service VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

Downloaded from www.Manualslib.com manuals search engine
We
thank you for the confidence you have placed in us through
:he purchase of the new Caravelle/Transporter.

~~e
new Caravelle/Transporter has been completely redesigned. In

:~'s
process the years of experience
with
several million Trans- porters and
front
wheel drive passenger cars has been put to good

__e
new Caravelle/Transporter is distinguished by the generous
amount of inside space it offers and by its modern aerodynamic styl-
-g.
In addition it also has a high payload, variability, driving comfort
and driving safety.
Environmental factors played a large part in its design, selection of
materials and manufacture. The result speaks for itself: TheVolks- .vagen is
thrifty
with
petrol is low pollutant, only requires a small
amount of servicing at long intervals, has extremely long-life wear- "ng parts and is extensively recyclable. Therefore it has all the typical

Volkswagen
virtues such as, economy, quality, reliability and value retention.
t is also reassuring for you to know
that
one of the largest and most
efficient organizations in the world is available to look after your

Volkswagen.
In Europe alone there is a network of about 9000 Volks­ wagen dealers
that
work economically and professionally in accord­

ance
with
factory guidelines.
The Volkswagen dealers also guarantee
that
everything is OK on your CaravelleATransporter. They offer you
• 1 year warranty against defects -
with
no mileage
limit
In the majority of countries there is a complete package of additional
warranty cover and services offered, like for example:
• 6 years warranty against rusting-through on the bodywor< -
without
expense for interim treatment.
• 1 year warranty on workshop repairs
• 1 year warranty on all genuine parts and on Volkswagen
acces­
sories
approved by us.
• The quick, value for money Express Service for the smaller jobs
• A reasonably priced replacement car for the period
that
yours is being serviced or repaired - ask your dealer.
• The Volkswagen Accessory Service
Tested,
factory approved accessories and the professional installa­

tion
- hereto please also read the note on
Page
116.

Volkswagen
dealers will gladly supply details on the above-men­ tioned services and possible country specific deviations.
Please
see

also
the notes in the Service Schedule.

We
wish you pleasant and safe motoring at all times.

Your
VOLKSWAGEN
AG
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
VEHICLE LITERATURE
In the vehicle wallet you will find, in addition
to this
Instruction
manual,
a Service Schedule and a Service address
list.

Also
depending on vehicle model and equip­ ment there can be various Supplements

(e.g.
for car radio, Multivan or Camper).
If one of these publications appears to be

missing
or you have the impression
that
the
information on some equipment or model
version is not complete, please contact your

Volkswagen
dealer. He will be pleased to help you.

You
can naturally also get in touch direct

with
our Service Department or
with
the Im­ porter in your country. The telephone numbers and addresses are to be found in
the Service address list.
The
Instruction
Manual
should be read carefully as soon as possible
so
that
you get to know your vehicle quickly.

Your
special attention is drawn to the
chapter "Driving tips" in this instruction
manual.
There you will see how you can
drive
safely,
economically
and envi­
ronment
consciously.
For
safety
reasons
please
note
also
the
information
on Accessories,
modifications
and the
renewal
of

parts
on
page
117.
The other chapters are of course also im­ portant because the correct operation of the
vehicle serves - in addition to regular care
and maintenance - to maintain the value of
the vehicle and is, in many
cases,
also one of the stipulations for upholding warranty

claims.

At the end of this manual we have made a list of the checks which you should carry out
regularly to keep your vehicle roadworthy at
all times.
The Service Schedule
contains
- identification data for your car - the Service intervals
- the Service operations
- important details about Warranty
Service
work which has been carried out is

also
confirmed in the Service
Schedule.
This

can
be important when a claim is made under Warranty.

Your
should always present the Service
Schedule
when taking the vehicle to
a
Volks­
wagen dealer.
The Service address
list

contains
- addresses and telephone numbers of
Volkswagen
dealers in Europe and over­
seas.

- important information on the Volks­ wagen dealer emergency services
Notes
on the
layout
of
this
Manual:

It describes the largest possible range of
equipment envisaged at the time of going to

press.
Some of the equipment may be avail­
able later on or not at all or will not be offered in certain Export markets.

Items
of equipment marked
with
a * are
only standard on certain model versions or
are only available as optional extras on cer­
tain models.
All blocks of
text
which
have
this

colour
backing
and the
title
"At­

tention"
refer
to
potential
acci­
dent
or
injury
risks.

Texts
following
this
symbol
and

printed
in
italics
are
important

notes
on
environmental
protection.

One
final
request:

When you sell your car please give the com­ plete Vehicle Wallet to the new owner be­

cause
the vehicle literature belongs to the

vehicle.

