fuel filter 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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GENERAL
MAINTENANCE
Diesel engines
Diesel
fuel
I
DIN 51 601.
CN1'
not
lower
than
45.
Driving
in
winter
When
using summer Diesel trouble may be
experienced
at temperatures below 0 de
grees
C because the fuel thickens due to
wax
separation.
Br
this
reason,
winter
Diesel
which is more
"esistant
to cold is sold during the winter in
Germany,
and this works satisfactorily
:Dwn
to between -15 and -22 degrees C,
cepending
on the type of fuel
used.
I countries with different climatic condi-
" :ns the Diesel fuels offered have a differ
ent
temperature characteristic.
Check
with ; kswagen dealers or filling stations in the
::
jntry
concerned regarding the character-
s:
cs of Diesel fuels.
Filter
preheating
The
vehicle is
fitted
with a filter preheater.
This
will ensure, that the fuel system re
mains
operational down to about - 25 de
grees
C provided that winter Diesel which
is
cold resistant down to - 15
degrees
C is
used.
Diluting with petrol is then no longer
necessary
under these conditions.
If, at temperatures below - 25 degrees C
the fuel is waxed to such an extent that the
engine
will not start it is sufficient to place
the vehicle in a warm room for a while.
Fuel
additives
(anti-waxing agents and
similar
fluids) must not be mixed with the
Diesel
fuel.
Cetane
Number, indicates the ignitability of
Diesel
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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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Page 118 of 164

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GENERAL
MAINTENANCE
Winter
driving
T
Ac
The an«
safe
high
ensi
supf
with
poin
sub:
tech latei
• /
fori
any
thro
SWc
pete
A
In
m
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V
G
u
P
SI
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r<
In winter the following points should be
noted:
• Winter weather is particularly hard on the
battery
and it should therefore be
checked,
preferably by a Volkswagen
dealer, before the onset of cold weather. If the vehicle is not driven for several weeks
when the temperatures are very low, the
battery
should be taken out - for
further
in
formation see page 107.
• On a vehicle
with
a Diesel engine, winter
Diesel
must be used at temperatures below
0 degrees C - see page 87.
• The water should be drained out of the
Diesel
fuel
filter
before the onset of
winter.
This
operation is also included in the Lubri cation
Service.
• The anti-freeze in the cooling system should be checked before the cold
season
starts - see page 101.
• The engine oil viscosity must be correct for the ambient temperature - see page 99.
• Particularly in
winter,
frequent washing and waxing of the vehicle is the best way to protect it against harmful environmental in
fluences.
• In winter the windscreen washer
sys
tem should always be filled
with
a window
cleaning solution containing an anti-freeze
additive.
• To remove snow and ice
from
the win dows and mirrors, a plastic scraper should be used - see page 90.
• The road holding and handling can be im proved in winter road conditions by the use
of winter or All-weather tyres - see pages 114and146.
• When driving in mountainous districts in winter it is advisable to take snow chains
with
you. On some such roads, snow chains
are obligatory - see also page 114.
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Page 138 of 164

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TECHNICAL
DESCRIPTION
Engine
• 4 stroke petrol/Diesel engine, trans
verse
installation
• 4/5 cylinders in-line
• Cast-iron cylinder block
• 5/6 bearing crankshaft
• Sheet metal sump
• Alloy cylinder head
• Valves operated via toothed belt and overhead camshaft
• Maintenance free valve gear
with
hy draulic tappets
• Cooling system filled for life of vehicle
• Radiator
with
separate expansion tank • Electric radiator fan controlled by ther-
moswitch
• Maintenance free electronic ignition
• Long-life spark plugs
• Optical and acoustic oil pressure warn ing
• Low maintenance battery
with
high starting capacity
• Long-life low maintenance V-belts
• Thermostatically controlled intake air preheating
• Dry air cleaner
with
paper element • Fuel
injection
engines
have fully
electronic engine management (combined
control of injection and ignition systems).
• Emission control system
with
Lambda probe on petrol engines (not in all Export
markets)
•
Diesel
engines
with
distributor injec
tion
pump
with
cold start aid,
filter
preheat
ing,
self-bleeding fuel system
• Long life exhaust system.
'36
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Page 140 of 164

