towing 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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CONTROLS
AND EQUIPMENT
Notes on driving Starting

\
e
engine
can only be started when
selec-
pr
ever
is at
"N"
or
"P".
See
also
"Starting

Br:
re" on
page
37.

Selecting
a driving range When the vehicle is stationary and
the engine is running always de­
press
the foot brake when selecting
i gear.
When the vehicle is stationary do
•ot depress the accelerator when
•electing a gear. f the lever is moved accidentally nto "IM" when driving, release ac­
celerator and let the engine speed
trop to idling before selecting a for­
ward
gear again.

•
Attention
•
When the engine is running it
is
necessary to hold the vehicle

with
the foot brake in all gears.
Because
with
an automatic gear­
box the transfer of power is not
fully interrupted even at idling

speed
- and the vehicle tends to
"creep".
When the vehicle is stationary
and a gear is engaged, the

throttle
must not be opened inad­

vertently
on any account (for in­

stance
by hand from the engine
compartment). Otherwise the ve­hicle
will
move immediately -
even if the handbrake has been
fully applied.
Before working on the vehicle

with
the engine running, apply
the handbrake and put the selec­
tor lever in "P".
Moving off

Select
driving
range
(R, D, 3, 2, 1).
Wait

until
the gearbox has
shifted
and the

power
flow
is made to the
driving

wheels
(light
selection
jerk
perceptible).

Then
one can accelerate.

Stopping

To
stop
vehicle
temporarily
such
as at traffic
lights,
it is only
necessary
to
apply
the

brakes.
It is not
necessary
to
move
selector

lever
to
"N".
The
engine
should
however

only
be running at idling
speed.
Parking

On
level
ground all you
need
do is
engage

the
parking
lock.
On a gradient the
hand­
brake
should
be
applied
firmly first
and
then

the
parking
lock
engaged.
This
will
ensure

that the
locking
mechanism
is not too
heav­
ily
loaded
and
makes
the
lock
easier
to
dis­

engage.

Tow starting
On
vehicles
with
automatic
gearbox
the en­

gine
cannot
be started by towing or
pushing

the
vehicle.
See
page
133.

When
the battery is flat, the
engine
can be
started
from the battery of another
vehicle

by
using
jumper
cables.
See
"Emergency

starting",
page
130.
Towing If the
vehicle
has to be towed at any time,

you
must
read
the instructions in the
sec­

tion
"Towing/tow
starting on
page
132.
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CONTROLS AND EQUIPMENT

Starting
the
engine

General
hints
Attention

When
starting
the
engine
in con­

fined
spaces
there
is a
danger
of poisoning.
• Before starting, move gear lever to neu- ml
(with
automatic gearbox, selector lever -
"P"
or "N" position) and apply handbrake
I 'mly.
• On vehicles
with
a manual gearbox de-
:"9ss
the clutch pedal when operating

=:arter
so
that
starter only has to
turn
en­
gine.

• As soon as engine starts, release the gnition key so
that
starter can disengage.
• After starting a cold engine it may sound
_oisy
for a moment or two because the oil pressure has to build up in the hydraulic
tappets
first.
This is normal and no cause for
a
arm. Do not
warm
engine
up by run-
W>
ning
it
with
vehicle
stationary.
Drive
off
straight
away.

Do
not overrev or use
full
throttle
until the
engine has reached the normal operating
Temperature. • On vehicles
with
a
catalytic
con­

verter
the
engine
must
not be

started
by
towing
the
vehicle
in ex­

cess
of 50 m.
Otherwise
unburnt

fuel
can pass
into
the
converter
and
lead
to
damage.

•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see
page
130.
Petrol
engines

These
engines are equipped
with
a cer: ~-
jection system
that
automatically s^c; es the correct fuel/air mixture at ail anc e~:
temperatures.

When
engine is cold or at
operating

temperature
do not accelerate before or
during the starting procedure.
Applicable to all engines:
If the engine does not start at once, stop

using
the starter after 10
sees,
wait about
half a minute and then try again. If the engine still does not start, the electric
fuel pump fuse may have blown - see page
122.

When
the engine is
very
hot it may be
necessary
to accelerate slightly after the
engine has started.
37
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CONTROLS
AND EQUIPMENT

The
warning lamp flashes when ignition is
switched
on. the lamp must go out when

engine
has started.
If the warning lamp does not go out or

flashes
when driving - a buzzer also sounds
at engine speeds above 2000 rpm - stop,
switch
engine
off, check oil level and if
necessary,
add oil - see page 97.
If the lamp comes on although the oil level

is
in order, do not
drive
on. Do not even
run the engine at idling speed-call in expert

assistance.

