heater 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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INSTRUMENT PANEL AND CONTROLS
page
1 - Air vents 51
2 - Light switch and thumb wheel for instrument illumination 46
3 - Safety belt and brake warning lights 43, 47
4 - Speedometer with trip odometer 40 5 — Warning/indicator lights 6, 43
6 - Clock or tachometer with fuel gauge and coolant temperature gauge 40,41
7 - Rear window defogger switch 47
8 - Emergency flasher switch 46 9 - For additional switch
10 - Air vents, left and right 51
11 - Ashtray 64
12 - Loudspeaker grille
13 - Fuses 128 14 - Turn signal/headlight dimmer switch lever 48
15 - Horn page
16 - Digital clock 40
17 - Steering lock/ignition/starter switch 38
18 - Temperature switch for auxiliary heater 57
19 - Windshield wiper/washer lever 50
20 - Secondary heat exchanger switch 53
21 - Emission Control System (ECS) 45
22 - Climate controls 51
23 - Air vents 51
24 - Radio1)
25 - Cigarette lighter 63 26 - Glove compartment 64
1) A separate brochure is provided for your factory-installed

radio.
If you replace your radio, please be sure to read the notes
in the chapter "Do-it-yourself Service", page 135.
Note
Some features mentioned are standard equipment on some
models only or are options on others.


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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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AUXILIARY HEATER*
CONTROLS AND EQUIPMENT
~jrn the auxiliary heater on and off with the :amperature switch, located on the right of
fee steering column. Use the same switch

ID
regulate the heat.
depending on vehicle model, the warm air
lows from the footwell vents for the pas­ senger compartment and/or from a con-
tollable vent under the driving seat. The a r distribution cannot be controlled.
While driving, the heater can be operated rontinuously. When the engine is not run-

-:ng,
the heater will shut off automatically
after 10 minutes to save battery power.
"he auxiliary heater is running on fuel from our fuel tank. Fuel consumption varies
according to operating conditions and
-eat output (approx. 1 US qt or one liter
zer hour). 0
Switch knob positions 0 - Heater off.
0—1 — Heateron (engine stationary)
2 - Heateron (engine running)
2-3 - Temperature adjustment range. Engine stationary/ignition off
Heater on:
From position 0, push knob in and turn
clockwise. Switch knob control light will
come on. Knob will spring back out when
released.
Adjust temperature by turning
knob between positions 2 and 3.
Heater off:
The clockwork in the temperature regulat­ ing switch switches the heater off auto­
matically after about 10 minutes and the
lamp goes out.
To switch off before clockwork has run

down:
Turn temperature regulating switch
anti­

clockwise to 0. The lamp goes out and
clockwork runs down.


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CONTROLS AND EQUIPMENT

Engine
running

Heater
on -
Turn knob clockwise to position 2. Switch knob control light will come on. Adjust
temperature by turning knob between positions 2 and 3.

Heater
off -
Turn switch knob counter-clockwise to position 0. Switch knob control light will go
out.
Notes

• Every time the heater is switched off,
the warm air and combustion air blowers continue running briefly to cool the heater
down quicker.
• To avoid draining the battery, do not
run the heater repeatedly when the engine

is
not running.
• When the heater is running on the
clockwork time switch, it must be switched
off by hand before attempting to start the
engine at low temperatures so
that
the

full
battery capacity is available to
turn
the
engine.

WARNING
Never
start
the
heater
or let the
engine

or the
heater
run in an enclosed, un-

ventilated
area.
Exhaust
fumes
from

the
engine
or the
heater
contain
carbon monoxide,
which
is colorless and
odorless. Carbon monoxide,
however
is a
very
harmful
gas, and may be
fatal

if inhaled.
Due to the
risk
of
fire
the
heater
must

not be used
when
vehicle
is
parked
on
dry grass, brush or leaves.
Maintenance

During the winter and when driving over
very poor roads, mud or snow may tend to

accumulate
in the exhaust and combus­
tion air intake pipes. Have these pipes
checked
for blockage from time to time so

that
the heater can continue to work.
58


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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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CONTROLS AND EQUIPMENT

Setting
the
time
•
Press
and hold clock button E.
• Set clock
with
buttons A.

The
display lights up as long as button is
oressed.
When button is released the dis­
play goes out or, if a time has been pre­

selected,
the selected time lights up for 2

sees.

To
switch
heater
on or off • This is done by pressing button
F.
When
-eater is switched on the warning lamp G ghts up.

To
ensure
that
the heater starts the lever ;or the heat output must be pushed fully to
:ie
right.
This
closes
an electrical contact.
Preselecting
starting
time
for
heater
stationary operation, ignition off)
With buttons C two different switch-on
:imes
can be selected within 24 hours.
•
Press
and hold button. The appropriate
*:gure 1 or 2 appears in display. The ready- •or-action lamp lights up.
• Set required switch-on time
with
but­
tons A. The display remains on for about 20 seconds after releasing button C.
To
ensure
that
the heater starts up at the

selected
time, the lever for the heat output must be pushed fully over to the
right.
In
addition to this the blower must be
switched to Stage 1. On account of the higher current consumption, a higher

stage
should only be selected in isolated

cases.

