wheel 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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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

Seats
in cab

The correct adjustment
of the
seats
is im­
portant
for:

- reaching
the
controls safely and quickly
- relaxed low-fatigue body position
- maximum protection from the seat belts. The
front
seats should
be
adjusted before
putting
on the
seat belt.
After every fore and
aft
adjustment
of the
seat
check,
by
jerking
with
the
body,
that

the retainers are properly engaged.
[B70-160J
Driver and front passenger
seats
To
move seat backwards and for­ wards (1)

Lift
lever and move seat. Then release lever
and move seat
further
so
that
the catch en­
gages.

The driver's seat should be adjusted so
that

the pedals can
be
fully depressed
with
the
legs
slightly angled.

Attention
For
safety reasons the driver's
seat must only be moved back­
wards or forwards when vehicle
is
stationary.
Adjusting
backrest angle (2)

Take
weight
off
backrest and
turn
knob.
The backrest
of
the driver's seat should
be

adjusted
so
that
the top of the
steering
wheel can be reached
with
the arms angled slightly.

Attention
Do
not lower the backrest too far
when on the move because the seat belts are
then
no longer fully
effective.

20
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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.
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CONTROLS AND EQUIPMENT

Brake servo Attention
The servo
is
operated
by
vacuum which
is
only generated when
en­

gine
is
running.
For
this reason
the vehicle should
not be
allowed
to roll with
the
engine switched off.
When
the
brake servo
is not

working because,
for
example,
the vehicle
is
being towed
or be­
cause
a
defect
has
occurred
on

the brake servo itself,
the
brake pedal must
be
pressed consider­
ably harder
to
compensate
for

the absence
of
servo assistance. Anti-locking brake system
*
The ABS plays a major part in increasing the
active safety of the vehicle. The big advan­
tage when compared with a conventional brake system is that even when braking
hard on a slippery road surface the best
possible steerability is retained for the road
condition because the wheels do not lock.
However, one must not expect the ABS sys­
tem to shorten the braking distance in all conditions. When driving on gravel or on
fresh snow covering a slippery surface, i.e.
when one should be driving very carefully in
any case, the stopping distance may even be slightly longer.

How
the ABS
system works

When the turning speed of a wheel reaches
a level which is too lowforthe vehicle speed
and it tends to lock, the brake pressure to
this wheel is reduced. On the front axle the brake pressure is regulated for each wheel
individually, whereas on the rear axle, the
pressure is regulated for both wheels at the
same time. As a result the braking effect is
the same for both rear wheels and the driv­ ing stability is retained as far as possible.
This regulating process makes itself known by movement of the brake pedal and is ac­
companied by noises. This is done deliber­
ately as a warning to the driver that a wheel
or the wheels are in the locking range. So
that the ABS can regulate effectively in this range the brake pedal must remain de­ pressed - on no account should it be

pumped!

Attention However
the ABS
system cannot
overcome
the
physical limits.
This must
be
borne
in
mind par­
ticularly
on
slippery
or wet
roads.
When
the ABS
comes into
the
control range
the
speed must
im­
mediately
be
adapted
to the
road
and traffic conditions.
The in­

creased amount
of
safety avail­
able must
not
tempt
one
into tak­ ing risks.

If a defect occurs on the ABS it is indicated
by a warning lamp - see page 49.
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CONTROLS AND
EQUIPMENT

Emergency
programme
~.~:;ional defects occur in the electronic
. ;:e~ the gearbox can, amongst other ' "is. carry on operating in two emergency
: ::_s~imes:
• Tre gearbox continues to change up and x ••- automatically as before but hard
shift
- 3 are however noticeable. The vehicle •<:- 3 be taken to a Volkswagen dealer.