Note

The oil pressure
warning
lamp
is not an oil
level
indicator.
The oil
level
should
therefore
be checked at reg­

ular
intervals,
preferably
every
time

the
fuel
tank
is filled.
3 -
High
beams 10 4 - Turn signals

The
warning lampflashes when
turn
signals

are
switched on. If a
turn
signal fails, the
warning lamp flashes twice as fast. (Not
when towing a trailer).

Further
details are given on pages 49

and
52. 5 -
Brake
system «^

The
warning lamp comes on when
• the handbrake is on
• the brake fluid level is too low
The
ignition must be switched on.

Attention
If the
lamp
does not go out
when

handbrake
is released or comes
on
when
driving, the
fluid
level
in
the reservoir is too low. If an in­ crease in
pedal
free
travel
is no­

ticed
at the same
time,
one of the
brake
circuits may
have
failed.
You can
drive
on
carefully
to the

nearest
Volkswagen
dealer
but

allow
for
higher
pedal
pressures and longer
braking
distances on
the way.

The
warning lamp comes on when high
beams
are on or when the headlight flasher

is
used.

48
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CONTROLS
AND
EQUIPMENT

6-Alternator
Q

~ne warning lamp comes on when the
igni-

I
on
is
switched on and must go out when

She
engine
is
started.
i the warning lamp comes on when driving,

stop,
switch
engine
off
and
check
the
alternator V-belt.
f the V-belt
is
broken or loose do not
drive

on with
a
vehicle which
has a 4 cylinder
engine
because the coolant pump
is
then
no
longer being driven. The V-belt must
be

tensioned
or
renewed.
ehicles with
a 5
cylinder engine
can
nor­
mally
be
driven to the nearest Volkswagen
dealer when
the
V-belt
is
broken
or
loose oecause
the
coolant pump
is
driven separ­
ately but then the battery will discharge
con­

tinuously
and all
non-essential electrical consumers should
be
switched
off.

f the warning lamp comes on although
the

belt
is
not broken, one can normally drive on

to
the nearest Volkswagen dealer (all engine

types)
but the
battery will then discharge
continuously
- see
previous paragraph.
7-Glow
plugs
W

(Diesel engines only)

When
the engine
is cold
the warning lamp comes on when key
is
turned to Drive
posi­

tion
(ignition on).

If
the warning lamp does not come
on,
there
is
a
defect in the glow plug system
-
call
in

expert assistance.

When
the
lamp goes out,
start
the engine
immediately
-
see page
38.

When
the
engine
is warm the
glow plug
lamp
does
not
come on -the engine can
be

started straight
away.
(®)
-
Anti-locking
Brake

System
(ABS)*

The operational readiness
of the
essential electrical components
of the ABS are

checked,
both before moving off and when

driving,
by an electronic monitoring system.
The warning lamp lights up when
the
igni­

tion
is
switched on and
it
must go out again, at the latest, after the engine
has
started.

If
the warning lamp does not go out
or if it

comes on when driving the system
is
not
in

order.
The
vehicle can then only
be
braked
with
the
normal system
-
that
is
without
ABS-.The vehicle must be taken to a Volks­
wagen Dealership
as
soon
as
possible.
Further details on ABS
is
given on page
30.

<]1i>
-
Trailer
turn
signals

The warning lamp
*
flashes when turn
sig­
nals are switched on when towing
a
trailer.

If a
turn signal fails on the trailer or vehicle,
the warning lamp does not flash.
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CONTROLS
AND
EQUIPMENT

3
-
Emergency lights .
nen the emergency lights are on, a warn-
'z lamp in the switch flashes as well.
Ine system also works when the ignition is
;
.-.itched off.

4
-
Knurled wheel for seat
^Jf
heating*

~~e cushion and backrest of the
front
seats
:
=
n
be heated electrically when the ignition
s
on.

_~e
heating is switched on and regulated .vth the knurled wheel.

•
switch heating off,
turn
knurled wheel to

:_e
left
to the detent position.
5
-
Heated rear window
QpJ

The
heating works only when ignition is on.

When
heater is on a lamp in the switch lights up.

As soon
as
window
is
clear,

switch element
off. The
reduced
current consumption helps
to re­

duce
the
fuel
consumption
- see
also
page
80.

On
vehicles
with
electrically adjustable ex­
terior mirrors the mirrors are heated as long

as
the rear window heating is switched on.
6
-
Fog lights •/
|Q

Rear fog light

First
detent - fog lights

Second
-
front
and rear fog
detent lights, or rear fog
light
only

At the second position a warning lamp in the switch comes on.

The fog lights
work
with
the side lights (ignition on), low or high beams.

The rear fog light
works only
with
the fog lights or
with
the low or high beams.