Switching
preselected
time
off • The preselected time can be switched
off by briefly pressing the appropriate but­
ton C. The ready-for-action lamp and the figure in display then go out.
Fuses

The
fuses for the auxiliary heater are in an additional holder behind the main fuse
box.
Notes

• Every time the heater is switched off,
the warm air and combustion air blowers
continue running briefly to cool the heater
down quicker.
• To avoid draining the battery, do not run
the heater repeatedly when the engine is not running.
• When driving through mud and snow,
the exhaust pipe may tend to get blocked.
Have
a look at it occasionally to see
that
it

is
clear.

WARNING
Never
start
the
heater
or let the
engine

or the
heater
run in an enclosed,
unventilated
area.
Exhaust
fumes
from

the
engine
or the
heater
contain
carbon monoxide,
which
is colorless and odor­

less.
Carbon monoxide,
however
is a

very
harmful
gas, and may be
fatal
if in­ haled.
Due to the
risk
of
fire
the
heater
must

not be used
when
vehicle
is
parked
on
dry grass, brush or leaves.


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VEHICLE
CARE

ENGINE
COMPARTMENT LID

mu
have access to the engine compart-

•Mit
lid from inside the luggage compart- -ent.

"lb
open the
lid,
roll the floor covering out of
~9
way and
turn
both lock handles to the
Tb close the lid, reverse the above proce- ;jre.
ENGINE
COMPARTMENT
Always exercise extreme caution when
working on the engine. WARNING
•
Before you check anything in the en­
gine compartment, stop the engine,
fully set the parking brake and remove
the ignition key.

•
Do not work on
your
car if you are
tired or ill, under emotional stress or under influence of drugs, medication
or alcohol.

•
Always let the engine cool down. Hot
components will burn skin on contact.

•
Do not spill engine oil, ATF, brake

fluid,
antifreeze and washer solvent on hot engine components, especially not
on the exhaust system.
These
fluids
are
flammable.

•
Always disconnect the battery
ground strap if you must work on the

fuel
system or the electrical system.
Never
smoke or work near heaters or
other fire hazards if you must work
around
fuel.
Always keep an approved
fire extinguisher immediately
avail­
able.
Be
especially careful if engine is run­

ning:

•
If work must be done with the engine
running, always fully set the parking

brake,
and make sure the shift lever is
in Neutral (Manual transmission) or

Park
(Automatic transmission).

•
Always be alert and extremely
cau­

tious around the engine at
all
times par­
ticularly when the engine is running.

•
Always exercise extreme caution to

prevent
neckties,
jewelry,
long hair or
loose clothing from getting caught in
the fan blades, the V-belts, or any other
moving
engine parts.

•
To avoid electrical shock and per­

sonal
injury
never
touch ignition ca­
bles
or components of the high voltage
electronic ignition system while the en­
gine is running or even when starter is

cranked.

97


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VEHICLE
CARE
Winter operation During the winter months, battery capacity
tends to decrease as temperatures drop.
Additionally, more power is consumed while starting, and the headlights, heater, rear window defogger, etc., are used more
frequently. Curtail unnecessary power
consumption,
particularly in city traffic or
when travelling short distances only. Let
your
Volkswagen dealer test the battery's
capacity before winter sets in. A well
charged battery will not only prevent

starting
problems but will also live longer.
If
your
vehicle is left standing for several

weeks
at extremely low temperatures, the battery should be removed and stored
where it will not freeze.
This
will prevent it
from being damaged.
When removing the battery, first discon­ nect both cables (see Charging of Bat­

tery),
then unscrew the battery mounting.
WARNING
Always keep the battery well out of the reach of children.
Always heed WARNINGS on page
97.
Charging of battery
WARNING
•
Always shield
your
eyes and avoid

leaning
over
the battery whenever pos­

sible.

•
Charge battery in a well ventilated

area.
Keep away from open flame or

electrical
spark. Do not
smoke.
Hydro­ gen gas generated by the battery is ex­plosive.

•
Battery acid that may spill during
charging should be washed off with a solution of warm water and baking

soda
to neutralize the
acid.

•
If you get battery
acid
in
your
eyes or
on
your
skin,
immediately rinse with

cold
water for several minutes and
call

a
doctor.

•
Never charge
a
frozen battery. It may
explode because of gas trapped in the
ice.
Allow a frozen battery to thaw out
first.

•
Never use a fast charger as a boo­
ster to start the engine.
This
will
seri­

ously damage sensitive electronic
components,
such as relays, radio,

etc.,
as well as the battery charger.
•
Fast charging
a
battery
is
dangerous
and should only be attempted by a
competent mechanic with the proper
equipment.
Slow battery charging WARNING
•
Heed all WARNINGS and follow in­
structions that come with
your
battery

•
It is not necessary to remove the bat­

tery
from the engine compartment, and it
is
also not necessary to disconnect the

cables.

•
Make sure the electrolyte level in each

cell
is between the "min" and "max" marks. If the fluid level is below the "min" mark, le:

your
Volkswagen dealer correct the condi­

tion.

•
Connect charger cables.
Charger cables must be connected
POSITIVE
(+) to
POSITIVE
(+) and

NEGATIVE
(-) to
NEGATIVE
(-).
Do not connect or disconnect charger

cables
while charger is operating to re­
duce the danger of exploding.


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