roof 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
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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.
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CONTROLS AND
EQUIPMENT

Tailgate

To
open
the tailgate when key slot is hori­
zontal,
pull control behind finger strip on tail­
gate and
lift
tailgate.
To
open
from
inside
On
the inside of the tailgate there is, de­
pending on model, either an opening lever
or an emergency lock release which can be
reached
through a hole in the trim.

This
makes it possible for vehicle occupants
to leave the vehicle via the tailgate in an emergency.
Child
proof
lock*

Vehicles
with
an opening lever on the inside of the tailgate are
fitted
with
a child proof lock.
When the child proof catch is engaged - lever on lock moved down - the inner lever

is
blocked. The tailgate can then only be
opened from outside.
To close
tailgate
pull it down and slam it to gently.

To
make the tailgate easier to pull down there is a loop on the inside.
Attention

•
After
closing the
tailgate
al­

ways
pull
up on it to
make
sure

that
it is
properly
closed -
other­
wise
it could
open
suddenly

when
vehicle
is moving,
even

though
the key has
been
turned
in lock.
• The
tailgate
must
always
be

fully
closed
when
vehicle
is
mov­
ing,
otherwise
exhaust
gas
will

be
drawn
into
the
vehicle
in­

terior!

10
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CONTROLS
AND
EQUIPMENT

Notes

Pools of
water
under
the
vehicle

• When the ambient temperature is high
and
the air very humid, condensed water

can
drip off the evaporator and form a puddle under the vehicle. This is quite nor­

mal
and does not indicate a leak.

Operating
faults

• Should the air conditioner not work at
any
time, either:
- the ambient temperature is below about + 5 degrees C,
- the fuse has blown.

Check
fuse and if necessary renew it - see

page
122. If the trouble is not due to
a
defec­
tive fuse, switch the system off and have it
checked.

- the air conditioner has switched off due to the coolant temperature being too high -
see
page 41
also.

• If the cooling
output
drops off, switch the
A/C
off and have the system
checked.
Using air
conditioner

economically
In cooling operation the air conditioner
com­

pressor
places demands on the engine and
therefore influences the fuel consumption.

To
keep the period switched on as short as
possible,
the following points should be

noted:

• If the inside temperature is very high after the vehicle has been parked in the sun, it is recommended to open doors or win­

dows
briefly to enable the hot air to
escape.

• The air conditioner should not be
switched
on during a journey if the windows

or
sliding/tilting
roof*
are open.
• If the desired interior temperature can be attained
without
switching on the air condi­
tioner, the fresh air operation should be se­
lected.
Recirculating
air
switch

If badly contaminated air is to be prevented
from entering the vehicle, e.g. when driving
through a tunnel, the recirculating air switch in the instrument panel can be
pressed.

When
the recirculating air system is
switched
on, a small warning lamp lights up in the switch.

However,
the recirculating air system

should
only be used for a short period other­

wise
the windows will mist up.

60
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CONTROLS AND
EQUIPMENT

Air conditioner* in passenger compartment Recirculating air switch*
th the air conditioner in the passenger
:: apartment the rear seating area can also
:e comfortably cooled down.
air conditioner only functions if the air
:: iditioner in the cab is switched on - see
:;ge 57. However, adjustment of the out-
: can be performed independent of the
I stem in the cab. The control elements are : rated on the dash panel - see illustration.
air throughput can be set in any one of
;: J stages (left hand rotary switch).
Th e temperature infinitely variable with the ::ary control (right hand switch).
I Dckwise - increased cooling output
--ti-clockwise - decreased cooling output Air outlets
The air outlets are located in the roof area
above the rear seats.
The outlets can be closed or opened separ­
ately.
By pivoting the outlet grilles the direction of
air flow can also be adjusted.
This switch can be used to change over to recirculating air. This will prevent badiy con-
taminated air from entering the vehicle, e.g.
when driving through a tunnel.
Recirculating air operation should only be
used briefly otherwise the windows wil
mist up.
Switch to left - Recirculating air operation
Switch to right - Fresh air operation

Note

On vehicles with air conditioner a recirculat­ing air switch is located in the bank of
switches in the instrument panel.
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CONTROLS AND EQUIPMENT

Auxiliary
heater*
To
switch heater on
•
Press
rocker switch D on rent.
• Select desired heat
with
knee -
The
green heater in-operatior. =~~" _
comes
on.
Regulating
heat

The
heat is infinitely adjustable
with
:~e knob A.
After heater has been switched on it takes

a
little
time before heat can be
felt.

When
the set temperature is reached, the green in-operation lamp becomes darker.

The
temperature is then held fairly constant by the heater thermostatically.
w-^
=
jxiliary heater works independently of
me .ehicle heating. It is supplied
with
fuel
I: rr the vehicle tank.
He suxiliary heater can be used continu­

es
. when on the move or stationary.
|r~? current is supplied from a 2nd battery.

r~T
air flows from the outlets behind the p*.er's seat.
k- the summer the heater blower can be

(sed
to circulate the air in the vehicle with-
it.: heat.
5v. itching on and off and regulating the aux-
tey heater are done from the control panel
r the dash panel.
-
a
timer* is
fitted
(see page 65) the control

panel
is located on the roof cross member I the passenger compartment.
A
BCD

[J70~-T971

Control
elements

A
- Regulating heat output
B
- Overheating indicator (red)

C
- Heater in-operation lamp (green)
D
-
Rocker
switch for switching heater on
and
off and operating blower without heat.
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CONTROLS AND
EQUIPMENT

Sun
roof*

The roof is opened and closed
with
the
hand-wheel.

