VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE

Gearbox
oil
Specifications

Manual
gearbox
and
final
drive

•
Gear
oil,
API-GL
4, SAE 80 or
•
Gear
oil, G 50, SAE 75 W-90

Automatic
gearbox

• Final drive:
Gear
oil, G 50, SAE 75 W-90 I Gearbox part: ATF Dexron®
Checking oil
level
rVith
a
manual
gearbox
and
final

drive
the oil level does not need checking.
'.ith the
automatic
gearbox
the oil

•e.
el in the final drive does not need check- *g either.

"he
ATF
level
in
gearbox
part
must ": .'/ever be checked in between the inter-

•BS
given in Service Schedule. To do this
ire vehicle must be standing on a level sur-
fe:e.
The
level must only be checked when
He ATF is
warm.
(Approximately 10 km

Irrer
starting from
cold,
the ATF has re­
tted the required temperature.) If fluid is
l:: :: or too hot the reading will be incorrect.
1
he engine must be running at idling
speed,

the handbrake must be applied and the se­ lector lever at "N".

To
check, pull dipstick (see Fig.) out, wipe
with a clean lint-free rag and then insert it
fully
again.

Pull
the dipstick out and check ATF
level.

When
the ATF is
warm
the
level
must
be
between
the two
marks
- other­

wise
the vehicle must be taken to a
Volks­
wagen
dealer without delay so that they can
find the reason for the incorrect
level.
It is not sufficient to merely top up or drain off

ATF.
Changing oil

For
the manual
gearbox
with
final

drive
the oil does not need changing.
For the
automatic
gearbox
the :
the final drive does not need
chariC-g

either. The ATF in gearbox part must how­

ever
be changed at the intervals given in
Service
Schedule.
Because of the disposal
prob­

lems,
the
special
tools
necessary
and the
specialist
knowledge
re­
quired,
the ATF
changing
should

preferably
be
done
by a
Volkswagen
dealer.

Notes

•
When
there
is no
lubricant
in the
manual
or
automatic
gearbox,
the

engine
must
not be
started
and the
vehicle may only be
towed
with
the

driving
wheels
lifted.

• No
additives
may be
mixed
with
the lubricants.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE
Air
cleaner
Power
assisted
steering

The
paper
filter
element in the air cleaner is normally renewed as detailed in the Service

Schedule.
In very dusty conditions the el­
ement must be cleaned or renewed at
shorter intervals.
To clean or
renew
element

•
Release
clip (1 ) •
Press
locking handle ( 2 ) down and un­ hook it.
• Take
filter
housing out upwards.
• Take
filter
element out. •
Clean
element
with
compressed air or renew it.

The
element must not be washed
with
pet­ rol or moistened
with
oil.
Installing

• Insert
filter
housing. Ensure
that
the
plastic
lug on the rearend of the elementfits
in the recess in the mounting.
• Secure clip (1 ).
• Pull locking handle ( 2 ) up until it en­
gages.

The
reservoir is located in the engine com­partment on the
right
looking forward.

The
power assisted steering is filled
with
our hydraulic oil G 002 000.

The
correct oil level in the reservoir is
essen­

tial for the satisfactory operation of the power assisted steering.

The
level can only be checked
with
the en­ gine at normal operating temperature but not running.
100
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE
nere are two marks
with
which the oil level
:an be
checked.

• Outside on container (Fig.) • Inside on dipstick attached to the cap. ~he oil level should always be between the
MAX."
and "MIN" marks. When the level

"as
dropped down below the "MIN" mark

:^e
power assisted steering should be
:necked
at a Volkswagen dealer. It is not
sufficient merely to top up
with
hydraulic oil.

Note
f the power assisted steering fails at any
: me or when engine is not running (vehicle on tow) the vehicle remains fully steerable cut more force must be used to
turn
the
steering wheel. Cooling
system

Under
normal conditions the cooling
sys­

tem is almost maintenance-free.
The vehicle is
fitted
with
a hinged radiator
which can be folded forward when required
- see page 104.
The cooling system is filled at the factory
with
a permanent coolant which is not

changed.
The coolant consists of water and

a
40 % concentration of our coolant additive
G
11 V8B (anti-freeze on glycol basis
with

anti-corrosion additives). This mixture not
only gives the necessary frost protection
down to -25 degrees C but also protects the
alloy parts in the cooling system against cor­
rosion.
In addition it prevents scaling and ra­
ises
the boiling point of the coolant.
The concentration of the coolant therefore must not be reduced in the summer or in
warm countries, by topping up
with
plain
water. The
coolant
additive
propor­

tion
must
be at
least
40 %.
If greater protection against frost is re­
quired, the proportion of G 11 V8B additive

can
be increased, but only up to 60 % other­
wise the anti-freeze protection is reduced
and furthermore the cooling effect is im­
paired.
Vehicles
for export to cold countries -s~a .
have frost protection down to -35 decrees

C.

Only
our G 11 V8B or an additive v/rs :~e

specification
TL-VW 774 B (markea or
container) should be added to the coolant.
The additives can be obtained from
Volks­

wagen dealers.

