wheel VOLKSWAGEN TRANSPORTER 1992 T4 / 4.G Owner's Manual

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GENERAL
MAINTENANCE

•
Knowing
the
tyre
lettering and its
meaning
makes
the
selection
of the correct

tyres
easier.
Radial
ply tyres
have
the
fol­
lowing
lettering on the
sidewall:

e.g.:
195 / 70 R 15 97 S reinforced
195 =
Tyre
width in mm
70 = Height/width ratio in %

R
=
Radial
construction
code
letter
=
Radial

15 =
Wheel
diameter in
inches

97 =
Carrying
capability
code

S
=
Speed
code
letter
rein =
Reinforced
version

The manufacturing date is
also
to be
seen
on the tyre wall
(possibly
only on inner

side
of
wheel):

DOT
... 120 ...
means
that the tyre was
pro­

duced
in the 12th
week
of 1990.
Attention

Tyres
which are more than 6 years old should only be used in
an emergency and then
with
a particularly careful style of driv­

ing.
If you wish to fit your car
with
non­
standard wheels or tyres please note:
Attention

•
For technical reasons it is not normally possible to use wheels
from other vehicles - in certain
circumstances
not even wheels
from the same vehicle model!

•
Wheels and wheel bolts are matched to one another.

On
changing to a different type
of wheel (e.g. alloy wheels or
wheels
with
winter
tyres) the cor­ rect bolt
with
the proper length
and conical shape must be
used.
The security of the wheels and
the functioning of the brake
sys­

tem depend on this!

•
Using types of wheel and or
tyres which have not been ap­

proved
by us for your vehicle
model can be detrimental tc thi
safety of the vehicle. It can also
affect the vehicle under the
Con­

struction and Use regulations.

•
If wheel
trim
discs
are
subse­
quently installed it is essential to
ensure
that
the air flow remains
adequate to cool the brakes.

Volkswagen
dealers
have
a :ne
~e:e;5;~
information
about the
poss
;e :
~

of
wheels,
tyres and
wheel
trims.
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GENERAL
MAINTENANCE

Winter
tyres
In winter conditions winter tyres will dis­
tinctly improve the vehicle's handling. This
applies
in particular to vehicles that are
equipped
with wide tyres.
Because
of their
construction (width, rubber mixture, tread
formation etc.) these tyres provide
less
trac­
tion on ice and snow.

When
fitting
winter tyres note the follow­

ing:

• Only radial ply winter tyres may be fitted.
The
factory recommended tyre
sizes
are
givenonpagel
46.
• To obtain the best possible handling
characteristics,
winter tyres must be
fitted

on all four wheels. • Winter tyres are no longer fully effective
when the tread has worn down to a depth
of 4 mm.
• All-weather tyres can also be used in­
stead
of winter tyres.
• If you have a
flat
tyre the remarks on
using
the spare wheel on page 112 should

be
noted.
• Do not leave winter tyres
fitted
for an un­
necessary
long period because when the

roads
are free of snow and ice the handling
with summer tyres is better.
For
environmental
reasons

summer
tyres
should
be
fitted

again
as soon as possible
because
normally
they
are
quieter
in
running,
tyre
wear
is
reduced
and the
fuel

consumption is
lower.
Snow chains
Snow chains may only be
fitted
on
the
front
wheels.

Snow
chains must not be
fitted
on 215/65 F
16
tyres. When
necessary
the vehicle mus:

be
equipped with smaller tyres - see

Wheels,page146.

Only
use thin chains which do not stanc

clear
more than 15 mm (including ten-

sioner).

When
using snow chains wheel
trim
plates
and
trim
rings must be taken off. For safet
reasons
the wheel bolts must then be f ittec
with caps which are available from
Volks­

wagen
dealers.

When
driving over roads which are free of
snowyou
must remove the
chains.
On such
roads
they are detrimental to vehicle handl­

ing,
damage the tyres and wear out quickly.
In Germany, the maximum permissible

speed
with snow chains is 50 km/h.
114
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DO-IT-YOURSELF

Spare
wheel

The spare wheel is secured under the rear of the vehicle in a special hinged carrier.

Lowering
spare
wheel
carrier
Attention

When
loosening the screws it is
essential
to
keep
to the
following
sequence:
• Loosen safety screw B
until
it turns freely.

Note

The safety screw B is held at the end
with

a
clip so
that
it cannot be screwed out
com­
pletely. • Remove securing screw A completely.
The spare wheel carrier then rests on the safety screw B.

Attention
If the screws are loosened in the

opposite
sequence, the
carrier

can
fall
off
screw
B.
• Then insert the wheel spanner in the carrierto the stop as shown in illustration on
the
right.

