weight VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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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

Safety
for
children

Children
under
12
years
of age
should
normally
travel
on the
rear

seat1>(Caravelle,
Kombi,
Double-

cab).
Depending
upon
their
age,
height
and
weight,
they
must
be pro­

tected
with
either
a child
restraint
system
or the
seat
belt
provided.

A
child may also occupy the
front
passenger
seat
if the restraint system used has been

expressly
approved for this purpose by the
manufacturer. One should bear in mind however
that
they are generally safer on the
rear seat.
On no
account
should
children
- or

babies
travel
on an
adult's
lap.
• Babies up to about 9 months old/10 kg are best protected, in an accident,
with
a
safety seat or a special safety carrier.
• Experience has shown
that
babies and
small
children up to about 3 years/18 kg are
best protected in child seats or safety
carriers where they can lie or sit facing the rear of the car.
• Children up to about 7 years of age/25 kg, depending on their height, are safest when

secured
in a child seat or by a safety seat

cushion.
• Children over about 7 years of age may

use
the three point belts or two point belts
provided on the rear seats. It is important to
ensure
that
the diagonal part of the belt
fits

over the centre of the shoulder - and does not
make
contact
with
the
neck.
The
lap part of the belt must pass across the
pel­

vis
and not
over
the child's stomach. If this is not so a safety cushion must be

used
to raise the seating position.
When using the belt the section "Seat belts" should also be noted.
Note the following points when purchasing,
installing and using a child restraint system:
• For safety reasons always use a restraint system which conforms to the international
safety standard ECE R 44. Restraint
sys­

tems
that
can be connected to the seat belts provided in the car are recommended.
• Only use child seats or safety carriers of the type which have a large,
flat
area in
con­

tact
with
the car's seat upholstery. Child
seats
which have feet or tubular frames and no
flat
base can easily penetrate
into
the

car's
upholstery, and are therefore not so
safe.
• We recommend
that
child restraint
sys­

tems from the genuine accessory pro­gramme of the Volkswagen dealers are
used.
Here under the name "Bobsy" re­
straint systems for all age groups are of­

fered21.
These systems
fulfil
all the require­ ments mentioned and over and above this, have been developed and tested by us for

use
in Volkswagen vehicles.
• Special care must be taken if child re­ straint systems are used which are bolted
on at the same point as the belts provided in the vehicle. One must ensure
that
the bolt

is
long enough so
that
the
full
length of the
threaded hole is utilized and tightened to a
torque of 30 Nm
Furthermore, one should ensure
that
the
belt itself cannot become damaged by
sharp edged buckles etc.
• For the
installation
and use, at­
tention
must
be
paid
to the
legal
regulations
and the
instructions
of
the
restraint
system
manufacturer.

Not in all export markets

Observe
any statutory regulations to the
con­

trary.

18
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CONTROLS AND
EQUIPMENT

Seats
in cab

The correct adjustment
of the
seats
is im­
portant
for:

- reaching
the
controls safely and quickly
- relaxed low-fatigue body position
- maximum protection from the seat belts. The
front
seats should
be
adjusted before
putting
on the
seat belt.
After every fore and
aft
adjustment
of the
seat
check,
by
jerking
with
the
body,
that

the retainers are properly engaged.
[B70-160J
Driver and front passenger
seats
To
move seat backwards and for­ wards (1)

Lift
lever and move seat. Then release lever
and move seat
further
so
that
the catch en­
gages.

The driver's seat should be adjusted so
that

the pedals can
be
fully depressed
with
the
legs
slightly angled.

Attention
For
safety reasons the driver's
seat must only be moved back­
wards or forwards when vehicle
is
stationary.
Adjusting
backrest angle (2)

Take
weight
off
backrest and
turn
knob.
The backrest
of
the driver's seat should
be

adjusted
so
that
the top of the
steering
wheel can be reached
with
the arms angled slightly.

Attention
Do
not lower the backrest too far
when on the move because the seat belts are
then
no longer fully
effective.

20
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CONTROLS AND
EQUIPMENT

Luggage
compartment/load
surface

To
enlarge
luggage
space
Lower
backrest and seat as described on
page 23.

Notes
on loading
In the interests of good handling ensure
that

the load (persons and luggage) is distributed evenly. Heavy items should always be car­ried as near to the rear axle as possible or
better still, between the
axles.

The permissible axle and gross
weights must not be exceeded under any circumstances.
Attention
• It should be noted
that
when
transporting heavy items the handling
will
change due to the
displacement of the centre of
gravity. Driving style and speed must be altered to suit.
• The load must be stowed so

that
no items of luggage can fly
forward if brakes are applied suddenly. - If necessary use the lashing
eyes.
• One should ensure
that
the heater el­
ements in the rear window on the Variant
are not damaged by articles rubbing against
them.
• The stale air
escapes
through ventilation openings at the rear. The function of these openings must not be impaired.
Attention
• When vehicle is on the move no persons may be in the luggage
compartment. This includes

children.
Every passenger must
be belted in properly - see page
15.

