air conditioner VOLKSWAGEN TRANSPORTER 1992 T4 / 4.G Owners Manual

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CONTENTS
DASHBOARD AND

CONTROLS

Layout
4
i\='-:ng
lamps 6

CONTROLS
AND

EQUIPMENT

•
e.s. Central locking system 7, 8
I:cs, Tailgate 9, 10
I'I
~g doors 11

..
-^ows, Mirrors 12, 13
Sea: belts 15 5re:y for children 18
-ead restraints 19

Seats
20 _:ariing/sleeping surface 26

__ggage
compartment cover 27 __cgage compartment/load surface ... 28
-edals, Brakes 29 Vanual gearbox 31
--tomatic gearbox 32
gnition
lock 36
Starting / Stopping the engine .... 37, 38 "struments 40

.'.
arning lamps 47
Switches 50
~yn signal and dip lever 52

3'uise
control system 53 .'.'indscreen wiper 54
-eating and ventilation 55

Air
conditioner 57
Recirculating air switch 61
Auxiliary heater 63
Additional
water heater 67
Sun roof, Sliding/tilting roof 70, 71
nterior lights, Sun visors 72, 73
Ashtray, Cigarette lighter 73
-oof
rack 75
DRIVING
TIPS

The first 1500 km - and afterwards ... 76 Driving safely 78
Driving economically and

ecologically
79
Trailer towing 81

GENERAL
MAINTENANCE
Filling the tank, Fuel 85, 86
Care of car, Maintenance 88, 93 Bonnet, Engine compartment 94, 95
Engine oil, Gearbox oil 96, 99

Air
cleaner 100 Power assisted steering 100

Cooling
system 101
Brake fluid 104
Battery 106
Windscreen washer system 108
Wheels 110
Arduous operating conditions 115
Winter driving 116
Accessories, modifications and
renewal of parts 117
Mobile
telephones and two way
radios 117

DO-IT-YOURSELF

First
aid kit, Warning triangle 118
Vehicle tools 118 Spare wheel/changing wheel ... 119, 120
Fuses
122

Changing
bulbs 124
Adjusting/masking headlights .. 128,129
Headlights 129
Installing radio 129
Emergency starting 130
Tow starting/towing 132
Lifting vehicle 134
TECHNICAL
DESCRIPTION

Engine 136
Emission control system 137
Activated charcoal filter '38 Power flow '39
Steering, Axles 139 Brakes, Body -139,
1
AC
Environment compatibility 140

TECHNICAL
DATA
Engine 141
Performance 142
Fuel consumption 143
Spark plugs 145
V-belts 145
Wheels,
Tyre
pressures 146, 147

Weights,
Trailer weights 148, 151 Dimensions 152
Capacities 153
Vehicle identification data 154

SPECIAL
INFORMATION

Adjusting the brake pressure regulator 155

ALPHABETICAL
INDEX

Alphabetical index 156

CHECKS
WHEN
FILLING

THE TANK
Overview 160
3
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DASHBOARD AND CONTROLS

Page

| Remote controlled outside mirror
13

2
Switch for electric windows 12

3
Switches 50
-
Air
vents

55,
58

5
_urn signal and headlight dip lever

Cruise
control system 52

53

z
Emergency
light
system switch 51

Combi
instrument:
Warning lamps Instruments 47
40
I
Ignition
lock 36
9
Windscreen
wiper/washer lever

with
switch for
multi
function indicator 54
42
1 10
Switches

50

Air
vents
55,
58
I 12
Space
for auxiliary heater controls
63

'
3
Radio"

'-
Glove
box
74
' 5
Bonnet
release handle
94
0
Lola
starting aid (Diesel engines) 17

Fuse
box behind shelf
—
18 Horn ( only functions
with
ignition switched on

19
Controls
and switches for heating/ventilation
... air conditioner V-
20
Gear
lever (manual gearbox)

Selector
lever (automatic gearbox) 31
21
Switch
for recirculating air

s:

