automatic transmission 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

Swivel seats*
The forward or backward adjustment pro­ cedure outlined for the
front
bucket seats

also
applies to the swivel seats.
Before turning the driver's swivel seat:
•
Position shift lever in park (automatic
transmission) or in first gear (manual

transmission).

•
Block wheels if necessary to
prevent

vehicle from moving.

•
Release parking brake. WARNING
Swivel seats must be in forward facing
position while driving. Do not operate the locking lever of the
swivel seat while the vehicle is in mo­

tion.

To swivel the seat, move seat slightly for­ ward or open the door a crack.
Then
push
down the locking lever in
front
of the seat.
The passenger seat can be turned
180°
to the left
(half
circle).
The driver's seat can be turned
90°
to the
right
(quarter
circle).
The seats will lock automatically at
every
turn.

22
"where applicable


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CONTROLS AND
EQUIPMENT

=ailure
of one
brake
circuit
I the brake pedal travel should suddenly
icrease,
one of the brake circuits may

_ave
failed. Should this happen, you will
m able to bring your vehicle safely to a

s:op,
however, you will have to push hard­
er on the brake pedal and it will take a onger distance to stop the vehicle.
Con­

tact your Volkswagen dealership for as­
sistance.

Brake
wear

~he brakes on our automobiles are still subject to wear depending largely on oper­ating conditions and driving habits. On ve­

hicles
which are driven mostly in stop-and-
50 city
traffic
or which are driven hard, the
crake linings should be checked by your

Volkswagen
dealer more often than
specified
in the Maintenance brochure.

Front
spoiler
If you
install
a
front
spoiler on
your
vehi­
cle, be
sure
the air
flow
to the
front

brakes
is not
obstructed,
otherwise
the

brake
system
could
overheat.
Parking
brake
lever

The parking brake lever is located between the
front
seats.

• To set the parking brake, pull the lever

until
strong resistance is
felt.
The parking
brake must be pulled up all the way so
that

the vehicle cannot be moved. When the ig­ nition is on, the brake warning
light
will

light
up.
• Depress brake pedal and hold while re­

leasing
parking brake. To release the park­
ing brake, pull the lever slightly up, de­

press
the release
button
(arrow), and then
push the lever all the way down. When the parking brake is fully released, the brake
warning
light
will go out.
WARNING

•
Release
the
parking
brake
fully.
A

partially
engaged
brake
will
overheat

the
rear
brakes,
reduce
their
effective­
ness and cause excessive
wear.

•
Always
set the
parking
brake
when

parking
your
vehicle.
Move
the
selector
lever
to "P"
(Automatic
transmission)

or
move
the
gearshift
lever
to "R" or "1"
(Manual
transmission).
On
hills

also
turn
the
wheels
toward
the curb.
31


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CONTROLS AND EQUIPMENT
AUTOMATIC TRANSMISSION*
p R
f

N d
D
2
f

1 :'B33-395
Selector lever positions
WARNING Apply foot brake when engaging Drive or Reverse.
P - Park
Engage Park only when the vehicle is
sta­

nnary. Therefore, when parking your .snide, apply the parking brake first, and
:nen move the selector lever completely to cosition P. To do this depress the but­
ton in the handle of the selector lever and push it through R to P. The transmis-s on is then mechanically locked.
Depending on the model, your vehicle
~iay be equipped with an Automatic Shift _ock (ASL). To move the shift lever from
re
P-Park
position to any other position,
".vhere applicable you must depress both the brake pedal
and the button into handle of the selector lever.
Shift out of the Park position, before re­ leasing the parking brake.
When the vehicle is parked on a steep
hill,
shifting out of Park may be a little harder.
This is due to the vehicle's weight exerted on the transmission.
Warning buzzer
A warning buzzer will sound when you open the driver's door with the selector lever left in any other but
P-Park
position.
The warning buzzer will go off as soon as the selector lever is moved to the
P-Park
position.

R - Reverse
Reverse should be selected only when the
vehicle has come to a full stop and the en­
gine is running at idle speed.
Before you move the selector lever to the
reverse position you have to depress the
push button in the handle of the selector
lever.
N - Neutral
Shift to this position for standing with
brakes applied. Depending on the model, your vehicle
may be equipped with an Automatic Shift
Lock (ASL). To move the shift lever from
the N-Neutral position to any other
posi­

tion at speeds below 3 mph (5 km/h) or when the vehicle is stationary, you must
depress both the brake pedal and the button into handle of the selector lever.
Do not use Neutral for coasting downhill.
Coasting downhill with the transmission in Neutral and the engine not operating
will result in damage to the Automatic
transmission.
D - Normal driving position
Position D is for normal city and highway

driving.
It ranges from zero to top speed, and all three gears shift automatically,
depending on engine load and driving

speed.