Other
additives
can be
very
detri­

mental
to the
anti-corrosion
effect
in
particular.

The
subsequent
corrosion
damage
can
lead
to
coolant
loss
resulting
in

major
engine
damage.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
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
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE

"=
lot
of
coolant has been lost, only add cold
:_:olant after
the
engine has cooled down.

~~
is
will prevent engine damage.
Do
not
fill
above the MAX. mark.

~~e
excess
coolant will
be
forced
out

"rough
the
pressure relief valve
in the
cap .-.nen engine becomes
hot.

Screw
cap on again tightly. Attention
The coolant additive and the coolant are a danger to health.
The additive must therefore only be stored in the original
con­

tainer
well
out of reach of
children.
If the coolant has to be
drained at any
time
it must be
caught and also stored in a safe
place.

Drained
coolant
should
not nor-
W*
mally
be
reused,
it
must
be
dis­
posed
of,
bearing
in
mind
environ­
mental
protection
regulations.
Fan
The radiator
fan is
driven electrically
and
controlled by a thermoswitch from the
cool­

ant temperature (also from the engine
com­
partment temperature on some models).

Attention
After the engine has been
switched off the fan can
con­

tinue running for a
while
(up to
about 10 minutes)
with
the igni­
tion off. It can also
start
to run
again suddenly
after
a short time, if the coolant temperature in­

creases
due to
heat
build-up.

Special
care must therefore be
taken when working in the en­ gine compartment. Notes

•
If
the fan is not running although the
cool­
ant temperature
is
very high,
the rse

should
be
checked
and if
necessary
re­
newed
-
see page 122.
• The speed
of
the fan does not depeno
or
engine
speed.
The
cooling effect cannot
therefore
be
increased
by
changing down.

As
long as
the
engine runs smoothly and
a
gradient can
be
taken
without
a
large drop in speed
it
is not necessary to change down.

Driving in
winter

To
ensure
that
the
frost protection
is ad­
equate, the coolant concentration should be

checked
and
if
necessary corrected, before
the cold
season
begins.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE

Moving
radiator
forwards
For certain operations in the engine
com­

partment e.g. changing plugs or to reach the
V-belt it may be necessary to move the
radi­
ator forwards.
To do this
first
remove the four securing
screws
(left
illustration).
Then
lift the radiator and move it forward.
When work in the engine compartment is
finished the radiator must be moved back to
the normal position and secured with the screws.
Brake
fluid

The brake fluid reservoir is in the engine compartment.

Note
On
vehicles with righthand drive the reser­
voir is on the other side of the engine
com­
partment.
104
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE
'necking fluid level
Pe :orrect fluid level is essential to the sat-
:~=
:tory operation of the brake system. The
fc. Z level must always be between the
AX"
and "MIN" marks.
~- a "evel of fluid tends to sink slightly when
"a vehicle is used due to the automatic ad- ::ment of brake linings. This is quite nor-
-rwever, if the level sinks noticeably in a
srorttime or drops below the "MIN" mark
re system may be leaking. A low fluid level " the reservoir is indicated by the brake
w.arning lamp lighting up (see page 48 also), .nen this happens take car to a Volks­
wagen dealer immediately and have the
cake system checked. Renewing brake fluid
Brake fluid absorbs moisture. In the course
of time it takes in water from the ambient
air. Too high a content of water in the brake
fluid can in time cause corrosion damage in
the system. Furthermore the boiling point of
the brake fluid is reduced considerably. For
this reason the brake fluid must be renewed every two years.
Attention
When the brake fluid becomes
too old vapour bubbles can form in the brake system when the
brakes are used hard. The
effi­

ciency of the brakes and thus the
vehicle safety is then seriously

affected.
Only use our genuine brake fluio (see: - ra­
tion to US standard FMVSS 116 DO~-
.
~-e
fluid must be new.
Attention Brake fluid is poisonous!
It must therefore only be stored in the closed original container
out of reach of children.
Remember also that brake fluid will
attack the paintwork. Because of the disposal
prob­

lems,
the special tools necessary
and the specialist knowledge re­
quired,
the brake fluid changing
should preferably be done by a
Volk­
swagen
dealer.

It is advisable to have the fluid change car­
ried out during an Inspection Service.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE

Battery

The
battery is in the engine compartment on
the left looking forward. It can be
reached

when
the lid of the battery box is
removed.
2nd
battery*

The
2nd battery is located under the left
seat.

To
reach
it the
seat
must be
pushed
fully for­

ward
past the stop. The stop must be
freed.

To
do this - see page 21. Attention

•
Battery
acid is corrosive and must not get
into
the eyes or onto
skin and clothing.

Any
acid splashes must be
washed off thoroughly
with

water.
If necessary see a doctor.

•
Never short the
battery
ter­
minals (e.g.
with
tools) as this

causes
the
battery
to
heat
up
very quickly and it may burst.

•
To prevent any possibility of
short circuiting, detach
battery

earth
cable before doing any

work
on the electrical system.
When changing a bulb, it is suffi­cient to switch off the lamp
con­

cerned.

