change wheel VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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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

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
Turn signal and dip
lever

The
turn
signals only work when the ignition
is
switched on.

Right
turn
signals - lever up
Left
turn
signals - lever down

When
turn
signals are working, the warning lamp flashes as well - see page 48
also.

The
turn
signals cancel automatically after
completing a turn. To
signal
a
lane
change

Move
lever up or down to pressure point

and
hold in this position - the warning lamp must also be flashing.
To dip
headlights
Pull
lever past pressure point towards steer­
ing wheel. When high beams are on, the
high beam warning light will light up.
Headlight
flasher
Pull
lever towards steering wheel to pres­

sure
point - the high beam warning lamp lights up.

Parking
lights

The
parking lights only work when ignition
is
switched off.

Right
parking lights - lever up
Left parking lights - lever down. Note

The
use of the signals and lighting described
here
is subject to local regulations.

52
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CONTROLS AND EQUIPMENT
Windscreen
wiper
and
washer
system

Wipers
and washers only work when igni­
tion is switched on.
The
heated
windscreen
washer
jets*
are switched on when the ignition is switched on and the amount of heat is regu­lated automatically according to the ambi­
ent temperature

When
it is freezing, check
that
the wiper
blades
are not frozen to the glass before
switching the wipers on for the
first
time.
Windscreen
• Flick
wipe
Lift lever to pressure point before detent 1.
•
Wiper
slow
Lever
at position 1. •
Wiper
fast

Lever
at position 2.
•
Intermittent
wipe
Lever
at position 3

The
wipers work about every 6
seconds.

With an
infinitely
variable
intermit­

tent
wipe*
the wipe delay can be pro­grammed between about 1.5 and 22
sec­

onds:

- Switch on
intermittent
wipe
- Switch off
intermittent
wipe and then switch on again after the desired delay.

The
selected delay can be changed as often

as
required. After switching off the ignition
the selected pause reverts back to a six
sec­

ond interval.
•
Automatic
wash/wipe
facility
Pull
lever towards steering wheel - wipers

and
washer work.

Release
lever -

The
washer stops and the wipers carry on
for about 4
seconds.

Headlight washer system*

When
the headlights are on, the lenses are
washed
every time the windscreen is

washed.

At regular intervals such as when filling the
tank, caked-on
dirt
and insects should be

removed.
Rear
window

Press
lever away from steering wheel and

release
- the wiper works about every 6

seconds
(intermittent
wipe).
Pressing
and
releasing
lever again switches the wiper off.

Automatic
wash/wipe
Press
lever away from steering wheel, and
hold in this position -

The
wiper and washer work as long as the
lever
is held in this position.

Release
lever -

The
washer stops and the wiper carries on
for about 4
seconds.

Notes
Topping-up washer fluid
- see page 108.

Changing
windscreen wiper blades
- see page 109
54
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DRIVING
TIPS

• Where possible make
full
use of the maximum permissible drawbar weight on

call
of the towing bracket - see page 151 -
cut do not exceed it.
• While observing the permissible trailer
and
drawbar weight, distribute the load in
the trailer so
that
heavy objects are as near
as
possible to the axle. The objects must
a
so be secured so
that
they cannot slip
aoout.
• Check the
tyre
pressures on the towing
/ehicle
and the trailer.
• The headlight settings, should be
:hecked
with
trailer attached before mov- ng off and adjusted as necessary.

On
vehicles
with
headlight beam control it

is
only necessary to
turn
the knurled disc in
:ash
in the appropriate direction.
Driving
instructions

To
obtain the best possible handling of ve­
hicle
and trailer, the following should be

noted:

• Try to avoid driving
with
an unladen ve­
hicle
and a loaded trailer. If this cannot be

avoided,
only drive slowly to allow for the unfavourable weight distribution.
• As driving stability of vehicle and trailer
decreases
when the speed increases do not
drive at the maximum permissible top
speed
in unfavourable road, weather or
wind conditions - particularly when going downhill. In any
case
the speed must be reduced im­
mediately the trailer shows the slightest

sign
of snaking. On no account try to stop
the snaking by accelerating.
• For safety reasons one should not drive faster than 80 km/h (50 mph). This also
applies
in countries where higher speeds
are permitted. • Always brake in good time. If the trailer

has
an overrun brake, apply the brakes gen­
tly at
first
then firmly. This will avoid the
jerk­
ing caused by the trailer wheels locking.

