maintenance VOLKSWAGEN TRANSPORTER 1990 T4 / 4.G Owners Manual

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Your new
Volkswagen

may have all or some of the equipment

described
in this manual. Therefore, you may find explanations of equipment not
installed in your vehicle.

Check
with
your authorized Volkswagen

dealer
on available options or
accesso­
ries.

Note

WARNINGS
concern
safety
and are co­ lor
identified
throughout
this
manual.
Please
note
that
the items of equipment
marked
with
an asterisk* may be stand­
ard on certain models but are only avail­
able
as options on other models.
In addition to this Owner's Manual, your

Vanagon/Transporter
comes
with

• the Radio
Operating
Instructions*,
In Canada,

these
manuals are also available in
French.
To obtain a copy, contact your

dealer
or
write
to:

Au
Canada
on peut se procurer un exem- plaire de ce Manuel en francais aupres du

concessionnaire
ou du:

Volkswagen
Canada,
Inc.
Customer
Assistance/

Assistance
a la Clientele 1940 Eglinton Ave. East

Scarborough,
Ontario
M1L2M2

If you sell your
Volkswagen

the Owner's Manual, the Warranty booklet and the Maintenance booklet

should
be
left
in the vehicle to make
Warranty terms as well as all operating, safety and maintenance information avail­

able
to the next owner.
If you change your address or if
you
bought
this
Volkswagen
used

be
sure to send in a "Notice of Address

ChangeVNotice
of Used Car Purchase"
post card. This card can be found in the
Warranty booklet or obtained from your
Volkswagen
dealer.
It is in your own
interest
that
we can

contact
you should the
need
arise.
Your
Owner's
Manual

applies
to all Vanagon/Transporter models
currently sold in the USA and
Canada.
It
contains important operating safety infor­ mation. Keep this booklet in your glove
box at all times for ready reference.

Read
it before you drive your new vehicle.

Pay
particular attention to the "Break-in
period hints" and to all points listed under

"Vehicle
operation".

Acquaint
yourself
with
your vehicle's fea­ tures and know how to operate it more

safely.
The more you know about your

Volkswagen,
the more you will enjoy driving it. For your own protection and longer service life of your vehicle, always

heed
our instructions and warnings. Igno­
ring them could result in extensive da­

mage
or serious personal injury. • the
Warranty
Booklet
and
• the
Maintenance
Booklet.
Your
Warranty
booklet
which is a separate brochure, contains
detailed information about the warranties
covering your Volkswagen.
Your
Maintenance
booklet
which is a separate brochure, explains how you can keep your Volkswagen in top
driving condition by having it serviced regularly. Always have the Maintenance
booklet
with
you when you take your

vehicle
to a Volkswagen dealer for service.

Your
Service Adviser will record each
scheduled
service.


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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

=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

Malfunctions

if the
unit
does not
operate

• Outside temperatures may be below
41° For + 5°C.
• The air conditioner fuse may have blown. Turn the
unit
off and check fuse.

See
page 129 for use panel location.
General
hints

If
water
drips
under
the
vehicle

When outside temperature is high and the
air very humid, condensed water can drip
off the evaporator under the vehicle. This
is
normal and does not indicate a leak.

Payload
reduction

The weight of the air conditioner installed in your vehicle reduces the vehicle's load
carrying capacity. For weight information,

see
sticker on
left
doorjamb.

Maintenance
The condenser should be checked peri­
odically for cleanliness. If clogged
with

dirt
or insects, the condenser should be
washed down
with
water.
After the winter months and before ex­
tended summer
usage,
the air conditioner should be checked and, if necessary, ser­
viced by your Volkswagen dealer.


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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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VEHICLE OPERATION

OPERATE
YOUR VEHICLE ECONOMICALLY AND
MINIMIZE
POLLUTION
Your
personal
style
of
driving
determines your operating costs,
exhaust
emissions and noise levels. To obtain the best
possi­

ble fuel economy,
minimize
pollution
and

save
wear and tear on the engine, brakes
and tires, observe the following points:
• Keep a
light
foot
on the accelerator.
• Drive smoothly, avoid abrupt changes
in speed as much as possible.
• Avoid jack rabbit starts and sudden

stops.

• Avoid unnecessary idling. Turn the
engine off.
• "Warm up" idling wastes gas. Start the
engine
just
before you are ready to drive.

Accelerate
slowly and smoothly.
• Do not drive longer than necessary in
the lower gears. By upshifting early you
can
economize on fuel consumption. • Organize your trips to include in several
errands.
• Any additional weight carried in the
vehicle reduces fuel economy. Always keep cargo to a minimum and remove all

unnecessary
items.
• Remove roof and ski racks when not in

use.

