cooling 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

2
-
Coolant temperature
—
~~s
gauge starts
to
work
when ignition
is
=
.vitched on,
but it
takes some time before
~e needle reaches
its
final position.
-en ignition
is
switched
on the
warning
c~ip flashes
for a few
seconds
as a
func-

•
:nal check.

5
- Cold

-. Did
high
engine speeds and
do not
work

r-gine
too
hard
yet.

:
- Normal

nen
the
vehicle
is
driven normally
the

~eedle
should settle
down
in
this zone.
-en engine
is
working hard and the ambi-

r~t
temperature
is
high,
the
needle
may
-ove
a
long
way up. This is not serious as long as the
warning lamp does not flash.
Warning lamp
If
the lamp flashes when driving, check first
the indicated coolant temperature.

If the
needle
is in the
normal zone,
top the

coolant
up at the
next
opportunity.

If
the reading
is
in the upper zone, either the
coolant level
is too low or the
coolant tem­
perature
is too
high.
Stop,
switch
en­
gine off
and
try to
find cause
of
trouble
-

see
page 47.

Notes

•
Additional
lights
in
front
of the cooling air intake interfere
with
the

flow
of cooling air. At
high
ambient
temperatures and
full
throttle
there is a danger that the engine
will
then
overheat.
3
-
Digital clock
*

To
set the
time there
are two
buttons
on
lower left
of
instrument cluster.
The
hours
are
set
with
the
upper button
(h) and the
minutes
with
the
lower one
(min):

•
If
pressed briefly, preferably
with
a ball
pen,
the time changes one hour
or
one min­

ute.
•
If
pressed continuously the hours
or
min­
utes
change continuously.

With
the minute button the clock can be set exactly
to the
second:

•
Press button until time shown
by
clock
is
one minute before time
to be set.

•
Press button
at the
moment when
the
seconds
indicator
of an
accurate clock
shows a full minute
or
when the time signal
is
heard
on the
radio.
41
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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

Air
conditioner*
in cab

Description

T".e air conditioner is a combined cooling srd heating system which provides the
r-aximum possible comfort all the year
rcjnd.

Tpe air conditioner works only when the en-

pie
is running and the ambient tempera- t.re is above about + 5 degrees C.
,ien air conditioner is switched on it re-
bjces not only the temperature inside the
•
ehicle but also the air humidity. When the

=-nbient
air humidity is high this not only
Iakes
the vehicle occupants feel more
comfortable but also prevents the windows
""Dm
misting up.
~ne cooling system works best when all the
v.indows are closed.
Controls

A
-Blower
switch

The blower has four speeds.
B -
Temperature
lever

The temperature can be regulated over the
full range for each programme lever
posi­

tion.

C
-Programme
lever

E] -
System
switched
off -
Maximum
cooling

(Temperature lever B fully to
left)
Air from
side and centre outlets
SSI -
Cooling
normally
(Temperature lever position as required)

Air
from side and centre outlets
SS§i
-
Comfort
setting

(Temperature lever position as requ rez

Air
comes from the side and centre
OJ:
e:s
and into footwell. Slight flow of air to
•:.
-z- screen and side windows.
H-
Ventilating
(Depending on position of temperature
lever, heated or unheated fresh air - not

cooled
air)

Air
from side and centre outlets,
dj -
Heating

(Temperature lever position as required)

Air
to the footwell, slight flow of air to wind­ screen and side windows and the side and
centre outlets
Wi -
Defrosting
and
demisting

(Temperature lever position as required)

Air
to windscreen and to side windows, slight flow of air to footwell and to the side
and centre outlets.
57
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CONTROLS
AND EQUIPMENT
Air
vents
Depending
on the position of lever B heated

or
unheated fresh air or cooled air flows
from all vents.

The
vents 3 and 4 can be opened and closed
separately:

Knurled
disc up - outlet
closed.

Knurled
disc down - outlet open.
By
swinging the complete outlet grille of
vents 3 and 4 the air flow can be moved
vertically.

When
the knurled disc in the grille is rotated
to and fro the air flow direction is altered lat­
erally.