22
Ashtray
73
23
Cigarette lighter/electric socket

Notes

• Some of the items listed are only
fitted
on certain mi optional extras.
• On righthand drive vehicles the arrangement of the sv the location of some items can vary. The symbols on tr are the same as for lefthand drive vehicles.
11
Vehicles
with
a factory
fitted
radio have a radio instruction iea
When
service installing a radio pay
attention
to the ins
page
129 in the "Do-it-yourself" section.
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CONTROLS AND
EQUIPMENT

Air
conditioner*
in cab

Description

T".e air conditioner is a combined cooling srd heating system which provides the
r-aximum possible comfort all the year
rcjnd.

Tpe air conditioner works only when the en-

pie
is running and the ambient tempera- t.re is above about + 5 degrees C.
,ien air conditioner is switched on it re-
bjces not only the temperature inside the
•
ehicle but also the air humidity. When the

=-nbient
air humidity is high this not only
Iakes
the vehicle occupants feel more
comfortable but also prevents the windows
""Dm
misting up.
~ne cooling system works best when all the
v.indows are closed.
Controls

A
-Blower
switch

The blower has four speeds.
B -
Temperature
lever

The temperature can be regulated over the
full range for each programme lever
posi­

tion.

C
-Programme
lever

E] -
System
switched
off -
Maximum
cooling

(Temperature lever B fully to
left)
Air from
side and centre outlets
SSI -
Cooling
normally
(Temperature lever position as required)

Air
from side and centre outlets
SS§i
-
Comfort
setting

(Temperature lever position as requ rez

Air
comes from the side and centre
OJ:
e:s
and into footwell. Slight flow of air to
•:.
-z- screen and side windows.
H-
Ventilating
(Depending on position of temperature
lever, heated or unheated fresh air - not

cooled
air)

Air
from side and centre outlets,
dj -
Heating

(Temperature lever position as required)

Air
to the footwell, slight flow of air to wind­ screen and side windows and the side and
centre outlets
Wi -
Defrosting
and
demisting

(Temperature lever position as required)

Air
to windscreen and to side windows, slight flow of air to footwell and to the side
and centre outlets.
57
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CONTROLS
AND
EQUIPMENT

Notes

Pools of
water
under
the
vehicle

• When the ambient temperature is high
and
the air very humid, condensed water

can
drip off the evaporator and form a puddle under the vehicle. This is quite nor­

mal
and does not indicate a leak.

Operating
faults

• Should the air conditioner not work at
any
time, either:
- the ambient temperature is below about + 5 degrees C,
- the fuse has blown.

Check
fuse and if necessary renew it - see

page
122. If the trouble is not due to
a
defec­
tive fuse, switch the system off and have it
checked.

- the air conditioner has switched off due to the coolant temperature being too high -
see
page 41
also.

• If the cooling
output
drops off, switch the
A/C
off and have the system
checked.
Using air
conditioner

economically
In cooling operation the air conditioner
com­

pressor
places demands on the engine and
therefore influences the fuel consumption.

To
keep the period switched on as short as
possible,
the following points should be

noted:

• If the inside temperature is very high after the vehicle has been parked in the sun, it is recommended to open doors or win­

dows
briefly to enable the hot air to
escape.

• The air conditioner should not be
switched
on during a journey if the windows

or
sliding/tilting
roof*
are open.
• If the desired interior temperature can be attained
without
switching on the air condi­
tioner, the fresh air operation should be se­
lected.
Recirculating
air
switch

If badly contaminated air is to be prevented
from entering the vehicle, e.g. when driving
through a tunnel, the recirculating air switch in the instrument panel can be
pressed.

When
the recirculating air system is
switched
on, a small warning lamp lights up in the switch.

However,
the recirculating air system

should
only be used for a short period other­

wise
the windows will mist up.