• Grip wheel spanner
firmly
with
both
hands,
lift
slightly and swing to the
right
until

the large hole in the carrier can be swung
over the safety screw and down.
• Take spare wheel out.
Lifting
spare
wheel
carrier

•
Insert
wheel spanner in spare carrier.
•
Place
wheel on carrier
with
well up­ wards, swing carrier up
with
wheel spanner
and hook it on the safety screw.
• Screw in securing screw A
first,
then
.safety screw B.
• Then tighten both screws fully.

Attention
For
safety
reasons the
spare

wheel
carrier
must
always
be

firmly
secured so
that
the
spare
wheel
cannot
fall
down
acciden­

tally.

Note

The rear mounting of the spare wheel
carrier can be adjusted in height to cater for
tyres of different widths.
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Changing
wheels

Park
the vehicle as far as possible away
from the
traffic
flow, if necessary switch on emergency warning lights and place the
warning triangle in position - note legal re­
quirements.
• All vehicles occupants should leave the vehicle and move to a safe area (e.g. behind
the barrier).
• Apply handbrake firmly. If the car is on a
slope,
block one of the wheels on the oppo­
site side
with
a stone or some similar object.
• Take the tools out of the vehicle.
• Take spare wheel out of carrier at rear of vehicle - see previous page.
JB70
- 121J
•
Push
the wheel spanner as far as
poss­
ible onto the wheel bolt as shown and
turn

the spanner anti-clockwise. When doing this, grip the spanner as far as possible to­
wards the lever end.
If the bolts cannot be loosened, one can in
an emergency, carefully push the spanner
down
with
a
foot
on the end of the lever.
One
should ensure
that
one has a
firm

stance
and a good grip on the vehicle.

Loosen
wheel bolts about one turn. 8"" 1 •>!
•
Place
jack under vehicle: - Depressions in the side member at
front
and rear indicate the points at which the
jack must be
fitted
- see arrows in illus­
tration. On the sliding door side
ensure

that
the
claw
of the
jack
does not
fit
under
the sliding door.
- On the Pick-.up the jack is placed under the mounting of the trailing arm (triangu­lar mark) at the rear.
- If the
jack
is not
placed
at the
marked
points, the
vehicle
can be

damaged.

120
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- Wind jack arm up by turning the crank handle
until
the jack
just
goes under the

vehicle.

- The claw of the jack must fit round the vertical rib on the side member so
that

the jack cannot slip when vehicle is
lifted

- see illustration.
- If the ground is soft, place a large strong
piece
of packing under the jack base
plate.
- Align jack and at same time wind claw up
further
until
it contacts the vertical rib on
side
member. •
Lift
vehicle
until
the defective wheel is

clear
of ground.
• Remove wheel bolts and place them on
a
clean surface (hub cap, cloth, paper) next
to the jack and take the wheel off.
• Fit spare wheel and lightly tighten all bolts. The wheel bolts must be clean and

easy
to
turn
- do not under any circum­

stances
use grease or oil!
• Lowervehicleand fully tighten bolts indi- agonal sequence.
• Refit the wheel trim.
•
Place
defective wheel in spare wheel carrier and secure it - see page 119.

Notes

• Pay attention to the following after changing a wheel:
- Check the
tyre
pressure immediately on the spare wheel which has been fitted.
- Have the tightening torque of the wheel bolts checked
with
a torque wrench as

soon
as possible. The torque for steel
and alloy wheels is 160 Nm. If it has been established when changing
the wheel
that
wheel bolts are corroded and hard to screw in, they must be renewed be­
fore checking the tightening torque.
Until these checks have been carried out
one should, for safety reasons, only drive at

a
moderate
speed.

• The defective wheel should be repaired
as
soon as possible.

Attention
If the
vehicle
is to be
subsequent­
ly
fitted
with
wheels
or
tyres

which
differ
from
those
fitted
by
the
factory,
it is
essential
to
read

the
remarks
in the
centre
and
right
hand
columns on
page
113.
121
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Adjusting
headlights
I he setting of the headlights is very import­
ant to traffic safety. The adjustment should
tnerefore only be done
with
a special
appliance.
Note official regulations when
setting headlights.
On vehicles
with
beam
control* the
knurled disc on the instrument panel must

be
in the
basic
position (-).
Both illustrations show the adjustment on
the
right
hand headlight. On the
left
hand headlight the adjustment is symmetrically

opposite.

Main
headlights

The
headlights are adjusted from the
front

with
a suitable Phillips screwdriver
(from
ve­
hicle
tools). The bonnet must be released or

open..

A
- Vertical adjustment
Turning clockwise lowers the headlights.
B
- Lateral adjustment
PIPS
|B7Q-
)55|

Fog
lights*

The
front
foglights are adjusted by a knurled
wheel mounted on the foglight behind the bumper. To adjust, push the
flat
end of a
screwdriver through the opening adjacent
to the foglight (see Fig.) and rotate knurled

wheel.