The
outlets 2 serve to defrost the wind­
screen
wiper blades.
Setting
instructions

Defrosting
windscreen
and side

windows

• Move upper lever to position ES .
• Move lower lever fully to the
right.

• Set blower switch to stage ES , •
Close
centre outlets.
• Direct side outlets to side windows.
• For optimum defrosting of the wind­
screen
the side outlets should also be

closed.

Demisting
windscreen
and side

windows

• Move upper lever to position ES . For very effective demisting of the windows,
the cooling system switches in automati­

cally
from about + 5° C ambient tempera­
ture.
• Move the lower lever into the heating
range
at low ambient temperatures, and at
high temperatures and high air humidity
(tropics) into the cooling range.
• Set blower switch to stage El or 4 .
•
Close
centre outlets.
• Direct side outlets towards side win­
dows.

58
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CONTROLS
AND
EQUIPMENT

Heating
interior
quickly

I Move upper lever to . I Move lower lever fully to the
right.

I Set blower switch to E3 .
I
Close
centre outlets.
I Direct side outlets towards side win-

5:
.vs.

•(eating
interior
comfortably

I Move upper lever to SSi (comfort set­ 's) or to CS depending on where you
• : jId like the air flow to be.
I Set air temperature as desired
with

: .ver lever.
I Set blower switch to stage 1 or 2.
I Adjust side and centre outlets as re-
:. 'ed. At low ambient temperatures it is
cvisable
to close the centre outlets and di-
ect flow from side outlets towards the side
I ndows. Fresh air
operation

• Move upper lever to
EH
.
• Set air temperature as desired
with
lower lever.
• Set blower switch to desired stage.
• Adjust side and centre outlets as re­
quired.

Maximum
cooling
•
Close
all windows. • Move upper lever to •
• Move lower lever fully to
left
or set as re­
quired.

• Set blower switch to stage 4.
• Adjust side and centre outlets as re­
quired.
However, at least one
outlet
mustal-

ways
be open otherwise the cooling
sys­

tem may ice up.
With this setting the air is drawn from inside
the vehicle and cooled (recirculating air operation).
Normal
cooling
• Move upper lever to EM or
ESS*
.
• Set air temperature as desired .-. :~ lower lever.
• Set blower to stage 1 - 4 as desired.
• Adjust side and centre outlets as re­
quired.
In position EM at least one
outlet
must always be open otherwise the cooling

system
may ice up.
With this setting ambient air is drawn in and
cooled.
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CONTROLS
AND
EQUIPMENT

Notes

Pools of
water
under
the
vehicle

• When the ambient temperature is high
and
the air very humid, condensed water

can
drip off the evaporator and form a puddle under the vehicle. This is quite nor­

mal
and does not indicate a leak.

Operating
faults

• Should the air conditioner not work at
any
time, either:
- the ambient temperature is below about + 5 degrees C,
- the fuse has blown.

Check
fuse and if necessary renew it - see

page
122. If the trouble is not due to
a
defec­
tive fuse, switch the system off and have it
checked.

- the air conditioner has switched off due to the coolant temperature being too high -
see
page 41
also.

• If the cooling
output
drops off, switch the
A/C
off and have the system
checked.
Using air
conditioner

economically
In cooling operation the air conditioner
com­

pressor
places demands on the engine and
therefore influences the fuel consumption.

To
keep the period switched on as short as
possible,
the following points should be

noted:

• If the inside temperature is very high after the vehicle has been parked in the sun, it is recommended to open doors or win­

dows
briefly to enable the hot air to
escape.

• The air conditioner should not be
switched
on during a journey if the windows

or
sliding/tilting
roof*
are open.
• If the desired interior temperature can be attained
without
switching on the air condi­
tioner, the fresh air operation should be se­
lected.
Recirculating
air
switch

If badly contaminated air is to be prevented
from entering the vehicle, e.g. when driving
through a tunnel, the recirculating air switch in the instrument panel can be
pressed.

When
the recirculating air system is
switched
on, a small warning lamp lights up in the switch.