2
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
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.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
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.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
I

DRIVING
TIPS

After
the
running-in
period

I
jn vehicles with gear change marks on

~r
speedometer dial the
gears
must be
CE'ged
up at the latest by the time the
r^eaie reaches the marks.

I
Dn vehicles with a rev counter* the
r;;.;mum permissible engine speed is
r:
-vn
by the beginning of the red zone on

H
"ev counter scale. The needle of the
c.^.ter
must not move into this zone.
!"~e additional red dotted area which some
r:;e!s
have before the red zone can be

k£r3
in isolated cases, for example when

c
staking - see
page
46. If a rev counter is to be service installed the

following
maximum engine speeds must be marked on the scale:
Engine Speed

Petrol
engines
Diesel engines 5300 rpm
4300 rpm
On all petrol injection and Diesel engines

the
maximum engine speed is governed
automatically.

77
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
DRIVING
TIPS

The technical
prerequisites

"or
a low fuel consumption and efficiency were "built in" at the factory. Particular im­
portance was placed on the lowest possible

disturbance
to the environment. To retain

and
make the best possible use of these
characteristics
attention should be paid to
the following points:

Vehicles
fitted
with
a
catalytic

converter
may
only
be
driven
on

unleaded
petrol.

Even
those
vehicles
which
do
not
have
a
catalytic
converter

should
be
driven
on
unleaded
petrol
for the
sake
of the
environment.

The
prescribed
maintenance

operations
should
be
carried
out

exactly
as
specified
in the
Service
Schedule - see
also
page
93.
Having your vehicle regularly serviced by
a Volkswagen dealer not
only
ensures
that
it is always operationally fit, but it
also ensures economy, lowest possible burden on the environment and a long
service
life.
Check the
tyre
pressures
every
4

weeks.

Low
tyre
pressures increase the rolling

resistance.
This not
only
increases the

fuel
consumption and
tyre
wear,
but the
handling is also impaired.
Do not
carry
unnecessary
ballast

in the
luggage
boot

Particularly in
town
traffic
when one has to accelerate
often,
weight
has a
great
in­
fluence on the
fuel
consumption. As a

rule
of
thumb:
For every 100 kg of
weight

the consumption increases by approxi­
mately
litre
per 100 km.

Remove
roof
rack
immediately

after
use
Particularly at
high
speeds the increased
air resistance makes
itself
felt
consider­

ably.

gCK
Electrical
consumers
should
only
be
switched
on
when
they

are
actually
required

Heated rear windows, additional driving

lights
and heater blower consume a con­
siderable amount of
current.
The higher
alternator
load
also increases the
fuel

consumption. For instance, over a period of 10 hours, the heated rear window
will

increase
the
fuel
consumption by ap­
proximately 1
litre.
Check the
fuel
consumption
reg­

ularly

The
fuel
consumption should be checked
each
time
the
tank
is
filled
up. By doing
this
inconsistencies on the vehicle which
lead to an increased
fuel
consumption
can be discovered sooner.
• Check the
engine
oil
level
each
time
the
tank
is
filled
up

The
oil consumption depends to a great ex­

tent
on the engine load and
speed.
Depend­
ing on the style of driving the consumption

can
be as much as 1.0 litres/1000 km.
It is normal for the oil consumption of a new

engine
to reach its lowest level after a cer­
tain mileage has been covered. The
con­
sumption cannot be properly
assessed
until
the vehicle has run approx. 5000 km.

This
also
applies to the fuel consumption
and
the engine output.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
DRIVING
TIPS

• As the factory installation of a towing bracket includes the modification of the

cooling
system, this should also be done
when service installing a bracket. Other­

wise
overheating may occur when the en­ gine is pulling hard (mountains, high ambi­
ent temperature, heavy trailer loads).

Certain
vehicle versions can be equipped

with
a heavy-duty cooling system ex fac­

tory,
even though the vehicle is delivered

without
a towing bracket. Details can be ob­
tained from Volkswagen dealers.
• Volkswagen dealers have all the
necess­
ary information on the installation of towing
brackets
and the
fitting
of a heavy-duty

cooling
system. The installation should
therefore be done by them.
• If, when towing a trailer for commercial
purposes,
the permissible
total
weight of

vehicle
and trailer - also
with
passenger
cars
- exceeds 3500 kg, it is necessary to in­
stall and use a tachograph in most European

countries.
Operations
instructions

• When inserting the 13 plug
into
the
socket
on the vehicle, the ribbed sleeve on
the plug must be turned fully to the
right.

The
lid of the socket then engages over the
boss
on the
sleeve.