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TECHNICAL
DESCRIPTION
Attention
Due to high temperatures which
can occur in the catalytic
con
verter in very unfavourable conditions, the vehicle should not be parked so that the catalyt
ic converter can come into
con
tact with inflammable materials.
If whilst driving, the engine mis
fires, loses power and runs uneven ly,
this
could be due to a fault in the ignition system. In a
case
like this,
unburnt fuel can enter the exhaust
system and then escape to atmos
phere.
Furthermore, the catalytic
converter could become damaged
due to overheating. The vehicle
speed must be reduced immediately
and the defect should be eliminated
at the nearest Volkswagen dealer.
Note
Even
in the
case
of a
perfectly working
ex
haust emission control system there can, under certain engine operating conditions,
be
a
sulphur-type exhaust
smell.
This
depends upon
the
sulphur content
in
the fuel being
used.
Quite often this can
be
remedied
by
select
ing another brand
of
fuel
or,
filling
up
with
unleaded premium petrol.
50
kW
Diesel
engine
An
oxidation catalytic converter
is
fitted
in
the exhaust system
of
this Diesel engine.
It
consists
of
a steel-cased ceramic body
con
taining
a
multitude
of
longitudinal
passages
which are vapour coated
with
platinum. The catalytic converter largely eliminates
the
unpleasant smelling hydrocarbons
and
turns carbon monoxide
into
carbon dioxide.
In addition
an
exhaust
gas
turbocharger
forces
air
into
the
cylinder, causing
the
en
gine
to
operate
with
a high
excess
of
air. The
fuel which is then injected in is so complete ly
burnt,
that
under
full
load soot is no longer
visible
in the
exhaust.
As
the
diesel engine catalytic converter
does
not get
hotter than
a
conventional
ex
haust system, under normal conditions
there
is
nothing special
to be
noted, this
applies
also
to
parking.
The system does
not
require any additional
care
or
maintenance.
Activated
charcoal
filter*
Vehicles
with
a
regulated catalytic
con
verter,
in
Germany
and
other export countries, have
a
fuel system which
in
cludes
an activated charcoal
filter
(petrol vapour accumulator).
The activated charcoal
filter
prevents
the
fuel vapour escaping
into
the
atmosphere.
These
vapours
pass
into
a
container filled
with
activated charcoal and, when
the en
gine
is
stationary they
are
accumulated
in
the activated charcoal. When
the
engine
is
running,
the
container
is
automatically
ventilated
by
opening
a
valve
and the
fuel
vapour
is fed
into
the
engine
for
combus
tion.
The system works completely automati
cally
and
is
maintenance-free.
138
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Capacities
(in litres)
Fuel
tank
of
that
reserve about 80
about 10
Windscreen
washer
with
headlight washer about 5
about 7
Engine
oil
(with/without
filter
change)
4 Cylinder engines
5
Cylinder engines
The
oil level must be checked while topping up.
Do
not overfill (see page 97 )! about 5.0/4.5
about 5.5/5.0
Automatic
gearbox (ATF) about 3.0
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ALPHABETICAL
INDEX
A
Acceleration
figures 142
Accessories
117 Activated charcoal
filter
138
Additional heater 62
Additional water heater 67
Adjusting brake pressure regulator . . 155
Adjusting headlights 128 Adjusting washer
jets
108
Air
cleaner 100
Air
conditioner 57
Air
distribution 55
Alloy
wheels 91
Analog
clock 46
Anti-dazzle
inside mirror 13
Anti-freeze 101 Anti-locking brake system (ABS) .... 30
Arduous operating conditions 115
Armrests 21
Ashtrays
73
ATF
99
Automatic gearbox 32
Automatic wash plants 88
Auxiliary heater 63
Axle
loads 148
B
Battery 106
Belt height adjustment 16
Blower
55
Bonnet 94
Brake
fluid
104
Brake
servo 30
Brake
system 104
Brake
warning lamp 48
Brakes
29, 139
c
Capacities
153
Capacity
141
Care
of body 88
Care
of car 88
Catalyst
137
Cavity
preservation 92
Central
locking system 8
Cetane
Number 87
Changing
bulbs 124
Changing
front
turn
signal bulb 125
Changing
wheels 120
Chassis
number 154
Checks
when
filling
the
tank
160
Child
safety 18
Child
seats 18
Child-proof catch 9 Cigarette lighter 73
Cleaning
and anti-corrosion
treatment
of engine compartment 91
Clock
46
Cold
starting aid 38
Combined
weight 151
Compression
ratio
141
Consumption figures 143
Coolant
additive 101
Coolant
level 47, 102
Coolant
temperature - Gauge 41
Cooling
system 101
Cruise
control system 53
D
Dash
panel 4
Dashboard
and controls 4
Defrosting windows 56, 58
Diesel
fuel 87
Dimensions
152
Dip lever 52
Dipstick - Automatic gearbox 99
- Engine 97
Direction indicators 48
Do-it-yourself 118
Door
locks 9
Doors
9 Drawbar weight 83
Driver's seat 20
Driving abroad 115
Driving on holiday 115
Driving safely 78 Driving tips 76
E
Electric
socket 73
Electric
window
lifters
12
Emergency
lights 51
Emergency
starting 130
Emission
control system 137
56
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ALPHABETICAL
INDEX
Engine
-Code
letters 154
-Data
141
- Intervals of oil change 93
-Number
154
-Oil
96 - Oil capacity
1
53
- Oil change intervals 98
- Oil consumption 97
- Oil level 97
- Oil pressure 47
- Starting/stopping 37
Engine
compartment 95
Engine
compartment
light
72
Engine
number 154 Environment
- Activated charcoal
filter
738
-Battery
707
- Brake
fluid
705 - Care of car 88
- Coolant 103
- Driving environment consciously 79 - Driving
with
low emissions/noise 79
- Emission
control
system 737
- Engine oil 98
- Filling the
tank
85
-Fuel 86 - Maintenance 93
-Old oil 98 - Old
tyres
712 - Petrol vapour accumulator .... 738
-
Tyre
pressure
7
70
- Tyres 7 72
- Unleaded
fuel
86
- Washing the vehicle 89
F
Fan
103
Filling
the tank 85
Filter
preheating 87
First
aid kit 118
Fog
lights 51, 125
Folding
seat 25
Foot
mats 29
Fresh
air ventilation 56
Front axle load 148 Front seats 20
Fuel
86
-Additives
86, 87
-Consumption
79,143
- Filter 116
- Filter preheating 87 - Gauge 46
- Saving 79
Fuses
122
G
Gear
change marks 40, 77
Gear
lever 31
Gearbox
oil 99
Glove
box 74
Glow
plugs 38
H
Handbrake
31
Head
restraints 19
Headlight
beam control 50
Headlight
flasher 52
Headlight
washer system 54
Heated
rear window 51
Heating
55, 57
High
beams 48
Horn
4
I
Identification data 154
Ignition
lock 36
Increased
payload 149
Inertia
reel belts 16 Inside mirror 13
Inspection intervals 98
Installing seat 22
Instrument
lighting 50
Instruments 40
Interior
lights 72, 126
Intervals of inspection 93
Intervals of oil change 93
J
Jack
120
Jacking
points 120
Jumper
cable 130
157
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