However,
the recirculating air system

should
only be used for a short period other­

wise
the windows will mist up.

60
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CONTROLS AND
EQUIPMENT

Air conditioner* in passenger compartment Recirculating air switch*
th the air conditioner in the passenger
:: apartment the rear seating area can also
:e comfortably cooled down.
air conditioner only functions if the air
:: iditioner in the cab is switched on - see
:;ge 57. However, adjustment of the out-
: can be performed independent of the
I stem in the cab. The control elements are : rated on the dash panel - see illustration.
air throughput can be set in any one of
;: J stages (left hand rotary switch).
Th e temperature infinitely variable with the ::ary control (right hand switch).
I Dckwise - increased cooling output
--ti-clockwise - decreased cooling output Air outlets
The air outlets are located in the roof area
above the rear seats.
The outlets can be closed or opened separ­
ately.
By pivoting the outlet grilles the direction of
air flow can also be adjusted.
This switch can be used to change over to recirculating air. This will prevent badiy con-
taminated air from entering the vehicle, e.g.
when driving through a tunnel.
Recirculating air operation should only be
used briefly otherwise the windows wil
mist up.
Switch to left - Recirculating air operation
Switch to right - Fresh air operation

Note

On vehicles with air conditioner a recirculat­ing air switch is located in the bank of
switches in the instrument panel.
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DRIVING
TIPS

• As the factory installation of a towing bracket includes the modification of the

cooling
system, this should also be done
when service installing a bracket. Other­

wise
overheating may occur when the en­ gine is pulling hard (mountains, high ambi­
ent temperature, heavy trailer loads).

Certain
vehicle versions can be equipped

with
a heavy-duty cooling system ex fac­

tory,
even though the vehicle is delivered

without
a towing bracket. Details can be ob­
tained from Volkswagen dealers.
• Volkswagen dealers have all the
necess­
ary information on the installation of towing
brackets
and the
fitting
of a heavy-duty

cooling
system. The installation should
therefore be done by them.
• If, when towing a trailer for commercial
purposes,
the permissible
total
weight of

vehicle
and trailer - also
with
passenger
cars
- exceeds 3500 kg, it is necessary to in­
stall and use a tachograph in most European

countries.
Operations
instructions

• When inserting the 13 plug
into
the
socket
on the vehicle, the ribbed sleeve on
the plug must be turned fully to the
right.

The
lid of the socket then engages over the
boss
on the
sleeve.

• If the
traffic
behind the trailer cannot be
seen
properly
with
the standard rear view mirrors, additional outside mirrors will be

necessary.
Both outside mirrors must be

fitted
on folding arms and adjusted to give
a
good view to the rear at all times.
• Pitching movements between towing
vehicle
and trailer can be reduced by heavy-
duty springs and shock absorbers on the rear axle. If these springs and shock ab­

sorbers
have not already been
fitted
at the
factory, they can, in many
cases,
be servi­

ce-installed
by a Volkswagen dealer.
• Pitching and snaking movements can
also
be reduced by stabilizers which can be
obtained from and
fitted
by Volkswagen
dealers
in most European countries. • The permissible trailer weight11 - see

page
151 -must not be
exceeded
on any
ac­

count.
• When towing a trailer in mountainous re­
gions,
note
that
the trailer weights given ir
the "Technical data" are only valid for gradi­ ents up to 10 or 12 %. If the trailer weigh'
is
below the permissible maximum a corre­
spondingly steeper gradient can be

climbed.

• The given trailer weights are only appli­
cable
for altitudes up to 1000 m above see
level.
As the engine
output
and thus the
climbing ability drops due to the decreasing
air density, the weight of vehicle and trailer must also be reduced by 10 % for eacr

further
1000 m or part thereof.
1 The permissible vehicle/trailer weight
con­
sists
of the permissible
total
weight of tow­ing vehicle plus the permissible
total
weight
of trailer. If the permissible trailer load is to be
fully utilized it may be necessary to reduce
the weight of the towing vehicle appropriate­ ly. The towing vehicle must however not be
lighter than the trailer.
82
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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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