power steering 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

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
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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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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[
VEHICLE
CARE

LUBRICANTS I
Climate Tropical
40'
30-
20- 10-
0-

10'

20

30'
Single grade oil
Multi grade oil
Gasoline Engines
|B25-565/21

Engine
Your engine was factory filled with an all- season high quality engine oil. If you need
to add oil between oil changes use any high quality petroleum or synthetic based
oil with correct specifications.
The following term must appear on the oil container singly or in combination with
other designations: "API Service SF or
SG".

Engine oils are graded according to their
viscosity. The proper grade to be used in your engine depends on existing climatic
or seasonal conditions. Refer to the temperature chart when
selecting engine oil. As temperature ranges of the different oil grades overlap,
brief variations in outside temperatures
are no cause for alarm. It is also permissi­ ble to mix oil of different viscosities if you
find it necessary to add oil.
When using SAE 10 W or SAE 5 W-20 or SAE 5 W-30 engine oil, avoid high speed
long distance driving if outside tempera­
ture rises above the indicated limits.
Engine Oil Identification Symbol
Select an oil for your vehicle which
con­

forms to the standards of the American Pe­
troleum Institute (API). A symbol has been added to the top of some oil containers to help in selecting the correct oil.
-l -l
/ / SAE '. j -2
t—i iow-3o jji -3

1B25-
532
98 (1) The top portion indicates the oil quality
by API designations.
(2) The center portion shows the SAE oil
viscosity grade.
(3) The lower portion indicates that the oil
has fuel saving capabilities. Transmission
Manual transmission: Hypoid oil SAE 80 (Mil-L-2105 or

API/GL4).

Automatic transmission:
ATF Dexron® or Dexron II® for torque cor
verter and hypoid oil SAE 90 (Mil-L-2105
E

orAPI/GL5) for final drive.
Front axle differential (Syncro only)
Hypoid oil SAE 80 (Mil-L 2105 B M
API/GL 4) or synthetic transmission oi
G50,
SAE75W-90.
The lubricant used does not have to be
changed.

Should the need arise to add oil, it shoulc
only be done with the necessary workshop equipment.
Power steering
ATF Dexron®
Lubricant additives
Volkswagen does not recommend the use of oil additives. It may adversely af­
fect your warranty.


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VEHICLE
CARE
I

AIR CLEANER
A
dirty
filter
element reduces engine
out­
put and increases fuel consumption and

can
cause premature engine wear.
Normally, it is not required to service the
air cleaner more often than recommended in the Maintenance booklet. If the vehicle

is
driven on very dusty roads, the air

cleaner
must be serviced more frequently,

even
daily. We recommend
that
you have
the air cleaner serviced by your
Volks­

wagen dealer or a qualified workshop.
If
your
air
filter
must
be
changed more
frequently,
we
recommend
that
you have
your
Volkswagen dealer show
you the
procedure
before
you
attempt
doing
it

yourself.

The
paper
filter
element must never
be
cleaned
or
soaked
with
gasoline, clean­

ing
solvents or oil. POWER STEERING*
The
fluid
reservoir is located behind the
licence
plate lid.

The
power steering is filled
with
ATF Dexron®.

A
correct
fluid
level in the reservoir is im­
portant
for the proper functioning of
power steering.
With the engine running, the
fluid
level in the power steering system must be
checked
at regular intervals. The
fluid
level
should always be between the "max"
and "min" markings. If the level should go below the "min" marking, have the power
steering system inspected by your
Volks­

wagen dealer. It is not sufficient to
just
add hydraulic fluid.
WARNING

•
Be
sure
not to
confuse brake fluid

and
hydraulic fluid.
If
the wrong fluid
is
used,
the systems may fail.

•
If the
power steering system should

fail,
or if the
engine
is not
running
(for

example
while
being
towed),
you
will
still
be
able
to
steer
the
vehicle, how­
ever, more
effort
will
be required.
Note

Since
the hydraulic
fluid
also functions as

a
lubricant, serious damage to the pump
and to other components of the system
could result if there is insufficient hydraulic

fluid
in the system.

