VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Repair Manual

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CONTROLS
AND
EQUIPMENT

Heating
interior
quickly

I Move upper lever to . I Move lower lever fully to the
right.

I Set blower switch to E3 .
I
Close
centre outlets.
I Direct side outlets towards side win-

5:
.vs.

•(eating
interior
comfortably

I Move upper lever to SSi (comfort set­ 's) or to CS depending on where you
• : jId like the air flow to be.
I Set air temperature as desired
with

: .ver lever.
I Set blower switch to stage 1 or 2.
I Adjust side and centre outlets as re-
:. 'ed. At low ambient temperatures it is
cvisable
to close the centre outlets and di-
ect flow from side outlets towards the side
I ndows. Fresh air
operation

• Move upper lever to
EH
.
• Set air temperature as desired
with
lower lever.
• Set blower switch to desired stage.
• Adjust side and centre outlets as re­
quired.

Maximum
cooling
•
Close
all windows. • Move upper lever to •
• Move lower lever fully to
left
or set as re­
quired.

• Set blower switch to stage 4.
• Adjust side and centre outlets as re­
quired.
However, at least one
outlet
mustal-

ways
be open otherwise the cooling
sys­

tem may ice up.
With this setting the air is drawn from inside
the vehicle and cooled (recirculating air operation).
Normal
cooling
• Move upper lever to EM or
ESS*
.
• Set air temperature as desired .-. :~ lower lever.
• Set blower to stage 1 - 4 as desired.
• Adjust side and centre outlets as re­
quired.
In position EM at least one
outlet
must always be open otherwise the cooling

system
may ice up.
With this setting ambient air is drawn in and
cooled.
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CONTROLS
AND
EQUIPMENT

Notes

Pools of
water
under
the
vehicle

• When the ambient temperature is high
and
the air very humid, condensed water

can
drip off the evaporator and form a puddle under the vehicle. This is quite nor­

mal
and does not indicate a leak.

Operating
faults

• Should the air conditioner not work at
any
time, either:
- the ambient temperature is below about + 5 degrees C,
- the fuse has blown.

Check
fuse and if necessary renew it - see

page
122. If the trouble is not due to
a
defec­
tive fuse, switch the system off and have it
checked.

- the air conditioner has switched off due to the coolant temperature being too high -
see
page 41
also.

• If the cooling
output
drops off, switch the
A/C
off and have the system
checked.
Using air
conditioner

economically
In cooling operation the air conditioner
com­

pressor
places demands on the engine and
therefore influences the fuel consumption.

To
keep the period switched on as short as
possible,
the following points should be

noted:

• If the inside temperature is very high after the vehicle has been parked in the sun, it is recommended to open doors or win­

dows
briefly to enable the hot air to
escape.

• The air conditioner should not be
switched
on during a journey if the windows

or
sliding/tilting
roof*
are open.
• If the desired interior temperature can be attained
without
switching on the air condi­
tioner, the fresh air operation should be se­
lected.
Recirculating
air
switch

If badly contaminated air is to be prevented
from entering the vehicle, e.g. when driving
through a tunnel, the recirculating air switch in the instrument panel can be
pressed.

When
the recirculating air system is
switched
on, a small warning lamp lights up in the switch.

However,
the recirculating air system

should
only be used for a short period other­

wise
the windows will mist up.

60
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CONTROLS AND
EQUIPMENT

Air conditioner* in passenger compartment Recirculating air switch*
th the air conditioner in the passenger
:: apartment the rear seating area can also
:e comfortably cooled down.
air conditioner only functions if the air
:: iditioner in the cab is switched on - see
:;ge 57. However, adjustment of the out-
: can be performed independent of the
I stem in the cab. The control elements are : rated on the dash panel - see illustration.
air throughput can be set in any one of
;: J stages (left hand rotary switch).
Th e temperature infinitely variable with the ::ary control (right hand switch).
I Dckwise - increased cooling output
--ti-clockwise - decreased cooling output Air outlets
The air outlets are located in the roof area
above the rear seats.
The outlets can be closed or opened separ­
ately.
By pivoting the outlet grilles the direction of
air flow can also be adjusted.
This switch can be used to change over to recirculating air. This will prevent badiy con-
taminated air from entering the vehicle, e.g.
when driving through a tunnel.
Recirculating air operation should only be
used briefly otherwise the windows wil
mist up.
Switch to left - Recirculating air operation
Switch to right - Fresh air operation

