brake 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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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

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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CONTROLS
AND EQUIPMENT

igggage
compartment cover*

I
-
/ehicles with
a
rear seat bench,
a
lug-

zazs
compartment cover
can
be
installed, :e rending
on the
vehicle version.
~en loading,
the
luggage compartment
::.
er
can
be
tipped upwards.
Attention
When
the
vehicle
is
moving
no
persons,
animals
or
heavy items
of luggage
are to be
carried
on

the luggage compartment cover
- danger
of
injury when brakes are applied suddenly
or
when ve­hicle
is
involved
in
an
accident.
further important instructions
on
oading are
to
be
found
on
page 28.

27
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CONTROLS AND
EQUIPMENT

Luggage
compartment/load
surface

To
enlarge
luggage
space
Lower
backrest and seat as described on
page 23.

Notes
on loading
In the interests of good handling ensure
that

the load (persons and luggage) is distributed evenly. Heavy items should always be car­ried as near to the rear axle as possible or
better still, between the
axles.

The permissible axle and gross
weights must not be exceeded under any circumstances.
Attention
• It should be noted
that
when
transporting heavy items the handling
will
change due to the
displacement of the centre of
gravity. Driving style and speed must be altered to suit.
• The load must be stowed so

that
no items of luggage can fly
forward if brakes are applied suddenly. - If necessary use the lashing
eyes.
• One should ensure
that
the heater el­
ements in the rear window on the Variant
are not damaged by articles rubbing against
them.
• The stale air
escapes
through ventilation openings at the rear. The function of these openings must not be impaired.
Attention
• When vehicle is on the move no persons may be in the luggage
compartment. This includes

children.
Every passenger must
be belted in properly - see page
15.

• Never drive
with
the tailgate or
wing doors not properly closed otherwise exhaust gas can be
drawn
into
the vehicle
interior.
On
vehicles
with
lashing eyes the load
should always be secured to the
eyes.

Each
eye has a tensile strength of 500 kg.
28
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CONTROLS AND EQUIPMENT

3edals
• e ~ cvement of the pedals must not be re-
:: :~is reason, do not put articles in the
—•".•.ell which could roll or slide underneath

—-E-
zedals.

•Vr^-d the pedal area there should not be •r. -;otmatsorotheradditionalfloorcover- •: -aterials:
• In the
case
of defects on the brake sys-
r~
3 greater pedal travel may be
necess-

• : should always be possible to depress
~3
: _tch and accelerator pedals fully.
• - pedals must be able to return, unhin-
z-z'^z.
to their rest positions,
""•e'efore, the only
foot
mats which may be
are those which leave the pedal area
::—oletely free and which are prevented . " slipping. Brakes
The following points are of particular import­
ance
to the safe operation of the brakes.
• New brake linings must also be run in and do not have the optimum
friction
prop­
erties during the
first
200 km. The slightly reduced braking effect can be compen­
sated for by more pressure on the brake

pedal.
This also applies when new linings have been fitted.
• If the brake pedal travel increases suddenly, it may be
that
one of the two
brake circuits has failed. You can still drive
on to the next Volkswagen dealer but be prepared to use more pressure on the pedal
and allow for longer braking distances on
the way.
• The brake
fluid
level must be checked regularly-see page 105.
The brake warning lamp
will
come on to indi­ cate
that
the brake
fluid
level is too low (see

also
page 48).
• Brake lining wear depends to a large ex­
tent
on the operating conditions and style of driving. On vehicles which are used mainly in
town
traffic
and stop/start conditions or
are driven hard it may be necessary to have
the thickness of the brake linings checked by a Volkswagen dealer in between the in­
tervals given in the Service Schedule.
• Change down in good time when driving downhill, in orderto make use of the engine braking effect. This relieves strain on the
brake system. When the brakes are applied do not keep them on con::rjc_s , =" .
and release alternately.
• Under certain operating conditions, *c example after driving through water, a^e' heavy rain or after washing the vehicle the
braking effect may be retarded by wet, or in
winter iced-up brake discs and linings - the brakes must be dried out
first
by applying
the footbrake.
The
full
braking effect may also be delayed when vehicle has been driven for some time
on heavily salted roads
without
using the
brakes,
because the layer of salt on discs
and pads has to be removed
first.

Attention
If a
front
spoiler,
full
size
wheel

trims
etc., is
retrofitted,
it is necessary to
ensure
that
the
flow

of air to the
front
brakes
is not re­

stricted
-
otherwise
the
brakes

can
overheat.
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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

-andbrake

~: ;:dy the handbrake pull lever up
firmly.

Zr - s the
1
st gear or
with
automatic gear- :ne parking lock should also be en-

r'zz^z.
The handbrake should always be

ace
53 so
firmly
that
it is not possible to
zr .9 nadvertently
with
the handbrake on.