60
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CONTROLS AND
EQUIPMENT

Air conditioner* in passenger compartment Recirculating air switch*
th the air conditioner in the passenger
:: apartment the rear seating area can also
:e comfortably cooled down.
air conditioner only functions if the air
:: iditioner in the cab is switched on - see
:;ge 57. However, adjustment of the out-
: can be performed independent of the
I stem in the cab. The control elements are : rated on the dash panel - see illustration.
air throughput can be set in any one of
;: J stages (left hand rotary switch).
Th e temperature infinitely variable with the ::ary control (right hand switch).
I Dckwise - increased cooling output
--ti-clockwise - decreased cooling output Air outlets
The air outlets are located in the roof area
above the rear seats.
The outlets can be closed or opened separ­
ately.
By pivoting the outlet grilles the direction of
air flow can also be adjusted.
This switch can be used to change over to recirculating air. This will prevent badiy con-
taminated air from entering the vehicle, e.g.
when driving through a tunnel.
Recirculating air operation should only be
used briefly otherwise the windows wil
mist up.
Switch to left - Recirculating air operation
Switch to right - Fresh air operation

Note

On vehicles with air conditioner a recirculat­ing air switch is located in the bank of
switches in the instrument panel.
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CONTROLS AND EQUIPMENT

Additional
heater*

With the additional heater the rear seating
area
can also be comfortably heated.
Its blower can be switched on
with
a three

stage
rotary switch in the dash panel
(left
hand illustration).
Temperature regulation is carried out to­ gether
with
the temperature regulation of
the normal heater - see page 55 .
On
vehicles
with
an airconditionertempera-
ture regulation forthe additional heater is by way of a rotary control on the
right
adjacent
to the blower switch (centre illustration).

Clockwise
- increased heat output

Anti-clockwise
- decreased heat output
On
vehicles
with
seating arrangement the
outlet is located under the centre row of
seats.
This outlet can be closed by pushing it in.

On
the Delivery van, Multivan and Camper
the outlet is located behind the
front
pass­
enger's
seat.
62
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DO-IT-YOURSELF
Fuse
layout

<*'om
left
to
right)

No.
Component
A11
' - Dipped beam
left,
headlight range control
left
10
I- Dipped beam
right,
headlight range control
right
10
3-
Instrument
and number plate lighting 10
--
Rear
wiper, seat heating 15

5-
Windscreen wiper,
windscreen and rear window

washer/elec.
heated

washer
jets 15

5-
Blower, air conditioner 30
/- Tail and side
light
right,
engine compartment
light
10

3-
Tail and side
light
left
10
9-
Rear
window heating, mirror heating 20

10-
Fog lights, rear fog
light
15
II- High beam
left,
high beam
warning lamp 10

12-
High beam
right
10

13-
Horn, radiator fan (run-on) 10
1 Ampere No.
Component
A

14-
Reversing lights, electric outside mirrors, sliding/tilting
roof,
shift pattern auto, gearbox,

cruise
control system
(cancel contacts on the brake
and clutch pedal) 10

15-
Engine electronics 10

16-
Warning lamps,
dash
panel insert,
glove box
light
15

17-
Turn signals 10

18-
Electric fuel pump,

Lambda
probe 20

19-
Radiator fan, air conditioner 30

20-
Brake lights 10

21-
Interior
and luggage compartment lights, make-up mirror
light,

clock,
radio,
central locking 15

22-
Cigarette lighter 10
Additional
fuses
(in separate holders)
• above the relays A11

Fuse
for electric windows 20
• In the engine compartment on the bulk­
head
above the brake servo:

Glow
plugs21 50
• Under the driver's seat

Fuse
for additional water heater 10

Fuse
for heater blower .30

Fuse
for water heater
glow plug 20
Fuse
for auxiliary heater3' 25
Fuse colour code:

Red:
10 Ampere

Blue:
15 Ampere

Yellow:
20 Ampere

Green:
30 Ampere
21 This fuse should only be renewed by
a
Volks­
wagen dealer.
31 On vehicles
with
swivelling seats this fuse
can
be found in the side
trim
behind the
driver's seat.

