stop start VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual
[x] Cancel search | Manufacturer: VOLKSWAGEN, Model Year: 1992, Model line: CARAVELLE, Model: VOLKSWAGEN CARAVELLE 1992 T4 / 4.GPages: 164, PDF Size: 25 MB
Page 5 of 164
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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
3edals
• e ~ cvement of the pedals must not be re-
:: :~is reason, do not put articles in the
—•".•.ell which could roll or slide underneath
—-E-
zedals.
•Vr^-d the pedal area there should not be •r. -;otmatsorotheradditionalfloorcover- •: -aterials:
• In the
case
of defects on the brake sys-
r~
3 greater pedal travel may be
necess-
• : should always be possible to depress
~3
: _tch and accelerator pedals fully.
• - pedals must be able to return, unhin-
z-z'^z.
to their rest positions,
""•e'efore, the only
foot
mats which may be
are those which leave the pedal area
::—oletely free and which are prevented . " slipping. Brakes
The following points are of particular import
ance
to the safe operation of the brakes.
• New brake linings must also be run in and do not have the optimum
friction
prop
erties during the
first
200 km. The slightly reduced braking effect can be compen
sated for by more pressure on the brake
pedal.
This also applies when new linings have been fitted.
• If the brake pedal travel increases suddenly, it may be
that
one of the two
brake circuits has failed. You can still drive
on to the next Volkswagen dealer but be prepared to use more pressure on the pedal
and allow for longer braking distances on
the way.
• The brake
fluid
level must be checked regularly-see page 105.
The brake warning lamp
will
come on to indi cate
that
the brake
fluid
level is too low (see
also
page 48).
• Brake lining wear depends to a large ex
tent
on the operating conditions and style of driving. On vehicles which are used mainly in
town
traffic
and stop/start conditions or
are driven hard it may be necessary to have
the thickness of the brake linings checked by a Volkswagen dealer in between the in
tervals given in the Service Schedule.
• Change down in good time when driving downhill, in orderto make use of the engine braking effect. This relieves strain on the
brake system. When the brakes are applied do not keep them on con::rjc_s , =" .
and release alternately.
• Under certain operating conditions, *c example after driving through water, a^e' heavy rain or after washing the vehicle the
braking effect may be retarded by wet, or in
winter iced-up brake discs and linings - the brakes must be dried out
first
by applying
the footbrake.
The
full
braking effect may also be delayed when vehicle has been driven for some time
on heavily salted roads
without
using the
brakes,
because the layer of salt on discs
and pads has to be removed
first.
Attention
If a
front
spoiler,
full
size
wheel
trims
etc., is
retrofitted,
it is necessary to
ensure
that
the
flow
of air to the
front
brakes
is not re
stricted
-
otherwise
the
brakes
can
overheat.
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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
Stopping engine
•
Applies to all engines: I*I"en engine has been running fast
•:'
a long time, let it idle for about
2 —inutes so
that
it can
cool
down
:
ghtly before being switched off.
Attention
After the engine has been
stopped
the fan can continue
running for a
while
(up to about 10 minutes)
with
the ignition
switched off. It can also
start
to
run again suddenly
after
a short
time
if
-
the coolant temperature in
creases
due to
heat
build-up
-
when engine is hot and the en gine compartment is heated
additionally by strong
sun
light.
Special
care must therefore be
taken when working in the en gine compartment.
•
Applicable to vehicles
with
cata
lytic converter *:
The
ignition must not be switched off as long as the vehicle is rolling
with
a gear engaged, otherwise, un- burnt fuel can
pass
into the catalytic
converter and cause damage.
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CONTROLS AND EQUIPMENT
2
-
Coolant temperature
—
~~s
gauge starts
to
work
when ignition
is
=
.vitched on,
but it
takes some time before
~e needle reaches
its
final position.
-en ignition
is
switched
on the
warning
c~ip flashes
for a few
seconds
as a
func-
•
:nal check.
5
- Cold
-. Did
high
engine speeds and
do not
work
r-gine
too
hard
yet.
:
- Normal
nen
the
vehicle
is
driven normally
the
~eedle
should settle
down
in
this zone.
-en engine
is
working hard and the ambi-
r~t
temperature
is
high,
the
needle
may
-ove
a
long
way up. This is not serious as long as the
warning lamp does not flash.
Warning lamp
If
the lamp flashes when driving, check first
the indicated coolant temperature.
If the
needle
is in the
normal zone,
top the
coolant
up at the
next
opportunity.
If
the reading
is
in the upper zone, either the
coolant level
is too low or the
coolant tem
perature
is too
high.
Stop,
switch
en
gine off
and
try to
find cause
of
trouble
-
see
page 47.
Notes
•
Additional
lights
in
front
of the cooling air intake interfere
with
the
flow
of cooling air. At
high
ambient
temperatures and
full
throttle
there is a danger that the engine
will
then
overheat.
3
-
Digital clock
*
To
set the
time there
are two
buttons
on
lower left
of
instrument cluster.
The
hours
are
set
with
the
upper button
(h) and the
minutes
with
the
lower one
(min):
•
If
pressed briefly, preferably
with
a ball
pen,
the time changes one hour
or
one min
ute.
