brake fluid 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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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

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
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DRIVING
TIPS

Driving
safely
Attention

The
operational
condition of your
vehicle
is
essential
to
safe

driving.
Therefore before moving off, always check
the following points:
• Lights and
turn
signals
•
Mirror
settings
• Cleanliness of
headlights,
lenses and
windows

Also
check at regular intervals, preferably
when filling the tank, all the checks listed on
page160

Furthermore compliance
with
the specified Inspection intervals - in particular the brake
fluid changing - is of great importance for operational safety - pages 93 and 98.
Attention

Safety
on the
road
depends to a

large
extent
on the personal
atti­

tude
and
style
of driving.

To
be on the safe side you should:
•
Always
put
seat
belt
on
before
moving
off -
even
in
town
traffic
-

and

• Ensure
that
all your passengers - including
those
on the
rear
seat
- are

wearing
their
belts
correctly
- page
15

Passengers
without seat belts can en­

danger
not only themselves, but also the
driver.
•
Adjust
head
rests
to body size.
The
upper edge of headrest must be ap­proximately at eye
level.

• Ensure
that
no
articles
interfere
with
operation
of pedals - page 29
•
Stow
all
luggage
correctly:
- in
boot
- page 28
- on the shelves - page 27
- on the
roof
- page 75 • Do not
drive
when
you
feel
tired.

Stop
for a break at the latest after driving for
two hours.
•
Never
drive
when
your
reactions
are
impaired
in any way. Not only alcohol but also drugs and many

medicines
can be very detrimental to your

reactions.

•
Adapt
vehicle
speed to
traffic
and
road
conditions.
Remember
that
particularly on smooth slip­
pery roads the handling and braking is li­
mited by the adhesion of the tyres. On wet

roads
the
front
wheels can aquaplane at
high
speeds.
The vehicle can then no longer

be
steered and braked properly.
•
Strictly
adhere
to the
traffic
regu­
lations
-
particularly
the speed li­

mits
-.
Further instructions on safety are given in
the various chapters in this manual.
78
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GENERAL
MAINTENANCE

Attention
Do
not have the belts cleaned

chemically
because the cleaning

compounds
damage the webbing
material. Ensure
that
the belts do not come into contact
with
cor­

rosive
fluids.

Steel wheels
~ne wheels and
the
wheel trims should
be
:!eaned
thoroughly
at
regular intervals .'.hen the vehicle
is
being washed. This
will

"event brake dust,
dirt
and road salt
from
•cumulating
on the
wheel. Persistent "grained brake dust can
be
removed
with

="
industrial grime remover. Paint damage ;~ould
be
repaired before rust can form.
Alloy wheels - order
to
maintain
the
smart appearance
• alloy wheels
for a
long period, regular pre
is
necessary.
In
particular, salt
and

•Bke
pad dust must
be
washed
off
thor-

cghly
at
least every two weeks otherwise re surface
of the
alloy
will
be
damaged.
-~er
being washed,
the
wheels should
be

~f3ted
with
an
acid-free cleaner
for
alloy
"eels.
About every three months
it is

"f:essary
to
give wheels
a
good rubbing
». :n hard wax. Paint polish or other abrasive
•c
„tions must not be
used.
If
the protective

BE
-.t
coat has been damaged, e.g. by stone react,
the
damaged spots should be dealt
with
as soon
as
possible.
Cleaning and anti-corrosion
treatment
of
engine compart­ ment

Attention Before doing any
work
in the en­
gine compartment it is essential
to read the notes on page 95!

The
engine compartment and
the
outside
surface
of
the power
unit
are given anti-cor­
rosion treatment
at the
factory.
In
the
winter when
the
vehicle
is
being
driven frequently
on
salted roads, good
anti-corrosion treatment
is
very important.
For
this reason
the
entire engine compart­
ment should
be
thoroughly cleaned before
and after
the
salting period
and
then pre­

served
so
that
the
salt cannot have
a
dam­
aging effect. The
ignition must be switched off
before washing the engine.

