tyre pressure 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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DRIVING
TIPS

The
first
1500 km - and
afterwards
Running-in
I/-c :he
first
few operating hours the en-

5ine
internal friction is higher than later on .-.hen all the moving parts have bedded

down.
How well this running-in process is

::cne
depends to a considerable extent on
the way the vehicle is driven during the
first
1500
km.
Up to 1000
kilometers

the following general rules apply:
• Do not use
full
throttle

• Do not
drive
faster
than
3/4 of top speed
• Avoid
high
engine
speeds
• Trailer towing should if possible be
avoided.

Attention

• New
tyres
must
also be "run in" because
they
do not
have

maximum
adhesion at the
start.

This
must
be
taken
into
account by
driving
carefully
during
the

first
100 km. • New
brake
linings
must
also be
run in and do not
have
the opti­
mum
friction
properties
during

the
first
200 km. The
slightly
re­ duced
braking
effect
can be com­
pensated
for by
more
pressure on
the
brake
pedal. This also applies
when
new linings
have
been

fitted.

From 1000 - 1500 km

The
speed can be gradually increased to the road or engine maximum.
During
and
after
the
running-in

period
the
following
applies:

• Do not overrev the engine when cold - either in neutral or in the gears.

All
speeds and revs given are only valid
when engine is
properly
warm.

Do not
drive
with
the
engine

speed
unnecessarily
high

changing
up
early
helps
to
save
fuel,

reduces
noise
and
protects
the
envi­
ronment
- see
also
page
79.
• Do not let engine labour - change down when engine no longer runs smoothly.
76
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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.
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DRIVING
TIPS

• Where possible make
full
use of the maximum permissible drawbar weight on

call
of the towing bracket - see page 151 -
cut do not exceed it.
• While observing the permissible trailer
and
drawbar weight, distribute the load in
the trailer so
that
heavy objects are as near
as
possible to the axle. The objects must
a
so be secured so
that
they cannot slip
aoout.
• Check the
tyre
pressures on the towing
/ehicle
and the trailer.
• The headlight settings, should be
:hecked
with
trailer attached before mov- ng off and adjusted as necessary.

On
vehicles
with
headlight beam control it

is
only necessary to
turn
the knurled disc in
:ash
in the appropriate direction.
Driving
instructions

To
obtain the best possible handling of ve­
hicle
and trailer, the following should be

noted:

• Try to avoid driving
with
an unladen ve­
hicle
and a loaded trailer. If this cannot be

avoided,
only drive slowly to allow for the unfavourable weight distribution.
• As driving stability of vehicle and trailer
decreases
when the speed increases do not
drive at the maximum permissible top
speed
in unfavourable road, weather or
wind conditions - particularly when going downhill. In any
case
the speed must be reduced im­
mediately the trailer shows the slightest

sign
of snaking. On no account try to stop
the snaking by accelerating.
• For safety reasons one should not drive faster than 80 km/h (50 mph). This also
applies
in countries where higher speeds
are permitted. • Always brake in good time. If the trailer

has
an overrun brake, apply the brakes gen­
tly at
first
then firmly. This will avoid the
jerk­
ing caused by the trailer wheels locking.

Change
down before going down a steep hill so
that
the engine can act as a brake.
• When a long climb in a low gear
with
ex­ tremely high engine revs must be nego­
tiated at exceptionally high ambient tem­peratures the coolant temperature gauge must be observed. When the gauge needle

moves
to the
>~zza'
e~z of :ne
scale,
the road speed must be reduced immediately. If nevertheless ~g amp flashes,
stop immediately and si ow the engine to

cool
off at idling speed for several minutes.
• The cooling effect of the radiator fan
can­
not be increased by changing down, be­

cause
the speec of t~e
~a~
s ~o! dependent
on the engine
speed.
One should therefore not change down even when towing a
trailer as long as :-e e-g -e zar cope with­ out the vehicle speed dropping too much.
83
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GENERAL
MAINTENANCE

Washing
the
vehicle
by
hand
In the
interests
of
environmental

B
protection
the
vehicle
should

only
be
washed
in
specially
pro­
vided
wash
bays.
In
some
districts,
washing
cars
elsewhere
may
even

be
forbidden.

Irst
soften the
dirt
with
plenty of water and
-ise
off as well as possible.
~nen clean the car
with
a soft sponge, glove
or brush starting on the roof and going from :3p to bottom using only slight pressure. :aint shampoo should only be used for very
cersistent
dirt.

=
:nse
the sponge or glove out thoroughly at
snort intervals.