The roof can be
tilted
at the rear as desired or taken out altogether.

Raising

Turn the hand-wheel clockwise.

Lowering

Turn the hand-wheel anti-clockwise.
To take
out
• With the roof closed
turn
the retaining
screw
(A) in centre of the hand-wheel one
quarter
turn
clockwise
with
a screwdriver.
• Then raise the roof and press it up.
•
Press
up locking lever (B).
• Detach the
roof.

•
Lift
the roof from outside and pull it out to the rear.

To
put
back

• Slide the roof back
into
the hinges and let it drop lightly
into
the retainers.

Attention Ensure that
the
roof
is
properly
inserted into
the two
retaining
hinges
at the
front,
and
secured
at
the
rear.
The roof must only
be
released when vehicle
is
stationary.

70
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CONTROLS AND
EQUIPMENT

Sliding/tilting
roof*

! I I
[B
70-3201

. th ignition switched on, the roof can be

::ened
and closed
with
switch.
~o
open
: de switch to rear.
To close : de switch to
front.

To
lift
at
rear
,','ith
roof closed, press switch up at rear.
To
lower
-JII
rear of switch down.
Note

• When opening the glass roof the screen to prevent sun rays shining in will also open
automatically. If required it can be closed by hand when the roof is closed.

Attention
Be
careful
when
closing the
roof!

Careless or
uncontrolled
closing
of the
roof
could cause
injuries.

Therefore,
when
leaving
the ve­
hicle
always
take
the
ignition
key

with
you.
Emergency
operation

If the system should develop a t:~e

can
be closed by hand.
• Using a screwdriver, press the cove' -
front
of the sliding/tilting roof panel upv.e'os at the rear and take off.
• Turn protective cap of crank opening
clockwise.

• Pull crank out of retainer, insert it in i^e opening and close sliding
roof.

• Replace crank in retainer, and fit protec­ tive cap over crank opening.
• Replace cover.
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CONTROLS AND
EQUIPMENT

Roof
rack
"en loads are to be carried on the
roof,
the
~: cwing should be noted:
• As the rain channels are moulded
into
~e roof for streamlining reasons, the nor- type of roof rack cannot be
used.
To
izd risks we advise
that
only the cross
:5"s
provided by the factory are
used.

• _hese cross bars are the basis for a com- : e:e roof load carrying system. For safety

pasons
when carrying luggage, bicycles, K-~f boards, skis and boats, the appropriate

::ecial
adapters are required.
- :he components of this system are avail- .-: e
from
Volkswagen dealers. • The roof rack system must be secured
exactly as described in the instructions
supplied.

• Any damage which may occur to the ve­ hicle as a result of using other roof load
carrying systems or by incorrect
fitting
will
not be covered by the Warranty.
• Distribute the load evenly.
Each
cross bar may carry 50 kg if loaded uniformly over
the
full
length. The permissible roof load (in­ cluding the carrier system) of 100 kg and the permissible gross vehicle weight must not
be exceeded - see page 148 . • When carrying heavy or large objects on
the
roof,
bear in mind
that
the vehicle handl­ing changes due to the displacement of the
centre of gravity and the increased area ex­
posed
to the wind. Driving style and speed
must be adapted to allow for this.
75
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DRIVING
TIPS

Driving
safely
Attention

The
operational
condition of your
vehicle
is
essential
to
safe

driving.
Therefore before moving off, always check
the following points:
• Lights and
turn
signals
•
Mirror
settings
• Cleanliness of
headlights,
lenses and
windows

Also
check at regular intervals, preferably
when filling the tank, all the checks listed on
page160

Furthermore compliance
with
the specified Inspection intervals - in particular the brake
fluid changing - is of great importance for operational safety - pages 93 and 98.
Attention

Safety
on the
road
depends to a

large
extent
on the personal
atti­

tude
and
style
of driving.

To
be on the safe side you should:
•
Always
put
seat
belt
on
before
moving
off -
even
in
town
traffic
-

and

• Ensure
that
all your passengers - including
those
on the
rear
seat
- are

wearing
their
belts
correctly
- page
15

Passengers
without seat belts can en­

danger
not only themselves, but also the
driver.
•
Adjust
head
rests
to body size.
The
upper edge of headrest must be ap­proximately at eye
level.

• Ensure
that
no
articles
interfere
with
operation
of pedals - page 29
•
Stow
all
luggage
correctly:
- in
boot
- page 28
- on the shelves - page 27
- on the
roof
- page 75 • Do not
drive
when
you
feel
tired.

Stop
for a break at the latest after driving for
two hours.
•
Never
drive
when
your
reactions
are
impaired
in any way. Not only alcohol but also drugs and many

medicines
can be very detrimental to your

reactions.

•
Adapt
vehicle
speed to
traffic
and
road
conditions.
Remember
that
particularly on smooth slip­
pery roads the handling and braking is li­
mited by the adhesion of the tyres. On wet

roads
the
front
wheels can aquaplane at
high
speeds.
The vehicle can then no longer

be
steered and braked properly.
•
Strictly
adhere
to the
traffic
regu­
lations
-
particularly
the speed li­

mits
-.
Further instructions on safety are given in
the various chapters in this manual.
78
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