To
prevent damage to the system
the jet from the cleaning appliance must not be directed into the
intake

openings
for the heating and venti­lation. The openings are located
above the air cleaner.
If
the engine compartment is cleaned
at
any
time
with
grease removing solutions1'
or if

one has the engine washed, the anti-corro­
sion
compound is nearly always removed as

well.
It is
therefore essential
to
ask
for
dur­

able
preservation
of all
surfaces,
seams,

joints
and components
in the
engine com­ partment
to
be carried out. This applies also
when corrosion protected parts
are re­
newed.

Volkswagen
dealers have stocks
of the
high-quality cleaning and preservation ma­
terials recommended
by the
factory
and
have
the
equipment necessary
to
apply
them.
Because
when
washing
the en­

gine
petrol,
grease
and oil de­

posits
are
washed
off, the
dirty
water
must
be
cleaned
by an oil
sep­

arator.
For
this
reason
engine
wash-
11
Only
the
correct
cleaning
solutions may
be
used
-
on no account petrol
or
Diesel.

91
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GENERAL
MAINTENANCE

Maintenance

-s
the
vehicle
is
fitted
with
modern
low
~aintenance
technical components only

small
amount
of
regular servicing
is re­
tired
in
order
to
maintain
the
roadworthi-
"sss,
economy and reliability.
~ne Inspection Service offered by the Vol ks-
I
agen dealers takes into account
to a
large
extent
the
individual annual mileage
cov-

e-ed and helps thus
to
keep
the
operating
:osts
as
low as possible.

Regular maintenance helps to

-J
ensure
that
the emissions - and
thus the environmental burden are

kept
as low as possible.

The
Inspection
Service
is
required
every
12
months
or
every
30 000 km,

. nichever occurs
first.

I
a mileage
of
15 000
km
(petrol engines)
or

"500
km
(Diesel engines)
is
reached before "2 months
has
elapsed,
the Oil
change
Service must
be
carried out. See page
98

5
so and
the
Service Schedule.
~ie Service Schedule also shows what »rk
is
done
at the
Inspection
and Oil

Inange
Services.
In
arduous
operating
conditions, e.g.
extremely low ambient temperatures, very
dusty conditions etc. certain service oper­
ations should be carried
out
between the in­
tervals specified.

This
applies
in
particular
to:

• Changing
the
engine
oil

• Cleaning
or
changing
the air
cleaner
el­
ement
• Draining water from
or
renewing the fuel
filter
on the
Diesel engine

The
service operations should be carried out by
a
Volkswagen dealer because this work
requires specialist knowledge, workshop
equipment and special tools. Furthermore
this work must
be
done
in
accordance
with
out instructions.

Complete
proof
of
servicing
by a
Volks­
wagen dealer can be one
of
the stipulations
for
the
upholding
of any
warranty claims during
the
one year warranty period.

Attention
Safety
regulations
place
very

strict
limits
on the
amount
of re­

pairs
and
adjustments
to
engine

and
running
gear
parts
which
can
be
done
by the
owner.
By
tinker­
ing
with
parts
which affect
the

safety
of a
motor
vehicle
one can

endanger
oneself
and
other road users.

Altering the engine settings is detrimental to the
exhaust

emissions.
This means
that
the envi­
ronment is burdened unnecessarily
and the
fuel
consumption
also
in­
creases.

The disposal of old oil, used brake

fluid,
dirty
coolant, defective
bat­

teries or worn-out tyres etc. must be
done according to environmental
protection regulations. It is even
better
if old operating fluids and parts are used
again
and
do not become a burden on the envi­
ronment. Through "recycling" valu­

able
raw-materials and
energy
are
saved and at the same
time
it re­ lieves the load on the toxic waste

dumps.
Volkswagen dealers collect
all reusable materials and parts and

passes
them
on to the correct
agency
for recycling.
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GENERAL
MAINTENANCE

Engine
compartment

Page

Windscreen
washer
container
.. 108
Power
assisted
steering

fluid
reservoir*
100
Engine
oil filler
opening
97

Engine
oil
dipstick
97

Coolant
expansion
tank 102
Brake
fluid
reservoir
104

Battery
106 Attention
Particular care should be
taken

when working in the engine
com­
partment!

