check engine VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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VEHICLE LITERATURE
In the vehicle wallet you will find, in addition
to this
Instruction
manual,
a Service Schedule and a Service address
list.

Also
depending on vehicle model and equip­ ment there can be various Supplements

(e.g.
for car radio, Multivan or Camper).
If one of these publications appears to be

missing
or you have the impression
that
the
information on some equipment or model
version is not complete, please contact your

Volkswagen
dealer. He will be pleased to help you.

You
can naturally also get in touch direct

with
our Service Department or
with
the Im­ porter in your country. The telephone numbers and addresses are to be found in
the Service address list.
The
Instruction
Manual
should be read carefully as soon as possible
so
that
you get to know your vehicle quickly.

Your
special attention is drawn to the
chapter "Driving tips" in this instruction
manual.
There you will see how you can
drive
safely,
economically
and envi­
ronment
consciously.
For
safety
reasons
please
note
also
the
information
on Accessories,
modifications
and the
renewal
of

parts
on
page
117.
The other chapters are of course also im­ portant because the correct operation of the
vehicle serves - in addition to regular care
and maintenance - to maintain the value of
the vehicle and is, in many
cases,
also one of the stipulations for upholding warranty

claims.

At the end of this manual we have made a list of the checks which you should carry out
regularly to keep your vehicle roadworthy at
all times.
The Service Schedule
contains
- identification data for your car - the Service intervals
- the Service operations
- important details about Warranty
Service
work which has been carried out is

also
confirmed in the Service
Schedule.
This

can
be important when a claim is made under Warranty.

Your
should always present the Service
Schedule
when taking the vehicle to
a
Volks­
wagen dealer.
The Service address
list

contains
- addresses and telephone numbers of
Volkswagen
dealers in Europe and over­
seas.

- important information on the Volks­ wagen dealer emergency services
Notes
on the
layout
of
this
Manual:

It describes the largest possible range of
equipment envisaged at the time of going to

press.
Some of the equipment may be avail­
able later on or not at all or will not be offered in certain Export markets.

Items
of equipment marked
with
a * are
only standard on certain model versions or
are only available as optional extras on cer­
tain models.
All blocks of
text
which
have
this

colour
backing
and the
title
"At­

tention"
refer
to
potential
acci­
dent
or
injury
risks.

Texts
following
this
symbol
and

printed
in
italics
are
important

notes
on
environmental
protection.

One
final
request:

When you sell your car please give the com­ plete Vehicle Wallet to the new owner be­

cause
the vehicle literature belongs to the

vehicle.

2
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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

Wing
doors*

Righthand
door

From
outside
the wing door can be rcked and unlocked with the key. When un-
;cking the locking knob goes up, when
:eking it goes down.

From
inside
the door is locked by pressing down the knob.

-s
long as the knob is pressed down the

;3or
cannot be opened from inside or out.
- the fully open position (approx. 90°) the
;cor is held by a check strap.
Lefthand
door

The lefthand door can be opened when the righthand door is open.
To open, pull release lever (see illustration) and open door.

Note

When
closing
the
wing
doors
always
ensure
that
the
left
door
is
closed

first.
Unhooking
door
check
strap

Both doors are held in the open position (ap­
prox. 90°) by check straps.
To open the doors further the check strap can be unhooked (see illustration).
When doors are closed the check straps en­ gage again automatically.
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Mirrors

CONTROLS
AND
EQUIPMENT

dow open.
Adjusting mirrors

The rear view mirrors should always
be
ad­
justed properly before moving
off so
that
good vision
to the
rear
is
obtained.

Anti-dazzle
inside
mirror

The lever
on the
lower edge
of the
mirror should
be
pointing forwards when
the
basic

setting
is
made.

To
set the
anti-dazzle position, pull lever
to

the rear.

Outside mirror

The outside mirror should
be
adjusted
so

that
the side
of
your own vehicle can
just
be
seen.
This setting ensures the best possible
field
of
view, and
in
addition
it
serves
as an
instant check
on the
mirror setting.

Normal outside mirrors
are
adjusted
by

pressing
the
edge
of the
mirror surface
in

the mirror housing. / R
/
(B707T76]

Electrically
adjustable
mirrors* are

set
by
moving
the
knob
in the
driver's door
trim.
Turning
the
knob from
L to
R switches
con­

trol
from
left
to
right
mirror.

If the
electrical control
of the
mirror fails
at

any time
the
mirrors can
be
adjusted man­ ually
by
pressing
on the
edge
of the
mirror

surface.