Due
to the amount of
dazzle
it
causes
the

rear
fog
light
should only be switched on
when the visibility is very poor (in Germany
for example, below 50 metres).

Note
The
electrical system of the factory
fitted

tow bar* is wired-up so
that
when towing

a
trailer
fitted
with
rear fog lights, the rear
fog
light
on the towing vehicle are automati­
cally
switched off.
51
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DRIVING
TIPS

The
first
1500 km - and
afterwards
Running-in
I/-c :he
first
few operating hours the en-

5ine
internal friction is higher than later on .-.hen all the moving parts have bedded

down.
How well this running-in process is

::cne
depends to a considerable extent on
the way the vehicle is driven during the
first
1500
km.
Up to 1000
kilometers

the following general rules apply:
• Do not use
full
throttle

• Do not
drive
faster
than
3/4 of top speed
• Avoid
high
engine
speeds
• Trailer towing should if possible be
avoided.

Attention

• New
tyres
must
also be "run in" because
they
do not
have

maximum
adhesion at the
start.

This
must
be
taken
into
account by
driving
carefully
during
the

first
100 km. • New
brake
linings
must
also be
run in and do not
have
the opti­
mum
friction
properties
during

the
first
200 km. The
slightly
re­ duced
braking
effect
can be com­
pensated
for by
more
pressure on
the
brake
pedal. This also applies
when
new linings
have
been

fitted.

From 1000 - 1500 km

The
speed can be gradually increased to the road or engine maximum.
During
and
after
the
running-in

period
the
following
applies:

• Do not overrev the engine when cold - either in neutral or in the gears.

All
speeds and revs given are only valid
when engine is
properly
warm.

Do not
drive
with
the
engine

speed
unnecessarily
high

changing
up
early
helps
to
save
fuel,

reduces
noise
and
protects
the
envi­
ronment
- see
also
page
79.
• Do not let engine labour - change down when engine no longer runs smoothly.
76
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DRIVING
TIPS

Trailer
towing

~~e
vehicle is intended mainly for the trans-
cctation of persons and luggage but it can, th the appropriate technical equipment,

=
so be used to tow a trailer.
Ibiler towing not only places more stress : - the vehicle, it also calls for more concen-
ration from the driver.
::r this reason the operating and driving in­ductions on the next pages must be strict- . adhered to.
Technical
requirements
" :he vehicle is supplied
with
a factory-
• ::ed towing bracket, all
that
is technically -
d
legally necessary for trailer towing will =ve been taken into account.
: should be noted
that
a 13 pin socket is
::ed
instead of the 7 pin one used previous- . This new socket makes it possible to con-
ect additional electrical components on trailer for which there were no connec-

ns
in the previous socket, such as a
cara-

n refrigerator, reversing lights etc.
the following table the wiring of the ter-
nals
in the 7 pin socket is compared
with

at of the 13 pin socket.
I a 7

13
Trailer electrical

Pin Pin
components

L
1 Turn signal
left

54g
2
Rear
fog light
31
311

Earth
for the circuits 1-8

R
4
Turn signal
right

58
R
5
Tail
light, outline -, marker
- and number plate lights

right

54 6
Brake
lights

58L
7
Tail
light, outline -, marker
- and number plate lights

left

- 82>

Reversing
light
-
92!

Power
supply (cont. +)
-
102!

Charging
wire + for battery
in trailer
- 11
free
- 12
free
-
1311

Earth
for circuits 9-12
1) Both earth wires must not be connected to­ gether on the trailer side.
21 Not connected at the factory. If the trailer to be towed has a 7 pin plug,
either a 13 pin plug can be
fitted
as shown
in the table or an adapter cable can ce zz-
tained from a Volkswagen dealer.
If the vehicle is to be
fitted
with
a towing
bracket subsequently, the following must

be
noted:
• The towing bracket is a safety part. Only
a
bracket which has been designed and
type-approved for this vehicle may be
used.
It is advisable to use towing brackets from
the Volkswagen range of accessories as

these
are identical to the ones
fitted
by the
factory. The
fitting
instructions supplied

with
these brackets have also been ap­ proved by the factory.
• The trailer socket must be connected properly to the electrical system of the ve­
hicle.
This applies to terminal 54 g in the 7
pin socket or for terminals 2 and 8 -13 in the
13
pin socket.
81
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DRIVING
TIPS

• As the factory installation of a towing bracket includes the modification of the

cooling
system, this should also be done
when service installing a bracket. Other­

wise
overheating may occur when the en­ gine is pulling hard (mountains, high ambi­
ent temperature, heavy trailer loads).