Always
heed WARNINGS on page
97. "where applicable


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TECHNICAL
DESCRIPTION

FRONTWHEEL SUSPENSION
• Independent upper and lower control
arm
• Stabilizer
•
Coil
springs • Shock absorbers
Syncro • Independent wheel suspension by

means
of double wishbones
with
coil
springs and telescopic shock absorbers.
• Double
jointed
shafts
• Stabilizer bar
•
Viscous
coupling

Steering
•
Rack
and pinion
• Safety steering column REAR WHEEL SUSPENSION
• Independent semi-trailing arms
with

integrated axle support
•
Coil
springs
• Shock absorbers
Syncro • Independent wheel suspension by way
of diagonal arm axle
with
coil springs and

telescopic
dampers.
• Double
jointed
drive shafts
• Differential lock as optional extra.
BRAKES

• Hydraulic dual-circuit power-assisted
brake system
with
pressure regulator for rear wheel circuit. Front wheels
with
disc

brakes,
rear wheels
with
self-adjusting
drum brakes.
• Parking brake for rear wheels.
Body/Chassis • All steel unitized body
• Frame plates reinforced
with
side and

cross
members.

143


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TECHNICAL DATA

V-BELTS
CAPACITIES
for waterpump/alternator. 9.5 x 1100 LA
Fuel
tank 16.0 gal/60 liters
for A/C compressor . . . 12.5x1153 LA Syncro:
for power steering .... 9.5 x 1080 18.5 gal/70 liters Noteg
Reserve
(of
total
capacity) >. .. 2.5 gal/10 liters
The V-belts are among the most severely Coolin3
sVstem186
^t/17-5 ll,ers
stressed
parts of a vehicle. The belts there- Automatic
fore have very high quality requirements. transmission fluid (ATF) 3.2 qt/3.0 liters
When replacing a belt, it is not sufficient to Windshield washer container 4.3 qt/4.2 liters
use
just
any belt of the same
size.
For safe
operation, use only Original Volkswagen
Rear
window washer container 1.1 qt/1.0 liters

V-belts
specially designed for your Engine oil

vehicle.
The correct belts can be obtained
with
filter
change 4.8 qt/4.5 liters at your Volkswagen dealership.
without
filter
change 4.2 qt/4.0 liters

Do
not
fill
above "max" mark.
The oil level should be checked while topping up.
Difference between "min" and "max" marks
on the dipsticks is approx. 1 qt/1 liter


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GAS
STATION
INFORMATION

1 -
Jack
and tools, see page 123.

2
- Windshield washer container, capacity 4.3 qt/4.2 liters.

3
-
Fuse
box, see page 128.
4 - Brake
fluid
reservoir, see page 108.

5
- Spare wheel, see page 124.
6 - Battery, see page 109.
7 -
Fuel
filler neck (rear wheel drive), capacity 16 gal/60 liters.
8 -
Rear
window washer container, capacity 1.1 qt/1.0 liters.
9 -
Fuel
filler neck (syncro), capacity 18.5 gal/70 liters.
10 - Air cleaner, see page 103.
11 - Power steering
fluid
reservoir, see page 103.
12 - Engine oil dipstick/oil filler neck, see page 99.

13
- Coolant
refill
tank, see page 105.
14 - ATF dipstick, see page 102.
157


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ALPHABETICAL INDEX
page
Introduction 2
Instrument illumination 46
Instrument panel 4 Instruments 40
Interior light 63,133
Jack and tools 123 Jack points 126
Keys 7
Kickdown 37
Lane changer 48
License plate lights 133 Lifting vehicle 140
Light switch 46 Light alloy wheels 92
Lights 46,130
Locks 7
Lubricants 98
Luggage compartment 28
Maintenance 95
Maintenance booklet 2
Manual Transmission 32 Manual Transmission Oil 102
Mirrors 13
Notes to owner 2 page
Octane rating 86
Oil change 100
Oil filter changing 101 Oil pressure warning light 43
OXS (Oxygen sensor) 144
Parking 31,145
Parking brake 31 Pedals 29
Power steering 103
Power windows 12
Radio 5, 135
Rear lid 11 Rear seat bench/bed combination 26
Rear view mirrors 13
Rear window defogger 47
Rear window wiper/washer 50
Refill Tank 105
Reverse 32
Roof rack 68
Safe driving hints 70
Safety belts 14
Safety belts warning light 18
Safety compliance sticker 151
Seats 20 Secondary heat exchanger 53
Selector lever 35 page
Service manuals 152 Side marker lights 132
Sliding door 10 Sliding roof 62
Sliding windows 12
Snow chains 119 Spare wheel 124
Spark plugs 146
Speedometer 40
Speed ranges 69
Starter switch 38 Starting procedures 39
Steering lock 38
Stopping engine 39
Sunroof 62 Sun visors 67
Switches 46
Swivel seats 22 Syncro Differential lock 33
Driving with the-all-wheel-drive . . 75
Snow chains 119
Technical Information 142 Towing 139
Tachometer 41
Tail lights 132
Technical data 146


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