• Never drive
with
the tailgate or
wing doors not properly closed otherwise exhaust gas can be
drawn
into
the vehicle
interior.
On
vehicles
with
lashing eyes the load
should always be secured to the
eyes.

Each
eye has a tensile strength of 500 kg.
28
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CONTROLS AND
EQUIPMENT

Roof
rack
"en loads are to be carried on the
roof,
the
~: cwing should be noted:
• As the rain channels are moulded
into
~e roof for streamlining reasons, the nor- type of roof rack cannot be
used.
To
izd risks we advise
that
only the cross
:5"s
provided by the factory are
used.

• _hese cross bars are the basis for a com- : e:e roof load carrying system. For safety

pasons
when carrying luggage, bicycles, K-~f boards, skis and boats, the appropriate

::ecial
adapters are required.
- :he components of this system are avail- .-: e
from
Volkswagen dealers. • The roof rack system must be secured
exactly as described in the instructions
supplied.

• Any damage which may occur to the ve­ hicle as a result of using other roof load
carrying systems or by incorrect
fitting
will
not be covered by the Warranty.
• Distribute the load evenly.
Each
cross bar may carry 50 kg if loaded uniformly over
the
full
length. The permissible roof load (in­ cluding the carrier system) of 100 kg and the permissible gross vehicle weight must not
be exceeded - see page 148 . • When carrying heavy or large objects on
the
roof,
bear in mind
that
the vehicle handl­ing changes due to the displacement of the
centre of gravity and the increased area ex­
posed
to the wind. Driving style and speed
must be adapted to allow for this.
75
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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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DRIVING
TIPS

• As the factory installation of a towing bracket includes the modification of the

cooling
system, this should also be done
when service installing a bracket. Other­

wise
overheating may occur when the en­ gine is pulling hard (mountains, high ambi­
ent temperature, heavy trailer loads).

Certain
vehicle versions can be equipped

with
a heavy-duty cooling system ex fac­

tory,
even though the vehicle is delivered

without
a towing bracket. Details can be ob­
tained from Volkswagen dealers.
• Volkswagen dealers have all the
necess­
ary information on the installation of towing
brackets
and the
fitting
of a heavy-duty

cooling
system. The installation should
therefore be done by them.
• If, when towing a trailer for commercial
purposes,
the permissible
total
weight of

vehicle
and trailer - also
with
passenger
cars
- exceeds 3500 kg, it is necessary to in­
stall and use a tachograph in most European

countries.
Operations
instructions

• When inserting the 13 plug
into
the
socket
on the vehicle, the ribbed sleeve on
the plug must be turned fully to the
right.

The
lid of the socket then engages over the
boss
on the
sleeve.

• If the
traffic
behind the trailer cannot be
seen
properly
with
the standard rear view mirrors, additional outside mirrors will be

necessary.
Both outside mirrors must be

fitted
on folding arms and adjusted to give
a
good view to the rear at all times.
• Pitching movements between towing
vehicle
and trailer can be reduced by heavy-
duty springs and shock absorbers on the rear axle. If these springs and shock ab­

sorbers
have not already been
fitted
at the
factory, they can, in many
cases,
be servi­

ce-installed
by a Volkswagen dealer.
• Pitching and snaking movements can
also
be reduced by stabilizers which can be
obtained from and
fitted
by Volkswagen
dealers
in most European countries. • The permissible trailer weight11 - see

page
151 -must not be
exceeded
on any
ac­

count.
• When towing a trailer in mountainous re­
gions,
note
that
the trailer weights given ir
the "Technical data" are only valid for gradi­ ents up to 10 or 12 %. If the trailer weigh'
is
below the permissible maximum a corre­
spondingly steeper gradient can be

climbed.

• The given trailer weights are only appli­
cable
for altitudes up to 1000 m above see
level.
As the engine
output
and thus the
climbing ability drops due to the decreasing
air density, the weight of vehicle and trailer must also be reduced by 10 % for eacr

further
1000 m or part thereof.
1 The permissible vehicle/trailer weight
con­
sists
of the permissible
total
weight of tow­ing vehicle plus the permissible
total
weight
of trailer. If the permissible trailer load is to be
fully utilized it may be necessary to reduce
the weight of the towing vehicle appropriate­ ly. The towing vehicle must however not be
lighter than the trailer.
82
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DRIVING
TIPS

• Where possible make
full
use of the maximum permissible drawbar weight on

call
of the towing bracket - see page 151 -
cut do not exceed it.
• While observing the permissible trailer
and
drawbar weight, distribute the load in
the trailer so
that
heavy objects are as near
as
possible to the axle. The objects must
a
so be secured so
that
they cannot slip
aoout.
• Check the
tyre
pressures on the towing
/ehicle
and the trailer.
• The headlight settings, should be
:hecked
with
trailer attached before mov- ng off and adjusted as necessary.