Change
down before going down a steep hill so
that
the engine can act as a brake.
• When a long climb in a low gear
with
ex­ tremely high engine revs must be nego­
tiated at exceptionally high ambient tem­peratures the coolant temperature gauge must be observed. When the gauge needle

moves
to the
>~zza'
e~z of :ne
scale,
the road speed must be reduced immediately. If nevertheless ~g amp flashes,
stop immediately and si ow the engine to

cool
off at idling speed for several minutes.
• The cooling effect of the radiator fan
can­
not be increased by changing down, be­

cause
the speec of t~e
~a~
s ~o! dependent
on the engine
speed.
One should therefore not change down even when towing a
trailer as long as :-e e-g -e zar cope with­ out the vehicle speed dropping too much.
83
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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
nere are two marks
with
which the oil level
:an be
checked.

• Outside on container (Fig.) • Inside on dipstick attached to the cap. ~he oil level should always be between the
MAX."
and "MIN" marks. When the level

"as
dropped down below the "MIN" mark

:^e
power assisted steering should be
:necked
at a Volkswagen dealer. It is not
sufficient merely to top up
with
hydraulic oil.

Note
f the power assisted steering fails at any
: me or when engine is not running (vehicle on tow) the vehicle remains fully steerable cut more force must be used to
turn
the
steering wheel. Cooling
system

Under
normal conditions the cooling
sys­

tem is almost maintenance-free.
The vehicle is
fitted
with
a hinged radiator
which can be folded forward when required
- see page 104.
The cooling system is filled at the factory
with
a permanent coolant which is not

changed.
The coolant consists of water and

a
40 % concentration of our coolant additive
G
11 V8B (anti-freeze on glycol basis
with

anti-corrosion additives). This mixture not
only gives the necessary frost protection
down to -25 degrees C but also protects the
alloy parts in the cooling system against cor­
rosion.
In addition it prevents scaling and ra­
ises
the boiling point of the coolant.
The concentration of the coolant therefore must not be reduced in the summer or in
warm countries, by topping up
with
plain
water. The
coolant
additive
propor­

tion
must
be at
least
40 %.
If greater protection against frost is re­
quired, the proportion of G 11 V8B additive

can
be increased, but only up to 60 % other­
wise the anti-freeze protection is reduced
and furthermore the cooling effect is im­
paired.
Vehicles
for export to cold countries -s~a .
have frost protection down to -35 decrees

C.

Only
our G 11 V8B or an additive v/rs :~e

specification
TL-VW 774 B (markea or
container) should be added to the coolant.
The additives can be obtained from
Volks­

wagen dealers.

Other
additives
can be
very
detri­

mental
to the
anti-corrosion
effect
in
particular.

The
subsequent
corrosion
damage
can
lead
to
coolant
loss
resulting
in

major
engine
damage.
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GENERAL
MAINTENANCE
*
^

v
J
l B43
-
155~|

Changing
the wheels round If
the
front
tyres are worn more than the rear
it
is
advisable
to
change
the
wheels round

as
shown.
All
tyres will then have approxi­ mately
the
same length
of
service life.
With certain types
of
tread wear
it
can be an advantage
to
change the wheels diagonally.

Volkswagen
dealers have
the
necessary
in­

formation.
Renewing wheels/tyres

Wheels
and tyres are important design
fea­
tures. The wheels and tyres approved by us should be
used.
They are specially matched
to
the
model concerned
and
contribute largely
to the
excellent road holding
and

safe
driving characteristics.

Volkswagen
dealers have the up-to-date in­
formation
on
which brands
of
tyres are ap­ proved
by us.

• Fitting
and
repairing tyres requires
ex­
pert knowledge and special tools. This work
may only be carried out by specialist person­

nel.

djn
Because
of the
problem
of dis-
<^>
posing
of the old
tyres,
the

special
tools
necessary
and the
specialist
knowledge
required,
tyre
changing
should
preferably
be
done

by
a
Volkswagen
dealer.

Furthermore, many Volkswagen dealers
stock
an
attractive range
of
wheels
and

tyres.
•
For
safety reasons
the
tyres should
be
renewed
in
pairs and
not
singly. The tyres

with
the deepest tread should always be on
the
front
wheels. • Only combine radial
ply
tyres
of the

same
type,
size
(rolling circumference) anc if possible
the
same tread pattern
on all 4

wheels.

•
If the
spare wheel differs from
the
ver­
sion
fitted
on the
vehicle (e.g. winter tyres
or wide tyres)
the
spare may only
be
usee briefly
to
replace
a
flat
tyre
and
with
an
ap­propriately careful style
of
driving.
It
mus:
be replaced
with
the
normal wheel as soor

as
possible.
• Never
fit
used tyres where their previous history
is not
known.
112
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