spring clip over bulb plate.

Squeeze
clip together and engage it in the retaining lugs.
• Attach wire again.
• Install cap and
turn
to
right.

• Have headlight setting checked.
131


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IB25-325I

Front
turn
signal / parking
light
bulb/

front
side
marker
light
bulb

• Remove
the two
Phillips screws
and

take
off
the lens cover.
• Pull
out
bulb holder and push down
the

rubber boot.
•
Press
spring clip inward
and
take
out

bulb holder.
• Give bulb
a
left
turn
and remove.
• Replace bulb
and
reverse
the
above
procedure
to
install bulb holder
and
lens

cover.
Rear
turn
signal, stop /
tail
/
back-up
light
bulb

• Remove
the
four Phillips screws
and

take
off
lens cover
with
bulb housing. • Squeeze
the two
side springs inward

(arrow)
and
lift
out
the bulb housing.
•
Press
defective bulb
into
bulb holder

turn
left
and take
out
bulb.
• Replace bulb
and
reverse
the
above
procedure
to
install bulb housing
with
lens

cover.

132


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Rear
side
marker
bulb
• Remove the two Phillips screws and
take off lens cover.
• Pull out bulb holder and push down the
rubber boot.
•
Press
spring clip outward and take out
bulb holder.
• Give bulb a
right
turn
and remove. • Replace bulb and reverse the above
procedure to install bulb holder and lens

cover.
Interior
light

• To remove lamp, press against spring
clip on
left
side and
lift
out the housing.
• Take out bulb from between the two
spring contacts and install new bulb.
• Install lamp by inserting switch side of
housing
into
cut-out
first.

• Then press in the other side
until
spring
clip engages. License
plate
light
bulb

There is one bulb housing on each side of the license plate. Only if both bulbs are
operative is the license plate properly illuminated.
• Take the bulb housing off by pulling it
down.
• Remove the two Phillips screws and
take off lens cover.
•
Press
bulb
into
housing,
turn
left
and
take out.
• Replace bulb and reverse above proce­
dure to install bulb housing and lens cover.

Make
sure the spring clip on each side of
the housing is securely engaged in the
cutouts provided at upper edge of cross
panel.

133


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HEADLIGHT ADJUSTMENT
The proper headlight adjustment is very important for
traffic
safety. The headlight
adjustment should therefore only be done

with
a special appliance.
Adjust the headlight using the Phillips screwdriver from the vehicle tools. The illustration show the adjustment on
the
right
headlights. On the
left
headlights the adjustment are symmetrically oppo­

site.

A
- lateral adjustment
B
- hight adjustment

To
reduce the beam range,
turn
the screwdriver clockwise.
134


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INSTALLING
/
REPLACING
A
RADIO

If
you wish
to
install
a
radio
or
replace
the

factory installed radio*, please note
the

following:
• The factory installed connectors*
are

designed
for
Original Volkswagen
Radios.

When
installing
a
different
radio, diffi­ culties could arise such as:
-
the
radio
may not fit
into
the
provided
space

-
the
electrical connections
may not be
compatible
-
different
connector terminals
may be
needed.
• Therefore,
we
recommend
that
you

have
your authorized Volkswagen dealer
install
or
replace
the
radio. They
are the

most familiar
with
the technical features
of

your vehicle. They also offer Original

Volkswagen
Radios
with
the
necessary installation components and instructions.

WARNING
Improperly
installing a radio
could
risk
a short circuit. This could result in an
electrical fire.

'where
applicable


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