VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Service Manual

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

Downloaded from www.Manualslib.com manuals search engine
CONTROLS AND EQUIPMENT
Instruments
The arrangement of the instruments de­ pends on the model concerned and the en­
gine fitted. 70 - 126

1-
Speedometer 40

2-
Coolant temperature 41
3- Digital clock* 41 or multi-function indicator* 42

4-
Fuel gauge 46 5- Rev counter* 46 or analog clock 46 1 - Speedometer
During the running-in period the instruc­
tions on page 76 should be noted.
Mileage recorder
The upper counter registers the total dis­
tance driven and the lower one the short

trips.

The last figure of the lower counter
indi­
cates 100 m or Vio mile.
The trip recorder can be set back to zero by pressing the knob in the speedometer
dial.

40
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

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

Downloaded from www.Manualslib.com manuals search engine
CONTROLS
AND
EQUIPMENT

3
-
Multi
function
indicator
* In addition to the time display, the multi­
function indicator (MFI) gives a whole range of additional information:
• Driving time
• Average fuel consumption
• Distance driven
• Average speed
• Engine oil temperature
• Ambient temperature With the exception of the time, the symbol for the function switched on appears at the upper edge of the display (in illustration the

average
fuel consumption is shown).
A
B

|B33-
695

By
repeatedly pressing button B in the wind­

screen
wiper lever
with
the ignition
switched on, the additional information is

displayed,
starting
with
the time.
If the button B is pressed for longer than 1

sec,
the function being displayed at
that

time will change over automatically to the time display. The
memories

The
system is equipped
with
two automatic

memories:

A
single
journey
memory
collects the
following data from the time the ignition is switched on to when it is switched off. Driv­ing time, distance covered and fuel
used.
From
this data the average driving speed

and
the average consumption is worked
out.
If the journey is resumed within two hours
of switching off the ignition, the new figures
are automatically included in the calculation. If the journey is interrupted for more than
two hours, the stored information is auto­ matically
erased.

A
total
journey
memory
stores the data
from any number of individual journeys up
to a total of 100 hours driving time, a dis­
tance of 10000 km (6214 miles) and 1000 litres (220 gallons) of fuel consumed. This

data
is only used to work out the consump­
tion and speed averages for all the individual
journeys.
If one of the given figures is exceeded, the
memory is erased and calculation starts
from the beginning again. Contrary to the
single
journey memory, this memory is not

erased
after a journey pause of more than
two hours.
42
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS AND EQUIPMENT
call up the data the memories are se-
r ::ed by means of the switch A in the wiper
- Single journey memory
'- - Total journey memory

_~e
"allowing data can be obtained from the ~ r~iories:
• Driving time • -verage fuel consumption
• Distance driven
• -verage speed
E-asing the
memories
:~ the ignition switched on, both mem-
: es can be erased separately in each
: :ch position by pressing switch A : --sed the appropriate detent position to 0
::; tion for longer than one
second.

" :~.e battery is disconnected for any rea-
::" the stored information is automatically

Ksed.
The displays

When
the ignition is switched on
"MF11"
or
"MFI 2" appears in the display according to
which memory is switched on.
No symbol -
Time

The
time is shown even when the ignition is switched off.

The
time can be set
with
the buttons (h and min) on the lower
left
of instrument cluster
- see "Digital
Clock"
page 41.
—'— -
Driving
time

In
switch
position 1 the driving time
which has elapsed since ignition was
switched on or the memory cancelled is indicated - see previous page also "Single
journey memory".
In
switch
position 2 the total driving
time for all individual journeys is indicated -
see
previous page also "Total journey mem­
ory".

The
maximum time in both switch positions
is
99 hours 59 minutes. When this figure is

exceeded
the indication starts at zero again. MPG
(1/100
km) -
Average

fuel
consumption

The
average consumption is indicated not
the actual consumption at the time of read­
ing.

The
average fuel consumption is indicated,
after switching on the ignition or erasing the memory being
used,
after a distance of
about 100 metres. Up to this point a dash

appears
instead of a figure. When vehicle is moving the indicated value is up-dated
every 5
seconds.

In
switch
position 1 the average
con­

sumption for the single journey is indicated.
In
switch
position 2 the average
con­

sumption indicated is
that
obtained during

all
single journeys - see "Total journey memory" on previous page
also.

Note

The
amount of fuel used is not indicated.

43
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS AND
EQUIPMENT

Miles
(km) - Distance covered
_ne remarks made under "Driving time" also apply in principle to "Distance cov­
ered".
The maximum distance indicated is
9999 km or 6214 miles.
MPH
(km/h)
- Average speed
The remarks made under "Average fuel consumption" also apply here in principle.

cfer-
°C _ Engine oil temperature
Oil temperatures (within a range of + 50 de­
grees C and + 160 degrees C) are shown.
When no oil temperature indication is
shown,
the engine is still not warm, and it
should not therefore be worked hard. The engine speed should be reduced if the oil
temperature rises to + 145 degrees C. of* -• -

«>*
'i* - Ambient temperature
The measuring range is from - 40 degrees
C to + 50 degrees C..
When the vehicle is stationary or only moving very slowly, the indicated tempera­
ture could be slightly higher than the actual ambient temperature due to heat radiation
from the engine or use of the auxiliary heater.
Attention If the ambient temperature read­
ing is used as an ice warning, re­
member that ice can form on the road at temperatures above 0 C.
Note Both temperatures are momentary values.
They are not stored in the memory.
44
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS
AND
EQUIPMENT

~5chograph* i ----. European countries the installation of a tachograph is obligatory for the

:
ng vehicles:

.
ehicles used for the commercial trans-

zort
of goods
with
a permissible total .-.eight including trailer or articulated

"3
ler of more than 3.5 tons. It is imma­
terial whether the vehicle and the trailer
"
only
one of the two is used for com­
mercial goods transport.

1
.ehicles which according to their de-
s
gn and equipment are suitable for and "tended to carry more than 9 persons

ncluding
the driver.
Z M= s of the regulations can be obtained
i: - ocal vehicle licensing authorities.
operation of the tachograph is de-

::-
;sd in a special leaflet from the tacho-

ra;~
manufacturers.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS
AND EQUIPMENT

4
-
Fuel gauge
^u

This gauge works
when
ignition
is
switched on
but it
takes some time for
the
needle
to
reach
its
final
position.

The tank holds about
80
litres.

When
the needle reaches the start of the
re­
serve
zone
(arrow)
there is about 10 litres
(2

gallons)
of
fuel left
in the
tank. 5
-
Analog clock
To
set the
time press
the
button
on
lower
right
in
combi instrument:
•
If
pressed briefly, preferably with
a
ball
pen,
the
time
is
advanced
one
minute.
•
If
pressed continuously the minute hand goes faster and
at
the same time
the
hours
are
set as
well.

With
the button the clock can
be set
exactly to
the
second:
•
Press
button until time is one minute be­ fore 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. 5
-
Rev counter
*

The
rev
counter needle must not move into
the
red
zone
of the
scale
on any
account.
The additional
red
dotted zone before
the
red zone
on the
scale which some models

have
shows
the
maximum engine speed

permitted
briefly
e.g.
when
overtaking

when
engine
has
been run in and
is
warm
-
see page
76
also.
It is
advisable
to
change up
or
reduce engine speed
at the
latest
by

the time
the
needle reaches this
zone..

rijp
Changing
up in good time helps
<-^>
to
save
fuel and keeps the noise

down.

Change down
to
the next lower gear before
the engine
no
longer runs smoothly.
The green or green shaded area on the scale shows the speed
at
which
the
engine
is de­

veloping
its
most favourable torque
and is

working
most economically. Drive
as
often as possible with needle
in
this area.

During
the
running-in
period,
high engine

revs
should
be
avoided.
46
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
CONTROLS
AND
EQUIPMENT

Warning
lamps

~ne layout of the warning lamps depends on
:ne model and the engine fitted. The sym-
: ols shown here are also on the actual warn-ng lamps.
|- Coolant temperature/ coolant level 47
1- Engine oil pressure 47
I- High beams 48
-- Turn signals 48

5-
Brake system 48
V Alternator 49
" Glow plugs 49 Coolant
temperature/

Coolant level1'

This
lamp flashes for a few seconds as a
functional check when ignition is switched
on.

If the lamp does not go out afterwards or

flashes
when driving, either the coolant
temperature is too high orthe coolant level1'
too low:
Stop,
switch
engine
off and check

level.
Add coolant if necessary.
11 Only on vehicles
with
automatic coolant level monitor(see page 102).
Attention

• Be
careful
when
opening the

coolant
expansion
tank!
When
the
engine
is hot the cooling
sys­

tem is
under
pressure -
Danger
of scalding!
Therefore
let
engine
cool
down
before
unscrewing

the cap.
• Do not
touch
the fan. The fan can
switch
on suddenly -
even

when
ignition
is
switched
off.

For
further details see pages 102 and 103.
If the coolant level is in order the trouble
may be due to failure of the radiator fan.

Check
radiator fan fuse and renew if
necessary-seepage
122.
If the warning lamp does not go out al­
though coolant level and fan fuse are in order, do not
drive
on - call in expert as­

sistance.

If the trouble is only caused by the fan and

assuming
coolant level is in order and tem­ perature warning lamp is out - one can drive
on to the nearest Volkswagen dealer. In
order to make good use of the air stream for

cooling,
do not let engine idle or drive very
slowly.
2 - Engine oil pressure -7
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

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