~e
gearbox no longer changes up and - automatically.
"•= rearbox can then be shifted manually
:- tie selector lever positions "D", "3"
;': 2" only the 3rd gear is available.
- selector lever positions "1" and "R", the =: and reverse gears are available as nor-
-: .vever, the converter must, due to the ab-

;-s~ce
of 2nd gear
work
harder, and under
:e~ain
circumstances this
causes
the con- r~er to overheat. In a
case
such as this the
•eiide should be taken, as soon as
poss-
: e, to a Volkswagen dealer.
Selector
lever
lock

In positions "P" and "N"
with
the ignition
switch on the selector lever is locked. To move the selector lever out of these
posi­

tions the brake pedal must be depressed
and the selector lever
button
pushed-in.

This
prevents a gear being engaged inadver­

tently
and the vehicle unintentionally mov­ ing off.

A
delay circuit prevents the selector lever

from
locking when it is moved quickly past
the "N" position (for instance
from
"R" to
"D").
This enables for example the vehicle
to be "rocked" out of a "bogged down" position. The
shift
lock only locks the
selec­

tor lever if it is
left
in the "N" position for more than about
1
second
without
the brake
pedal being depressed.
At speeds above 5 km/h the selector lever lock is automatically switched-off in
posi­

tion
"N". In the dash panel there is a display tra:

shows
the currently selected selects' eve' position.

Selector
lever
positions

P -
Parking
lock

The driving wheels are locked mechanics .
The parking lock may only be engagec
the vehicle is stationary. Before mov -g :_e lever in or out of the "P" position tre" ::•

button
in the selector lever handle r-_s: re­

pressed.
Before moving the
se!e:::"

out of the "P" position, the ca-e ;e:s must also be depressed when 're z~;z~ ;
switched on.
11 Depending upon the rrc~e ~._e : s; = :;~
also
be
fitted
in the Cc~: e":
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CONTROLS
AND EQUIPMENT
Notes on driving Starting

\
e
engine
can only be started when
selec-
pr
ever
is at
"N"
or
"P".
See
also
"Starting

Br:
re" on
page
37.

Selecting
a driving range When the vehicle is stationary and
the engine is running always de­
press
the foot brake when selecting
i gear.
When the vehicle is stationary do
•ot depress the accelerator when
•electing a gear. f the lever is moved accidentally nto "IM" when driving, release ac­
celerator and let the engine speed
trop to idling before selecting a for­
ward
gear again.

•
Attention
•
When the engine is running it
is
necessary to hold the vehicle

with
the foot brake in all gears.
Because
with
an automatic gear­
box the transfer of power is not
fully interrupted even at idling

speed
- and the vehicle tends to
"creep".
When the vehicle is stationary
and a gear is engaged, the

throttle
must not be opened inad­

vertently
on any account (for in­

stance
by hand from the engine
compartment). Otherwise the ve­hicle
will
move immediately -
even if the handbrake has been
fully applied.
Before working on the vehicle

with
the engine running, apply
the handbrake and put the selec­
tor lever in "P".
Moving off

Select
driving
range
(R, D, 3, 2, 1).
Wait

until
the gearbox has
shifted
and the

power
flow
is made to the
driving

wheels
(light
selection
jerk
perceptible).

Then
one can accelerate.

Stopping

To
stop
vehicle
temporarily
such
as at traffic
lights,
it is only
necessary
to
apply
the

brakes.
It is not
necessary
to
move
selector

lever
to
"N".
The
engine
should
however

only
be running at idling
speed.
Parking

On
level
ground all you
need
do is
engage

the
parking
lock.
On a gradient the
hand­
brake
should
be
applied
firmly first
and
then

the
parking
lock
engaged.
This
will
ensure

that the
locking
mechanism
is not too
heav­
ily
loaded
and
makes
the
lock
easier
to
dis­

engage.

Tow starting
On
vehicles
with
automatic
gearbox
the en­

gine
cannot
be started by towing or
pushing

the
vehicle.
See
page
133.