• All electrical consumers contribute to

increased
fuel consumption. Therefore,

use
fan, rear window defogger, etc., only
when needed.
• Check your vehicle's fuel consumption
regularly. Keep a
written
tally sheet or use
the
trip
odometer. Fuel consumption will
vary
with
traffic, road and weather condi­
tions.
• Have your vehicle serviced by an

Volkswagen
dealer at the specified inter­
vals
(see page 95 and your Maintenance brochure). • Air cleaner should be inspected to

assure
proper engine "breathing".
• Battery should be fully charged.
• Wheels should be properly aligned.
• Tires should be inflated to correct pres­

sures.
Check
tire
pressures regularly - at least once a month.
• The published ENVIRONMENTAL-
PROTECTION AGENCY (EPA) and Trans­

port
Canada
mileage
estimates
may not

agree
with
your
actual
highway
mileage

which
will
vary,
depending
upon
vehicle
load
and speed,
road
and
weather
condi­

tions,
trip
length,
etc.
• Have the engine oil level checked
with

every fuel filling. Engine oil consumption
is
normal but tends to be higher when the
engine is new. The use of quality engine oil
and a correct engine oil level are essential
for vehicle performance and economical operation at all times.
72


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iLER TOWING
VEHICLE OPERATION
phLT .'jlkswagen was primarily designed
pr : assenger transportation. If you plan to
m*
B.
trailer you should be mindful that

MLT
:ar will be performing a service it was
•cr "tended for. The additional load will
Wee durability and economy of per-
m~ ance. • :. :ow a trailer, your Volkswagen may
mc. -9 more frequent maintenance due to
ft* extra
load.

Gc not tow a trailer during the break-in kriod of your vehicle.
Keep an eye on your coolant tempera-
fere gauge. If coolant temperature warn- rc light comes on pull off the road to a sa's place to allow engine to cool down.
Maximum trailer weight
A vailer for your vehicle is limited to a
typi-

ca class I trailer. The maximum gross
Bier weight and the tongue load must not
eoeed the specifications listed in the
[fechnical Information/Data section of this
ranual.

Do not exceed the gross vehicle weight
•rhich is the weight of the driver, passen­ ger, luggage, trailer hitch and tongue
weight of the loaded trailer. Trailer hitch
Use a weight-carrying hitch conforming to
the gross trailer weight. The hitch must be suitable for your vehicle and trailer and
securely bolted to the body. Always check
with the trailer hitch manufacturer to make
sure that you are using the correct hitch. Do not use a bumper hitch.
The hitch must be installed in a way not to interfere with the impact-absorbing
bumper system. No modifications should
be made to the vehicle exhaust and brake
systems. From time to time check that all hitch mounting bolts remain securely fas­

tened.

If not towing a trailer for a long period of

time,
remove the trailer hitch. This pre­
vents the hitch from causing damage should your vehicle be struck from behind.
When removing the trailer hitch, seal all bolt holes to prevent water and exhaust
fumes from entering the vehicle.
Trailer brakes If your trailer is equipped with a braking

system,
check to be sure that it conforms
to all regulations.
The trailer brake system must not be di­ rectly connected to the vehicle's brake sys­

tem.
Tire pressure
When towing a trailer, inflate the tires of
your vehicle to the cold tire pressure listed on the label on the left front door jamb. In­
flate trailer tires to trailer and tire manufac­
turer's specifications.
Safety chains
Always use safety chains between your car and trailer.
Trailer lights
Trailer lights must meet all regulations. Do not connect the trailer light system directly
to the light system of your vehicle. Be sure
to check with your Volkswagen dealer for
correct wiring, switches and relays.
Before you tow a trailer
Correct and even load distribution. All ob­
jects inside the trailer should be held securely in place to guard against shifting, be it forward, backward or sideways.
Never allow a passenger in a moving
trailer.


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ADVERTISEMENT

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Accessories ...specially designed
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Volkswagen.

You'll find
a
wide selection
of
"Autobahn" Accesso­
ries to help you make
your
Volkswagen fit
your
lifestyle
even better.
For
a
sporty
flair, there are spoilers, wind-deflectors,

fog
lights and driving lights.
Select from "Sound Choice" audio components.
They

are designed
to
add
to
your
listening pleasure: Electronic radio/cassette combinations with state-of-the-art features
and micro switch controls, full-frequency-range high

compliance
speakers, antennas with fully retractable
telescopic masts
—
manual
or
automatic
—
some even with electronic signal amplification.
And there are
roof-
and rear-deck carriers with

special
attachments
for
extra luggage
or
sporting
equipment
—
ski-,
bike-, surfboard carriers, etc.
— to
expand the usefulness and convenience
of
your

Volkswagen even further.
Autobahn care and protective maintenance products
— splashguards, floor mats, chemicals
—
will help protect
your
investment in
your
Volkswagen's good running condition and appearance
—
inside and out
—

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Your
Dealership Parts Department Professionals will

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you
in
selecting from our complete line
of

Autobahn Accessories
...
all designed for
your

Volkswagen.
Autobahn
Items available
at
time
of
purchase may differ from those shown here.


