1990 VOLKSWAGEN TRANSPORTER fuel pressure

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CONTROLS
AND
EQUIPMENT

WARNING continned •
The
engine compartment
of any

motor vehicle
is a
potentially hazard­
ous
area.
Before you check anything in the engine compartment, stop
the

engine and
let it
cool down. Always
exercise extreme caution when work­
ing
one the
engine. Heed
all of the

WARNINGS on page
97.

Reduce the risk
of
scalding from
hot

coolant by following these steps.
• If the coolant reservoir cap must be
removed, wait until
the
engine
has

cooled down.
• Protect face, hands
and
arms
by

covering
the cap
with
a
large, thick
rag
to
protect against escaping fluid
and
steam.

• Carefully and slowly
turn
cap
one

turn
to
allow excess pressure
to es­
cape before completely removing

cap.

•
To
help avoid being burned,
do not

spill
antifreeze
or
coolant
on the ex­

haust system
or hot
engine parts.
Under
some conditions, the ethylene
glycol
in
engine coolant
is
combusti­
ble.
If a
visual check shows that coolant level
and V-belt
are
normal,
but the
warning light continues to
flash,
contact
your
near­
est dealer
to
have
the
cause located
and

corrected.
For more details see "Cooling system"
on

page 104.

If the
coolant gauge needle nears
the

upper end
of
the scale and the engine ap­
pears
to be
overheating,
turn
off the air

conditioner.
Do
not
install accessories
(fog
lights
or
in­
sect screens,
for
example)
on top of the

front
bumper.
They
may
restrict engine
cooling.
5
-
Fuel gauge
The needle
in
the fuel gauge will indicate the fuel level
in the
tank shortly after
the
ignition is switched on.
The fuel tank capacity is
16
gal/60
(syncro
18.5/70)
liters.
When
the
needle reaches the
red
area
at
the bottom there
is a
reserve
of
about 2.6 U.S. gal.
or
10 liters
of
fuel left in the tank.
Time to refuel.


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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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3REAK-IN
PERIOD

VEHICLE
OPERATION]
DURING AND
AFTER
BREAK-IN PERIOD

Turing
the first few operating
hours,
the

r-gine's
internal friction is higher than
a:er
when all the moving parts
have
been

:-oken
in. How well this break-in
process

e
done
depends
to a
considerable
extent
:n
the way the
vehicle
is driven during the

-"-3t
900
miles
(1500 kilometers).

For
the first 600 miles
(1000 kilometers):

•
Do not use full
throttle.

•
Do not drive faster
than
3A of top

speed.

•
Avoid high engine speeds.

From
600 to 900 miles
(1000 to 1500 kilometers):

The
speed
can gradually be
increased
to
:he
maximum road
speed
or
engine
speed.

After break-in period
The maximum permissible engine speed
is
5200
rpm and should not be exceeded.
Shift into the higher gear before reach­ing the red area at the end of the scale of
the tachometer. See page 41.

Excessive
engine
speeds
are automati­

cally
reduced.
•
Details
on how to operate the
Manual

and
Automatic
transmission
are outlined

in
the
"Controls
and
equipment"
chapter.

•
Avoid full
throttle
starts and abrupt

stops.

•
Try to avoid running the engine at
maximum speed. Shifting up early helps
to save fuel and reduces noise.

•
Do not overstrain engine; select pro­
per gear before reaching top speeds.

•
Do not let engine labor. Shift down
when engine no longer runs smoothly.

•
All
revs
are only
valid
when
engine
is

properly
warm.

•
Always
observe
local
and national

speed
limits.

Applies
in addition to vehicles
with
Automatic
Transmission:

Make
it a habit to
accelerate
gradually

instead
of
using
full throttle. During
gra­

dual
acceleration
the
transmission
shifts

earlier
into the next higher
gear
thus

saving
fuel.
WARNING

•
New tires do not
possess
maximum
traction. They tend to be slippery. Break new tires in by driving cautiously
at moderate speed for the first 100 miles (160 kilometers).