•
If
pressed continuously the hours
or
min
utes
change continuously.
With
the minute button the clock can be set exactly
to the
second:
•
Press button until time shown
by
clock
is
one minute before time
to be set.
•
Press button
at the
moment when
the
seconds
indicator
of an
accurate clock
shows a full minute
or
when the time signal
is
heard
on the
radio.
41
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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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DRIVING
TIPS
Driving economically and ecologically
.'arious
factors determine the fuel
con
sumption,
the burden on the environment
and
the wear on the engine, brakes and
lyres.
The personal style of driving
Determines
to a great extent the economi-
:al
aspect and the exhaust and noise
devel
opment:
jOp
Do not
warm
up the
engine
with
W» the
vehicle
stationary.
At idling speed it takes a very long
time
until
the engine becomes operationally
warm. However, in the warm-up phase,
wear and the discharge of pollutants is
oarticularly high. For
this
reason, drive
off immediately the engine has started
and avoid
high
engine speeds.
f
h Avoid
full
throttle
acceleration.
of only is the
fuel
consumption reduced
considerably
if one accelerates
with
feel
ing, but the disturbance to the environ
ment
and the wear are also reduced.
rflri
Do not
drive
with
unnecessarily
high
engine
revs
-
change
up as
soon as possible,
only
change
down
when
the
engine
no
longer
runs
smoothly.
The
fuel
consumption is for example
more
than
twice as
high
in 2nd gear
than
it is in top
gear.
At the same
time,
the re duced engine speed means a reduction
in engine noise.
On vehicles
with
an automatic gearbox
the economy programme should be se
lected.
c^p
Try not to
drive
at
maximum
TO
speed.
The
fuel
consumption, exhaust pollution
and noise increase disproportionately at
high
speeds. If approximately only 3
quarters of top speed is utilised, the
fuel
consumption
will
be reduced by about
half.
Experience has shown
that
the loss in
time
is only marginal.
c
j-,
Drive
as
smoothly
as possible and
look
well
ahead.
Unnecessary
acceleration and braking
must
be paid for
with
higher
fuel
con
sumption and more disturbance to the environment.
Switch
the
engine
off
during
hold-ups. The individual
operating
condi
tions
Naturally
also
affect fuel consumption.
The
following factors for instance are not fa
vourable
to good fuel consumption:
•
High traffic density, particularly large
.towns with numerous traffic lights.
•
Frequent stop/start driving, always restarting and warming up the engine.
•
Driving in heavy, slow moving traffic in
low
gear so that the engine speed is
rela
tively high in relation to the distance cov
ered.
CQ~, One
should,
therefore,
plan
trips
in
advance
and try to
avoid
local
traffic
and
overcrowded
motor
ways.
Obviously
the fuel consumption is
also
af
fected
by factors over which the driver has
no
control. It is for example normal for the
consumption
to increase in the winter or in
arduous
conditions (bad roads, trailer tow ing etc.).
79
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GENERAL MAINTENANCE
Paint damage
Small marks in the paint such as scratches
or stone damage should be touched up im mediately with paint (Volkswagen touch-up
stick or spray can) before the metal starts to rust.
However, should rust be found at any time
it must be removed thoroughly and then the
area treated first with an anti-corrosion primer and then the correct paint applied.
You can of course have this work done by a
Volkswagen dealer.
The number of the original vehicle paint is given on the data sticker (see page 154 ).
Windows
Remove snow and ice from windows and
mirrors with a plastic scraper only. To avoid
scratches due to dirt on the glass, the
scraper should only be pushed in one direc
tion and not moved to and fro.
Traces of rubber, oil, wax, grease or silicone
can be removed with a window cleaning
sol
ution or a silicone remover.
The windows should also be cleaned on the inside at regular intervals. Do not dry the windows with the leather
used for the paintwork because traces of
paint cleaner will cause streaks to appear on
the glass.
To avoid damaging the
heating element
wires
in the rear window do not put
stickers over the wires on the inside.
Door, boot
and
window
weatherstrips
The weatherstrips will remain flexible and last longer if they are rubbed lightly with a
rubber protective compound from time to
time.
This will also stop the weatherstrips
from freezing on in the winter.
Plastic parts
and
leatherette
Exterior plastic parts are cleaned with nor
mal washing and interior parts with a damp
cloth.
If this is not sufficient, these parts and leatherette may only be cleaned with
special solvent-free
plastic cleaners.
Curtains
The curtains may only be cleaned chemi cally. They should not be washed as the.
could shrink, and/or the fire-resistant properties could be washed out.
Upholstery cloth
and
textile
trim
Upholstery cloth and textile trim on doc-
panels, parcel shelves, luggage compart ment covers, headlining etc. must be
cleaned with special cleaners or dry foarr
and a soft brush.
Cleaning seat belts Keep belts clean
because they may nc:
retract properly if very dirty.
Dirty belts can be cleaned by washing with
a mild soap solution without taking the belt; out of the vehicle.
Note
Inertia reel belts should be completely dr.
before they are allowed to roll up.
90
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