•
When disconnecting the
bat­

tery
from the vehicle electrical system
first
disconnect the nega­

tive
cable and
then
the positive cable.
The
battery
must not be discon­ nected
with
the engine running,
as this
will
damage the electrical
system (electronic components).
•
When reconnecting the
bat­

tery
connect the positive cable
first
and
then
the negative cable.
The connecting cables must on no account be interchanged - can

cause
wiring
to burn out.

Starting
by
connecting
an additional battery

is
described
in the Do-it-yourself
section.

Checking
acid level In normal operating conditions the battery

requires
hardly any maintenance. At high

ambient
temperatures however it is
advis­
able
to
check
the
acid
level at regular inter­

vals.
It should always be between the MIN
and
MAX marks on the battery. If the
acid
level
drops below the MIN mark, the af­

fected
cells
must be topped-up to the MAX
mark
with distiled water.
It is recommended that the
acid
level is

checked
and corrected by a
Volkswager

dealer.

106
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE

Winter
driving
A/inter weather
is
particularly hard
on the

cattery. Furthermore at low temperatures
it

has
only a part
of
the capacity
it
has
at
nor­ mal temperatures.
We
recommend there-
-'ore
that
the battery should be checked pre­
ferably
by a
Volkswagen dealer before
the

onset
of
cold weather
and
charged
if
"ecessary.
At
the same time,
if
necessary,
the terminals will
be
cleaned
and
special
grease
applied. This will
not
only result
in
quicker, more reliable starting but will help
:o prolong the life
of
the battery.

If the
vehicle
is not
driven
for
sev­

eral
weeks
when
temperatures
are

very
low, the
battery
should
be

taken
out
and
stored
in a
frost-free
room, so
that
it
cannot
freeze
up and
become damaged.

Attention
Store
the
battery
out of
reach
of

children.

To
take battery out,
first
disconnect the two
cables
(see previous page) and then remove
-etainer.
Charging
battery

When
charging
with
a low current (e.g.
with

a
small charger) the battery cables need not normally be taken off. The instructions from
the charger manufacturer must however be
noted.

Before
Quick charging,
that
is
charging

with
a
high current, both battery cables must be disconnected
-
see previous page.

The
following information must be noted:
• When charging
the
battery
do not re­
move
caps.

•
A
discharged battery can freeze
at - 10
degrees
C. It is
essential
to
thaw
out a

frozen battery before
it is
given
a
quick
charge
otherwise
it
may explode!
• The mains cable
of the
charger should not be connected until after the clips
of
the

charger
have been properly secured
to the

battery terminals:

Red
=
plus
(or
positive)

Black
=
minus
(or
negative)
• Reconnect cables correctly after charg­ ing battery.
Attention

The
gas
given
off
during
the

charging process
is
highly
in­

flammable
so
keep
sources
of
ignition
(naked
flames,
burning

cigarettes
etc.)
well
away
from

the
battery.

Renewing
a battery If the
battery has
to be
renewed,
the
new
battery must have the same capacity, volt­

age
(12 Volts), current capacity and shape.

Volkswagen
dealers have
a
range
of
suit­

able
batteries.
Because
of the
problem
of
dis­

posing
of
the
old
battery
the re­

newal
of
a
battery
should
preferably

be
done
by a
Volkswagen
dealer.

Batteries
contain,
amongst
other
things,
sulphuric
acid
and
lead
and

must
on no
account
be put
with
nor­

mal
household
waste.

107
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE
Windscreen
washer
system
"he fluid container is on the
right
of the en­ gine compartment. The container holds
about 5 litres, on vehicles
with
headlight
washer
system* about 7 litres.

The
rear window washer is supplied
with
fluid from the container in the engine com-oartment. Filling the
container

Pull
the cap off and
fill
container to the brim

with
washer fluid.
Press
cap on
tightly
again,
then switch on ignition and check
operation of washer system.
It is advisable to add a window cleaning
sol­

ution
with
a wax remover
(with
anti-freeze
additive in winter) to the water because plain water is not usually sufficient to clean
the glass and headlight lenses quickly and
thoroughly. The mixing ratios on the win­ dow cleaner packaging must be adhered to.

Even
when
heated
windscreen

washer
jets*
are fitted, a window clean­ ing solution containing anti-freeze should

be
added to the water in the winter.

Note

If at any time no window cleaning solution

with
anti-freeze additive is available, methylated spirits can be
used.
Do not,
under any circumstances, add engine
cool­

ing system fluid or other additives.
Adjusting
washer
jets

When
the vehicle is stationary, the water
should
hit the windscreen approximately as

shown.

The
jet for the rear window washer is in the
wiper shaft. The water jet should hit the
glass
in the centre of the wiped area.

The
jets can be adjusted
with
a needle.

The
jets for the
headlight
washer
sys­
tem*
can only be adjusted
with
a specia

tool.
When adjustment is necessary,
con­

tact your Volkswagen dealer.
:=
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans