check oil VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual
[x] Cancel search | Manufacturer: VOLKSWAGEN, Model Year: 1992, Model line: CARAVELLE, Model: VOLKSWAGEN CARAVELLE 1992 T4 / 4.GPages: 164, PDF Size: 25 MB
Page 5 of 164
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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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Page 49 of 164
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CONTROLS
AND
EQUIPMENT
Warning
lamps
~ne layout of the warning lamps depends on
:ne model and the engine fitted. The sym-
: ols shown here are also on the actual warn-ng lamps.
|- Coolant temperature/ coolant level 47
1- Engine oil pressure 47
I- High beams 48
-- Turn signals 48
5-
Brake system 48
V Alternator 49
" Glow plugs 49 Coolant
temperature/
Coolant level1'
This
lamp flashes for a few seconds as a
functional check when ignition is switched
on.
If the lamp does not go out afterwards or
flashes
when driving, either the coolant
temperature is too high orthe coolant level1'
too low:
Stop,
switch
engine
off and check
level.
Add coolant if necessary.
11 Only on vehicles
with
automatic coolant level monitor(see page 102).
Attention
• Be
careful
when
opening the
coolant
expansion
tank!
When
the
engine
is hot the cooling
sys
tem is
under
pressure -
Danger
of scalding!
Therefore
let
engine
cool
down
before
unscrewing
the cap.
• Do not
touch
the fan. The fan can
switch
on suddenly -
even
when
ignition
is
switched
off.
For
further details see pages 102 and 103.
If the coolant level is in order the trouble
may be due to failure of the radiator fan.
Check
radiator fan fuse and renew if
necessary-seepage
122.
If the warning lamp does not go out al
though coolant level and fan fuse are in order, do not
drive
on - call in expert as
sistance.
If the trouble is only caused by the fan and
assuming
coolant level is in order and tem perature warning lamp is out - one can drive
on to the nearest Volkswagen dealer. In
order to make good use of the air stream for
cooling,
do not let engine idle or drive very
slowly.
2 - Engine oil pressure -7
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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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Page 82 of 164
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DRIVING
TIPS
The technical
prerequisites
"or
a low fuel consumption and efficiency were "built in" at the factory. Particular im
portance was placed on the lowest possible
disturbance
to the environment. To retain
and
make the best possible use of these
characteristics
attention should be paid to
the following points:
Vehicles
fitted
with
a
catalytic
converter
may
only
be
driven
on
unleaded
petrol.
Even
those
vehicles
which
do
not
have
a
catalytic
converter
should
be
driven
on
unleaded
petrol
for the
sake
of the
environment.
The
prescribed
maintenance
operations
should
be
carried
out
exactly
as
specified
in the
Service
Schedule - see
also
page
93.
Having your vehicle regularly serviced by
a Volkswagen dealer not
only
ensures
that
it is always operationally fit, but it
also ensures economy, lowest possible burden on the environment and a long
service
life.
Check the
tyre
pressures
every
4
weeks.
Low
tyre
pressures increase the rolling
resistance.
This not
only
increases the
fuel
consumption and
tyre
wear,
but the
handling is also impaired.
Do not
carry
unnecessary
ballast
in the
luggage
boot
Particularly in
town
traffic
when one has to accelerate
often,
weight
has a
great
in
fluence on the
fuel
consumption. As a
rule
of
thumb:
For every 100 kg of
weight
the consumption increases by approxi
mately
litre
per 100 km.
Remove
roof
rack
immediately
after
use
Particularly at
high
speeds the increased
air resistance makes
itself
felt
consider
ably.
gCK
Electrical
consumers
should
only
be
switched
on
when
they
are
actually
required
Heated rear windows, additional driving
lights
and heater blower consume a con
siderable amount of
current.
The higher
alternator
load
also increases the
fuel
consumption. For instance, over a period of 10 hours, the heated rear window
will
increase
the
fuel
consumption by ap
proximately 1
litre.
Check the
fuel
consumption
reg
ularly
The
fuel
consumption should be checked
each
time
the
tank
is
filled
up. By doing
this
inconsistencies on the vehicle which
lead to an increased
fuel
consumption
can be discovered sooner.
• Check the
engine
oil
level
each
time
the
tank
is
filled
up
The
oil consumption depends to a great ex
tent
on the engine load and
speed.
Depend
ing on the style of driving the consumption
can
be as much as 1.0 litres/1000 km.
It is normal for the oil consumption of a new
engine
to reach its lowest level after a cer
tain mileage has been covered. The
con
sumption cannot be properly
assessed
until
the vehicle has run approx. 5000 km.
This
also
applies to the fuel consumption
and
the engine output.