Note

On vehicles with air conditioner a recirculat­ing air switch is located in the bank of
switches in the instrument panel.
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CONTROLS AND EQUIPMENT

Additional
heater*

With the additional heater the rear seating
area
can also be comfortably heated.
Its blower can be switched on
with
a three

stage
rotary switch in the dash panel
(left
hand illustration).
Temperature regulation is carried out to­ gether
with
the temperature regulation of
the normal heater - see page 55 .
On
vehicles
with
an airconditionertempera-
ture regulation forthe additional heater is by way of a rotary control on the
right
adjacent
to the blower switch (centre illustration).

Clockwise
- increased heat output

Anti-clockwise
- decreased heat output
On
vehicles
with
seating arrangement the
outlet is located under the centre row of
seats.
This outlet can be closed by pushing it in.

On
the Delivery van, Multivan and Camper
the outlet is located behind the
front
pass­
enger's
seat.
62
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CONTROLS AND EQUIPMENT

Auxiliary
heater*
To
switch heater on
•
Press
rocker switch D on rent.
• Select desired heat
with
knee -
The
green heater in-operatior. =~~" _
comes
on.
Regulating
heat

The
heat is infinitely adjustable
with
:~e knob A.
After heater has been switched on it takes

a
little
time before heat can be
felt.

When
the set temperature is reached, the green in-operation lamp becomes darker.

The
temperature is then held fairly constant by the heater thermostatically.
w-^
=
jxiliary heater works independently of
me .ehicle heating. It is supplied
with
fuel
I: rr the vehicle tank.
He suxiliary heater can be used continu­

es
. when on the move or stationary.
|r~? current is supplied from a 2nd battery.

r~T
air flows from the outlets behind the p*.er's seat.
k- the summer the heater blower can be

(sed
to circulate the air in the vehicle with-
it.: heat.
5v. itching on and off and regulating the aux-
tey heater are done from the control panel
r the dash panel.
-
a
timer* is
fitted
(see page 65) the control

panel
is located on the roof cross member I the passenger compartment.
A
BCD

[J70~-T971

Control
elements

A
- Regulating heat output
B
- Overheating indicator (red)

C
- Heater in-operation lamp (green)
D
-
Rocker
switch for switching heater on
and
off and operating blower without heat.
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CONTROLS
AND EQUIPMENT
To
switch
heater
off
• Move rocker switch D to centre position.
The
heater in-operation lamp C then goes out, but the biower continues to run for a
short time.

Note

The
warning lamp B flashes if the heater

overheats.
If this happens, check whether
the air intake or the warm air outlet are
blocked.
Switching
blower
on
without
heat

Press
rocker switch D on the
left.
The green
in-operation lamp C comes on.

Switching
off
• Move switch D to centre position. The in-operation lamp goes out.
Stipulation is
that
the heater is not being
controlled at the same time by the timer
(see
next page).

Attention

The
heater
must
be
switched
off in enclosed spaces and
when
fil­

ling
the
tank.

Notes

• Every time the heater is switched off the blower continues to run for a while to cool
the heater down quicker. When filling tank it is not necessary to wait to end of run-on.
• When driving cross-country or through mud or deep snow the heater exhaust pipe

can
become blocked. Before switching the heater on intheseconditions, check thatthe
pipe is clear. • The
following
official
regulation

is
applicable
in
Germany:

The
heat exchanger of the heater may be
used
for 10 years. After this period the heat

exchanger
must be replaced by a Genuine heat exchanger in a Volkswagen Dealer­

ship.
To enable this period of time to be monitored the year when the heater is taken
into use is marked on the maker's plate on
the heater (under vehicle floor).

