1990 VOLKSWAGEN TRANSPORTER manual transmission

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VEHICLE CARE

CORROSION
PROTECTION

The transmission,
front
and rear axle
assembly
surfaces have been treated at
the factory
with
a wax based coating for protection against corrosion. However, we
recommend to have the and the underside
inspected twice a year for any damage to
the protective coating preferably before and after the winter
season.
Have
neces­

sary
repairs done as soon as possible.
See
your dealer for correct procedures
and materials.

WARNING
Do not
apply
additional
undercoating

or
rustproofing
on or
near
the
exhaust
manifold,
exhaust
pipes,
catalytic

converter
or
heat
shields.
During
driv­
ing, the substance used for
under-

coating
could
overheat
and cause a

fire.

Engine
Compartment
When washing the engine compartment, only use commercially available grease
cutting solvents made especially for this
purpose.
Carefully follow directions
print­

ed
on the container by the manufacturer.
WARNING

Never
use gasoline,
Diesel
fuel
or sol­

vents
which
could
damage
rubber
parts
or
painted
surfaces and could
cause a
fire.

Chassis

The lower body shell of your Volkswagen
is
thoroughly protected against corrosion. However, it is recommended to have the
underside inspected twice a year. Any de­
tected damage to the undercoating, due to road hazards, should be repaired prompt­
ly. Oil based protective sprays must not be

applied.
Only tar or wax based anticorro-

sion
protectors are compatible
with
the
factory applied undercoating. Before ap­ plication, road
dirt,
salt spray deposits and
oily substances must be removed.

Whenever
the lower body
shell,
axle, transmission or engines assemblies have been repaired, the lost anti-corrosion
coating of the affected surfaces should be
reapplied.

Your
Volkswagen dealer has the appro­ priate materials, the necessary equipment
and is familiar
with
the application proce­
dure. Therefore, any additional corrosion protection work should be performed by a

Volkswagen
dealer.
Body
cavity sealing

All
body cavities which could be affecte: by corrosion have been given a thorouc"
protection at the factory.

This
sealing does not require any inspe:
tion
or additional treatments. If any wa should seep out of the cavity when tN
ambient temperature is high, it can M removed
with
a plastic scraper and -.
suitable solvent. Be sure to observe a
safety and environmental regulations.
94


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VEHICLE
CARE

ENGINE
COMPARTMENT LID

mu
have access to the engine compart-

•Mit
lid from inside the luggage compart- -ent.

"lb
open the
lid,
roll the floor covering out of
~9
way and
turn
both lock handles to the
Tb close the lid, reverse the above proce- ;jre.
ENGINE
COMPARTMENT
Always exercise extreme caution when
working on the engine. WARNING
•
Before you check anything in the en­
gine compartment, stop the engine,
fully set the parking brake and remove
the ignition key.

•
Do not work on
your
car if you are
tired or ill, under emotional stress or under influence of drugs, medication
or alcohol.

•
Always let the engine cool down. Hot
components will burn skin on contact.

•
Do not spill engine oil, ATF, brake

fluid,
antifreeze and washer solvent on hot engine components, especially not
on the exhaust system.
These
fluids
are
flammable.

•
Always disconnect the battery
ground strap if you must work on the

fuel
system or the electrical system.
Never
smoke or work near heaters or
other fire hazards if you must work
around
fuel.
Always keep an approved
fire extinguisher immediately
avail­
able.
Be
especially careful if engine is run­

ning:

•
If work must be done with the engine
running, always fully set the parking

brake,
and make sure the shift lever is
in Neutral (Manual transmission) or

Park
(Automatic transmission).

•
Always be alert and extremely
cau­

tious around the engine at
all
times par­
ticularly when the engine is running.

•
Always exercise extreme caution to

prevent
neckties,
jewelry,
long hair or
loose clothing from getting caught in
the fan blades, the V-belts, or any other
moving
engine parts.