123
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TECHNICAL
DESCRIPTION

Body
• Unitary construction body/ chassis • Floor frame reinforced by side and cross members
• Long term body protection
with
special high-quality materials-this makes possible
the long warranty period for paint defects
and
rust penetration (see Service Schedule)
Environment
compatibil­

ity Protection of the environment played a de­

cisive
role in the construction, selection of materials and manufacture. Amongst other
things special attention was given to the fol­ lowing points:

Constructive
measures
for econ­
omic recycling
• Disassembly-friendly design of joints
•
Easier
disassembly by modular
con­
struction methods
• Improved
purity
of materials
• All larger plastic parts marked in accord­
ance
with
VDA recommendation 260.

Selection
of
material

• Refrigerant for air conditioner*
CFC
free
• Materials which can be recycled are
used
as far as possible
• Use of similar plastic
within
an assembly group
• Use of materials which have been re­
cycled

• PVC not
used,
when possible to use an alternative material
• No Cadmium
• No Asbestos
• No leaded paint
• Reduction in vapours emitted by plastics
Manufacture

• Recycled material used for the manufac­
ture
of plastic parts
• Solvents abandoned for the cavity
seal­
ing
• Use of water based paints
• Solvent free transport preservation • Use of solvent free bonding agents
•
CFCs
abandoned as far as possible dur­ ing manufacture
• Surplus material recycled as far as
poss­
ible to gain energy and manufacturing sup­

port
materials
• The water required during manufacture
is
reprocessed.
140
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TECHNICAL DATA

Performance

Maximum
speed flaps,
very
wide
tyres
etc. which affect the

in
km/h performance.
The performance figures were measured
without the vehicle being fitted with any
equipment
such as air conditioner, mud
Caravelle, Kombi,
Multivan,

Delivery van
Pick-up

High
roof Kombi,

High
roof Delivery van
Double
cab

Petrol
engines
with
catalytic
converter

62 kW Manual gearbox 144 128
137 132
81 kW Manual gearbox 158 142
151 146

Automatic
154
138 147 142

Diesel
engines

45 kW Manual gearbox 128 115
122 117
50 kW Manual gearbox 132 119
126 121
57 kW Manual gearbox 137 124
131 126

Automatic
133 120
127 122

Petrol
engines
without
catalytic
converter

62 kW Manual gearbox 144
128 137
132
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TECHNICAL DATA
Vehicles
with 4
cylinder
engines
(Figures
for 5
cylinder
engine
in
brackets)
Reduced
payload

(K800)

(in
kg)
Wheelbase

in
mm
Permissible

GVW
Unladen

weight
(with
driver)
Payload

Permissible

front
axle load
Perm,

rear axle load
Perm,

roof

load21

Van
2920
2320 (2395) 1520 (1595)
800 (800) 1200 (1280) 1200 100

Kombi
2920
2320 (2395)

152011
(1595)11 800 (800) 1280 (1350) 1200 100

Notes

• Other model versions
and
optional
ex­
tras
-
e.g.
air
conditioner, automatic gear­box, sliding
roof,
towing bracket
etc. and

service
installation
of
accessories
in­

creases
the unladen weight and the payload
has
to be
reduced
by
this amount.
•
The
load must
be
stowed
so
that
it
can­
not slide about
or fly
forward when
the

brakes
are
applied.
If
necessary
use the
lashing eyes provided. • When carrying heavy loads,
the
load

should,
in
the
interests
of
good handling,
be
placed,
where possible, between
the
axles.
The permissible axle
and
gross vehicle weights must
not be
exceeded
on any
ac­
count. Bear
in
mind also
that
the
load will
alter
the
vehicle handling. Driving style
and
speed
must therefore
be
adapted
to
suit. Without driver

Use
only
the
roof load carrying system
ap­

proved
by us.
Distribute load evenly.
Do not

exceed
permissible roof load including roof rack
- and
permissible vehicle weight.
For

further
details see page
75

On
vehicles
with
a
pop-up roof
the
unladen
weight
is
increased
by 60 kg
and which corre­
spondingly reduces
the
payload.
150
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