belt VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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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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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

Safety
for
children

Children
under
12
years
of age
should
normally
travel
on the
rear

seat1>(Caravelle,
Kombi,
Double-

cab).
Depending
upon
their
age,
height
and
weight,
they
must
be pro­

tected
with
either
a child
restraint
system
or the
seat
belt
provided.

A
child may also occupy the
front
passenger
seat
if the restraint system used has been

expressly
approved for this purpose by the
manufacturer. One should bear in mind however
that
they are generally safer on the
rear seat.
On no
account
should
children
- or

babies
travel
on an
adult's
lap.
• Babies up to about 9 months old/10 kg are best protected, in an accident,
with
a
safety seat or a special safety carrier.
• Experience has shown
that
babies and
small
children up to about 3 years/18 kg are
best protected in child seats or safety
carriers where they can lie or sit facing the rear of the car.
• Children up to about 7 years of age/25 kg, depending on their height, are safest when

secured
in a child seat or by a safety seat

cushion.
• Children over about 7 years of age may

use
the three point belts or two point belts
provided on the rear seats. It is important to
ensure
that
the diagonal part of the belt
fits

over the centre of the shoulder - and does not
make
contact
with
the
neck.
The
lap part of the belt must pass across the
pel­

vis
and not
over
the child's stomach. If this is not so a safety cushion must be

used
to raise the seating position.
When using the belt the section "Seat belts" should also be noted.
Note the following points when purchasing,
installing and using a child restraint system:
• For safety reasons always use a restraint system which conforms to the international
safety standard ECE R 44. Restraint
sys­

tems
that
can be connected to the seat belts provided in the car are recommended.
• Only use child seats or safety carriers of the type which have a large,
flat
area in
con­

tact
with
the car's seat upholstery. Child
seats
which have feet or tubular frames and no
flat
base can easily penetrate
into
the

car's
upholstery, and are therefore not so
safe.
• We recommend
that
child restraint
sys­

tems from the genuine accessory pro­gramme of the Volkswagen dealers are
used.
Here under the name "Bobsy" re­
straint systems for all age groups are of­

fered21.
These systems
fulfil
all the require­ ments mentioned and over and above this, have been developed and tested by us for

use
in Volkswagen vehicles.
• Special care must be taken if child re­ straint systems are used which are bolted
on at the same point as the belts provided in the vehicle. One must ensure
that
the bolt

is
long enough so
that
the
full
length of the
threaded hole is utilized and tightened to a
torque of 30 Nm
Furthermore, one should ensure
that
the
belt itself cannot become damaged by
sharp edged buckles etc.
• For the
installation
and use, at­
tention
must
be
paid
to the
legal
regulations
and the
instructions
of
the
restraint
system
manufacturer.

Not in all export markets

Observe
any statutory regulations to the
con­

trary.

18
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CONTROLS AND
EQUIPMENT

Head
restraints*

The
front
head restraints are adjustable for rake and height and should be set to suit the

size
of the person in the seat. Correctly ad­
justed head restraints together
with
the
seat
belts offer effective protection.

Adjusting
height*

• Grip sides of head restraint
with
both hands and pull up or push down.
• The best protection is obtained when the upper edge of restraint is roughly at eye
level.

Note

In vehicles
with
a high partition the head re­
straints are not adjustable.
Removing
and
installing

To
remove head restraints in
front
seat
backrests,
pull restraints up to the stop,
press
both buttons (arrows) and atthe same
time take restraints out.

To
install again, push the restraint rods
into

the guides
until
they are heard to engage.
Note

On
some models, head restraints are
fitted

which are retained by spring clips.

To
remove the spring clips from the seat backrest guide rings, pull or push the clip out
to one side
with
a small screwdriver.
When reinstalling, insert the head restraint
first,
and then push the spring clips in so
that

the straight leg is at the rear.
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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
Attention
When installing the seats the fol­ lowing points are important for
the safety of the vehicle
occu­
pants:

•
The seats must always be firm­ ly engaged in the mountings so

that
they cannot become de­
tached when braking or in an

accident.

•
The seats must always be in­
stalled in the correct direction
and position so
that
the belts pro­
vided for each place can be worn properly.
Rear seat bench
(three-seater)

~:
ncrease
the
size
of the
luggage
area
the
"ear
seat,
or the
backrest
only,
can be tipped

"crward.
Attention!
When taking off the rear
three

point seat belts the belts must be
pushed
underneath the loops
provided on the side
trim
panels.

This
will
prevent the belts from
becoming
damaged when the
rear seat backrest is folded for­
wards.

Folding
backrest forwards

•
Push
lever
at right or left of
backrest
for­
wards.

•
Fold
backrest
down.
Tipping
seat bench

•
Fold
backrest
forwards

•
Pull
loop
on lower part of
seat
bench
•
Tip
bench
forwards.
23
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CONTROLS AND
EQUIPMENT

Removing
rear
seat

To
increase the luggage/loading area, the rear seat can be removed:
• Fold backrest of centre seat forwards
• If fitted, fold folding seat* out of way -
see
page 25
• Remove lower seat frame trim* from rear seat
• Remove head restraints* - see page 19
• Fold backrest down - see page 23
• Tip seat forwards - see page 23
• Loosen and remove two bolts (arrows in the
left
illustration)
• Carefully fold seat back • Fold back carpet* to attain
access
to the

front
bolts
• Loosen and remove
front
bolts (arrows in the
right
illustration)
• Remove seat to rear
• Screw in and tighten all four bolts in the securing points.

Fitting
rear
seat

• Fold down backrest of centre bench seat
• If fitted, fold folding seat out of way.
• Fold back carpet and retain
with
some­ thing heavy
• Remove the four bolts • Fit seat
into
position
• Tighten
front
bolts by hand
(right
illustra­
tion)

• Carefully fold seat back
•
Insert
rear bolts
(left
illustration) and tighten all four bolts

Attention
Ensure
that that
the
rear
seat

bench securing
bolts
are
tigh­

tened
again,
as the
security
of
the
seat
belts
and
therefore
the
safety
of the passengers
depends
upon
it.
• Fold backrest up
Notes

• It is expedient for two people to carry out the removal and
fitting
of the rear bench
seat.

• When removing and
fitting
the seat en­ sure
that
the belts, side trim, loudspeaker
grilles etc. are not damaged or soiled.
24
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CONTROLS AND
EQUIPMENT

Folding
seat*

[B70-296

The single seat next
to the
centre seat oench can
be
folded,
in
such
a
manner,
to

enable easy
access
to the
rear seat bench.
Folding
seat

• Unlatch
the
seat backrest
and tip
oackrest forwards
(left
hand illustration).
• Then,
tip the
seat sideways
to the
left
centre and
right
hand illustrations).
[B70-297

•
To
return
the
seat
to its
original position proceed
in the
reverse order.

Removing
seat

The seat can
be
removed
by
performing
a

few simple operations).
• Set seat
into
sitting
position.
•
Press
both
levers
on
foot
part
of
seat downwards.
•
Press
seat towards
left
hand side
in di­
rection
of
seat bench and take
out.

Installing
seat

• To install the seat, place seat on
left
hand
side
(as viewed
from
driving direction) next
to
the
securing elements
on
vehicle floor. [B
70-298

• Then, pull seat towards
right,
until
seat engages
firmly
in the
securing parts.

Attention

•
The seat must always be properly engaged in the retainers
to ensure
that
it cannot move if
the brakes are applied or the ve­ hicle is involved in an accident

•
The seat must always be rein­
stalled in the correct direction
and position. This ensures
that

the seat
belt
provided can always be properly
used.

25
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