ABS VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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DASHBOARD
AND
CONTROLS
Warning lamps

Symbol Page Symbol
Page
Coolant temperature/
Coolant level
47

A Emergency light system
51
Engine oil pressure f^i
47

m Rear
window
heating
51

ID
Headlight
high
beams

48

to Fog lights
rear fog light 51

Turn
signals
49

Notes
((D)
Brake
system l^i

48
•
If one of the lamps marked
with
comes on when driving
stop and switch engine off. Details can be found on the pages
given

B Some of the lamps shown here are
only
on certain models or are optional extras.

£3

Alternator
49 •
If one of the lamps marked
with
comes on when driving
stop and switch engine off. Details can be found on the pages
given

B Some of the lamps shown here are
only
on certain models or are optional extras.
m Glow plugs - Diesel

49
(©)
Anti-locking brake system (ABS)

49


Trailer turn signals

49
6
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CONTROLS AND EQUIPMENT

Brake servo Attention
The servo
is
operated
by
vacuum which
is
only generated when
en­

gine
is
running.
For
this reason
the vehicle should
not be
allowed
to roll with
the
engine switched off.
When
the
brake servo
is not

working because,
for
example,
the vehicle
is
being towed
or be­
cause
a
defect
has
occurred
on

the brake servo itself,
the
brake pedal must
be
pressed consider­
ably harder
to
compensate
for

the absence
of
servo assistance. Anti-locking brake system
*
The ABS plays a major part in increasing the
active safety of the vehicle. The big advan­
tage when compared with a conventional brake system is that even when braking
hard on a slippery road surface the best
possible steerability is retained for the road
condition because the wheels do not lock.
However, one must not expect the ABS sys­
tem to shorten the braking distance in all conditions. When driving on gravel or on
fresh snow covering a slippery surface, i.e.
when one should be driving very carefully in
any case, the stopping distance may even be slightly longer.

How
the ABS
system works

When the turning speed of a wheel reaches
a level which is too lowforthe vehicle speed
and it tends to lock, the brake pressure to
this wheel is reduced. On the front axle the brake pressure is regulated for each wheel
individually, whereas on the rear axle, the
pressure is regulated for both wheels at the
same time. As a result the braking effect is
the same for both rear wheels and the driv­ ing stability is retained as far as possible.
This regulating process makes itself known by movement of the brake pedal and is ac­
companied by noises. This is done deliber­
ately as a warning to the driver that a wheel
or the wheels are in the locking range. So
that the ABS can regulate effectively in this range the brake pedal must remain de­ pressed - on no account should it be

pumped!

Attention However
the ABS
system cannot
overcome
the
physical limits.
This must
be
borne
in
mind par­
ticularly
on
slippery
or wet
roads.
When
the ABS
comes into
the
control range
the
speed must
im­
mediately
be
adapted
to the
road
and traffic conditions.
The in­

creased amount
of
safety avail­
able must
not
tempt
one
into tak­ ing risks.

If a defect occurs on the ABS it is indicated
by a warning lamp - see page 49.
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CONTROLS
AND
EQUIPMENT

6-Alternator
Q

~ne warning lamp comes on when the
igni-

I
on
is
switched on and must go out when

She
engine
is
started.
i the warning lamp comes on when driving,

stop,
switch
engine
off
and
check
the
alternator V-belt.
f the V-belt
is
broken or loose do not
drive

on with
a
vehicle which
has a 4 cylinder
engine
because the coolant pump
is
then
no
longer being driven. The V-belt must
be

tensioned
or
renewed.
ehicles with
a 5
cylinder engine
can
nor­
mally
be
driven to the nearest Volkswagen
dealer when
the
V-belt
is
broken
or
loose oecause
the
coolant pump
is
driven separ­
ately but then the battery will discharge
con­

tinuously
and all
non-essential electrical consumers should
be
switched
off.

f the warning lamp comes on although
the

belt
is
not broken, one can normally drive on

to
the nearest Volkswagen dealer (all engine

types)
but the
battery will then discharge
continuously
- see
previous paragraph.
7-Glow
plugs
W

(Diesel engines only)

When
the engine
is cold
the warning lamp comes on when key
is
turned to Drive
posi­

tion
(ignition on).

If
the warning lamp does not come
on,
there
is
a
defect in the glow plug system
-
call
in

expert assistance.

When
the
lamp goes out,
start
the engine
immediately
-
see page
38.