2 - Position for hilly stretches
This position is to be used for mountain driving or slow driving, and also when you
want to make use of the engine's braking effect. In "2", only the first and second
gears will engage automatically.
The road speed must not exceed 54 mph or 87 km/h. Therefore, only shift down into position "2" when vehicle speed is
below this speed. It is not necessary to let
up on the accelerator. 35



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CONTROLS
AND EQUIPMENT
1 - Position for steep hills

This
position is to be
used
for mountain
driving
or
slow
driving.
It
also
provides
for
maximum
engine
braking effect. To
engage this gear depress the push but­
ton in the handle of the selector lever
first. In "1" the
transmission
will
stay
in first
gear
and will not upshift.
The road speed must not exceed 33 mph
or
53 km/h. Only shift down into "1"
when the speed is below this speeds.
WARNING
Do
not shift to a lower driving position
until vehicle speed has dropped below
the specified limits otherwise engine
speed
will
suddenly increase and may

cause
engine damage and
loss
of
vehicle control. Driving the automatic transmission
Starting the engine

The
selector
lever
must be in Neutral or Park. If one of the driving
positions
is

engaged
a
safety
switch will prevent the
engine
from
being
started.

Emergency
starting

Your
Volkswagen
with
Automatic
Transmis­
sion
cannot
be started by
pushing
or tow­
ing.
If
engine
does
not start
because
of
dis­

charged
battery, the
vehicle
can be started
with jumper
cables.
Refer
to
"Emergency

starting
with jumper
cables".
Should
the

engine
fail to start
consult
your
nearest

Volkswagen
dealer.
Selecting
a driving position
WARNING
•
Apply the foot brake before select­
ing a driving position when the vehicle

is
stationary.
When the selector lever is in a driving
position,
the vehicle may creep even at
idle speed. Therefore, do not release
the parking brake or foot brake until

you
are ready to move, because power
is
transmitted to the wheels as soon as
a driving position is engaged.

•
Do not accelerate
while
selecting
a driving position. At this
time
the en­
gine must run at idle speed so
that
no undue stress
will
be placed on the auto­
matic clutches in the transmission.

•
Never have any position engaged
when checking in the engine compart­ ment. Make sure the selector lever is

securely
locked into the P position
with

the parking brake firmly set. Otherwise, any increase in engine speed may set
the vehicle in motion, even
with
the parking brake applied.




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CONTROLS
AND
EQUIPMENT

•
Never shift into Reverse (R) or Park
(P) when the vehicle is in motion.

•
Do not remove the key from the ig­
nition steering lock until you have
parked the vehicle, because removal
of the key
will
lock the steering wheel.

•
If the selector lever is unintention­
ally moved into Neutral (N)
while
driv­

ing,
take
your foot off the accelerator pedal and
wait
until the engine speed

has
dropped to idling before selecting
a driving position.
Maneuvering
•'/hen
alternating between forward and

-averse
- for
instance,
while
maneuvering

ne
vehicle
into a tight parking
space
-
:nly
shift when the
vehicle
has
come
to a
full stop and the
engine
is running at idle
soeed.
Stuck
in snow, mud or sand

When
alternating between forward and
reverse
in an effort to free the
vehicle,

depress
the
accelerator
pedal
slightly

while
the
transmission
is in
gear,
and
release
the
accelerator
pedal
while

shifting.
Do not
race
the
engine
and
avoid

spinning
the
wheels.
Do not repeat
"rocking"
back and
forth
with
wheels

spinning
at high engine speed and heavy
throttle,
as serious damage may
be caused to the automatic transmis­

sion
and other critical parts.

Kickdown
device

The
kickdown
device
gives
maximum
acceleration
when the
accelerator
pedal
is

pressed
down
past
the full throttle
posi­

tion.
Depending
on
road
speed
and
engine
speed,
either the upshift is
delayed
(forced
throttle) or the box
changes
down

into
the next lower
gear.

WARNING
Be
careful when using the kickdown on

slippery
roads. Rapid acceleration may

cause
skidding.
Stopping

•
When
stopping briefly, at a traffic light

for
example,
it is not
necessary
to
move

the
selector
lever
to
Neutral.
Simply
apply

the
brakes.
To start
again
release
brake
and
accelerate.