•
Switch off engine, remove ignition key.

•
Pull handbrake on firmly.

•
Move gear lever into neutral or
"P"
position.

•
Allow engine to cool off.

•
As long as the engine is at op­
erating temperature:

-
Do not put your hand into the radiator fan, it could switch on

suddenly.

-
Do not open the radiator cap be­
cause
the cooling system is

under
pressure.

•
Avoid causing short circuits in
the electrical system - particular­ ly at the
battery
-.
•
If tests have to be
carried
out

with
the engine running,
there
is
an additional danger
present

from rotating parts - e.g.
V-belts,
generator, radiator fan etc. - and
from the high voltage ignition
system.

Attention must be paid to the warnings given in this Instruc­
tion Manual and to the generally
applicable
safety regulations.
When topping up fluids one
should
ensure
that
they are not mistaken,

one
for the other, under any
circum­

stances,
otherwise serious
func­

tional defects
will
result.
So
that
leaks
are quickly de­
tected
the ground underneath
the vehicle should be checked
reg­

ularly.
If spots as caused by oil or

other
operating fluids can be seen, the vehicle should be
taken
to the
workshop for checking.
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GENERAL
MAINTENANCE

Gearbox
oil
Specifications

Manual
gearbox
and
final
drive

•
Gear
oil,
API-GL
4, SAE 80 or
•
Gear
oil, G 50, SAE 75 W-90

Automatic
gearbox

• Final drive:
Gear
oil, G 50, SAE 75 W-90 I Gearbox part: ATF Dexron®
Checking oil
level
rVith
a
manual
gearbox
and
final

drive
the oil level does not need checking.
'.ith the
automatic
gearbox
the oil

•e.
el in the final drive does not need check- *g either.

"he
ATF
level
in
gearbox
part
must ": .'/ever be checked in between the inter-

•BS
given in Service Schedule. To do this
ire vehicle must be standing on a level sur-
fe:e.
The
level must only be checked when
He ATF is
warm.
(Approximately 10 km

Irrer
starting from
cold,
the ATF has re­
tted the required temperature.) If fluid is
l:: :: or too hot the reading will be incorrect.
1
he engine must be running at idling
speed,

the handbrake must be applied and the se­ lector lever at "N".

To
check, pull dipstick (see Fig.) out, wipe
with a clean lint-free rag and then insert it
fully
again.

Pull
the dipstick out and check ATF
level.

When
the ATF is
warm
the
level
must
be
between
the two
marks
- other­

wise
the vehicle must be taken to a
Volks­
wagen
dealer without delay so that they can
find the reason for the incorrect
level.
It is not sufficient to merely top up or drain off

ATF.
Changing oil

For
the manual
gearbox
with
final

drive
the oil does not need changing.
For the
automatic
gearbox
the :
the final drive does not need
chariC-g

either. The ATF in gearbox part must how­

ever
be changed at the intervals given in
Service
Schedule.
Because of the disposal
prob­

lems,
the
special
tools
necessary
and the
specialist
knowledge
re­
quired,
the ATF
changing
should

preferably
be
done
by a
Volkswagen
dealer.

Notes

•
When
there
is no
lubricant
in the
manual
or
automatic
gearbox,
the

engine
must
not be
started
and the
vehicle may only be
towed
with
the

driving
wheels
lifted.

• No
additives
may be
mixed
with
the lubricants.
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GENERAL
MAINTENANCE

Moving
radiator
forwards
For certain operations in the engine
com­

partment e.g. changing plugs or to reach the
V-belt it may be necessary to move the
radi­
ator forwards.
To do this
first
remove the four securing
screws
(left
illustration).
Then
lift the radiator and move it forward.
When work in the engine compartment is
finished the radiator must be moved back to
the normal position and secured with the screws.
Brake
fluid

The brake fluid reservoir is in the engine compartment.

Note
On
vehicles with righthand drive the reser­
voir is on the other side of the engine
com­
partment.
104
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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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