1992 VOLKSWAGEN TRANSPORTER fuel pressure

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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

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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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

The technical
prerequisites

"or
a low fuel consumption and efficiency were "built in" at the factory. Particular im­
portance was placed on the lowest possible

disturbance
to the environment. To retain

and
make the best possible use of these
characteristics
attention should be paid to
the following points:

Vehicles
fitted
with
a
catalytic

converter
may
only
be
driven
on

unleaded
petrol.

Even
those
vehicles
which
do
not
have
a
catalytic
converter

should
be
driven
on
unleaded
petrol
for the
sake
of the
environment.

The
prescribed
maintenance

operations
should
be
carried
out

exactly
as
specified
in the
Service
Schedule - see
also
page
93.
Having your vehicle regularly serviced by
a Volkswagen dealer not
only
ensures
that
it is always operationally fit, but it
also ensures economy, lowest possible burden on the environment and a long
service
life.
Check the
tyre
pressures
every
4

weeks.

Low
tyre
pressures increase the rolling

resistance.
This not
only
increases the

fuel
consumption and
tyre
wear,
but the
handling is also impaired.
Do not
carry
unnecessary
ballast

in the
luggage
boot

Particularly in
town
traffic
when one has to accelerate
often,
weight
has a
great
in­
fluence on the
fuel
consumption. As a

rule
of
thumb:
For every 100 kg of
weight

the consumption increases by approxi­
mately
litre
per 100 km.

Remove
roof
rack
immediately

after
use
Particularly at
high
speeds the increased
air resistance makes
itself
felt
consider­

ably.

gCK
Electrical
consumers
should
only
be
switched
on
when
they

are
actually
required

Heated rear windows, additional driving

lights
and heater blower consume a con­
siderable amount of
current.
The higher
alternator
load
also increases the
fuel

consumption. For instance, over a period of 10 hours, the heated rear window
will

increase
the
fuel
consumption by ap­
proximately 1
litre.
Check the
fuel
consumption
reg­

ularly

The
fuel
consumption should be checked
each
time
the
tank
is
filled
up. By doing
this
inconsistencies on the vehicle which
lead to an increased
fuel
consumption
can be discovered sooner.
• Check the
engine
oil
level
each
time
the
tank
is
filled
up

The
oil consumption depends to a great ex­

tent
on the engine load and
speed.
Depend­
ing on the style of driving the consumption

can
be as much as 1.0 litres/1000 km.
It is normal for the oil consumption of a new

engine
to reach its lowest level after a cer­
tain mileage has been covered. The
con­
sumption cannot be properly
assessed
until
the vehicle has run approx. 5000 km.

This
also
applies to the fuel consumption
and
the engine output.
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GENERAL
MAINTENANCE

Checking
coolant
level

The
expansion tank
is in the
engine
com­
partment on the bulkhead
-
see Fig.

The
correct coolant level
is
essential
to
the satisfactory operation
of
cooling system.
For
this reason, the coolant level should
be

checked
regularly,
and
this
is
best done
when refueling.

The
level
can
only
be
checked properly
when engine
is
not running.

The
coolant level must be between the MIN
and
MAX marks
on the
expansion tank
when engine
is
cold
and can be
slightly
above
the MAX mark when
it
is warm.
When
the
coolant level
is too low on ve­

hicles
with
an automatic coolant level moni­
toring device,
it is
indicated by the coolant
temperature/coolant level warning lamp
flashing continuously (see page 47).

Coolant
losses

Coolant
loss normally indicates leaks in the

system.
In
this
case
the
cooling system
should
be checked by a Volkswagen dealer

without
delay.
It is
not sufficient merely
to

add
coolant.
In
a
sealed system
losses
can only occur
if

the boiling point
of
the coolant is exceeded
as
a
result
of
overheating, and coolant
is

forced out
of
the system.
Overheating can occur
if:

• the flow
of
cooling air is reduced, e.g.
by
a
radiator
muff,
very
dirty
radiator fins
(leaves,
dust, insects)
or
additional driving
lights
in
front
of
the cooling air intake.
• the boiling point
of
the coolant has been lowered by an incorrect mixture
-
see previ­

ous
page.
•
the
radiator
fan is not
working
- see
"Fan"
on next page
-
or, • the vehicle
is
driven up
a
long hill
in too

low a gear
with
engine speed very high and
at very high ambient temperatures
-
see
"Fan"
on
next page.
If
the
cause
of the
overheating cannot
be

found
and
eliminated, contact
a
Volks­
wagen dealer
as
soon
as
possible other­

wise
serious damage may
be
done
to the
engine.