When
the battery is flat, the
engine
can be
started
from the battery of another
vehicle

by
using
jumper
cables.
See
"Emergency

starting",
page
130.
Towing If the
vehicle
has to be towed at any time,

you
must
read
the instructions in the
sec­

tion
"Towing/tow
starting on
page
132.
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CONTROLS
AND EQUIPMENT
Ignition
lock

Petrol
engines
1 -
Ignition
off/engine
stationary

-
Steering
can be
locked
2
-
Ignition
on
3
-
Starting
engine
Diesel
engines

1 -
Fuel supply
cut
off/engine
sta­
tionary
-
Steering can
be
locked
2
-
Glow
and
drive
position
No
other current consumers should
be

switched
on together with the glow plugs
-

this avoids draining the battery
unnecessar­
ily.
3
-
Starting
engine
For
all
vehicles:

Position
1:

To
lock
the
steering
wheel
withdraw
key
and turn wheel until you hear the locking
pin engage.

Attention
Do
not
withdraw
key
from
lock
until
vehicle
is
stationary!
The

steering lock could
be
uninten­

tionally
engaged.
Position
2: If
the key is difficult to turn in the lock or
can­

not be turned to this position at
all,
the steer­
ing wheel must be rocked
to
and fro slightly
to release the locking pin.
Position
3:
In this position
the
headlights
and
other

heavy
current consumers are switched
off.

Before
the starter can be operated again the

key
must be turned back
to
position 1. The
non-repeat
mechanism
in the
ignition lock

prevents
the
starter from being operated

when
engine
is
running, as this could
dam­

age
the starter.

36
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CONTROLS
AND
EQUIPMENT

3
-
Emergency lights .
nen the emergency lights are on, a warn-
'z lamp in the switch flashes as well.
Ine system also works when the ignition is
;
.-.itched off.

4
-
Knurled wheel for seat
^Jf
heating*

~~e cushion and backrest of the
front
seats
:
=
n
be heated electrically when the ignition
s
on.

_~e
heating is switched on and regulated .vth the knurled wheel.

•
switch heating off,
turn
knurled wheel to

:_e
left
to the detent position.
5
-
Heated rear window
QpJ

The
heating works only when ignition is on.

When
heater is on a lamp in the switch lights up.

As soon
as
window
is
clear,

switch element
off. The
reduced
current consumption helps
to re­

duce
the
fuel
consumption
- see
also
page
80.

On
vehicles
with
electrically adjustable ex­
terior mirrors the mirrors are heated as long

as
the rear window heating is switched on.
6
-
Fog lights •/
|Q

Rear fog light

First
detent - fog lights

Second
-
front
and rear fog
detent lights, or rear fog
light
only

At the second position a warning lamp in the switch comes on.

The fog lights
work
with
the side lights (ignition on), low or high beams.

The rear fog light
works only
with
the fog lights or
with
the low or high beams.

Due
to the amount of
dazzle
it
causes
the

rear
fog
light
should only be switched on
when the visibility is very poor (in Germany
for example, below 50 metres).

Note
The
electrical system of the factory
fitted

tow bar* is wired-up so
that
when towing

a
trailer
fitted
with
rear fog lights, the rear
fog
light
on the towing vehicle are automati­
cally
switched off.
51
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CONTROLS
AND EQUIPMENT
Turn signal and dip
lever

The
turn
signals only work when the ignition
is
switched on.

Right
turn
signals - lever up
Left
turn
signals - lever down

When
turn
signals are working, the warning lamp flashes as well - see page 48
also.

The
turn
signals cancel automatically after
completing a turn. To
signal
a
lane
change

Move
lever up or down to pressure point

and
hold in this position - the warning lamp must also be flashing.
To dip
headlights
Pull
lever past pressure point towards steer­
ing wheel. When high beams are on, the
high beam warning light will light up.
Headlight
flasher
Pull
lever towards steering wheel to pres­

sure
point - the high beam warning lamp lights up.

Parking
lights

The
parking lights only work when ignition
is
switched off.

Right
parking lights - lever up
Left parking lights - lever down. Note

The
use of the signals and lighting described
here
is subject to local regulations.

52
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