1990 VOLKSWAGEN TRANSPORTER brakes

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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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^EDALS
BRAKES CONTROLS AND EQUIPMENT
WARNING • The movement of the pedals must
never be obstructed by a floor mat or
any other object.
• In case one of the two brake circuits

fails,
increased brake pedal travel is required to bring your vehicle to a full
stop.
• It should always be possible to
depress the clutch and accelerator pedals fully.
• All pedals must be able to return
freely to their normal positions.
Only use floor mats which leave the pedal area free and can be secured with
floor mat fasteners. Functioning of brake system
Your vehicle is equipped with a power assisted hydraulic dual circuit brake
system with disc brakes at the front and
self-adjusting drum brakes at the rear. Both circuits function independently.
One brake circuit operates the front
wheels and the other the rear wheels. In the unlikely event of hydraulic failure of
one circuit, push the brake pedal down
firmly and hold it in that position. A mechanical linkage activates the second
circuit, and you will be able to bring the
vehicle to a stop.
WARNING Failure of one brake circuit will impair
the braking capability resulting in an increased stopping distance. If one brake circuit fails, the other will still
operate. However, you will notice an increased pedal travel when you step on
the brake. Should you encounter such experience, bring your vehicle safely to a
full stop.
Avoid driving the vehicle and have it
towed to the nearest Volkswagen dealer or qualified workshop.
Brake operation and brake
warning light
Make it a habit to check the operation of
your brakes before driving. The brake
warning light will light up while the engine is cranking and the parking brake is pulled
and/or the brake fluid level is too low. For more details see "Brake warning light" on
page 43.
Keep in mind that the braking distance
increases very rapidly as the speed increa­

ses.
At 60 mph or at 100 km/h, for example, it is not twice but four times longer than at 30 mph or at 50 km/h. Tire
traction is also less effective when the roads are wet and slippery. Therefore,
always maintain a safe distance from the
vehicle in front of you.
29



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CONTROLS
AND
EQUIPMENT

Brake
booster
The brake booster works
only
when
the engine is running.

WARNING

When the vehicle is moving while the engine is not running, more force on
the brake pedal is required to bring the
vehicle to
a
stop. Conditions affecting braking
efficiency
Moisture or road salt

WARNING
•
Under
certain
climatic
and
operating
conditions such as passing
through

water, driving in
heavy
rain or after
washing the vehicle the effectiveness of the brakes can be reduced. In
winter
ice
can accumulate on the brake pads,
linings, discs and drums. Cautiously
apply brakes for a test. Brakes will dry,
ice
coatings will be cleaned off after a
few cautious brake applications.
• Driving for an extended period of

time
on salt covered roads
without
using
your
brakes can also affect brak­
ing
efficiency. The accumulated salt

coating
must be cleaned off the brake

discs
and brake pads be
a
few cautious brake applications.
• Do not "ride the brakes" by resting

your
foot
on the pedal
when
not in­
tending to brake.
This
may cause the brakes to overheat, premature wear
and increased stopping distance. • Before descending
a
steep grade, re­
duce speed and shift transmission into

a
lower
gear or
lower
driving position to control speed. Do not
ride
the
brakes or hold the pedal
down
too long, or too

often.
This
could cause the brakes to get hot
and
diminish
braking efficiency.
New brake pads or linings • New brake pads and linings do not have
optimum friction properties and must be
"broken in" during the initial 100 to 150
miles
(150 to 200 kilometers) of normal
city driving. You can compensate for this by applying more pressure on the brake

pedal.
This
also applies later
when
new
pads or linings are installed.

Brake
fluid level • If the brake fluid level is too low,
malfunctions or
even
a failure in the brake
system could result.
Therefore,
it is important to check
your
brake fluid level
regularly. See page 108 for more details.
Low brake fluid is indicated by the brake
warning light (see page 43).



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CONTROLS AND
EQUIPMENT

=ailure
of one
brake
circuit
I the brake pedal travel should suddenly
icrease,
one of the brake circuits may

_ave
failed. Should this happen, you will
m able to bring your vehicle safely to a

s:op,
however, you will have to push hard­
er on the brake pedal and it will take a onger distance to stop the vehicle.
Con­

tact your Volkswagen dealership for as­
sistance.

Brake
wear

~he brakes on our automobiles are still subject to wear depending largely on oper­ating conditions and driving habits. On ve­

hicles
which are driven mostly in stop-and-
50 city
traffic
or which are driven hard, the
crake linings should be checked by your

Volkswagen
dealer more often than
specified
in the Maintenance brochure.

Front
spoiler
If you
install
a
front
spoiler on
your
vehi­
cle, be
sure
the air
flow
to the
front

brakes
is not
obstructed,
otherwise
the

brake
system
could
overheat.
Parking
brake
lever

The parking brake lever is located between the
front
seats.