Topping
up
coolant
Switch
engine
off
and let
it
cool down. Then

cover
expansion tank cap
with
a
cloth and

turn
cap carefully
to
the
left
and remove.

Attention
Do
not
remove
expansion
tank

cap
when
engine
is
hot
-
Danger
of scalding.

System
is
under
pressure.

If, in an
emergency only water
can be

added,
the
correct mixture concentration must be restored
with
the specified coolant
additive (see previous page)
as
soon
as
possible.

•02
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GENERAL
MAINTENANCE

Wheels

General
notes

• New tyres do not give maximum grip straight away and should therefore be run in
at moderate speeds and a careful style of
driving for about the
first
100 km. This will help to make the tyres last longer.
• Check tyres for damage from time to time (cuts, splits, cracks and lumps) and re­move any foreign bodies embedded in the
treads.
• To avoid damage to tyres and wheels crive over curbs and similar obstacles very
slowly and as nearly at
right
angles as
poss­
ible.
Damage
to wheels and tyres is not always

easy
to see, so if you
think
that
a wheel is
damaged,
it must be checked by a Volks­
wagen dealer.
• Keep grease, oil and fuel off the tyres.
• Replace missing dust caps as soon as
possible.

• Mark wheels before taking them off so
that
they rotate in the same direction when put back on again. • When taken off, the tyres should be
stored in a
cool,
dry and preferably dark
place.

Tyres
which are not on wheels should be stored in a vertical position.

Tyre
life

Tyre life depends to a considerable extent on the following factors:

Inflation
pressure
The inflation pressure is very important par­
ticularly at high
speeds.
Therefore, the pres­
sures
should be checked at least once a month and before every long journey.
At this opportunity do not forget the spare

wheel:

• The spare wheel should always be in­ flated to the highest pressure required on
the vehicle.
Always
check the pressures when the tyres are cold.
When
warm,
the pressure is
higher
but do not
reduce.
The pressur­

es
are given on page 147 and on a sticker on
the driver's door lock pillar.
Pressures
which are too high or too low
shorten
tyre
life - quite apart from the detri­ mental influence on vehicle handling.

Attention

At
continuous
high
speeds a
tyre
in
which
the pressure is too low

flexes
more
and
heats
up excess­
ively.
This can cause
tread
separ­

ation
and
tyre
blow
out.

pCU
A
pressure
which
is too low in- oo
creases
the
fuel
consumption

and
this
burdens
the
environment
unnecessarily.

Mode
of
driving
Fast
cornering, hard acceleration and viol­
ent braking also increase
tyre
wear.
'0
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TECHNICAL
DESCRIPTION

Engine
• 4 stroke petrol/Diesel engine, trans­
verse
installation
• 4/5 cylinders in-line
• Cast-iron cylinder block
• 5/6 bearing crankshaft
• Sheet metal sump
• Alloy cylinder head
• Valves operated via toothed belt and overhead camshaft
• Maintenance free valve gear
with
hy­ draulic tappets
• Cooling system filled for life of vehicle
• Radiator
with
separate expansion tank • Electric radiator fan controlled by ther-
moswitch
• Maintenance free electronic ignition
• Long-life spark plugs
• Optical and acoustic oil pressure warn­ ing
• Low maintenance battery
with
high starting capacity
• Long-life low maintenance V-belts
• Thermostatically controlled intake air preheating
• Dry air cleaner
with
paper element • Fuel
injection
engines
have fully
electronic engine management (combined
control of injection and ignition systems).
• Emission control system
with
Lambda probe on petrol engines (not in all Export
markets)
•
Diesel
engines
with
distributor injec­
tion
pump
with
cold start aid,
filter
preheat­
ing,
self-bleeding fuel system
• Long life exhaust system.
'36
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