~T"
handbrake is applied
with
the ignition
• :_e brake warning lamp comes on.
~: "e ease handbrake, pull lever up slightly,
: r;s locking knob in and push lever
right
Manual
gearbox

Note

When driving you shot z ' z: est .: ~ E~ :
on the gear lever. The press^-e z~ .:„'-="
is
transmitted to the selectc ~z'-~ - ~T
gearbox and can cause pren-a:_"5 .-, ~z' z~
the forks.
Gear
gate

• All forward gears are baulk synchro­
nised.
The synchronising hubs enable easy
noise-free selection of the forward gears.
• Only engage reverse gear when vehicle
is
stationary. When engine is running, de­

press
clutch
fully
and
wait
a few seconds
before moving gear lever, to prevent grating

noises.

When reverse gear is engaged
with
ignition
on,
the reversing lights come on.

3'
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CONTROLS AND
EQUIPMENT

Emergency
programme
~.~:;ional defects occur in the electronic
. ;:e~ the gearbox can, amongst other ' "is. carry on operating in two emergency
: ::_s~imes:
• Tre gearbox continues to change up and x ••- automatically as before but hard
shift
- 3 are however noticeable. The vehicle •<:- 3 be taken to a Volkswagen dealer.

~e
gearbox no longer changes up and - automatically.
"•= rearbox can then be shifted manually
:- tie selector lever positions "D", "3"
;': 2" only the 3rd gear is available.
- selector lever positions "1" and "R", the =: and reverse gears are available as nor-
-: .vever, the converter must, due to the ab-

;-s~ce
of 2nd gear
work
harder, and under
:e~ain
circumstances this
causes
the con- r~er to overheat. In a
case
such as this the
•eiide should be taken, as soon as
poss-
: e, to a Volkswagen dealer.
Selector
lever
lock

In positions "P" and "N"
with
the ignition
switch on the selector lever is locked. To move the selector lever out of these
posi­

tions the brake pedal must be depressed
and the selector lever
button
pushed-in.

This
prevents a gear being engaged inadver­

tently
and the vehicle unintentionally mov­ ing off.

A
delay circuit prevents the selector lever

from
locking when it is moved quickly past
the "N" position (for instance
from
"R" to
"D").
This enables for example the vehicle
to be "rocked" out of a "bogged down" position. The
shift
lock only locks the
selec­

tor lever if it is
left
in the "N" position for more than about
1
second
without
the brake
pedal being depressed.
At speeds above 5 km/h the selector lever lock is automatically switched-off in
posi­

tion
"N". In the dash panel there is a display tra:

shows
the currently selected selects' eve' position.

Selector
lever
positions

P -
Parking
lock

The driving wheels are locked mechanics .
The parking lock may only be engagec
the vehicle is stationary. Before mov -g :_e lever in or out of the "P" position tre" ::•

button
in the selector lever handle r-_s: re­

pressed.
Before moving the
se!e:::"

out of the "P" position, the ca-e ;e:s must also be depressed when 're z~;z~ ;
switched on.
11 Depending upon the rrc~e ~._e : s; = :;~
also
be
fitted
in the Cc~: e":
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CONTROLS AND
EQUIPMENT

R -
Reverse
gear

The reverse gear should only be engaged
when the vehicle is stationary and
with
the engine idling. Before engaging the position
"R"
from the positions "P" or "N" the brake
pedal must be depressed and the lock
but­

ton in the selector lever handle must also be
pressed.

The reversing lights come on then the
selec­

tor lever is in the " R" position
with
the igni­

tion
switched on.
IM -
Neutral
(idling
position)

To
move the lever out of neutral when
sta­

tionary or at speeds below 5 km/h and
with
ignition switched on depress the brake
pedal and press the lock
button
in the
selec­

tor lever handle.
D -
Normal
driving
position

The four forward gears are shifted up and down automatically depending upon

throttle
opening and programme selected.

Under
certain driving conditions it is advan­
tageous to engage one of the following de­

scribed
selector lever positions. 3 - Position for
hilly
regions

The 1st, 2nd and 3rd gears are shifted up and down depending upon engine load, road

speed
and programme selected. The 4th

gear
is not engaged. This increases the en­
gine braking effect when the accelerator pedal is released.

This
selector position is recommended in situations where the gearbox alternates fre­
quently between 3rd and 4th gears in the
"D"
position.
2 - Position for
steep
hills

This
selector lever position is suitable for long climbs and descents.
The 1st and 2nd gears are shifted up and down automatically depending on engine
load,
road speed and programme selected.

To
prevent unnecessary changing up 3rd
and 4th gears are not engaged. This
further
increases
the engine braking effect on

deceleration.

1 - Position for
very
steep
hills

This
selector lever position is recom­ mended for very steep climbs and de­

scents.
To
engage this gear, the lock
button
in the

selector
lever handle must be pressed in.
The vehicle only moves in
1
st gear. The 2nd, 3rd and 4th gears are not engaged.
Maxi­
mum possible engine braking effect is now

available.

The cruise control * cannot be used in
posi­
tion
"1".

Note

When changing down manually the selector lever can be moved
into
the positions "3",
"2"
and "1", but the gearbox will not

change
down
until
it is no longer possible to
over-rev the engine.

Kick-down
device

The kick-down device gives maximum ac­ celeration. When the accelerator pedal is
pressed
right
down past the
full
throttle

position, depending on road speed and en­
gine
speed,
the box changes down
into
a lower gear. The upshift
into
the next higher

gear
then takes place as soon as the maxi­ mum specified engine speed is reached.
34
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