• To set the parking brake, pull the lever

until
strong resistance is
felt.
The parking
brake must be pulled up all the way so
that

the vehicle cannot be moved. When the ig­ nition is on, the brake warning
light
will

light
up.
• Depress brake pedal and hold while re­

leasing
parking brake. To release the park­
ing brake, pull the lever slightly up, de­

press
the release
button
(arrow), and then
push the lever all the way down. When the parking brake is fully released, the brake
warning
light
will go out.
WARNING

•
Release
the
parking
brake
fully.
A

partially
engaged
brake
will
overheat

the
rear
brakes,
reduce
their
effective­
ness and cause excessive
wear.

•
Always
set the
parking
brake
when

parking
your
vehicle.
Move
the
selector
lever
to "P"
(Automatic
transmission)

or
move
the
gearshift
lever
to "R" or "1"
(Manual
transmission).
On
hills

also
turn
the
wheels
toward
the curb.
31


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CONTROLS AND EQUIPMENT
AUTOMATIC TRANSMISSION*
p R
f

N d
D
2
f

1 :'B33-395
Selector lever positions
WARNING Apply foot brake when engaging Drive or Reverse.
P - Park
Engage Park only when the vehicle is
sta­

nnary. Therefore, when parking your .snide, apply the parking brake first, and
:nen move the selector lever completely to cosition P. To do this depress the but­
ton in the handle of the selector lever and push it through R to P. The transmis-s on is then mechanically locked.
Depending on the model, your vehicle
~iay be equipped with an Automatic Shift _ock (ASL). To move the shift lever from
re
P-Park
position to any other position,
".vhere applicable you must depress both the brake pedal
and the button into handle of the selector lever.
Shift out of the Park position, before re­ leasing the parking brake.
When the vehicle is parked on a steep
hill,
shifting out of Park may be a little harder.
This is due to the vehicle's weight exerted on the transmission.
Warning buzzer
A warning buzzer will sound when you open the driver's door with the selector lever left in any other but
P-Park
position.
The warning buzzer will go off as soon as the selector lever is moved to the
P-Park
position.

R - Reverse
Reverse should be selected only when the
vehicle has come to a full stop and the en­
gine is running at idle speed.
Before you move the selector lever to the
reverse position you have to depress the
push button in the handle of the selector
lever.
N - Neutral
Shift to this position for standing with
brakes applied. Depending on the model, your vehicle
may be equipped with an Automatic Shift
Lock (ASL). To move the shift lever from
the N-Neutral position to any other
posi­

tion at speeds below 3 mph (5 km/h) or when the vehicle is stationary, you must
depress both the brake pedal and the button into handle of the selector lever.
Do not use Neutral for coasting downhill.
Coasting downhill with the transmission in Neutral and the engine not operating
will result in damage to the Automatic
transmission.
D - Normal driving position
Position D is for normal city and highway

driving.
It ranges from zero to top speed, and all three gears shift automatically,
depending on engine load and driving

speed.

2 - Position for hilly stretches
This position is to be used for mountain driving or slow driving, and also when you
want to make use of the engine's braking effect. In "2", only the first and second
gears will engage automatically.
The road speed must not exceed 54 mph or 87 km/h. Therefore, only shift down into position "2" when vehicle speed is
below this speed. It is not necessary to let
up on the accelerator. 35



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CONTROLS
AND
EQUIPMENT

•
Never shift into Reverse (R) or Park
(P) when the vehicle is in motion.

•
Do not remove the key from the ig­
nition steering lock until you have
parked the vehicle, because removal
of the key
will
lock the steering wheel.

•
If the selector lever is unintention­
ally moved into Neutral (N)
while
driv­

ing,
take
your foot off the accelerator pedal and
wait
until the engine speed

has
dropped to idling before selecting
a driving position.
Maneuvering
•'/hen
alternating between forward and

-averse
- for
instance,
while
maneuvering

ne
vehicle
into a tight parking
space
-
:nly
shift when the
vehicle
has
come
to a
full stop and the
engine
is running at idle
soeed.
Stuck
in snow, mud or sand

When
alternating between forward and
reverse
in an effort to free the
vehicle,

depress
the
accelerator
pedal
slightly

while
the
transmission
is in
gear,
and
release
the
accelerator
pedal
while

shifting.
Do not
race
the
engine
and
avoid

spinning
the
wheels.
Do not repeat
"rocking"
back and
forth
with
wheels

spinning
at high engine speed and heavy
throttle,
as serious damage may
be caused to the automatic transmis­

sion
and other critical parts.

Kickdown
device

The
kickdown
device
gives
maximum
acceleration
when the
accelerator
pedal
is

pressed
down
past
the full throttle
posi­

tion.
Depending
on
road
speed
and
engine
speed,
either the upshift is
delayed
(forced
throttle) or the box
changes
down

into
the next lower
gear.

WARNING
Be
careful when using the kickdown on

slippery
roads. Rapid acceleration may

cause
skidding.
Stopping

•
When
stopping briefly, at a traffic light

for
example,
it is not
necessary
to
move

the
selector
lever
to
Neutral.
Simply
apply

the
brakes.
To start
again
release
brake
and
accelerate.