•
The driving
positions
must
never
be

used
for holding the
vehicle
at rest
uphill.

Always
use your foot
brakes
when
stopped
on
inclines.

WARNING
•
Never get out of the driver's seat
when the engine is running and the
selector
lever is not securely locked in
the P position.

•
If you must leave the vehicle move
the selector lever securely into the P
position
and apply parking brake
firmly.
Towing

To
tow the
vehicle
see instructions
"Emergency
towing" on
page
138.




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CONTROLS
AND
EQUIPMENT

STARTING
PROCEDURES
WARNING
•
Fasten safety belts before driving.

•
Never
start or let the engine run in a
confined or enclosed, unventilated

area.
Exhaust fumes from the engine
contain carbon monoxide, which is a

colorless
and odorless gas. Carbon monoxide can be
fatal
if inhaled.

•
Never
leave engine idling unatten­

ded.
An unattended vehicle with a run­
ning
engine is potentially hazardous.

•
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.

•
Do not leave engine unattended at

idle.
When starting engine, be ready to
drive off immediately. Maintain moder­
ate
speed until the engine is
com­

pletely warm. Remember that
your
en­
gine performs best at operating
tem­
perature.
Automatic
Transmission
Engine will only start with selector lever in
Neutral or Park.

Manual
Transmission
Start with gearshift lever in Neutral, clutch

pedal
depressed, so that the starter only

has
to crank the engine.

Starting
engine
•
Do not depress accelerator pedal
when starting. At extrem low temperatures
the engine will probably start better, if you depress accelerator pedal slighly.

•
As soon as the engine starts, release
the ignition key.

•
If the engine does not start the first time
or
stalls,
turn
the ignition off and restart. Depress the accelerator pedal slowly
during the second starting attempt.

•
Operate the starter for no more than

10
seconds.
•
Allow about 30 seconds between each

starting
attempt.
STOPPING
ENGINE

Do not stop engine immediately after
hard or extended driving. Keep engine
running for about two minutes to pre­

vent
excessive heat build-up.
WARNING
•
Before you check anything in the
engine compartment, stop the engine and let it cool down. Hot components

can
burn skin on contact.

•
The radiator fan switches on auto­

matically
when the coolant reaches a cer­

tain
temperature and will continue to run
(even
with ignition off) until the coolant
temperature drops.

39




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3REAK-IN
PERIOD

VEHICLE
OPERATION]
DURING AND
AFTER
BREAK-IN PERIOD

Turing
the first few operating
hours,
the

r-gine's
internal friction is higher than
a:er
when all the moving parts
have
been

:-oken
in. How well this break-in
process

e
done
depends
to a
considerable
extent
:n
the way the
vehicle
is driven during the

-"-3t
900
miles
(1500 kilometers).

For
the first 600 miles
(1000 kilometers):

•
Do not use full
throttle.

•
Do not drive faster
than
3A of top

speed.

•
Avoid high engine speeds.

From
600 to 900 miles
(1000 to 1500 kilometers):

The
speed
can gradually be
increased
to
:he
maximum road
speed
or
engine
speed.

After break-in period
The maximum permissible engine speed
is
5200
rpm and should not be exceeded.
Shift into the higher gear before reach­ing the red area at the end of the scale of
the tachometer. See page 41.

Excessive
engine
speeds
are automati­

cally
reduced.
•
Details
on how to operate the
Manual

and
Automatic
transmission
are outlined

in
the
"Controls
and
equipment"
chapter.

•
Avoid full
throttle
starts and abrupt

stops.

•
Try to avoid running the engine at
maximum speed. Shifting up early helps
to save fuel and reduces noise.

•
Do not overstrain engine; select pro­
per gear before reaching top speeds.

•
Do not let engine labor. Shift down
when engine no longer runs smoothly.

•
All
revs
are only
valid
when
engine
is

properly
warm.

•
Always
observe
local
and national

speed
limits.

Applies
in addition to vehicles
with
Automatic
Transmission:

Make
it a habit to
accelerate
gradually

instead
of
using
full throttle. During
gra­

dual
acceleration
the
transmission
shifts

earlier
into the next higher
gear
thus

saving
fuel.
WARNING

•
New tires do not
possess
maximum
traction. They tend to be slippery. Break new tires in by driving cautiously
at moderate speed for the first 100 miles (160 kilometers).