The
Volkswagen dealer enters the date of
replacement on the plate on the heater.
64
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CONTROLS
AND EQUIPMENT

12
3 4 5 6 m.bc
"fy

7 8 9 10 111

Timer*
'. ih the timer in the instrument panel up to
r-ee different switch-on times can be se­
eded
for the auxiliary heater*. It is thus

::ssible
to start the heater without having
go
to the vehicle.

e
heater runs for maximum 120 minutes

ie'.d
it switches itself off. It can be switched
c~
prematurely by pressing button 9. The

preset
time is stored and can be called up

again
so that the heater switches on again =: the same time.

~ne
switch-on time can be programmed up :: one week in advance. 1- Display for 3 possible pre-selected
times

2-
Time display/pre-selected time

3-
System malfunction display

4-
Temperature display*
5-
"On" or "Off" display

6-
Display for pre-selected day 7-
Push
button for time and day of week

8-
Push
button for selecting time and day

9-
Push
button for "On" or "Off"
10-
Push
button for re-setting time or pre­
selected
time and calling up remaining running time

11-
Push
button for setting time or pre-se­
lected
time, setting pre-selected day

and
temperature display*

Notes

• As a temperature sender is not
fitted
at the factory an incorrect temperature figure
appears
when button 11 is
pressed.

• Displays 2 and 6 appear continuously after switching on the ignition. After switch­ing off the ignition both displays will only ap­

pear
if button 7 is
pressed.
Setting
the
actual
time

•
Press
and hold button 7.
• Set correct time with buttons
":1c".

Setting
the
actual
day of week
•
Press
and hold button 7.
• Set correct day of week with button 8.
Switching
heater
on (without preset
operation)
•
Press
button 9; symbol 5 appears r 're
display.

A
prerequisite is that rocker switch D z" control panel of heater is in centre pos : z~
With the ignition switched off the heate' .•.
be
switched on for approx. max. MZ —-

utes.

The
remaining running time can ce := e: by pressing button 10 briefly. If the c_r.c~

is
pressed longer than one second :~e
ning time will be shortened.

Note

If continuous operation of :~e -ea:e •

wanted,
it must be switcher :" B: re ::'-

trol
panel (see page 63).
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CONTROLS AND
EQUIPMENT

Switching
heater
off
•
Press
button
9/symbol 5 disappears.
Setting
the
pre-selected
times

•
Press
button
8/the
three possible pre­
selected
times and actual time can be called up separately as follows:
1st pre-selected time
2nd pre-selected time
3rd pre-selected time

Actual
time etc.
At the same time the day of week is dis­ played in each level.

For
the initial input and for each change to
an old input
first
call up the corresponding pre-selected time level
with
button
8. It is
then possible to set the desired pre-se­ lected time in each level
with
buttons 10 or
11.
If a time is set before the actual time of
day, the next day of the week appears in the display automatically. If a different day of the week is desired, it is

necessary
to wait
until
the weekday display

flashes
before setting the new day of the
week by pressing
button
11.
The inputs are stored in the memory if no

further
inputs are made
within
about 10
sec­

onds after setting a pre-selected time and
day of the week. With the ignition switched
on the actual time is
displayed,
with
the igni­

tion
switched off the display disappears. However the numbers 1,2 or 3 remain in the
display 1 to indicate
that
a pre-selected
time is activated.
Notes

• If not activated the heater will not start at the pre-selected time!
• Only one pre-selected time can be acti­
vated,
which in
turn
also runs only once. However, the time can be repeated by acti­
vating again. When doing this the inputs re­ main stored in the memory.
• The switched-on period is determined
as
described in the "Switching heater on"
section (see previous page).
If the activation (not the pre-selected set­
tings!) is to be cancelled, press
button
8
until
the number in display
1
is no longer vis­
ible.