•
The driving
positions
must
never
be

used
for holding the
vehicle
at rest
uphill.

Always
use your foot
brakes
when
stopped
on
inclines.

WARNING
•
Never get out of the driver's seat
when the engine is running and the
selector
lever is not securely locked in
the P position.

•
If you must leave the vehicle move
the selector lever securely into the P
position
and apply parking brake
firmly.
Towing

To
tow the
vehicle
see instructions
"Emergency
towing" on
page
138.




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I CONTROLSAND EQUIPMENT
WARNING If the brake warning
light
does not go
out
with
the engine running and the parking brake released or lights up
while driving, the fluid level
in
the brake
fluid reservoir may
be
too low.
This might be
due
to
a
leak in one of the two independently functioning brake circuits.
If the brake pedal travel has increased,
one of the brake circuits may have

failed.
Avoid driving the vehicle and have it towed to the nearest Volkswa­
gen dealer or qualified workshop for re­ pair.
If brake pedal travel has not increased

and
braking performance remains un­
impaired,
proceed carefully to
your

nearest Volkswagen dealer or qualified
workshop to have the braking system inspected and corrected.

For detailed information see
"Brakes" on

page 29. 2-
Safety belt
|
A
FASTEN
BELTS

Refer
to
"Safety belts"
on
page
14 for

details.

3
-
Turn
signals E^

Refer
to
"Turn
signal/headlight dimmer
switch lever" on page 49 for details.
4
- Alternator

This
light comes
on
when
the
ignition
is
turned on and goes out after the engine
is
started.
If the
light does
not go out
after

starting
and
revving-up
the
engine
momentarily
or
lights
up
while driving,
there may be a malfunction
in
the electrical system
or
the V-belt
to
the alternator may be loose
or
broken.

In
this
case,
turn
the engine off and

contact
your
Volkswagen dealer.

5
- For additional
light

6
- For additional
light
7
- Engine Oil pressure

When
the
ignition
is
turned
on, the oil
pressure warning light comes on for a bulb

check.
It
should
go out
after
the
engine
has
started.

If the
warning light does
not go out or

flashes
while driving
(above
2000
engine rpm a buzzer
will
sound simultaneously),
it

indicates,
that the oil pressure is too low.

Stop the engine immediately, check the
engine
oil
level
and add
oil, if necessary.
If engine oil level is normal, but the
light

continues to flash, do not continue to
operate the vehicle. This could damage
the engine.

Turn
the engine off and contact the nearest Volkswagen dealer for assistance.

The oil pressure warning
light
is not an indicator for low engine oil level. To

check
the oil level, always use dipstick
(see page 99).

Make
it a habit to have the engine oil
level checked
with
every
fuel filling.


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VEHICLE OPERATION

OPERATE
YOUR VEHICLE ECONOMICALLY AND
MINIMIZE
POLLUTION
Your
personal
style
of
driving
determines your operating costs,
exhaust
emissions and noise levels. To obtain the best
possi­

ble fuel economy,
minimize
pollution
and

save
wear and tear on the engine, brakes
and tires, observe the following points:
• Keep a
light
foot
on the accelerator.
• Drive smoothly, avoid abrupt changes
in speed as much as possible.
• Avoid jack rabbit starts and sudden

stops.

• Avoid unnecessary idling. Turn the
engine off.
• "Warm up" idling wastes gas. Start the
engine
just
before you are ready to drive.

Accelerate
slowly and smoothly.
• Do not drive longer than necessary in
the lower gears. By upshifting early you
can
economize on fuel consumption. • Organize your trips to include in several
errands.
• Any additional weight carried in the
vehicle reduces fuel economy. Always keep cargo to a minimum and remove all

unnecessary
items.
• Remove roof and ski racks when not in

use.

• All electrical consumers contribute to

increased
fuel consumption. Therefore,

use
fan, rear window defogger, etc., only
when needed.
• Check your vehicle's fuel consumption
regularly. Keep a
written
tally sheet or use
the
trip
odometer. Fuel consumption will
vary
with
traffic, road and weather condi­
tions.
• Have your vehicle serviced by an

Volkswagen
dealer at the specified inter­
vals
(see page 95 and your Maintenance brochure). • Air cleaner should be inspected to

assure
proper engine "breathing".
• Battery should be fully charged.
• Wheels should be properly aligned.
• Tires should be inflated to correct pres­

sures.
Check
tire
pressures regularly - at least once a month.
• The published ENVIRONMENTAL-
PROTECTION AGENCY (EPA) and Trans­

port
Canada
mileage
estimates
may not

agree
with
your
actual
highway
mileage

which
will
vary,
depending
upon
vehicle
load
and speed,
road
and
weather
condi­

tions,
trip
length,
etc.
• Have the engine oil level checked
with

every fuel filling. Engine oil consumption
is
normal but tends to be higher when the
engine is new. The use of quality engine oil
and a correct engine oil level are essential
for vehicle performance and economical operation at all times.
72


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