On
vehicles
with
headlight beam control it

is
only necessary to
turn
the knurled disc in
:ash
in the appropriate direction.
Driving
instructions

To
obtain the best possible handling of ve­
hicle
and trailer, the following should be

noted:

• Try to avoid driving
with
an unladen ve­
hicle
and a loaded trailer. If this cannot be

avoided,
only drive slowly to allow for the unfavourable weight distribution.
• As driving stability of vehicle and trailer
decreases
when the speed increases do not
drive at the maximum permissible top
speed
in unfavourable road, weather or
wind conditions - particularly when going downhill. In any
case
the speed must be reduced im­
mediately the trailer shows the slightest

sign
of snaking. On no account try to stop
the snaking by accelerating.
• For safety reasons one should not drive faster than 80 km/h (50 mph). This also
applies
in countries where higher speeds
are permitted. • Always brake in good time. If the trailer

has
an overrun brake, apply the brakes gen­
tly at
first
then firmly. This will avoid the
jerk­
ing caused by the trailer wheels locking.

Change
down before going down a steep hill so
that
the engine can act as a brake.
• When a long climb in a low gear
with
ex­ tremely high engine revs must be nego­
tiated at exceptionally high ambient tem­peratures the coolant temperature gauge must be observed. When the gauge needle

moves
to the
>~zza'
e~z of :ne
scale,
the road speed must be reduced immediately. If nevertheless ~g amp flashes,
stop immediately and si ow the engine to

cool
off at idling speed for several minutes.
• The cooling effect of the radiator fan
can­
not be increased by changing down, be­

cause
the speec of t~e
~a~
s ~o! dependent
on the engine
speed.
One should therefore not change down even when towing a
trailer as long as :-e e-g -e zar cope with­ out the vehicle speed dropping too much.
83
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DRIVING
TIPS

General
notes

• During the running-in period avoid trailer "owing as much as possible.
• It is advisable to have the vehicle ser-
.ced
between the Inspection intervals if it
s
used frequently for towing a trailer.
• ""he trailer and drawbar load figures on
:re
data plate of the towing bracket are for
:es:
certification only. The correct figures

forthe
vehicle, which may be lower than the
acove
figures, are given in the vehicle docu-

~e~:s
and in this manual.
• The towing bracket increases the un-
535"
weight of the towing vehicle and the

pay-load
must be reduced to correspond. In some countries (for example Germany)
the following additional legal requirements
apply:
• A special warning lamp must be
fitted
within
the driver's range of vision to show

that
the trailer
turn
signals are working.
• The maximum draw bar weight - see
page
151 - must be shown on a clearly
vis­

ible sticker at the rear of the towing vehicle.
• The installation of a towing bracket must
be
passed by a legally approved test centre

and
then proof of installation is entered in
the vehicle documents by the
traffic
author­ ity.
• The maximum speed permissible when towing a trailer is 80 km/h (50 mph).
84
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TECHNICAL
DATA

Weights

Vehicles
with
4
cylinder engines
(Figures for 5
cylinder engine
in
brackets)
Normal
payload
Wheelbase
Permissible Unladen weight
Payload
Permissible
Perm.
Perm.

(in
kg)
in
mm
GVW

(with
driver)
front
axle load rear axle
roof

(in
kg)

load
load2'

Caravelle
2920
2465
(2540)

156511
(1640)11
900
(900)

1350
(1430)
1300

100

3220
2565
(2640)
166511
(1740)1'

900
(900)
1430
(1520)
1300
100

lowered
suspension
2920
2365
(2440)

15651)(1640)1)
800
(800)
1280
(1350)
1200
100

Multivan31
2920
2500
(2540)
17051i(1780)l:'

800
(760)

1350
(1430)
1300

100

lowered
suspension31
2920

2430
(2505)
^os^mo)11
725
(725)
1350
(1430)
1200
100

Kombi
2920

2525
(2590)
15201,(1595)1»
995
(995)
1280
(1350)
1380
100

3320
2565
(2640)
15701'
(1645)1)

995
(995)
1350
(1430)
1380
100

High-roofed
Kombi
3320

2565
(2640)
16201,(1695)11

945
(945)
1350
(1430)

1380

-

Van
2920
2525
(2590)

1520
(1595)
995
(995)
1280
(1350)
1380
100

3320
2565
(2640)
1570
(1645)
995
(995)
1350
(1430)
1380
100

High-roofed
Van
3320

2565
(2640)
1620
(1695)
945
(945)

1350
(1430)
1380

-

Pick-up
2920

2465
(2540)
1470
(1545)

995
(995)
1200
(1280)

1380
50

3320
2525
(2590)
1520
(1595)

995
(995)
1280
(1350)
1380
50

Low
loader
3320

2525
(2590)
1520
(1595)

995
(995)
1280
(1350)
1380

50

Chassis
and cab
2920

2465
(2540)
1315
(1390)

-
1200
(1280)

1380
50

3320
2525
(2590)
1340
(1415)

-
1280
(1350)

1380
50

Double
cab
3320

2515
(2590)
1590
(1665)
925
(925)
1350
(1430)
1460
75

Chassis
with Double
Cab
3320

2515
(2590)
1460
(1535)

-
1350
(1430)

1460
75

Remarks
and
footnotes
- see
page
150
148
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