66
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CONTROLS
AND
EQUIPVE\

Additional
water
heater*
E
additional water heater heats the
cool-

— ;he heater circuit and supplies the nor- • ^eating heat exchanger and the addi-

:~a
heat exchanger* for heating up the
rsaenger
compartment
with
heated
cool-
' ""e engine coolant circuit is not heated.
I current is supplied from a 2nd battery.

:ching
on and off and pre-selecting the
. :ch on/off times is effected via the timer,
- :h can be found in the instrument panel.

~a
air distribution and the air flow is ef-

:::ed
via the normal heating and ventila- : li aontrol elements (operating see page

a
additional water heater can be used

•en
stationary (short term operation) or -g the journey (continuous operation). If

.a;
when the vehicle is stationary the

•Her
runs for maximum 30 minutes,
;eoy
preserving the battery. Apart from
• 5 t switches off automatically, when a .: ant temperature of 92 degrees C is

Bcned.

"
an
the coolant temperature has dropped
-: .v 84 degrees C the heater switches on
The
additional water heater is supplied
with

fuel from the vehicle tank. It consumes up
to
1
litre
of fuel per hour. The heater output

is
approx. 7.0 kW.

Notes

• If the coolant temperature in the heater circuit reaches 55 degrees C, the fresh air
blower is automatically switched to stage 2.
• The additional water heater will only switch on when the temperature selector
lever
(see page 55, lever C) is pushed fully
to the
right.

• With the heater switched on the tem­ perature selector lever must not be pushed
to the
left.

• Regulating the heat output is not
poss­
ible
with
the temperature selector lever.
• When driving across country through mud or deep snow the heater exhaust pipe

can
become blocked. Therefore under

these
conditions check
that
the pipe is clear before switching on the heater.
Attention

The
heater
must
be s . ::'-
a
: : in confined spaces and when fil­

ling
the
tank.

•
Each
time the heater is sw :ce:
circu
at .-' pump and the comes::-blower continues to run for a v. K.e :: :::
down the heater
unit
quicker. Wher,-:. rg
the tank it is not necessary to vva :
end
of the run-on.
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CONTROLS
AND EQUIPMENT
1 2 3 4 5 6
7 8 9 10 11

Timer
With the timer in the instrument panel up to
three different switch-on times can be se­
lected
for the additional water heater. It is
thus possible to start the heater without
having
to go to the vehicle.

The
heater runs for maximum 30 minutes
and
then switches itself
off.lt
can be
switched
off prematurely by pressing but­
ton 9. The preset time is stored and can be

called
up again so that the heater switches on again at the same time.

The
switch-on time can be programmed up
to one week in advance. 1- Display for 3 possible pre-selected
times

2-
Time display/pre-selected time

3-
System malfunction display

4-
Temperature display*
5-
"On" or "Off" display

6-
Display for pre-selected day
7-
Push
button for time

8-
Push
button for selecting time and day

9-
Push
button for "On" or "Off"
10-
Push
button for re-setting time or pre­
selected
time and calling up remaining running time

11-
Push
button for setting time or pre-se­
lected
time, setting pre-selected day

and
temperature display*

Notes

• As a temperature sender is not
fitted
in the factory an incorrect temperature figure
appears
when button 11 is
pressed.

• Displays 2 and 6 appear continuously after switching on the ignition. With the igni­
tion switched off both displays will only ap­
pear
if button 7 is
pressed.
Setting
the
actual
time

•
Press
and hold button 7.
• Set correct time with buttons 10 or 11.
Setting
the
actual
day of
week

•
Press
and hold button 7.
• Set correct day of week with button 8. Switching on
heater
(without pre-set
operation)
•
Press
button 9; symbol 5 appears in the
display.

A
prerequisite is that the temperature
selec­

tor lever is pushed fully to the right.
With ignition switched off the heater will be
switched
on for approx. max. 30 minutes.

The
remaining running time can be
called-
up by pressing button 10 briefly. If the but­
ton is pressed for longer than 1
second,
the running time will be shortened.

Note

Continuous
operation of the additiona
water heater is only possible with the igni­
tion switched on. Additionally the heater must be switched on at the timer with but­
ton 9.

68
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