cooling VOLKSWAGEN TRANSPORTER 1990 T4 / 4.G Owners Manual
[x] Cancel search | Manufacturer: VOLKSWAGEN, Model Year: 1990, Model line: TRANSPORTER, Model: VOLKSWAGEN TRANSPORTER 1990 T4 / 4.GPages: 165, PDF Size: 24.87 MB
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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
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
Operating controls
A
— Fan switch
• Adjust
air
volume
by
turning switch
either one
of
the three
speeds.
• With
fan
switch knob
OFF,
the air
con
ditioner will
not
operate. B
— Temperature control switch
• Turn switch knob
right
for
cooler
air.
• Turn switch knob
left
for
warmer air.
Operating hints
Comfort cooling
• Turn fan switch
A
to
speed
setting "1"
or
"2".
• Turn temperature control switch
B to
desired
position.
• Adjust
air
outlet
vents
as
desired.
Maximum cooling
• Turn fan switch
A to
extreme
right.
• Turn temperature control switch
to ex
treme
right.
• Adjust
air
outlet
vents
as
desired.
'where applicable
55
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VEHICLE OPERATION
OPERATE
YOUR VEHICLE SAFELY
A
lot has gone
into
the manufacture of your Volkswagen, including advanced engineering techniques, rigid quality
control and demanding inspections.
These
engineering and safety features will be enhanced by you, the safe driver,
• who knows the vehicle and all controls
• who maintains the vehicle properly
• who uses driving skills wisely.
For
your own safety as well as
that
of
those around you - be a responsible
driver. If you
drink,
do not
drive.
The use
of alcohol, drugs and certain medications
will seriously impair perception, reactions and driving ability, substantially increasing
the risk of an accident and personal
injury.
Do not
drive
if you are
tired,
ill or
under
emotional
stress.
The
following
points
are also
important
for
your
safety,
please
observe
them
all.
First
things
first...
• Turn the engine off before performing
any checks or repairs on the vehicle.
• Be sure tires are inflated correctly.
Check
for damage and
tire
wear.
• See
that
wheel bolts or nuts are pro
perly tightened and not loose or missing.
• Check engine oil level, add if neces
sary.
Make it a habit to have engine oil
checked
with
every fuel filling.
• Check coolant level to assure sufficient
engine cooling.
• Be sure you have a well charged
battery.
• Check brake fluid level. If too low, have
brake system checked.
• Replenish windshield washer fluid.
• Replace worn or cracked wiper blades.
• See
that
all windows are clear and un
obstructed.
• Check whether all
light
lenses are
clean.
• Be sure all lights are working and head
lights are aimed correctly.
• Check under vehicle for leaks.
• Make sure the movement of either
brake,
clutch or accelerator pedal is not hampered in any way.
• Be sure all luggage is stored securely.
You'll
find helpful hints on how to perform most of these checks in this manual. If in
doubt, have these checks performed by
your dealer or any other qualified
mechanic.
Emergency
equipment
It is good practice to carry emergency
equipment in your vehicle. Some of the
things you should have are: emergency
light,
first-aid kit, small shovel, and for the
winter
season,
an ice scraper, snow brush,
a
container or bag of sand or salt, etc.
70
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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
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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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VEHICLE
CARE
General notes
The original equipment tires
and
wheel
rims
on
your
vehicle comply with
all
applicable
Federal Motor Vehicle Safety
Standards.
If you
wish
to
equip
your
vehicle with tires
or wheels other than those installed
at the
factory, please note
the
following:
•
If
you plan
to
install other than the
ori
ginal
equipment tires
and
wheel rims,
ask
your
Volkswagen dealer.
•
For
technical reasons
it is not
possi
ble
in
every
case
to use
wheels from
other vehicles
-
under certain condi
tions
not
even wheels from
the
same
vehicle
model.
•
Wheel rims
and
wheel bolts
or lug
nuts are matched to fit
your
Volkswagen.
•
When installing different wheels
(for
example,
wheels with winter tires),
the
correct wheel bolts
or
lug nuts with
the
proper length
and
conical shape must
be used. The secure fit of the wheels and
the proper functioning
of the
brake system are dependent upon this.
•
Using tires and/or wheels which have
not been approved
by
the manufacturer
for
your
vehicle
type
can be detrimental
to vehicle safety.
•
If
wheel trim discs
or a
front
spoiler
are
installed,
make
sure the airflow for cooling
the brakes
is not
obstructed.
•
Before
you
plan
on
exchanging steel
wheels, light alloy wheels,
or
snow tires
already mounted on wheel rims, consult
your
Volkswagen dealer. He has the tech
nical
information necessary
to
advise
you which wheel rims and wheel bolts
or
lug
nuts are compatible with the original
factory installations.
WARNING
•
The
use of the wheel rims and wheel
bolts
or
lug nuts that do not meet
speci
fications
of the
original factory
install
ed equipment will affect the safe oper
ation
of
your
vehicle and may cause an
accident and personal
injury.
Tire specifications
Tire
specifications
are
imprinted
on the
sidewall
of
the tires.
If in
doubt, check with
your
Volkswagen dealer.
All
passenger car and some light trucks tires must conform
to
Federal Safety
Requirements
in
addition
to
these
grades.
Treadwear
The treadwear grade
is a
comparative
rating
based
on the
wear rate
of the
tire
when tested
on a
government test course. For example,
a
tire graded
150
would wear
one
and a
half
(IV2)
times
as
well
as a
tire
graded 100.
The
relative performance
of
tires depends
on
actual conditions
of use,
however,
and may
depart significantly
from
the
norm
due to
variations
in
driving
habits,
service practices
and
differences
in road characteristics and
climate.
Traction A, B, C
The traction grades, from highest
to
lowest,
are A, B and C and
represent
the
tire's ability
to
stop
on wet
pavement
as
measured
on
government test surfaces
of
asphalt
and concrete. Atire marked
C
may
have poor traction performance.
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t'/INTER
DRIVING
VEHICLE CARE
Remember
the following points when
criving in the
winter:
• Winter weather is particularly hard on
ne battery. We recommend having the cattery
checked,
preferably by a
Volks
wagen dealer, before the cold weather starts - see page 110.
If the vehicle is
left
standing for several
iveeks
at extremely low temperatures, the
rattery
should be removed - see page 111
=or
further
details. • Have the antifreeze concentration in
the cooling system checked before the cold weather starts - see page 107.
• The engine oil must have the correct
viscosity grade for the outside tempera
tures to be expected - see page 98.
• The best way to protect the bodywork is
to wash and wax it frequently, especially in
winter - see page 90.
• Always use a windshield washer
fluid
with
antifreeze for the windshield and rear
window washer system in winter - see page 112. • Use a scraper to remove snow and ice
from
the windows - see page 91.
• On winter roads the use of winter tires
or all-weather tires
will
improve handling;
this also applies to vehicles
with
all-wheel
drive - see pages 78 and 118.
• When driving in the mountains in winter
it is best to take along a set of snow chains.
Snow
chains may be compulsory for some
mountain roads, and this restriction also
applies
to vehicles
with
all-wheel drive -
see
pages 78 and 119.
121
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