•
New brake pads and linings do not
have optimum friction properties and
must be "broken in" during the
initial
100 to 150 miles (150 to 200 kilometers)
of normal city driving. You can compen­ sate for this by applying more pressure

on
the brake pedal. This also applies
later
when new pads or linings are
installed.


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VEHICLE
OPERATION

In the
driver's
seat
•
Check operation of horn.

•
Adjust seat for easy reach of controls.

•
Adjust head restraints to your
size.

•
Adjust inside and outside rear view mir-
brs.

•
Use safety belts as directed.

•
Assure yourself
that
all passengers,

especially
children, are properly buckled up.

•
Check operation of
foot
and parking

orakes.

•
Check all warning and indicator lights
v/hen starting the engine.

•
Do not leave vehicle idling unattended.

•
Lock all doors
from
inside to prevent in­ advertent opening of doors
from
inside
and unwanted
entry
from
outside. On the
road

•
Always drive defensively. Expect the

unexpected.

•
Observe speed
limits
and obey road

signs.

•
Use signals to indicate
turns
and lane

changes.

•
Turn on headlights at dusk.

•
Always keep a safe distance
from
the
vehicle in
front
of you, depending on
traf­

fic, road and weather conditions.

•
Reduce speed at
night
and during incle­
ment weather.

•
If you smell gas fumes in the vehicle,
drive
with
the windows open, but keep the rear lid
closed.
Have the cause im­
mediately located and corrected.

•
Make frequent rest stops, at least
after

every two hours of driving.

•
When
tired
pull off the road, stop and
take a rest. Turn the engine off. Do not sit in the vehicle
with
engine idling. Engine ex­haust is dangerous if inhaled.
•
When stopped or parked, always set
the parking brake. Move the selector lever
to "P" (Automatic transmission) or move
the gearshift lever to reverse or
first
gear (Manual transmission). When parking on

hills,
turn
wheels
toward
the curb.

•
When stalled or stopped for repairs,
move the vehicle well off the road. Turn on
emergency flasher and use other warning

devices
to alert other motorists. Do not park or operate the vehicle in areas where
the hot exhaust system may come in
con­

tact
with
dry
grass,
brush, fuel spill or other material which can cause a fire.

•
Make it a habit to have the engine oil

checked
with
every fuel filling.


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VEHICLE OPERATION

For
best roadability adjust your load to the
maximum allowed tongue load. To be sure

measure
tongue load of loaded trailer on
bathroom
scales.

Check
that
both sides of your trailer can be

seen
from the driver's seat. If necessary in­
stall extended rear-view mirrors.

Check
proper working of vehicle and
trailer lights.

Check
cold
tire
pressure of both vehicle

and
trailer.

Be
sure trailer safety chains are properly

connected
from trailer to the hitch on the

vehicle.
Leave enough slack in the chains
to permit turning corners.

Trailer
towing
tips
Your
vehicle handles differently when tow­ ing a trailer because of the additional
weight. Safety, performance and economy
will greatly depend on how carefully you
load
your trailer and operate your "rig."
Before
you actually tow your trailer, prac­
tice turning, stopping and reversing in an
area
away from
traffic
until
you learn the
feel of your vehicle and trailer
unit.

Reversing
is
difficult
and requires practice.

Steering
while reversing is generally oppo­
site of
that
when backing your vehicle with­
out a trailer.

Observe
speed limits. In some areas

speeds
for vehicles towing trailers are lower than for regular vehicles.
Maintain a greater distance between your

vehicle
and the one in
front.
You will need more room to stop.

When
passing remember
that
you cannot
accelerate
as fast as you normally would

because
of the added load. Make sure you
have
enough room to
pass.
After passing
allow plenty of room for your trailer before

changing
lanes again.

Avoid
jerky starts or sudden acceleration.
Slow
down in crosswinds and on rougi"

roads.
Be especially carefull when
pas­

sing
other vehicles and trucks.

When
parking always block the wheels o: both vehicle and trailer. Do not park
with
a
trailer on a slope. If it cannot be avoided dc
so
only after the following:
• Apply brakes.
• Have someone place wheel blocks
under both vehicle and trailer wheels.
• With wheel blocks in place slowly re­

lease
brakes
until
wheel blocks absorb the

load.

• Apply parking brake.
•
Place
transmission in
"P"
for automatic
or in
first
or reverse gear for manual trans­
mission.

74


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