• If the
traffic
behind the trailer cannot be
seen
properly
with
the standard rear view mirrors, additional outside mirrors will be

necessary.
Both outside mirrors must be

fitted
on folding arms and adjusted to give
a
good view to the rear at all times.
• Pitching movements between towing
vehicle
and trailer can be reduced by heavy-
duty springs and shock absorbers on the rear axle. If these springs and shock ab­

sorbers
have not already been
fitted
at the
factory, they can, in many
cases,
be servi­

ce-installed
by a Volkswagen dealer.
• Pitching and snaking movements can
also
be reduced by stabilizers which can be
obtained from and
fitted
by Volkswagen
dealers
in most European countries. • The permissible trailer weight11 - see

page
151 -must not be
exceeded
on any
ac­

count.
• When towing a trailer in mountainous re­
gions,
note
that
the trailer weights given ir
the "Technical data" are only valid for gradi­ ents up to 10 or 12 %. If the trailer weigh'
is
below the permissible maximum a corre­
spondingly steeper gradient can be

climbed.

• The given trailer weights are only appli­
cable
for altitudes up to 1000 m above see
level.
As the engine
output
and thus the
climbing ability drops due to the decreasing
air density, the weight of vehicle and trailer must also be reduced by 10 % for eacr

further
1000 m or part thereof.
1 The permissible vehicle/trailer weight
con­
sists
of the permissible
total
weight of tow­ing vehicle plus the permissible
total
weight
of trailer. If the permissible trailer load is to be
fully utilized it may be necessary to reduce
the weight of the towing vehicle appropriate­ ly. The towing vehicle must however not be
lighter than the trailer.
82
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
GENERAL
MAINTENANCE
Fuel

Petrol
engines
Vehicles
with
catalyst

62 and 81 kW Fuel
injection
en­
gines
Unleaded
regular
petrol

RON11 not
lower
than
91

rQp
On
vehicles
with
catalytic
con-
<35
verter
only
unleaded
petrol
may
be
used.

The
use of leaded petrol is very detrimental
to the functioning of the emission control
system
because the lead is deposited in the
catalytic converter.
rijK
Even
one
tankful
of
leaded
pet-
®5
rol
will
detract
from
the
effi­

ciency
of the
catalytic
converter.

Although unleaded fuel may again be used
afterwards the original efficiency of the
catalytic converter is never fully attained.
On
vehicles
with
Lambda probe2' the mix­
ture formation is also negatively affected.
11
Octane
Number, indicates the ignitability of
Diesel

2) Lambda = Air/petrol relationship Vehicles
without
catalytic
con­

verter

62 kW
Carburettor
engine

unleaded
or leaded
regular
petrol

RON1) not
lower
than
91

i-Op
In the
interests
of our
environ-

ment
unleaded
petrol
should
be

used
whenever
possible.

Notes

• Unleaded petrol must comply
with
DIN3' 51 607 and leaded petrol
with
DIN 51 600.
• Only good quality petrol containing addi­ tives should be used - see also" Petrol addi­

tives"
next column.
• If in an emergency the octane rating of the available petrol is lower than
that
re­quired by the engine, only drive
with
me­
dium engine speeds and low engine load­
ing.
High
engine
loading
with
full

throttle
or
high
revs
can cause en­
gine
damage.
Fill tank
with
petrol of the
correct rating as soon as possible.
31 Standards issued by the German Standards Institution.
Petrol
additives

The
quality of the fuel has a decisive influ­
ence
upon the running behaviour, perform­

ance
and service life of the engine. The addi­
tives which are mixed into the petrol are of particular significance. One is advised
therefore only to use good
quality
pet­
rol
containing
additives.

If such fuel is not available, or if engine
troubles such as starting difficulties, stalling during idling, vibration and loss of power
occur,
the appropriate additives should be
mixed
with
the petrol when filling the tank.
At temperatures between about 0 and 15
degrees
C, these additives prevent possible icing up of the carburettor, have an anti-cor­
rosion effect, clean the fuel system and pre­
vent deposits building up in the engine.

Petrol
additives available in accessory
outlets have not all shown themselves to be
effective. Therefore additives which have

been
tested for
Volkswagen
engines are av­

ailable
from Volkswagen dealers in
Ger­
many and in many export countries. The

Volkswagen
dealers are also informed
with
regard to the use of additives, and they know what to do in
cases
where deposits

have
already built up.

SB
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
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.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans

Downloaded from www.Manualslib.com manuals search engine
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.
www.vwT4camper.info - a useful website for owners and enthusiasts of VW T4 Transporter Campervans