.'.'heels
and sill panels should be cleaned
last, using a different sponge if possible.
After cleaning the vehicle, rinse thoroughly
vith
water and leather it off.
Notes

• The vehicle should not be washed in strong sunshine.
• If the vehicle is rinsed
with
a
hose,
do not direct the jet of water at the lock cylinders
- they can freeze up in the winter.

Washing
vehicle
with
high
pres­

sure
cleaner

• The operating instructions for the high
pressure
cleaner must be followed closely
- particularly
with
regard to pressure and working distance.
• Do not use a concentrated jet. • The water temperature must not be above 60 degrees C.

Attention

Tyres
must
never
be
cleaned
with
a
concentrated
jet! Even at a
rela­

tively
large
working
distance
and a
very
short
spraying
time,
dam­
age can occur.
Waxing

A
good coat of wax protects the .s~ : e
paintwork to a large extent against the e". -
ronmental influences listed under
"Wash­

ing"
on the previous page and even agars:
light
mechanical damage.
At the latest when water on the clean paint

does
not form small drops and roll off, the
vehicle should be protected by applying a
coat of good hard wax.
Even
when a wax solution is used regularly in the washing
water it is advisable to protect the paint
with

a
coat of hard wax at least twice a year.
Polishing

Should
only be done if paint has lost its shine
and gloss cannot be brought back
with
wax. If the polish used does not contain preserv­
ative compounds, the paint must oe waxed
afterwards.

Note

Matt
painted
and
plastic
parts
should not be treated
with
polish or hard wax..
89
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GENERAL
MAINTENANCE

Wheels

General
notes

• New tyres do not give maximum grip straight away and should therefore be run in
at moderate speeds and a careful style of
driving for about the
first
100 km. This will help to make the tyres last longer.
• Check tyres for damage from time to time (cuts, splits, cracks and lumps) and re­move any foreign bodies embedded in the
treads.
• To avoid damage to tyres and wheels crive over curbs and similar obstacles very
slowly and as nearly at
right
angles as
poss­
ible.
Damage
to wheels and tyres is not always

easy
to see, so if you
think
that
a wheel is
damaged,
it must be checked by a Volks­
wagen dealer.
• Keep grease, oil and fuel off the tyres.
• Replace missing dust caps as soon as
possible.

• Mark wheels before taking them off so
that
they rotate in the same direction when put back on again. • When taken off, the tyres should be
stored in a
cool,
dry and preferably dark
place.

Tyres
which are not on wheels should be stored in a vertical position.

Tyre
life

Tyre life depends to a considerable extent on the following factors:

Inflation
pressure
The inflation pressure is very important par­
ticularly at high
speeds.
Therefore, the pres­
sures
should be checked at least once a month and before every long journey.
At this opportunity do not forget the spare

wheel:

• The spare wheel should always be in­ flated to the highest pressure required on
the vehicle.
Always
check the pressures when the tyres are cold.
When
warm,
the pressure is
higher
but do not
reduce.
The pressur­

es
are given on page 147 and on a sticker on
the driver's door lock pillar.
Pressures
which are too high or too low
shorten
tyre
life - quite apart from the detri­ mental influence on vehicle handling.

Attention

At
continuous
high
speeds a
tyre
in
which
the pressure is too low

flexes
more
and
heats
up excess­
ively.
This can cause
tread
separ­

ation
and
tyre
blow
out.

pCU
A
pressure
which
is too low in- oo
creases
the
fuel
consumption

and
this
burdens
the
environment
unnecessarily.

Mode
of
driving
Fast
cornering, hard acceleration and viol­
ent braking also increase
tyre
wear.
'0
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GENERAL
MAINTENANCE
Arduous
operating
conditions
ne vehicle construction and equipment is
resigned for normal operating conditions.
his also applies to the frequency and the
extent of the maintenance laid down in the
service
Schedule.
f the vehicle is used in arduous operating
conditions (e.g. continuous trailer towing,
exceptionally high or low ambient tempera-

:ures,
very dusty conditions, poor quality

ruel,
etc.) it may be necessary to carry out
special
technical preparations, such as ;hanging the oil to the appropriate viscosity, ^stalling special air cleaners, modifying the
ignition timing etc. Furthermore, the main­
tenance must also be matched to the oper­
ating conditions - see also page 93.
Driving
abroad

If the vehicle is to be taken abroad, the fol­
lowing must also be borne in mind:
• If the vehicle has a catalytic converter, one must ensure
that
unleaded petrol will be available during the journey - see
page 86.The automobile clubs offer infor­ mation about the unleaded filling station
network.
• Although there are more than 10 000
Volkswagen
dealers all over the world to
service
Volkswagen vehicles there are
countries in which only a limited amount of

service
is available or none at all.
• In certain countries it is also possible
that
your vehicle model is not soid so
that
certain
spare
parts will not be available or
that
the

Volkswagen
personnel are not familiar
with
the repair procedure should anything go
wrong.
The Volkswagen
Sales
Centres in Germany or the
Importer
concerned will be only too
pleased
to give advice on the necessary
technical preparation of the vehicle, on the maintenance required and on the repair

possibilities.