•
To avoid electrical shock and per­

sonal
injury
never
touch ignition ca­
bles
or components of the high voltage
electronic ignition system while the en­
gine is running or even when starter is

cranked.

97


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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
AUTOMATIC TRANSMISSION FLUID / MANUAL TRANSMISSION OIL
Automatic Transmission Fluid
The torque converter and the transmis­
sion are lubricated with Automatic Trans­ mission Fluid (ATF).
The final drive requires hypoid oil SAE 90,
which does not have to be changed.
Checking the ATF level
The ATF has to be checked at frequent intervals, for instance, when the engine
oil is being checked or at least at the intervals specified in your Maintenance
booklet.
Always heed WARNINGS on page 97. A correct ATF level is very important for
transmission operation.
To obtain an accurate reading, the
vehicle must be on level ground, and the
fluid must have reached operating
tem­

perature. Normally, after a cold-start the
fluid will reach operating temperature when the vehicle has been driven for ab­
out 6 miles or 10 km. If the ATF is too cool
or too hot, the fluid level reading will be inaccurate.
WARNING Before checking the ATF, the selector
lever must be securely locked in the Park position and the parking brake ap­
plied firmly.
Checking the ATF level is potentially hazardous because the hot engine has
to be running during the check. Do not
attempt to check the ATF before read­ ing all WARNINGS on page 97.
The ATF filler neck is in the engine com- partement on the left hand side. The dip­
stick is attached to the
plug.
Pull it out
and wipe clean first before inserting it to
take a reading. The Automatic transmission may be da­
maged by even a tiny speck of dirt.
Only use lint free rags to wipe the dip­
stick.
To get a true reading, the ATF must be at operating temperature.
You have enough ATF if the fluid level is between the two marks on the dipstick. I:
should never be above or below these marks. If level is too high or too low do not
just add or drain ATF. Have your dealer check and correct the cause as soon as possible.
For correct ATF specifications, see "Lub­
ricants" on page 85.
Changing the ATF
The ATF has to be changed at the inter­ vals specified in your Maintenance boo­klet.
Do not tow the vehicle or run the engine
without ATF in the transmission.
Manual Transmisson Oil Both transmission and final drive are
combined in one housing. The lubrican: used is hypoid oil which does not have tc
be checked or changed. If you shoulc
suspect a leak, contact your VW dealer.


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DO-IT-YOURSELF-SERVICE

EMERGENCY
STARTING

Starting by
pushing
or towing

Vehicles
with
Automatic Transmission
cannot
be started by
pushing
or
towing.

Vehicles
with
Manual
Transmission
must
not
be started by
pushing
or
towing.

Damage to the catalytic converter and/or
other parts of the vehicle may result. Starting
with
jumper
cables

WARNING
•
Always shield your eyes and avoid
leaning over the battery whenever
pos­

sible.

•
Do not allow battery acid to contact

eyes
or
skin.
Flush any contacted area

with
water
immediately.

•
Improper use of booster battery to
start a vehicle may
cause
an
explosion.

•
Vehicles batteries generate explo­

sive
gases.
Keep sparks, flame and lighted cigarettes away from batteries.

•
Do not charge a frozen battery; allow
it to thaw out first. Gas trapped
in the ice may cause an explosion.

•
Do not try to jump start any vehicle

with
a low electrolyte level in the bat­ tery.

•
The voltage of the booster battery
must also have a 12-volt rating. The

capacity
(Ah) of the booster battery

should
not be lower than
that
of the
dis­

charged
battery. Use of batteries of dif­
ferent voltage or substantially different

Ah
rating may cause an explosion and
personal
injury.
•
Applying
a
higher
voltage
booster

battery
will
cause
expensive
damage
tc

sensitive
electronic
components,
such
as
relays,
radio,
etc...

