ignition 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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CONTROLS AND
EQUIPMENT

Key A is used for the ignition/steering lock, • Do not
leave
your
vehicle
unattended

the doors, the lockable tank cap and the
with
the key in the
ignition
lock.
Always
rear luggage compartment lid.
take
the key and lock the doors.

KEYS

B25-460

Your
Volkswagen comes
with
four keys: • two keys A
• two keys B

Key
A can be inserted
into
locks either
way. Key B is provided for vehicles equipped

with
a lockable glove compartment.
Tag C gives the key number.
For
your
protection
against
theft:
• Record the key number and keep it in a

safe
place, such as your wallet. Do not keep it in the vehicle.
• If you should lose a key, provide your
Vol­

kswagen dealer
with
the key number to
obtain a duplicate key.
In addition to the plastic tag, there may also
be a metal tag snowing part of the vehicle
identification number. This tag is no longer
required after the vehicle has been deliv­

ered.

Note

The syncro model has a separate key for the lockable tank cap.
A
chime
will sound when you open the
driver's door
with
the key
left
in the ignition lock. This is your reminder to remove the
key and lock the doors.

WARNING
• Do not
leave
children
unattended
in
the
vehicle
especially
with
access to
vehicle
keys. Unsupervised use of the
keys
can
result
in
starting
of the
engine

and use of
vehicle
systems such as
power
windows
etc. Unsupervised use
of
these
systems can
result
in serious
personal
injury.

• Do not
remove
key
from
steering

lock
while
you are
driving
or as the

vehicle
is
rolling
to a stop. The
steering

column
will
lock
when
you
remove
the key, and you
will
not be
able
to
steer
the

vehicle.


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CONTROLS AND EQUIPMENT
MIRRORS
Adjust
the
outside
and
inside mirrors
be­
fore driving and after adjusting your seat
to
proper driving position.
It is
important
for

safe driving that
you
have good vision
to

the rear.

WARNING
The right hand outside mirror may have a curved (convex) surface. Always re­member that vehicles or other objects
seen in a convex mirror will look
smaller and appear farther away than
when seen in a flat mirror. Do not use
this mirror to estimate distances of
following cars when changing lanes.
Whenever possible, use the inside mir­ ror to determine the actual distance
and size of vehicles or objects seen in
the convex mirror.

Outside mirrors
The outside mirrors
are
hinged
and
fold flat against
the
vehicle when pressed from either direction.
Fold mirrors flat against
the
side windows
when taking your vehicle through
an
auto­ matic
car
wash
to
prevent possible dam­

age.
Outside mirrors with electric
remote control*
These mirrors can
be
adjusted electrically from
the
inside
by
moving
the
knob
on the
driver's door panel. They work only with
the ignition
on. To
adjust either driver
or
passenger mirror, turn knob
to L or R.

If
the
electrical adjustment
of the
mirror
should
not
respond, adjust
the
mirror
by
hand
by
pushing lightly
on the
edge
of the

mirror glass.
When
the
rear window defogger
is
switched
on, the
outside mirrors
are

electrically heated
at the
same time
(see

page 47). |B28-021
|

Inside day-night mirror
You
can
adjust
the
day-night mirror from clear daylight visibility
to
non-glare visibili­
ty
at
night
by
moving
the
lever
at the
bot­
tom
of
the mirror.
To ensure
the
best possible anti-glare
ef­
fect,
the
lever should
be
pointing forwards
when
the
basic mirror setting
is
made.
daylight driving
-
lever front night driving
-
lever rear
*where applicable 13


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CONTROLS AND EQUIPMENT

Belt
warning
system

An
audio-visual warning system is inter­
connected
with
the driver's safety belt.

Every
time the ignition is turned on, the
safety belt warning light will come on for about six seconds as a reminder to buckle

up.
If the driver does not fasten the safety
belt, the chime will also come on for six

seconds.
With the driver's door
closed,
the
chime will go off as soon as the driver has
buckled
up.
Lap
belts

Seats
in the passenger compartment are
equipped
with
adjustable lap belts.
The
belts
must
always
be
kept
on top of the
seat
for
ready
use. Do not
permit

them
to get
caught
under
the
seat.

• To lengthen belt, hold belt tongue at a

right
angle to belt and loop out the required
portion. For
ease
of operation, press cap

and
tongue of buckle together.
• To tighten belt, buckle up and pull at

loose
end of the belt.

Take
up any slack by
moving
the slide on the
belt.
WARNING

• To
reduce
the
risk
of
injury
in an acci­

dent,
position the lap
belt
as low as
possible across the pelvis.
• To fasten lap belt, grasp belt tongue on
outboard side of seat, pull across pelvis
and
insert in inboard buckle.
• To unfasten belt, push release marked

PRESS
in the buckle.

During
pregnancy

Pregnant
women should always wear
safety belts. The lap belt must be worn as
snugly and as low as possible across the
pelvis.
To avoid pressure on the abdo­
men the
belt
must
never
pass
over
the

waist.

Injured
persons and the physically

impaired

We
recommend
that
injured persons and the physically impaired wear safety belts
whenever possible. Although the instruc­
tions provided above still apply, your doc­
tor can give you special recommendations
when necessary.

Always
heed
WARNINGS
on
page
14,15,16.




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CONTROLS AND EQUIPMENT
MANUAL TRANSMISSION
B25-352
Gearshift lever
Start engine with gearshift lever in Neu­

tral,
clutch pedal depressed.
Always depress the clutch pedal fully
when changing gears. Do not hold the vehicle on a steep hill with the clutch pedal partially depressed. This may
cause premature clutch wear or dam­

age.

Resting your hand on the shift lever
knob while driving will cause premature
wear in the transmission. The forward gears and the reverse gear
are arranged as illustrated.
Reverse
Shift into Reverse only when the vehicle is not moving.
To engage Reverse, move lever to left, press down, move further to left and them
push forward. Especially after some

driving,
depress the clutch pedal fully and rest the shift lever in Neutral for a few
seconds before shifting into Reverse.
Back-up lights go on when you engage Reverse gear with ignition on. JB25-519
Low-speed traction gear (L)
(Syncro models only)
The vehicle is equipped with a four speed manual transmission which has a
addi­

tional low-speed traction gear (L).
Engaging the Low Gear
Move the gearshift lever as far as possible
to the left in neutral, press down and move lever still further to the left and then pull
back.


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CONTROLS AND EQUIPMENT
STEERING LOCK/IGNITION/STARTER
SWITCH

The
steering is equipped
with
an
antitheft
ignition lock.
Switch
positions
1 -
Ignition
off/steering can be
locked.
•
Pull
out the key and
turn
steering wheel until it
locks.

WARNING
• This position
only
locks the
steering

wheel
and not the
shift
control
lever.
Sudden and
unexpected
vehicle
move­

ment
may occur if the
shift
control

lever
is
moved
out of P
(Park)
(automa­

tic
transmission)
or out of
gear
(manual

transmission)
and the
parking
brake
is not
firmly
set.
•
Never
remove
key
from
steering
lock
or
turn
key off
while
the
vehicle
is moving. The
steering
wheel
will
lock,
causing loss of control.

2-
Ignition
on/steering free. If it is difficult to
turn
the key from po­
sition 1 to 2, gently move the steering
wheel until the key turns freely.
3
- Starter engages.

Key
returns to Pos. 2 as soon as it is

released.

"Starting procedures" see next
pages.

In position 3, the power supply to
headlights, windshield wipers,
blower motor and rear window defog-

ger
is temporarily interrupted to
con­

serve
battery power.

Before
the starter can be operated again
the key must be turned back to position 1.

The
non-repeat lock in the ignition switch prevents the starter from being operated
when engine is running as this could

damage
the starter.
In position 2 and 3 several warning/in­
dicator lights will come on.
Refer
to
"Warning/indicator lights" for details.
Chime If you leave the key in the ignition/steering
lock, the chime will sound when the
driver's door is opened. This is your reminder to remove the key and lock the

doors.


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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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CONTROLS AND EQUIPMENT
I - Tachometer*
"he red shaded area at the end of the scale indicates the maximum permissible
engine rpm (revolutions per minute) for all gears after the break-in period. Before
'eaching this area, the next higher gear
snould be selected or the foot eased off
the accelerator pedal. Earlier shifting saves fuel and reduces noise.
Sniff to the next lower gear when the en-
; ne rpm drops below 1500 rpm.
~ne green shaded area on the scale snows the speed at which the engine is de-
•
eloping its most favourable torque.
3 - Normal clock*

~J
set the clock, depress the knob in the : al center and
turn.
4 - Coolant temperature
gauge X
tare applicable The needle in the coolant temperature
gauge will indicate the temperature of the
coolant shortly after the ignition is
switched on.
When ignition is switched on the warning light (c) will flash for a few seconds as a
functional check.
a - Engine cold
Avoid high engine speeds and heavy throt­ tle when the needle is still in this area of
the
dial.

b - Normal temperature During normal running the needle will re­
main somewhere in the middle of the
dial.
If the engine is working hard at hign a--
bient temperatures, the needle may as:
go further to the right, but this is no cause
for concern so long as the coolant
tem­
perature warning light does not start

flashing.

c - Warning light If the light flashes when driving first check
the coolant temperature gauge. If the nee­
dle is in the normal range, add coolant at the next opportunity. If the needle is in the warn­
ing range, either the coolant level is too low
or the coolant temperature is too high. Move the vehicle a safe distance off the

road,
stop the engine and depress the
emergency flasher switch.
The fan should be operating when the warning light is on (listen for fan, located in
front of car behind grille).
WARNING • To reduce the risk of being burned,
never open the hood if you see or hear
steam or coolant escaping from the
engine compartment. Wait until no
steam or coolant can be seen or heard
before carefully opening the hood.


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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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