oil filter 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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GENERAL
MAINTENANCE
Care
of car

Regular
and
careful
care
helps
to

maintain
the
value
of the
vehicle.

Furthermore
it can be one of the

stipulations
for the
upholding
of

warranty
claims should corrosion

damage
and
paint
defects
occur.

Every
Volkswagen dealer carries stocks
of

suitable car care materials. The instructions
for use on the container should be followed.

Attention

•
If
misused,
car
care
materials
can
be
injurious
to
health.

•
Car
care
materials
must
al­

ways
be
stored
in a
safe
place

where
they
are out of the
reach
of
children.

When
buying
car
care
materials

one
should
select
products

which
do not
damage
the
environ­

ment.
Empty
containers
which
these
materials
were in do not be­

long
with
household
waste.
Washing

The
best protection against environmental

influences
is frequent washing and waxing.

How
often this treatment
is
required
de­

pends,
amongst other things on
how
much
the vehicle is
used,
how
it
is parked (garage, in open under trees etc.),
the
seasons,

weather conditions
and
environmental
in­
fluences.

The
longer bird droppings, insects, tree
resin,
road
and
industrial grime,
tar
spots,
soot, road salt
and
other aggressive
ma­

terials remain on
the
vehicle paint the more lasting their destructive effect will be. High
temperatures e.g. from strong sunlight
in­

tensifies
the
corrosive effect.
In certain circumstances weekly washing

can
be
necessary,
in
other conditions monthly washing
with
appropriate waxing
may
be
fully adequate.
After
the
period when salt
is put on the

roads
the underside
of
the vehicle should al­

ways
be
washed thoroughly.
Automatic
wash
plants

The
vehicle paint
is so
durable
that
the ve­

hicle
can normally be washed without prob­

lems
in an
automatic wash plant. Howeve'
the influence on the paint depends
to
a large extent
on the
design
of the
plant,
the
filter­
ing
of
the wash water, the type
of
wash anc

care
material, etc.
If
the paint has a
matt
ap­
pearance
after going through
the
wash
plant
or is
even scratched this should
be

brought
to the
notice
of the
plant operate
immediately.
If
necessary
a
different wash
plant should
be
used.

Notes

• Before going through
the
wash plant, apart from
the
usual precautions (closing
windows and sliding roof, retracting the aer­ial) there
is
nothing further
to
note. How­

ever,
to
prevent damage
the
door mirrors

should
be
folded
in.

•
If
there are special
fittings
on the vehicle - such as spoilers, roof rack, two-way radio
aerial
etc.
it is
best
to
speak
to the
plant op­erator.
88
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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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GENERAL
MAINTENANCE

Topping
up
engine
oil Unscrew the cap from oil filler opening and
pour oil in 0.5 litres at a time. Then check
level with the dipstick.
On no account must the oil level be
above area C. Otherwise oil can be drawn into the engine via the crankcase breather
and escape into the atmosphere via the ex­ haust system. On vehicles fitted with a
catalytic converter, the oil could burn inside
the converter causing it damage. Attention
When topping up the oil, do not spill it onto hot engine compo­nents - danger of fire.
Carefully close the filler cap and push the oil
dipstick in as far as possible, this will pre­
vent oil spill when the engine is running.

Changing engine
oil Not only does the engine oil deteriorate due
to use when the engine is running, but also to ageing. The engine oil change intervals depend therefore on the mileage and also
on the time elapsed.
Petrol engines
Change engine oil every 15 000 km or every 12 months (whichever comes first).
Diesel engines
Change engine oil every 7500 km or every 12 months (whichever comes first).
For further details, see Service Schedule. For petrol and Diesel engines
If the vehicle is used continuously in ar­
duous conditions, the engine oil must be
changed at shorter intervals - see also page

93.

Recommended oil and viscosity classes -
see page 96.
Attention
Old oil must be stored out of reach of children until it is dis­
posed of in the correct manner.

ojfcj
On no account must oil be
earth.

Because of the disposal
problems,
the necessary special tools anc
specialist knowledge required the engine oil and filter changing shoulc
preferably be done by a Volkswagen
dealer.

Engine
oil
additives

No additives should be mixed with
the engine oil.
Any damage caused by the use o
such additives will not be coverec by the warranty.
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GENERAL
MAINTENANCE
Air
cleaner
Power
assisted
steering

The
paper
filter
element in the air cleaner is normally renewed as detailed in the Service

Schedule.
In very dusty conditions the el­
ement must be cleaned or renewed at
shorter intervals.
To clean or
renew
element

•
Release
clip (1 ) •
Press
locking handle ( 2 ) down and un­ hook it.
• Take
filter
housing out upwards.
• Take
filter
element out. •
Clean
element
with
compressed air or renew it.

The
element must not be washed
with
pet­ rol or moistened
with
oil.
Installing

• Insert
filter
housing. Ensure
that
the
plastic
lug on the rearend of the elementfits
in the recess in the mounting.
• Secure clip (1 ).
• Pull locking handle ( 2 ) up until it en­
gages.

The
reservoir is located in the engine com­partment on the
right
looking forward.

The
power assisted steering is filled
with
our hydraulic oil G 002 000.

The
correct oil level in the reservoir is
essen­

tial for the satisfactory operation of the power assisted steering.

The
level can only be checked
with
the en­ gine at normal operating temperature but not running.
100
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GENERAL
MAINTENANCE

Winter
driving
T

Ac

The an«

safe
high

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supf

with
poin

sub:

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fori

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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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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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Downloaded from www.Manualslib.com manuals search engine TECHNICAL DATA
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

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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