vin VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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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
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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
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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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DASHBOARD
AND
CONTROLS
Warning lamps

Symbol Page Symbol
Page
Coolant temperature/
Coolant level
47

A Emergency light system
51
Engine oil pressure f^i
47

m Rear
window
heating
51

ID
Headlight
high
beams

48

to Fog lights
rear fog light 51

Turn
signals
49

Notes
((D)
Brake
system l^i

48
•
If one of the lamps marked
with
comes on when driving
stop and switch engine off. Details can be found on the pages
given

B Some of the lamps shown here are
only
on certain models or are optional extras.

£3

Alternator
49 •
If one of the lamps marked
with
comes on when driving
stop and switch engine off. Details can be found on the pages
given

B Some of the lamps shown here are
only
on certain models or are optional extras.
m Glow plugs - Diesel

49
(©)
Anti-locking brake system (ABS)

49


Trailer turn signals

49
6
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CONTROLS AND EQUIPMENT
Keys he vehicle is supplied with two keys
"hese keys fit all locks on the vehicle.
Attention
When leaving
the
vehicle unat­
tended
-
even
if
only
for a few
moments
-
always take
the
keys
with
you.
Key
tag
The key number is on the plastic tag. With the aid of the number, a replacement key
can be ordered from a Volkswagen dealer. It must then be stated if it is the main key or
the second key.
The tag should be kept safely and separate­
ly (in your wallet for example) so that no un­
authorized person can order a key.
In addition to the plastic tag there may also
be a metal tag on which there is a part of the
vehicle identification number. This tag is no longer required after vehicle has been deliv­

ered.

7
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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.
9
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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

Windows

Mechanical
windows

The
windows are opened and closed
with
crank-handles
fitted
in the door
trim
panels.
Electric
windows*
Electric
windows offer the following
com­

fort
facilities:
• Single-touch opening for driver's and
front
passenger's door windows
• Single-touch closing of driver's door win­ dow

The
windows function
with
the ignition switched on. If the driver's door is not

opened
after switching off the ignition, the
windows can still be operated for about one hour. Apart from this, the windows can al­

ways
function when the driver's door is

open.
For safety reasons, the single-touch
closing
of the driver's door window only
functions when the ignition is on.
|B70
- 142]

The
switches are in the door
trim
panels.
The
window of the
front
passenger's door

can
also be opened and closed from the
driver's door.
a
- Driver's door b - Front passenger door

All
windows can be opened automatically by touching the lower part of the appropri­
ate switch. If more than one window is to be
opened
at the same time, this is done auto­matically, one afterthe other, in the selected

sequence.

If the appropriate switch is tapped once

again,
the window will stop immediately.
All
windows can be closed by pressing the
upper part of the appropriate switch. To

close
the driver's door window, when the ignition is switched on, it is sufficient to
touch the switch. If the switch is touched

again,
the window stops moving immedi­
ately.

Attention

• Be
careful
when
closing the

windows!
Careless or
uncontrolled
closing
of the
windows
can cause in­

juries.

Therefore
when
leaving
the ve­ hicle,
always
take
the
ignition

key
with
you. The
electric
win­

dows
are
then
only
put out of ac­

tion
if the
driver's
door is opened and closed again. As soon as the
driver's
door is opened again, the

windows
can once
again
func­
tion.
12
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Mirrors

CONTROLS
AND
EQUIPMENT

dow open.
Adjusting mirrors

The rear view mirrors should always
be
ad­
justed properly before moving
off so
that
good vision
to the
rear
is
obtained.

Anti-dazzle
inside
mirror

The lever
on the
lower edge
of the
mirror should
be
pointing forwards when
the
basic

setting
is
made.

To
set the
anti-dazzle position, pull lever
to

the rear.

Outside mirror

The outside mirror should
be
adjusted
so

that
the side
of
your own vehicle can
just
be
seen.
This setting ensures the best possible
field
of
view, and
in
addition
it
serves
as an
instant check
on the
mirror setting.

Normal outside mirrors
are
adjusted
by

pressing
the
edge
of the
mirror surface
in

the mirror housing. / R
/
(B707T76]

Electrically
adjustable
mirrors* are

set
by
moving
the
knob
in the
driver's door
trim.
Turning
the
knob from
L to
R switches
con­

trol
from
left
to
right
mirror.

If the
electrical control
of the
mirror fails
at

any time
the
mirrors can
be
adjusted man­ ually
by
pressing
on the
edge
of the
mirror

surface.

13
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CONTROLS AND EQUIPMENT

Three-point
inertia
reel
belts

The
inertia reel belt gives complete freedom
of movement when pulled slowly. Sudden braking however will cause the belt to lock.

The
mechanism will also lock the belt when
accelerating,
driving down steep gradients
or cornering.

Putting
belt
on
Pull
the tongue slowly and smoothly across
the chest and hips and push it into the lock part
fitted
on the seat until the tongue en­

gages
audibly (pull to check).
The shoulder
part
of
belt
must
run
roughly
across the
centre
of the
shoulder as
shown
- on no account

against
the
neck
- and be
firmly
in
contact
with
the body.
The backrests of the
front
seats
must
not be inclined too far to the
rear,
otherwise
the
belts
are no

longer
fully
effective.
With the aid of the
belt
height
adjust­

ment
the routing of the
front
seat shoulder
belt can be set to fit the body properly.
• To adjust, push button
with
relay
fitting
(see
right
illustration) up or down so
that
the

shoulder
part of belt runs roughly across the centre of the shoulder as shown on the
left

- on no account
against
the neck.
• After adjusting, pull the belt
with
a
jerk
to
ensure
that
the relay
fitting
is properly en­

gaged.

16
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