handbrake VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual
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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
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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Page 39 of 164

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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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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 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 101 of 164

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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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DO-IT-YOURSELF
Changing
wheels
Park
the vehicle as far as possible away
from the
traffic
flow, if necessary switch on emergency warning lights and place the
warning triangle in position - note legal re
quirements.
• All vehicles occupants should leave the vehicle and move to a safe area (e.g. behind
the barrier).
• Apply handbrake firmly. If the car is on a
slope,
block one of the wheels on the oppo
site side
with
a stone or some similar object.
• Take the tools out of the vehicle.
• Take spare wheel out of carrier at rear of vehicle - see previous page.
JB70
- 121J
•
Push
the wheel spanner as far as
poss
ible onto the wheel bolt as shown and
turn
the spanner anti-clockwise. When doing this, grip the spanner as far as possible to
wards the lever end.
If the bolts cannot be loosened, one can in
an emergency, carefully push the spanner
down
with
a
foot
on the end of the lever.
One
should ensure
that
one has a
firm
stance
and a good grip on the vehicle.
Loosen
wheel bolts about one turn. 8"" 1 •>!
•
Place
jack under vehicle: - Depressions in the side member at
front
and rear indicate the points at which the
jack must be
fitted
- see arrows in illus
tration. On the sliding door side
ensure
that
the
claw
of the
jack
does not
fit
under
the sliding door.
- On the Pick-.up the jack is placed under the mounting of the trailing arm (triangular mark) at the rear.
- If the
jack
is not
placed
at the
marked
points, the
vehicle
can be
damaged.
120
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TECHNICAL
DESCRIPTION
Power
flow
Manual
gearbox
• Mechanically or hydraulically operated single plate dry clutch
• Baulk synchronized five speed manual gearbox and final drive in one housing.
• Common lubrication for gearbox and final drive. Permanent oil filling
• Front wheel drive
Automatic
gearbox*
• Hydro-dynamic torque converter
with
lock-up clutch to eliminate converter slip in
3rd speed (under certain driving conditions)
and (always) in 4th speed
• Planetary gearbox
with
4 forward gears
• Two electronically controlled selectable driving programmes
• Flanged on final drive
with
separate lubri cation and life-long oil filling
• Front wheel drive
Steering,
Axles
Steering
• Maintenance free rack and pinion steer ing
• Steering column
with
angled joints
• Steering pinion and column connected by angled shaft
with
two universal joints
• Hydraulically assisted steering
(PAS)*
Front
axle
• Independent wheel suspension
with
double wishbones, shock absorbers and
anti-roll bars
• Longitudinal mounted torsion bar
Rear
axle
• Independent suspension
with
diagonally trailing arms, coil springs and shock ab
sorbers.
Brakes
• Hydraulic dual circuit brakes
•
Disc
brakes at
front
• Self adjusting drum brakes at rear
• Brake servo
• Pressure/load-sensitive brake pressure regulator for rear axle
• Mechanical handbrake effective on rear wheels
• Anti-locking brake system
(ABS)*
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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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