The addresses are given in the vehicle wallet. • When the vehicle is used in a country
which drives on the opposite side of the road to the home country the wedge

shaped
areas on the headlight lenses must be masked - see page 129.

Driving
on
holiday

Before starting off note the following
points:
• The roadworthiness and driving safety are particularly important when on holiday-

see
page 78.
• With a fully laden vehicle and/or roof rack, the handling changes. The driving
style must be adapted to the different condi­
tions - more information on loading is given
on page 28.
The
tyre
pressures must be checked - see
page147.

• When a trailer is to be towed, there are many special points to note - see page 81.
• If an oil change or an Inspection Service
is
probably going to become necessary dur­
ing the
trip,
it is advisable to have this work
done before going on holiday if possible.

115
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DO-IT-YOURSELF
- Wind jack arm up by turning the crank handle
until
the jack
just
goes under the

vehicle.

- The claw of the jack must fit round the vertical rib on the side member so
that

the jack cannot slip when vehicle is
lifted

- see illustration.
- If the ground is soft, place a large strong
piece
of packing under the jack base
plate.
- Align jack and at same time wind claw up
further
until
it contacts the vertical rib on
side
member. •
Lift
vehicle
until
the defective wheel is

clear
of ground.
• Remove wheel bolts and place them on
a
clean surface (hub cap, cloth, paper) next
to the jack and take the wheel off.
• Fit spare wheel and lightly tighten all bolts. The wheel bolts must be clean and

easy
to
turn
- do not under any circum­

stances
use grease or oil!
• Lowervehicleand fully tighten bolts indi- agonal sequence.
• Refit the wheel trim.
•
Place
defective wheel in spare wheel carrier and secure it - see page 119.

Notes

• Pay attention to the following after changing a wheel:
- Check the
tyre
pressure immediately on the spare wheel which has been fitted.
- Have the tightening torque of the wheel bolts checked
with
a torque wrench as

soon
as possible. The torque for steel
and alloy wheels is 160 Nm. If it has been established when changing
the wheel
that
wheel bolts are corroded and hard to screw in, they must be renewed be­
fore checking the tightening torque.
Until these checks have been carried out
one should, for safety reasons, only drive at

a
moderate
speed.

• The defective wheel should be repaired
as
soon as possible.

Attention
If the
vehicle
is to be
subsequent­
ly
fitted
with
wheels
or
tyres

which
differ
from
those
fitted
by
the
factory,
it is
essential
to
read

the
remarks
in the
centre
and
right
hand
columns on
page
113.
121
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TECHNICAL DATA

Tyre
pressures
Attention

The
tyre
pressures
must
be
checked
at
least
once
a
month.

They
are
very
important
particu­
larly
at
high
speeds-see
page
110.
These
pressures are for cold tyres. When
tyres are warm the pressure is higher but do
not reduce it.
The inflation pressures are given on a sticker on the inside of the driver's door lock pillar. As the pressures may be altered at
short notice fortechnical reasons there may

Tyre
pressures
for
vehicles
with
a
permissible
axle
load11 on one
axle
of less
than
1285 kg
Tyres
Pressure
in bar
Front
Rear

Spare

185 R 14 C 97/99N (or 97/99P) 3.0 3.8
3.8
195/70 R 15 97 S reinforced 2.6 3.4
3.4
205/65 R 15 98 S reinforced 2.6 3.4
3.4
215/65 R 15 100 T (or 102H) reinforced 2.4 3.0
3.0

Tyre
pressures
for a
vehicle
with
a
permissible
axle
load11 on one
axle
of 1285 kg or
more

Tyres
Pressure
in bar
Front
Rear

Spare

185 R 14 C 97/99N (or 97/99P) 3.4
3.8 3.8
195/70 R 15 97 S reinforced 3.0 3.4 3.4
205/65 R 15 98 S reinforced 3.0 3.4 3.4
21 5/65 R 15 100 T (or 102H) reinforced 2.4
3.0 3.0 be differences between sticker and Instruc­

tion
Manual. If this should be the
case,
ask your Volkswagen dealer for the correct
pressures.

The permissible
front
and rear axle loads are givenonpage148.
147
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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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