power steering 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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CONTROLS AND EQUIPMENT
Diesel
engines
Glow plug system
The
engine is
fitted
with
a glow plug
sys
tem.
The required glow plug warm-up time
is
indicated by a lamp which is controlled by
the coolant temperature - see page 49.
Cold
starting
aid
To
assist cold starting, there is a device (cold starting aid)
fitted
in the injection
pump.
The
cold starting aid is actuated when the knob on the
left
of the steering column is
fully
pulled out.
Starting
a cold
engine
• At ambient temperatures down to -15
degrees
C, pull the cold start knob our
fully
before operating the starter.
At lower temperatures, the knob should not
be
pulled out
until
engine
is
firing
reg
ularly
- the engine will then start more
readily.
• Turn the key in the ignition lock to
posi
tion 2 (see page 36) - the glow plug warning lamp comes on. It goes out when the igni
tion temperature is reached (see page 49).
While
the
glow
plugs are
working
do not
switch
on any
other
heavy
cur
rent
consumers because
this
would
place an unnecessary load on the
battery.
• When the warning lamp goes out, start the engine immediately.
Do
not depress the accelerator while start
ing.
If the engine only fires irregularly, continue
to operate the starter a few seconds longer (30 seconds at maximum) until the engine runs under its own power.
If the engine does not start, switch the glow
plugs on again and try starting it again as de
scribed.
If the engine still does not start the
fuse for the glow plugs may have blown -
page123.
•
Push
the cold start aid knob in fully as
soon
as the engine has reached its normal
operating temperature.
Starting
a
warm
engine
The
glow plug lamp does not come on - the engine can be started straight away. Do not pull the cold start aid knob and do not press
the accelerator pedal.
38
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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 102 of 164
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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
nere are two marks
with
which the oil level
:an be
checked.
• Outside on container (Fig.) • Inside on dipstick attached to the cap. ~he oil level should always be between the
MAX."
and "MIN" marks. When the level
"as
dropped down below the "MIN" mark
:^e
power assisted steering should be
:necked
at a Volkswagen dealer. It is not
sufficient merely to top up
with
hydraulic oil.
Note
f the power assisted steering fails at any
: me or when engine is not running (vehicle on tow) the vehicle remains fully steerable cut more force must be used to
turn
the
steering wheel. Cooling
system
Under
normal conditions the cooling
sys
tem is almost maintenance-free.
The vehicle is
fitted
with
a hinged radiator
which can be folded forward when required
- see page 104.
The cooling system is filled at the factory
with
a permanent coolant which is not
changed.
The coolant consists of water and
a
40 % concentration of our coolant additive
G
11 V8B (anti-freeze on glycol basis
with
anti-corrosion additives). This mixture not
only gives the necessary frost protection
down to -25 degrees C but also protects the
alloy parts in the cooling system against cor
rosion.
In addition it prevents scaling and ra
ises
the boiling point of the coolant.
The concentration of the coolant therefore must not be reduced in the summer or in
warm countries, by topping up
with
plain
water. The
coolant
additive
propor
tion
must
be at
least
40 %.
If greater protection against frost is re
quired, the proportion of G 11 V8B additive
can
be increased, but only up to 60 % other
wise the anti-freeze protection is reduced
and furthermore the cooling effect is im
paired.
Vehicles
for export to cold countries -s~a .
have frost protection down to -35 decrees
C.
Only
our G 11 V8B or an additive v/rs :~e
specification
TL-VW 774 B (markea or
container) should be added to the coolant.
The additives can be obtained from
Volks
wagen dealers.
Other
additives
can be
very
detri
mental
to the
anti-corrosion
effect
in
particular.
The
subsequent
corrosion
damage
can
lead
to
coolant
loss
resulting
in
major
engine
damage.
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Page 134 of 164
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DO-IT-YOURSELF
Tow
starting/towing
General
notes
• "owing eyes are provided on the
right
under
front
and rear bumpers.
Tow-ropes
or bars should be attached at
these
points only.
On
vehicles
with
a factory
fitted
towing bracket a towing eye is not fitted. On those
vehicles
the towing bracket can be used for
towing.
• The tow-rope should be slightly elastic to reduce the risk of damage to both ve
hicles.
It is advisable to use synthetic fibre
ropes,
or ropes of similar elastic material. It
is
however
safer
to use a
tow-bar!
Avoid
excessive towing
effort
and do not
jerk.
During towing operations on other than
surfaced
roads there is always the danger
that
the attachment points will be over
loaded
and damaged.
•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve
hicle
should be used for
starting
if
possible - see previous page. If the
vehicle
has to be tow
started
or
towed
at any
time,
the
following
must
be noted:
•
Check
whether there are any local traffic regulations concerning the towing of ve
hicles.
• Both drivers must be familiar
with
tow ing procedures. Inexperienced drivers
should
not attempt to tow start or tow.
• When using a tow-rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
• The driver of the vehicle being towed must ensure
that
the tow-rope is always
taut.
• The emergency lights must be switchec
on on both vehicles - unless local regula
tions differ.
• Turn ignition key to "Drive" position sc
that
the steering wheel is free and the
turr
signals,
horn, and, if necessary, the wind
screen
wiper and washer can be
used.
• As the brake servo only works when the engine is running, considerably more pres
sure
is required on the brake pedal when the
engine is not running.
• On vehicles
with
power assisted steer ing more force is required to
turn
steering
wheel when engine is not running.
• When there is no lubricant in the manua or automatic gearbox, the vehicle may only
be
towed
with
driving wheels lifted.
132
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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
K
Keys
7
34
L
^ambda probe 86, 137
Lap
belt 17
Lashing
eyes 28 Lifting vehicle 134
Lighting 50
Lighting switch 50
Loading/sleeping surface 26
Lubricant additives 99
Lubricants 96 Luggage compartment 28
Luggage compartment cover 27
M
M
& S tyres 116 Maintenance 93
Make-up mirror 73
Manual gearbox 31
Masking
headlights 129
Maximum engine speed 77 Maximum speed 142
Mileage
recorder 40
Mirror heating 14
Mirrors 13 Mobile telephones 117
Modifications 117
Moving radiator forwards 104
Multi function indicator 42
N
Number plate lights 126
o Octane rating 86
Oil
capacity 153
Oil
change intervals 98
Oil
consumption 97
Oil
pressure 47
Oil
specifications 96
Oils
96
Output 141
Outside mirror 13
P
Paint care 89
Paint number 154
Parking 138 Parking lights 52 Parking lock 33
Payload
148
Pedal
29 Performance figures 142
Permissible
GVW 148 Petrol
-Additives 86
- Consumption 143
- Quality 86
Petrol vapour accumulator 138
Pivoting seats 21
Power
assisted steering 100
Power
flow
139
R
Radio
129
Rear
axle load 148
Rear
fog
light
51, 126
Rear
lights 125
Rear
seat bench 23
Rear
window wash/wipe 54
Recirculating air switch 61 Removing seat 22
Renewal
of parts 117
Restraint systems 18
Rev
counter 46
Reverse
gear 34
Reversing
lights 31
Roof
load 75, 148
Roof
load carrying system 75
Roof
rack 75 Running-in 76
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