On
vehicles without a spoiler the knurled
wheel can also be turned by hand.

To
reduce the beam range,
turn
screwtothe
left.

128
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Tow
starting/towing

General
notes

• "owing eyes are provided on the
right
under
front
and rear bumpers.

Tow-ropes
or bars should be attached at

these
points only.

On
vehicles
with
a factory
fitted
towing bracket a towing eye is not fitted. On those

vehicles
the towing bracket can be used for
towing.
• The tow-rope should be slightly elastic to reduce the risk of damage to both ve­
hicles.
It is advisable to use synthetic fibre

ropes,
or ropes of similar elastic material. It
is
however
safer
to use a
tow-bar!

Avoid
excessive towing
effort
and do not

jerk.
During towing operations on other than
surfaced
roads there is always the danger

that
the attachment points will be over­
loaded
and damaged.
•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see previous page. If the
vehicle
has to be tow
started

or
towed
at any
time,
the
following

must
be noted:
•
Check
whether there are any local traffic regulations concerning the towing of ve­

hicles.

• Both drivers must be familiar
with
tow­ ing procedures. Inexperienced drivers

should
not attempt to tow start or tow.
• When using a tow-rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
• The driver of the vehicle being towed must ensure
that
the tow-rope is always

taut.
• The emergency lights must be switchec
on on both vehicles - unless local regula­
tions differ.
• Turn ignition key to "Drive" position sc
that
the steering wheel is free and the
turr
signals,
horn, and, if necessary, the wind­

screen
wiper and washer can be
used.

• As the brake servo only works when the engine is running, considerably more pres­

sure
is required on the brake pedal when the
engine is not running.
• On vehicles
with
power assisted steer­ ing more force is required to
turn
steering
wheel when engine is not running.
• When there is no lubricant in the manua or automatic gearbox, the vehicle may only

be
towed
with
driving wheels lifted.
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Lifting
vehicle

Trolley
jack

To
prevent damage to the underside of the vehicle it is essential to use
a
suitable rubber

On
no account should the vehicle be
lifted
under the engine, gearbox,
rear axle or
front
axle as this can

cause
serious damage.
Attention
• With the vehicle
lifted
never start the engine - danger of
acci­

dent!
• If work has to be done under­ neath the vehicle, the vehicle
must be supported on suitable

stands.
Vehicle
lift

Before driving over the vehicle
lift,

ensure
that
there is adequate clear­

ance
between
lift
superstructure
and low parts on underside of ve­
hicle.

To
lift
the Caravelle/Transporter only
twin
column/pillar hoists
with
sufficiently long
support arms should be
used.

Only
as an exception - for short wheel base

vehicles
in unladen condition - can a single
column hoist be
used.

Hoists
with
fluid cushions (Repair reception hoists) must not be used
to
lift
this vehicle.
Lifting
points
for
workshop

hoist
and
trolley
jack

The vehicle may only be
lifted
at the poin:
shown here.
Front
At the
front
cross member (illustration) At

us

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Rear
At mounting for the rear trailing arm (left i lustration) Short wheelbase vehicles, when unladen
can as an exception be lifted on a single
col­

umn hoist.
The lifting point is then at the side member at reinforcement plate (illustration).
Vehicle
jack

Lifting with the vehicle jack is described on
page 120.
135
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TECHNICAL
DESCRIPTION

Power
flow

Manual
gearbox

• Mechanically or hydraulically operated single plate dry clutch
• Baulk synchronized five speed manual gearbox and final drive in one housing.
• Common lubrication for gearbox and final drive. Permanent oil filling
• Front wheel drive

Automatic
gearbox*

• Hydro-dynamic torque converter
with
lock-up clutch to eliminate converter slip in
3rd speed (under certain driving conditions)
and (always) in 4th speed
• Planetary gearbox
with
4 forward gears
• Two electronically controlled selectable driving programmes
• Flanged on final drive
with
separate lubri­ cation and life-long oil filling
• Front wheel drive
Steering,
Axles

Steering

• Maintenance free rack and pinion steer­ ing
• Steering column
with
angled joints
• Steering pinion and column connected by angled shaft
with
two universal joints
• Hydraulically assisted steering
(PAS)*

Front
axle

• Independent wheel suspension
with
double wishbones, shock absorbers and
anti-roll bars
• Longitudinal mounted torsion bar

Rear
axle

• Independent suspension
with
diagonally trailing arms, coil springs and shock ab­

sorbers.
Brakes

• Hydraulic dual circuit brakes
•
Disc
brakes at
front

• Self adjusting drum brakes at rear
• Brake servo
• Pressure/load-sensitive brake pressure regulator for rear axle
• Mechanical handbrake effective on rear wheels
• Anti-locking brake system
(ABS)*
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