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AINTENANCE
VEHICLE CARE

Ibur
vehicle has been designed to help «eep maintenance requirements to a mini--jm. However, a certain amount of regu­
lar maintenance is still necessary to as­ s-re your vehicle's safety, economy and re- ability.

Maintenance
Service is
required
every

12
months
or
every
15,000
miles
(24,000

kilometers),
whichever occurs
first.

I addition, it is necessary to perform an oil

nange
6 months after each Maintenance

Service,
or after each 7,500 miles (12,000
•: (ometers) whichever occurs
first.

"he
first
oil change must be performed 6 ~ionths after the delivery of the vehicle or
after 7,500 miles (12,000 kilometers).
Under
difficult
operating
conditions, for

example
at extreme low outside tempera­
tures or in very dusty regions, etc., some
service
work should be performed bet­
ween the intervals specified.

This
applies particularly to: • oil changes, and
• cleaning or replacing the air
filter.

The
maintenance work should be per­ formed by Volkswagen dealers because
they have the expertise, the workshop facilities and the special tools required. It is important
that
this work is per­
formed according to the manufacturer's instructions.

Proof
of servicing in accordance
with
the
maintenance schedule may be a condition
for upholding a possible warranty claim
made
within the warranty period.
Safety
and
environmental
concerns

place
very strict limits on the nature of re­

pairs
and adjustment on engine and trans­
mission
parts which an owner can per­
form.
Tampering
with
safety-related
parts
can
endanger
you as
well
as
other

motorists.

Always
observe environmental regula­ tions when disposing of old engine oil,
used
brake fluid,
dirty
engine coolant,
spent batteries or worn out tires.

95


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VEHICLE CARE

Important
Consideration
for you and your car:

A
thorough and detailed preventive maintenance schedule has been de­

veloped
for your vehicle, which if followed

should
help assure you of years of reliable

and
dependable use. We strongly urge
you to give your dealer the opportunity to perform all scheduled maintenance and

necessary
repairs. He has the facilities,
original parts and trained specialists to
keep
your car running properly.

The
increasing use of electronics, sophisti­
cated
fuel injection and emission control

systems
together
with
the generally in­

creasing
technical complexity of today's automobiles has steadily reduced the

scope
of maintenance and repairs which

can
be carried out by vehicle owners.
Maintenance,
adjustments and repairs

usually
require special tools, testing de­

vices
and other equipment by specially
trained workshop personnel in order to as­
sure
proper performance, reliability and
safety of the vehicle and its many
sys­

tems.
Improper maintenance, adjust­ ments and repairs can impair the opera­
tion and reliability of your car and even
void your vehicle warranty. Above all oper­ ational safety can be adversely affected
creating unnecessary risks for vehicle oc­
cupants and others.
This
section describes a limited number of

procedures
which can be performed upon
your vehicle
with
ordinary tools, should the
need
arise and trained personnel be un­

available.
Before performing any of these

procedures,
always thoroughly read all of
the applicable
text
and carefully follow the instructions given. Always rigorously ob­

serve
the
WARNINGS
provided.

WARNING
Serious personal
injury
may occur as a
result
of
improperly
performed
main­

tenance,
adjustments
or
repairs.

• The
engine
compartment
of any

motor
vehicle
is a
potentially
hazard­
ous
area.

• Do not
attempt
any of the
mainten­

ance, checks or
repairs
described on
the
following
pages if you are not
fully

familiar
with
these
or
other
procedures

with
respect
to the vehicle, or are un­

certain
as to how to proceed.
Have
the necessary
work
done
by your Volks­

wagen
dealer
or any
other
properly
equipped
and
qualified
workshop.
•
Always support
your
vehicle
with

safety
stands if it is necessary to
work

underneath
the vehicle. The
jack

supplied
with
the
vehicle
is not

adequate
for
this
purpose. • If you
must
work
underneath
the . =-

hide
without
safety
stands but
with
t--t

wheels
on the ground,
always
ma-: sure the
vehicle
is on
level
ground, tr:
the
wheels
are
always
securely bloc ed and
that
the
engine
cannot
•

started.
Always
remove
the
ignitio-
key.
•
Always
be
extremely
careful
whe-

working
on the vehicle.
Always
folic commonly accepted
safety
practice*
and
general
common sense.
Never
ris• personal
injury.

Note

Incomplete or improper servicing ri

cause
problems in the operation of the r-
hicle
and may reduce or eliminate y;.
warranty coverage. If in doubt about a-
servicing,
have it done by your
Volks/
E-

gen
dealer or any other properly equips
and
qualified workshop.


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