13
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Seat
belts

CONTROLS AND EQUIPMENT
It has
been
proven
that
seat
belts

give
good
protection
in accidents. In

most
countries
therefore
the
wear­
ing of
seat
belts
is
required
by law.

Attention

The
belts
should be put on
before
every
journey
-
even
in
town

traffic.
This
applies
also to the
rear
seats.

Pregnant
women
too should al­

ways
wear
a
seat
belt.

The
routing
of the
belt
is of
major
importance
to the
protective
ef­

fect
of the
belt.
How the
belt

should be
worn
is described on
the
next
pages.
General
notes

• The
belt
must
not be
twisted.

• Two persons
(including
children)
must never be secured
with
one belt. It is
particularly dangerous to put the belt round

a
child sitting on a persons lap.
• The belt should not be worn over hard or
breakable
articles (glasses, ball pens, key
rings,
pipes, etc.) because this can cause in­

jury
to the body.
•
Loose,
bulky clothing (e.g. overcoats
over
jackets) affects the fit and function of
the belts.
• The belt must not be jammed anywhere or rub on any sharp edges.
• The lock tongue may only be inserted into the lock part belonging to the appropri­
ate seat otherwise, the protective effect is
impaired.
• The slot for the belt tongue rr„s: -;: ze

blocked
with
paper or anyth'-c s ~
otherwise the tongue cannot 5"a;e properly.
• The belts must be kept clean otherwise the retractors may not work properly (see
also
"Care
of car" section).
• Seat belts which have become damagec or have been stressed in an accident and stretched must be renewed - preferably by

a
Volkswagen dealer. The anchorages

should
also be checked.
• In some export countries seat belts
could
be used on which the functions differ
from those described on the next pages.
• On the Delivery Van there are no belt an­
chorage
points in the load compartment.

-DW
children can be carried safely in the ve- " cle is explained on page 18.
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CONTROLS AND EQUIPMENT

Three-point
inertia
reel
belts

The
inertia reel belt gives complete freedom
of movement when pulled slowly. Sudden braking however will cause the belt to lock.

The
mechanism will also lock the belt when
accelerating,
driving down steep gradients
or cornering.

Putting
belt
on
Pull
the tongue slowly and smoothly across
the chest and hips and push it into the lock part
fitted
on the seat until the tongue en­

gages
audibly (pull to check).
The shoulder
part
of
belt
must
run
roughly
across the
centre
of the
shoulder as
shown
- on no account

against
the
neck
- and be
firmly
in
contact
with
the body.
The backrests of the
front
seats
must
not be inclined too far to the
rear,
otherwise
the
belts
are no

longer
fully
effective.
With the aid of the
belt
height
adjust­

ment
the routing of the
front
seat shoulder
belt can be set to fit the body properly.
• To adjust, push button
with
relay
fitting
(see
right
illustration) up or down so
that
the

shoulder
part of belt runs roughly across the centre of the shoulder as shown on the
left

- on no account
against
the neck.
• After adjusting, pull the belt
with
a
jerk
to
ensure
that
the relay
fitting
is properly en­

gaged.

16
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CONTROLS AND EQUIPMENT
The lap part of belt must always fit tightly across the pelvis. If necess­
ary,
pull the belt tight.
Particularly in the case of pregnant

women,
the lap part of the belt should be as low across the pelvis as
possible so that no pressure is ex­
erted on the abdomen.
Taking belt off
K release the belt, press the orange-co- :_red button in the lock. The tongue will
"en spring out.
-ass the tongue towards the door by hand
so that the retractor can roll the belt up
oroperly. A plastic knob in the belt holds the
:ongue in a convenient position.
Lap belt
The belt lock is used in the same way as on the three-point inertia reel belts.
The belt must always fit tightly across the pelvis.
For safety reasons a lap belt not being used
should always be connected to the buckle. To lengthen belt hold the tongue at right
angles to belt and pull belt through to the re­
quired length - see illustration.
The belt is easier to adjust if tongue and cap are pressed together.
To shorten belt it is only necessary to pull
the free end of belt.
The surplus belt length is taken up by mov­ ing the plastic slide. Automatic retracting lap
beits

The single seats* in the ca;;e-;e'
;im­
pertinent are equipped with =- —5; ;
retracting lap belt.
Putting belt on
Pull the belt out and insert the tors_e ~:
the appropriate lock part until tongue en­ gages (pull to check).
The belt must always fit tightly across the pelvis, if necessary,
pull

the belt tight.
Note
If the belt is pulled too tight, it can
be released by pressing in the
but­

ton located on the belt reel.
Taking belt off
Press the orange-coloured button in the
lock part and guide belt by hand sc :na: :~s
retractor can roll the belt up properly.
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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

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

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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