•
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 compen­ sate for this by applying more pressure

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


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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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VEHICLE CARE
ENGINE OIL
Engine oil consumption t 3 normal for your engine to consume oil.

T-Q
rate of oil consumption depends on
re quality and viscosity of
oil,
the speed at
Mich
the engine is operated, the climate,

read
conditions as well as the amount of : ution and oxidation of the lubricant.

Because
of these variables, no standard
•e:e
of oil consumption can be esta-
:
shed,
but drivers should expect an in­
creased
oil consumption at high speeds
s.nd when the engine is new.
• The
engine
in your
vehicle
depends
on oil to
lubricate
and cool all of its
mov­

ing
parts.
Therefore
the
engine
oil
should be checked
regularly
and
kept
at
the
required
level.
•
Make
it a
habit
to
have
the
engine
oil

level
checked
with
every
fuel
filling.

• Lack of
sufficient
engine
oil may
lead

to
severe
engine
damage.

• The oil pressure
warning
light
is not
an oil
level
indicator.

Always
heed
WARNINGS
on
page
97.
The
engine oil dipstick and the oil filler

neck
are located behind the license plate

lid.

Checking the
engine
oil
level

The
best time to check the engine oil level
is
when the oil is warm.
• Turn off the engine.
• To get a true reading, the vehicle should

be
on level ground. After turning off the en­

gine,
wait a few minutes for the oil to return
to the crankcase.
• Flip license plate down.
• Pull out dipstick and wipe it clean
with
a

rag.

• Reinsert dipstick; push it in all the way. • Pull dipstick out again. The oil level is
correct if it is between the "max" and "min" marks on the dipstick.
• If oil level is below "min" mark, or not
showing on dipstick, add oil immediately.
• Make sure
that
the dipstick is com­
pletely in.
Adding
engine
oil • Unscrew cap from oil filler neck.
• Pull extension tube out of filler neck as
far as it will go.
• Only add the amount of oil needed. The
difference between the "min" and "max" marks on the dipstick is about
1
U.S. quart
or
1
liter. Always select a quality oil
with
the
correct specification. See "Lubricants" on
page
85.
Do not exceed the MAX
marking.

Otherwise,
the excess oil may be drawn in
through the crankcase breather into the exhaust system. The oil would then burn in
the catalytic converter and cause dam­
age.

•
Push
in the extension tube, replace fil­
ler cap and hand tighten securely.

WARNING

The oil
filler
cap
must
be secure to avoid oil spill causing
fire
hazard.


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I TECHNICAL
DESCRIPTION

ENGINE
MANUAL
TRANSMISSION

AUTOMATIC
TRANSMISSION

• Four stroke gasoline engine in rear.
• Four cylinder horizontally opposed.
• Crankshaft
with
four main bearings.
• Liquid cooling system, thermostatically
controlled.
• Thermoswitch operated electric fan. • Pressure oil feed
with
gear - type
pump and
full
flow
filter.

• Self-adjusting hydraulic valve filters.
• AFC (Airflow controlled) fuel injection.
•
Paper
element air cleaner.
• Exhaust emission control system
with

activated charcoal
filter
in the fuel system.
• Breakerless electronic ignition. • Single plate, dry clutch.
• Synchronized four speed transmission

and'
differential in one housing
with
com­

mon lubrication.
•
Rear
wheel drive,
with
two constant
velocity joints per drive shaft.
Syncro • Hydraulically operated single plate

clutch.

• Baulk synchronised 4-speed manual
transmission
with
additional Low-speed
traction gear (4+L transmission).
• Permanent four-wheel drive through

viscous
coupling.
• Manually operated differential lock for
rear final drive available as optional extra. • Hydrodynamic torque converter an:
planetary gearing
with
three forward an:
one reverse gear.
• Final drive in separate housing.
•
Rear
wheel drive,
with
two constar:
velocity joints per drive shaft.


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