•
Vehicle
with
discharged
battery: turn off

lights
and
accessories,
move
lever
to N or

P
(Automatic
transmission)
or into
Neutra

(Manual
transmission)
and set
parking

brake.

Always
heed WARNINGS on page 97.


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EMERGENCY
TOWING
WITH
COMMERCIAL TOWTRUCK

The
following information is to be used by
commercial
tow truck operators who know how to operate their equipment safely.
General
hints

•
Whenever possible, tow
with
front

wheels
off ground.

•
Vehicle may be
lifted
in rear and moved
to position for
front
hook-up.

•
The
Vanagon
cannot be towed
with
con­

ventional sling-type equipment. Towing
with

this type of equipment will cause bumper
and
body panel damage.

Vanagon
with
Automatic
Transmission

Tow
with
dollies under rear wheels or on
flat
bed truck to avoid damage to auto­matic transmission.

WARNING
Never
allow
passengers to
ride
in a

towed
vehicle
for any reason.
Front
Hook-up

•
Attach wheel
lift
equipment to wheels.

•
Attach safety straps to wheels.
•
Attach safety chains to axle platform.

•
Towing clearance: 6-12 inches
between tires and ground.

•
Towing
Speed/Miles:
Automatic
Transmission
-30 mph/30 mi

Manual
Transmission
-
50 mph/50 mi.

138


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GAS
STATION
INFORMATION!

• Attach safety chains on axle platform -
not
around
brake
lines.
Towing clearance: four inches between
tires and road.
Towing speed/distance:
Automatic Transmission - 30 mph/ 30 miles (48 kmh/48 km).

Manual
Transmission - 50 mph/50 miles
(80 kmh/80 km).

|
B25-586

Rear
Hook-up
• Attach wheel
lift
equipment to wheels.
• Attach safety straps to wheels.
• Attach safety chains to trailing arms.
• Towing clearance: 6-12 inches
between tires and ground.
• Towing Speed/Miles: Automatic Transmission -30 mph/30 mi

Manual
Transmission -
50 mph/50 mi.
Vanagon
Syncro

Front
and
Rear
Hook-up

The Vanagon Syncro cannot be towed
with
conventional sling-type towing equip­ment nor
with
wheel
lift
equipment or
wheel dollies to avoid damage to the all-
wheel drive system. Use flat-bed tow truck
only.
139


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DO-IT-YOURSELF-SERVICE

LIFTING
VEHICLE

The vehicle should
never
be lifted or
jacked
up from underneath the engine
oil
pan, the transmission housing, or the

front
or rear axle.
This
could lead to serious damage.
The same lifting points as illustrated for the hoist also apply when using a floor jack. To
avoid damage to the underbody or chassis

frame,
it is necessary to insert a rubber pad between the floor jack and the lift

points.

Lifting
with workshop hoist
and with floor jack

Make
sure there is sufficient clearance
between pads and vehicle before driving
vehicle on to hoist.
WARNING
When removing components such as engine block, transmission housing,

fuel
tank, wheels,
front
or rear axle, anchor vehicle to hoist or add corre­
sponding weights to maintain the cen­
ter of
gravity.
Otherwise the vehicle
might tilt or slip off the hoist, causing
serious damage or personal
injury.
•
To reduce the risk of serious perso­

nal
injury
and vehicle damage, lift
vehicle only at the special workshop hoist and floor jack lift points illustra­

ted.
Failure to lift vehicle at these points could cause the vehicle to tilt or
fall

from a lift when, for example,
heavy
components such as the engine block
or transmission are removed result­
ing
in a change in vehicle weight and

balance.

•
If you must lift
your
vehicle with a
floor jack to work underneath, be sure
the vehicle is safely supported on
stands
intended for this purpose.
Lifting
points

Front

At the
front
jacking point.
Rear

At rear cross member.
The vehicle must be lifted only at the lift
points illustrated.

Lifting
with vehicle jack Refer to the "Changing a wheel" on page

125.

140


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