When
the
engine
is warm the
glow plug
lamp
does
not
come on -the engine can
be

started straight
away.
(®)
-
Anti-locking
Brake

System
(ABS)*

The operational readiness
of the
essential electrical components
of the ABS are

checked,
both before moving off and when

driving,
by an electronic monitoring system.
The warning lamp lights up when
the
igni­

tion
is
switched on and
it
must go out again, at the latest, after the engine
has
started.

If
the warning lamp does not go out
or if it

comes on when driving the system
is
not
in

order.
The
vehicle can then only
be
braked
with
the
normal system
-
that
is
without
ABS-.The vehicle must be taken to a Volks­
wagen Dealership
as
soon
as
possible.
Further details on ABS
is
given on page
30.

<]1i>
-
Trailer
turn
signals

The warning lamp
*
flashes when turn
sig­
nals are switched on when towing
a
trailer.

If a
turn signal fails on the trailer or vehicle,
the warning lamp does not flash.
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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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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.
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DO-IT-YOURSELF

Front
turn
signals

To
change a bulb the
turn
signal housing must be taken out to the
front.

•
Insert
the
flat
blade of a screwdriver be­ tween headlight and
turn
signal
with
bonnet
open.
This presses the securing tabs which hold the
turn
signal housing to the
side.

• Swing screwdriver to
front
as shown in illustration so
that
the
turn
signal housing is

pressed
out forward. • Turn bulb holder out to the
left.

• Turn bulb out and renew.
•
Insert
bulb holder. •
Insert
turn
signal housing in the grooves provided (top and
bottom)
and press it in
until
the securing tabs engage.

Fog
lights*

The foglight bulbs can betaken out from un­
derneath the bumper.
• Turn cap on rear of fog
light
to the
left
to remove it.
• Unhook spring clip of bulb holder and swing it away.
• Take bulb out.
•
Insert
new bulb so
that
the locating lug on bulb plate engages
recess
in the reflec­
tor.
• Swing spring clip over bulb plate,
squeeze
it together and engage it in the re­
taining lugs.
• Fit cap again.
• Have beam alignment
checked.
Rear
lights

Renewal
of the bulbs for the rear lights is
done from the luggage compartment
through the rear panel trim.
•
Reach
into
the hole in the rear panel
trim
with
one hand and squeeze the two retain­ing tabs of bulb carrier together.
• Take bulb carrier out (illustration). •
Press
defective bulb
into
holder slightly,
turn
it to the
left
and take it out.
•
Insert
new bulb and
turn
fully to the
right

• Install bulb carrier.

125
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DO-IT-YOURSELF

Rear
fog
light

• Renewal of the bulbs for the rear lights
is
done from the luggage compartment
through the rear panel trim.
• Take housing out.
• Turn bulb holder out to the
left.

• Take bulb out and renew.
• Turn bulb holder back in.
•
Insert
left
side of housing in the recess
first
and press in
firmly
until
the tabs en­

gage.
Number
plate
lights

The lights are secured
with
2 screws.
• Take lens off
• Pull complete
light
out
• Pull bulb housing out • Pull defective bulb out and renew
•
Insert
bulb housing
• Secure lens
firmly

Interior
and
reading
light*

Interior
light
(A)
•
r.sert
a knife blade or something similar
into
gap between housing and lens and
carefully lever lens off.
• Change bulb.
• Dress lens
into
housing again, when doing this the lug on the lens must fit in the
recess
in the housing.
'26
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DO-IT-YOURSELF

Masking
headlights

When the vehicle is used in a country which drives on the opposite side
of
the road to the
home country,
the
asymmetric dipped neadlights
will
dazzle oncoming
traffic.

To prevent this,
the
wedge-shaped sector on the headlight lenses must be covered
up

with
an
opaque adhesive strip.
The illustration shows
the
strip installed
for

the change
from
right
hand
to
left
hand
traffic.
Installing
radio

When service installing
a
radio
or
replacing
a
set
installed
by the
factory
the
following points should
be
noted:
•
The
connection*
in the
vehicle
is for
Genuine
Volkswagen radios11
from
Model

Year
1988. The supply plug has the following
wire colours and connections:
Red/white Permanent positive
(+)

Brown Negative
(-)
vehicle earth
Grey/blue
Instrument
panel lighting
Brown/red* Control wire
for
"Ignition
key" switching radio
on/

off. On no account use this
connection
for
operating
voltage supply.
Blue/white*
Speed
signal
for
automatic volume control
•
Radios
with
other connections must
be
connected
with
an adapter cable which can

also
be obtained
from
a Volkswagen dealer.
11 Not available
in all
export markets
Attention

On
no account cut wires off and
leave
them
without
insulation. If

necessary
use a proper adapter.
Otherwise the wiring can be
overloaded or short circuits can
occur
- Fire danger!
Apart from this important elec­
tronic components can be damaged or the functioning impaired. If for
example the speed signal is
dis­

turbed this can lead to
faulty
man­ agement of engine, automatic gear­box, ABS etc.

Even
connecting the speed signal to
radio sets
with
speed dependent
vol­
ume control from other manufac­
turers can cause
such
faults.
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TECHNICAL
DESCRIPTION

Power
flow

Manual
gearbox

• Mechanically or hydraulically operated single plate dry clutch
• Baulk synchronized five speed manual gearbox and final drive in one housing.
• Common lubrication for gearbox and final drive. Permanent oil filling
• Front wheel drive

Automatic
gearbox*

• Hydro-dynamic torque converter
with
lock-up clutch to eliminate converter slip in
3rd speed (under certain driving conditions)
and (always) in 4th speed
• Planetary gearbox
with
4 forward gears
• Two electronically controlled selectable driving programmes
• Flanged on final drive
with
separate lubri­ cation and life-long oil filling
• Front wheel drive
Steering,
Axles

Steering

• Maintenance free rack and pinion steer­ ing
• Steering column
with
angled joints
• Steering pinion and column connected by angled shaft
with
two universal joints
• Hydraulically assisted steering
(PAS)*

Front
axle

• Independent wheel suspension
with
double wishbones, shock absorbers and
anti-roll bars
• Longitudinal mounted torsion bar

Rear
axle

• Independent suspension
with
diagonally trailing arms, coil springs and shock ab­

sorbers.
Brakes

• Hydraulic dual circuit brakes
•
Disc
brakes at
front

• Self adjusting drum brakes at rear
• Brake servo
• Pressure/load-sensitive brake pressure regulator for rear axle
• Mechanical handbrake effective on rear wheels
• Anti-locking brake system
(ABS)*
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ALPHABETICAL
INDEX

A
Acceleration
figures 142

Accessories
117 Activated charcoal
filter
138
Additional heater 62
Additional water heater 67
Adjusting brake pressure regulator . . 155
Adjusting headlights 128 Adjusting washer
jets
108

Air
cleaner 100

Air
conditioner 57

Air
distribution 55

Alloy
wheels 91

Analog
clock 46

Anti-dazzle
inside mirror 13
Anti-freeze 101 Anti-locking brake system (ABS) .... 30
Arduous operating conditions 115
Armrests 21

Ashtrays
73
ATF
99
Automatic gearbox 32
Automatic wash plants 88
Auxiliary heater 63
Axle
loads 148

B

Battery 106
Belt height adjustment 16
Blower
55
Bonnet 94
Brake
fluid
104
Brake
servo 30

Brake
system 104

Brake
warning lamp 48
Brakes
29, 139
c

Capacities
153

Capacity
141

Care
of body 88
Care
of car 88

Catalyst
137

Cavity
preservation 92
Central
locking system 8

Cetane
Number 87
Changing
bulbs 124

Changing
front
turn
signal bulb 125

Changing
wheels 120

Chassis
number 154
Checks
when
filling
the
tank
160

Child
safety 18

Child
seats 18
Child-proof catch 9 Cigarette lighter 73

Cleaning
and anti-corrosion
treatment
of engine compartment 91

Clock
46

Cold
starting aid 38

Combined
weight 151

Compression
ratio
141
Consumption figures 143

Coolant
additive 101
Coolant
level 47, 102
Coolant
temperature - Gauge 41

Cooling
system 101

Cruise
control system 53
D
Dash
panel 4

Dashboard
and controls 4
Defrosting windows 56, 58

Diesel
fuel 87
Dimensions
152
Dip lever 52
Dipstick - Automatic gearbox 99
- Engine 97
Direction indicators 48
Do-it-yourself 118

Door
locks 9

Doors
9 Drawbar weight 83
Driver's seat 20
Driving abroad 115
Driving on holiday 115
Driving safely 78 Driving tips 76

E

Electric
socket 73

Electric
window
lifters
12

Emergency
lights 51
Emergency
starting 130

Emission
control system 137
56
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