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Page 97 of 164
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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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Page 99 of 164
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GENERAL
MAINTENANCE
The
multigrade-improved
lubricity
oils as per VW
Specification
500 00 m/e in addition the following advantages:
-
All year round use at practically all tem peratures.
-
Low frictional
losses
in the engine.
-
Best possible starting even at very low temperatures.
»Jotes
I
Single
grade
oils. Due to their limited
i-scosity
ranges these oils are not generally
j_::eptable for all year round use. "erefore these oils should only be used in
-
:reme climatic
zones.
•
When using SAE 5 W-30 multigrade oil, xntinuous high engine speeds and engine
seeding
should be avoided. This restriction
::es
not apply to multigrade-improved lu-
r city oils.
Checking
oil
level
Every
engine uses a certain amount of oil.
The
oil
consumption
can be up to 1.0
litres per 1000 km - see also page 80. The
engine oil level must therefore be checked
at regular intervals, preferably when filling
the tank and before a long journey.
The
location of the dipstick is shown in the illustration.
The
vehicle must be on a level surface when
checking
the oil level. After stopping engine
wait a few minutes for the oil to drain back
to the sump.
Then
pull the dipstick out, wipe it
with
a
clean
cloth and insert again.
Then
pull dipstick out again and check the oil
level:
A
- Oil
must
be topped-L.c.
Afterwards it suffices v.-5-:_e : e e
is
somewhere in area B.
B
- Oil can be topped-up. It can then happen
that
the c e.e s -
area
C.
C
- Oil
must
not be topped-up.
When
the engine is working hard sue as -
sustained
high-speed motorway cruising in
summer, when towing a trailer or :re~
climbing mountain
passes,
the c: e.e
should
be kept at area C (not
above
Note
If the dipstick does not have a- c"ee: -
measuring
area,
the upper and lows- e~zi
of the etched area form the MAX.
a~
z '.'
marks.
The oil level must be betv.ee- re
two marks. If it has dropped to 're '.' ". mark, oil must be added,
however
on no
account
above
the MAX.
mark.
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GENERAL
MAINTENANCE
Topping
up
engine
oil Unscrew the cap from oil filler opening and
pour oil in 0.5 litres at a time. Then check
level with the dipstick.
On no account must the oil level be
above area C. Otherwise oil can be drawn into the engine via the crankcase breather
and escape into the atmosphere via the ex haust system. On vehicles fitted with a
catalytic converter, the oil could burn inside
the converter causing it damage. Attention
When topping up the oil, do not spill it onto hot engine components - danger of fire.
Carefully close the filler cap and push the oil
dipstick in as far as possible, this will pre
vent oil spill when the engine is running.
Changing engine
oil Not only does the engine oil deteriorate due
to use when the engine is running, but also to ageing. The engine oil change intervals depend therefore on the mileage and also
on the time elapsed.
Petrol engines
Change engine oil every 15 000 km or every 12 months (whichever comes first).
Diesel engines
Change engine oil every 7500 km or every 12 months (whichever comes first).
For further details, see Service Schedule. For petrol and Diesel engines
If the vehicle is used continuously in ar
duous conditions, the engine oil must be
changed at shorter intervals - see also page
93.
Recommended oil and viscosity classes -
see page 96.
Attention
Old oil must be stored out of reach of children until it is dis
posed of in the correct manner.
ojfcj
On no account must oil be
earth.
Because of the disposal
problems,
the necessary special tools anc
specialist knowledge required the engine oil and filter changing shoulc
preferably be done by a Volkswagen
dealer.
Engine
oil
additives
No additives should be mixed with
the engine oil.
Any damage caused by the use o
such additives will not be coverec by the warranty.
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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
Air
cleaner
Power
assisted
steering
The
paper
filter
element in the air cleaner is normally renewed as detailed in the Service
Schedule.
In very dusty conditions the el
ement must be cleaned or renewed at
shorter intervals.
To clean or
renew
element
•
Release
clip (1 ) •
Press
locking handle ( 2 ) down and un hook it.
• Take
filter
housing out upwards.
• Take
filter
element out. •
Clean
element
with
compressed air or renew it.
The
element must not be washed
with
pet rol or moistened
with
oil.
Installing
• Insert
filter
housing. Ensure
that
the
plastic
lug on the rearend of the elementfits
in the recess in the mounting.
• Secure clip (1 ).
• Pull locking handle ( 2 ) up until it en
gages.
The
reservoir is located in the engine compartment on the
right
looking forward.
The
power assisted steering is filled
with
our hydraulic oil G 002 000.
The
correct oil level in the reservoir is
essen
tial for the satisfactory operation of the power assisted steering.
The
level can only be checked
with
the en gine at normal operating temperature but not running.
100
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