Certain
vehicle versions can be equipped

with
a heavy-duty cooling system ex fac­

tory,
even though the vehicle is delivered

without
a towing bracket. Details can be ob­
tained from Volkswagen dealers.
• Volkswagen dealers have all the
necess­
ary information on the installation of towing
brackets
and the
fitting
of a heavy-duty

cooling
system. The installation should
therefore be done by them.
• If, when towing a trailer for commercial
purposes,
the permissible
total
weight of

vehicle
and trailer - also
with
passenger
cars
- exceeds 3500 kg, it is necessary to in­
stall and use a tachograph in most European

countries.
Operations
instructions

• When inserting the 13 plug
into
the
socket
on the vehicle, the ribbed sleeve on
the plug must be turned fully to the
right.

The
lid of the socket then engages over the
boss
on the
sleeve.

• If the
traffic
behind the trailer cannot be
seen
properly
with
the standard rear view mirrors, additional outside mirrors will be

necessary.
Both outside mirrors must be

fitted
on folding arms and adjusted to give
a
good view to the rear at all times.
• Pitching movements between towing
vehicle
and trailer can be reduced by heavy-
duty springs and shock absorbers on the rear axle. If these springs and shock ab­

sorbers
have not already been
fitted
at the
factory, they can, in many
cases,
be servi­

ce-installed
by a Volkswagen dealer.
• Pitching and snaking movements can
also
be reduced by stabilizers which can be
obtained from and
fitted
by Volkswagen
dealers
in most European countries. • The permissible trailer weight11 - see

page
151 -must not be
exceeded
on any
ac­

count.
• When towing a trailer in mountainous re­
gions,
note
that
the trailer weights given ir
the "Technical data" are only valid for gradi­ ents up to 10 or 12 %. If the trailer weigh'
is
below the permissible maximum a corre­
spondingly steeper gradient can be

climbed.

• The given trailer weights are only appli­
cable
for altitudes up to 1000 m above see
level.
As the engine
output
and thus the
climbing ability drops due to the decreasing
air density, the weight of vehicle and trailer must also be reduced by 10 % for eacr

further
1000 m or part thereof.
1 The permissible vehicle/trailer weight
con­
sists
of the permissible
total
weight of tow­ing vehicle plus the permissible
total
weight
of trailer. If the permissible trailer load is to be
fully utilized it may be necessary to reduce
the weight of the towing vehicle appropriate­ ly. The towing vehicle must however not be
lighter than the trailer.
82
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DRIVING
TIPS

• Where possible make
full
use of the maximum permissible drawbar weight on

call
of the towing bracket - see page 151 -
cut do not exceed it.
• While observing the permissible trailer
and
drawbar weight, distribute the load in
the trailer so
that
heavy objects are as near
as
possible to the axle. The objects must
a
so be secured so
that
they cannot slip
aoout.
• Check the
tyre
pressures on the towing
/ehicle
and the trailer.
• The headlight settings, should be
:hecked
with
trailer attached before mov- ng off and adjusted as necessary.

On
vehicles
with
headlight beam control it

is
only necessary to
turn
the knurled disc in
:ash
in the appropriate direction.
Driving
instructions

To
obtain the best possible handling of ve­
hicle
and trailer, the following should be

noted:

• Try to avoid driving
with
an unladen ve­
hicle
and a loaded trailer. If this cannot be

avoided,
only drive slowly to allow for the unfavourable weight distribution.
• As driving stability of vehicle and trailer
decreases
when the speed increases do not
drive at the maximum permissible top
speed
in unfavourable road, weather or
wind conditions - particularly when going downhill. In any
case
the speed must be reduced im­
mediately the trailer shows the slightest

sign
of snaking. On no account try to stop
the snaking by accelerating.
• For safety reasons one should not drive faster than 80 km/h (50 mph). This also
applies
in countries where higher speeds
are permitted. • Always brake in good time. If the trailer

has
an overrun brake, apply the brakes gen­
tly at
first
then firmly. This will avoid the
jerk­
ing caused by the trailer wheels locking.

Change
down before going down a steep hill so
that
the engine can act as a brake.
• When a long climb in a low gear
with
ex­ tremely high engine revs must be nego­
tiated at exceptionally high ambient tem­peratures the coolant temperature gauge must be observed. When the gauge needle

moves
to the
>~zza'
e~z of :ne
scale,
the road speed must be reduced immediately. If nevertheless ~g amp flashes,
stop immediately and si ow the engine to

cool
off at idling speed for several minutes.
• The cooling effect of the radiator fan
can­
not be increased by changing down, be­

cause
the speec of t~e
~a~
s ~o! dependent
on the engine
speed.
One should therefore not change down even when towing a
trailer as long as :-e e-g -e zar cope with­ out the vehicle speed dropping too much.
83
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans