light 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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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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DASHBOARD
AND
CONTROLS
Warning lamps

Symbol Page Symbol
Page
Coolant temperature/
Coolant level
47

A Emergency light system
51
Engine oil pressure f^i
47

m Rear
window
heating
51

ID
Headlight
high
beams

48

to Fog lights
rear fog light 51

Turn
signals
49

Notes
((D)
Brake
system l^i

48
•
If one of the lamps marked
with
comes on when driving
stop and switch engine off. Details can be found on the pages
given

B Some of the lamps shown here are
only
on certain models or are optional extras.

£3

Alternator
49 •
If one of the lamps marked
with
comes on when driving
stop and switch engine off. Details can be found on the pages
given

B Some of the lamps shown here are
only
on certain models or are optional extras.
m Glow plugs - Diesel

49
(©)
Anti-locking brake system (ABS)

49


Trailer turn signals

49
6
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CONTROLS
AND EQUIPMENT

Central
locking system*
With this system all the doors, and - de­
pending
on the position of the tailgate or
wing door lock - the tailgate or wing door

can
also be locked and unlocked.

The
system is operated from the
driver's
door or
front
passenger door - from

outside
with the key, from inside with the
locking
knob.

Note

The
central locking system can only func­
tion correctly when the driver's and
front
passenger
doors are properly
closed.

When
locking,
the locking knobs on all doors must move down. If the knob on one door

does
not move at any time, open the door

concerned
and close it properly.

Attention

•
When
the locking knobs in the

driver's
or
front
passenger doors
are pressed
down
all
other
doors
are locked
automatically.
Since it
would
be
difficult
to ren­
der assistance
from
the outside in an emergency,
when
the doors
are locked, children should
never
be
left
in the vehicle on
their

own. • Locking the doors can
prevent

them
from
bursting open in an
extraordinary
accident situation. Locked doors also
prevent
per­

sons
from
entering
the car forci­ bly e.g. at
traffic
lights.
However,
in an emergency
they
make
it

more
difficult
for outside
help
to
open the doors.
Notes: If the central locking system should develop

a
fault, all the locks can be operated nor­
mally,
see next page.

The
sliding door can be secured or released
separately
with the safety catch.
Sliding door and
tailgate
or
wing

door can be locked or unlocked separately
with the key.
To
unlock the tailgate or wing door insert key

and
turn
it to right (c). Hold in this position

and
press button in.
If the key is withdrawn in the horizontal
posi­

tion (a), locking of the tailgate or wing door
will be controlled by the central locking
sys­

tem when it is closed again.

When
the key is withdrawn in the vertical
position (b) and tailgate or wing door
closed,

it will be locked all the time. The tailgate can
then only be unlocked with the key.
8
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CONTROLS AND
EQUIPMENT

Doors
Cab doors
From outside
the
front
doors can be
coked
or unlocked
with
the key. When un-
D
eking,
the locking knobs go up, when lock-

"5
:hey go down.

Ihe
front
passenger door can be locked

from
outside
without
using the key: Just
:"5ss
locking knob down and close door.

~~e
driver's door cannot be locked when
coen
by pressing the locking knob down
and closing door. This prevents you from
esving
the key in the car and forgetting it.

From inside
all the doors can be locked by

messing
down the locking knobs.

-s
long as the knobs are pressed down the

coors
cannot be opened from inside or out-

skte.

Attention Locking
the
doors
can
prevent
them from bursting open
in an
extraordinary accident situation. Locked doors also prevent per­
sons from entering
the car
forci­
bly e.g.
at
traffic lights. However,
in
an
emergency they make
it

more difficult
for
outside help
to

open
the
doors.

Sliding door

From outside,
the sliding door can be

locked
and unlocked
with
the key.
The sliding door can also be locked from out­
side
without
using the key:
Press
locking knob down and close door.

From inside,
the sliding door is locked by
pushing down the locking knob.

As
long as the knob is pressed down the
door cannot be opened from inside or out­

side.

When the vehicle is moving, the door must always be properly
closed,
but when carry­ing passengers the locking knob should be

left
in the upper position so
that
the door can
be opened from outside in an emergency.

Note

In the opened position the sliding door is
held open by a retainer. Child-proof
catch

When the child-proof catch is engaged - lever on door lock down - the inner lock re­

lease
lever is inoperative. The door can only
be opened from outside
with
the locking
knob in the up position.
9
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CONTROLS AND
EQUIPMENT

Seats
in cab

The correct adjustment
of the
seats
is im­
portant
for:

- reaching
the
controls safely and quickly
- relaxed low-fatigue body position
- maximum protection from the seat belts. The
front
seats should
be
adjusted before
putting
on the
seat belt.
After every fore and
aft
adjustment
of the
seat
check,
by
jerking
with
the
body,
that

the retainers are properly engaged.
[B70-160J
Driver and front passenger
seats
To
move seat backwards and for­ wards (1)

Lift
lever and move seat. Then release lever
and move seat
further
so
that
the catch en­
gages.

The driver's seat should be adjusted so
that

the pedals can
be
fully depressed
with
the
legs
slightly angled.

Attention
For
safety reasons the driver's
seat must only be moved back­
wards or forwards when vehicle
is
stationary.
Adjusting
backrest angle (2)

Take
weight
off
backrest and
turn
knob.
The backrest
of
the driver's seat should
be

adjusted
so
that
the top of the
steering
wheel can be reached
with
the arms angled slightly.

Attention
Do
not lower the backrest too far
when on the move because the seat belts are
then
no longer fully
effective.

20
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CONTROLS AND
EQUIPMENT

Seat
stop
(3)*
the second battery* is located under the •ft seat. To get to the battery the seat can

:e
cashed forward past the normal stop:
• Dush seat fully forward
• Dul stop outwards and push seat
further
":~.vard.

Pivoting
seats*
me release mechanism of both seats is lo­ rded on each seat base at bottom
right.

Seats
are released by pulling up the lever.

E::^
seats are turned anti-clockwise so
:~at it might be necessary to push the seat
':".vard slightly or open the doors.

Attention

When
vehicle
is
moving
the
seats
must
be
facing
forward
and be

properly
secured.
Two-seater
passenger bench*

To
lower the backrest, press locking knob to
the rear.
When lowered, the backrest is locked. The locking knob must therefore be pressed
again to
lift
backrest up.

Attention
For
safety
reasons the
backrest

must
always
be locked
when
ve­

hicle
is in
motion.
Head
restraints

The head restraints should be ac _s:e; body
size
- see page 19.

Seat
heating*

Seat
cushion and backrest of
front
seats can
be heated electrically when ignition is on. Further details are given under "Switches",
page 51.
Armrests*
The armrests on the
front
seats can be hinged up if they are not required.
The angle of the armrests can be adjusted

as
required
with
a knurled knob, underneath
the armrest.

2!
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CONTROLS AND
EQUIPMENT

Seats
in passenger
compartment

Centre
seat
and
single
seats* Folding
backrest
down

To
fold backrest down press the locking knob to the rear.
When folded down the backrest is locked.

To
lift
it up the locking knob must therefore be pressed again.

Attention
For
safety
reasons the
backrest

must
always
be
vertical
when
ve­
hicle
is in
motion.
Removing
seat

The seat can be removed easily.
• To remove pull levers on
left
and
right
of frame (illustration).
• Pull seat to rear slightly and take it out.
Installing
seat

• To install, place seat in
front
of the secur­ ing parts in floor as shown.
•
Lift
levers on
left
and
right
of seat frame and push seat forward
until
it engages firm­ly in the securing parts.

Important
notes
on
installing
seats

are
given
on the
next
page.

22
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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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CONTROLS AND EQUIPMENT

Brake servo Attention
The servo
is
operated
by
vacuum which
is
only generated when
en­

gine
is
running.
For
this reason
the vehicle should
not be
allowed
to roll with
the
engine switched off.
When
the
brake servo
is not

working because,
for
example,
the vehicle
is
being towed
or be­
cause
a
defect
has
occurred
on

the brake servo itself,
the
brake pedal must
be
pressed consider­
ably harder
to
compensate
for

the absence
of
servo assistance. Anti-locking brake system
*
The ABS plays a major part in increasing the
active safety of the vehicle. The big advan­
tage when compared with a conventional brake system is that even when braking
hard on a slippery road surface the best
possible steerability is retained for the road
condition because the wheels do not lock.
However, one must not expect the ABS sys­
tem to shorten the braking distance in all conditions. When driving on gravel or on
fresh snow covering a slippery surface, i.e.
when one should be driving very carefully in
any case, the stopping distance may even be slightly longer.

How
the ABS
system works

When the turning speed of a wheel reaches
a level which is too lowforthe vehicle speed
and it tends to lock, the brake pressure to
this wheel is reduced. On the front axle the brake pressure is regulated for each wheel
individually, whereas on the rear axle, the
pressure is regulated for both wheels at the
same time. As a result the braking effect is
the same for both rear wheels and the driv­ ing stability is retained as far as possible.
This regulating process makes itself known by movement of the brake pedal and is ac­
companied by noises. This is done deliber­
ately as a warning to the driver that a wheel
or the wheels are in the locking range. So
that the ABS can regulate effectively in this range the brake pedal must remain de­ pressed - on no account should it be

pumped!

Attention However
the ABS
system cannot
overcome
the
physical limits.
This must
be
borne
in
mind par­
ticularly
on
slippery
or wet
roads.
When
the ABS
comes into
the
control range
the
speed must
im­
mediately
be
adapted
to the
road
and traffic conditions.
The in­

creased amount
of
safety avail­
able must
not
tempt
one
into tak­ ing risks.

If a defect occurs on the ABS it is indicated
by a warning lamp - see page 49.
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