gearbox 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
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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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DASHBOARD AND CONTROLS
Page
| Remote controlled outside mirror
13
2
Switch for electric windows 12
3
Switches 50
-
Air
vents
55,
58
5
_urn signal and headlight dip lever
Cruise
control system 52
53
z
Emergency
light
system switch 51
Combi
instrument:
Warning lamps Instruments 47
40
I
Ignition
lock 36
9
Windscreen
wiper/washer lever
with
switch for
multi
function indicator 54
42
1 10
Switches
50
Air
vents
55,
58
I 12
Space
for auxiliary heater controls
63
'
3
Radio"
'-
Glove
box
74
' 5
Bonnet
release handle
94
0
Lola
starting aid (Diesel engines) 17
Fuse
box behind shelf
—
18 Horn ( only functions
with
ignition switched on
19
Controls
and switches for heating/ventilation
... air conditioner V-
20
Gear
lever (manual gearbox)
Selector
lever (automatic gearbox) 31
21
Switch
for recirculating air
s:
22
Ashtray
73
23
Cigarette lighter/electric socket
Notes
• Some of the items listed are only
fitted
on certain mi optional extras.
• On righthand drive vehicles the arrangement of the sv the location of some items can vary. The symbols on tr are the same as for lefthand drive vehicles.
11
Vehicles
with
a factory
fitted
radio have a radio instruction iea
When
service installing a radio pay
attention
to the ins
page
129 in the "Do-it-yourself" section.
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CONTROLS
AND EQUIPMENT
-andbrake
~: ;:dy the handbrake pull lever up
firmly.
Zr - s the
1
st gear or
with
automatic gear- :ne parking lock should also be en-
r'zz^z.
The handbrake should always be
ace
53 so
firmly
that
it is not possible to
zr .9 nadvertently
with
the handbrake on.
~T"
handbrake is applied
with
the ignition
• :_e brake warning lamp comes on.
~: "e ease handbrake, pull lever up slightly,
: r;s locking knob in and push lever
right
Manual
gearbox
Note
When driving you shot z ' z: est .: ~ E~ :
on the gear lever. The press^-e z~ .:„'-="
is
transmitted to the selectc ~z'-~ - ~T
gearbox and can cause pren-a:_"5 .-, ~z' z~
the forks.
Gear
gate
• All forward gears are baulk synchro
nised.
The synchronising hubs enable easy
noise-free selection of the forward gears.
• Only engage reverse gear when vehicle
is
stationary. When engine is running, de
press
clutch
fully
and
wait
a few seconds
before moving gear lever, to prevent grating
noises.
When reverse gear is engaged
with
ignition
on,
the reversing lights come on.
3'
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CONTROLS AND
EQUIPMENT
Automatic
gearbox4
The vehicle is equipped with an electroni cally controlled 4-speed automatic gear
box.
The gearbox has a lock-up clutch which eliminates the system-inherent converter
slip in 4th gear, and in certain driving
condi
tions also in 3rd gear.
This
significantly im proves the efficiency of the gearbox in
these two gears and reduces the fuel
con
sumption.
Depending
on driving style the lock-up
clutch can cause more frequent gear shift
ing.
This
is normal and no cause for concern.
Programme
switch
The programme switch in the instrument panel can be used to select a sports
pro
gramme for a sporty type of driving (S -
warning lamp lights up) or for normal driving (warning lamp out).
The programme selection can be made by pressing the switch
(arrow)
when vehicle is
stationary or on the move.
Normal
driving
The programme by changing up early and changing down late, makes economical
driving possible.
S -
Sport
programme
For a sporty style of
driving,
this programme
should be selected. By changing up later full use can be made of the engine's power re
serve. Changing down is effected at higher
engine speeds than in the normal driving range.
Note
The programme which has been selected remains engaged even after the engine has
been switched off.
This
means that a
change of programme can only be effected
by operating the switch.
32
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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
R -
Reverse
gear
The reverse gear should only be engaged
when the vehicle is stationary and
with
the engine idling. Before engaging the position
"R"
from the positions "P" or "N" the brake
pedal must be depressed and the lock
but
ton in the selector lever handle must also be
pressed.
The reversing lights come on then the
selec
tor lever is in the " R" position
with
the igni
tion
switched on.
IM -
Neutral
(idling
position)
To
move the lever out of neutral when
sta
tionary or at speeds below 5 km/h and
with
ignition switched on depress the brake
pedal and press the lock
button
in the
selec
tor lever handle.
D -
Normal
driving
position
The four forward gears are shifted up and down automatically depending upon
throttle
opening and programme selected.
Under
certain driving conditions it is advan
tageous to engage one of the following de
scribed
selector lever positions. 3 - Position for
hilly
regions
The 1st, 2nd and 3rd gears are shifted up and down depending upon engine load, road
speed
and programme selected. The 4th
gear
is not engaged. This increases the en
gine braking effect when the accelerator pedal is released.
This
selector position is recommended in situations where the gearbox alternates fre
quently between 3rd and 4th gears in the
"D"
position.
2 - Position for
steep
hills
This
selector lever position is suitable for long climbs and descents.
The 1st and 2nd gears are shifted up and down automatically depending on engine
load,
road speed and programme selected.
To
prevent unnecessary changing up 3rd
and 4th gears are not engaged. This
further
increases
the engine braking effect on
deceleration.
1 - Position for
very
steep
hills
This
selector lever position is recom mended for very steep climbs and de
scents.
To
engage this gear, the lock
button
in the
selector
lever handle must be pressed in.
The vehicle only moves in
1
st gear. The 2nd, 3rd and 4th gears are not engaged.
Maxi
mum possible engine braking effect is now
available.
The cruise control * cannot be used in
posi
tion
"1".
Note
When changing down manually the selector lever can be moved
into
the positions "3",
"2"
and "1", but the gearbox will not
change
down
until
it is no longer possible to
over-rev the engine.
Kick-down
device
The kick-down device gives maximum ac celeration. When the accelerator pedal is
pressed
right
down past the
full
throttle
position, depending on road speed and en
gine
speed,
the box changes down
into
a lower gear. The upshift
into
the next higher
gear
then takes place as soon as the maxi mum specified engine speed is reached.
34
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CONTROLS
AND EQUIPMENT
Notes on driving Starting
\
e
engine
can only be started when
selec-
pr
ever
is at
"N"
or
"P".
See
also
"Starting
Br:
re" on
page
37.
Selecting
a driving range When the vehicle is stationary and
the engine is running always de
press
the foot brake when selecting
i gear.
When the vehicle is stationary do
•ot depress the accelerator when
•electing a gear. f the lever is moved accidentally nto "IM" when driving, release ac
celerator and let the engine speed
trop to idling before selecting a for
ward
gear again.
•
Attention
•
When the engine is running it
is
necessary to hold the vehicle
with
the foot brake in all gears.
Because
with
an automatic gear
box the transfer of power is not
fully interrupted even at idling
speed
- and the vehicle tends to
"creep".
When the vehicle is stationary
and a gear is engaged, the
throttle
must not be opened inad
vertently
on any account (for in
stance
by hand from the engine
compartment). Otherwise the vehicle
will
move immediately -
even if the handbrake has been
fully applied.
Before working on the vehicle
with
the engine running, apply
the handbrake and put the selec
tor lever in "P".
Moving off
Select
driving
range
(R, D, 3, 2, 1).
Wait
until
the gearbox has
shifted
and the
power
flow
is made to the
driving
wheels
(light
selection
jerk
perceptible).
Then
one can accelerate.
Stopping
To
stop
vehicle
temporarily
such
as at traffic
lights,
it is only
necessary
to
apply
the
brakes.
It is not
necessary
to
move
selector
lever
to
"N".
The
engine
should
however
only
be running at idling
speed.
Parking
On
level
ground all you
need
do is
engage
the
parking
lock.
On a gradient the
hand
brake
should
be
applied
firmly first
and
then
the
parking
lock
engaged.
This
will
ensure
that the
locking
mechanism
is not too
heav
ily
loaded
and
makes
the
lock
easier
to
dis
engage.
Tow starting
On
vehicles
with
automatic
gearbox
the en
gine
cannot
be started by towing or
pushing
the
vehicle.
See
page
133.
When
the battery is flat, the
engine
can be
started
from the battery of another
vehicle
by
using
jumper
cables.
See
"Emergency
starting",
page
130.
Towing If the
vehicle
has to be towed at any time,
you
must
read
the instructions in the
sec
tion
"Towing/tow
starting on
page
132.
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CONTROLS AND EQUIPMENT
Starting
the
engine
General
hints
Attention
When
starting
the
engine
in con
fined
spaces
there
is a
danger
of poisoning.
• Before starting, move gear lever to neu- ml
(with
automatic gearbox, selector lever -
"P"
or "N" position) and apply handbrake
I 'mly.
• On vehicles
with
a manual gearbox de-
:"9ss
the clutch pedal when operating
=:arter
so
that
starter only has to
turn
en
gine.
• As soon as engine starts, release the gnition key so
that
starter can disengage.
• After starting a cold engine it may sound
_oisy
for a moment or two because the oil pressure has to build up in the hydraulic
tappets
first.
This is normal and no cause for
a
arm. Do not
warm
engine
up by run-
W>
ning
it
with
vehicle
stationary.
Drive
off
straight
away.
Do
not overrev or use
full
throttle
until the
engine has reached the normal operating
Temperature. • On vehicles
with
a
catalytic
con
verter
the
engine
must
not be
started
by
towing
the
vehicle
in ex
cess
of 50 m.
Otherwise
unburnt
fuel
can pass
into
the
converter
and
lead
to
damage.
•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve
hicle
should be used for
starting
if
possible - see
page
130.
Petrol
engines
These
engines are equipped
with
a cer: ~-
jection system
that
automatically s^c; es the correct fuel/air mixture at ail anc e~:
temperatures.
When
engine is cold or at
operating
temperature
do not accelerate before or
during the starting procedure.
Applicable to all engines:
If the engine does not start at once, stop
using
the starter after 10
sees,
wait about
half a minute and then try again. If the engine still does not start, the electric
fuel pump fuse may have blown - see page
122.
When
the engine is
very
hot it may be
necessary
to accelerate slightly after the
engine has started.
37
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DRIVING
TIPS
Driving economically and ecologically
.'arious
factors determine the fuel
con
sumption,
the burden on the environment
and
the wear on the engine, brakes and
lyres.
The personal style of driving
Determines
to a great extent the economi-
:al
aspect and the exhaust and noise
devel
opment:
jOp
Do not
warm
up the
engine
with
W» the
vehicle
stationary.
At idling speed it takes a very long
time
until
the engine becomes operationally
warm. However, in the warm-up phase,
wear and the discharge of pollutants is
oarticularly high. For
this
reason, drive
off immediately the engine has started
and avoid
high
engine speeds.
f
h Avoid
full
throttle
acceleration.
of only is the
fuel
consumption reduced
considerably
if one accelerates
with
feel
ing, but the disturbance to the environ
ment
and the wear are also reduced.
rflri
Do not
drive
with
unnecessarily
high
engine
revs
-
change
up as
soon as possible,
only
change
down
when
the
engine
no
longer
runs
smoothly.
The
fuel
consumption is for example
more
than
twice as
high
in 2nd gear
than
it is in top
gear.
At the same
time,
the re duced engine speed means a reduction
in engine noise.
On vehicles
with
an automatic gearbox
the economy programme should be se
lected.
c^p
Try not to
drive
at
maximum
TO
speed.
The
fuel
consumption, exhaust pollution
and noise increase disproportionately at
high
speeds. If approximately only 3
quarters of top speed is utilised, the
fuel
consumption
will
be reduced by about
half.
Experience has shown
that
the loss in
time
is only marginal.
c
j-,
Drive
as
smoothly
as possible and
look
well
ahead.
Unnecessary
acceleration and braking
must
be paid for
with
higher
fuel
con
sumption and more disturbance to the environment.
Switch
the
engine
off
during
hold-ups. The individual
operating
condi
tions
Naturally
also
affect fuel consumption.
The
following factors for instance are not fa
vourable
to good fuel consumption:
•
High traffic density, particularly large
.towns with numerous traffic lights.
•
Frequent stop/start driving, always restarting and warming up the engine.
•
Driving in heavy, slow moving traffic in
low
gear so that the engine speed is
rela
tively high in relation to the distance cov
ered.
CQ~, One
should,
therefore,
plan
trips
in
advance
and try to
avoid
local
traffic
and
overcrowded
motor
ways.
Obviously
the fuel consumption is
also
af
fected
by factors over which the driver has
no
control. It is for example normal for the
consumption
to increase in the winter or in
arduous
conditions (bad roads, trailer tow ing etc.).
79
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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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