1992 VOLKSWAGEN CARAVELLE brakes

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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

Folding
seat*

[B70-296

The single seat next
to the
centre seat oench can
be
folded,
in
such
a
manner,
to

enable easy
access
to the
rear seat bench.
Folding
seat

• Unlatch
the
seat backrest
and tip
oackrest forwards
(left
hand illustration).
• Then,
tip the
seat sideways
to the
left
centre and
right
hand illustrations).
[B70-297

•
To
return
the
seat
to its
original position proceed
in the
reverse order.

Removing
seat

The seat can
be
removed
by
performing
a

few simple operations).
• Set seat
into
sitting
position.
•
Press
both
levers
on
foot
part
of
seat downwards.
•
Press
seat towards
left
hand side
in di­
rection
of
seat bench and take
out.

Installing
seat

• To install the seat, place seat on
left
hand
side
(as viewed
from
driving direction) next
to
the
securing elements
on
vehicle floor. [B
70-298

• Then, pull seat towards
right,
until
seat engages
firmly
in the
securing parts.

Attention

•
The seat must always be properly engaged in the retainers
to ensure
that
it cannot move if
the brakes are applied or the ve­ hicle is involved in an accident

•
The seat must always be rein­
stalled in the correct direction
and position. This ensures
that

the seat
belt
provided can always be properly
used.

25
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CONTROLS
AND EQUIPMENT

igggage
compartment cover*

I
-
/ehicles with
a
rear seat bench,
a
lug-

zazs
compartment cover
can
be
installed, :e rending
on the
vehicle version.
~en loading,
the
luggage compartment
::.
er
can
be
tipped upwards.
Attention
When
the
vehicle
is
moving
no
persons,
animals
or
heavy items
of luggage
are to be
carried
on

the luggage compartment cover
- danger
of
injury when brakes are applied suddenly
or
when ve­hicle
is
involved
in
an
accident.
further important instructions
on
oading are
to
be
found
on
page 28.

27
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CONTROLS AND
EQUIPMENT

Luggage
compartment/load
surface

To
enlarge
luggage
space
Lower
backrest and seat as described on
page 23.

Notes
on loading
In the interests of good handling ensure
that

the load (persons and luggage) is distributed evenly. Heavy items should always be car­ried as near to the rear axle as possible or
better still, between the
axles.

The permissible axle and gross
weights must not be exceeded under any circumstances.
Attention
• It should be noted
that
when
transporting heavy items the handling
will
change due to the
displacement of the centre of
gravity. Driving style and speed must be altered to suit.
• The load must be stowed so

that
no items of luggage can fly
forward if brakes are applied suddenly. - If necessary use the lashing
eyes.
• One should ensure
that
the heater el­
ements in the rear window on the Variant
are not damaged by articles rubbing against
them.
• The stale air
escapes
through ventilation openings at the rear. The function of these openings must not be impaired.
Attention
• When vehicle is on the move no persons may be in the luggage
compartment. This includes

children.
Every passenger must
be belted in properly - see page
15.

• Never drive
with
the tailgate or
wing doors not properly closed otherwise exhaust gas can be
drawn
into
the vehicle
interior.
On
vehicles
with
lashing eyes the load
should always be secured to the
eyes.

Each
eye has a tensile strength of 500 kg.
28
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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
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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DRIVING
TIPS

Driving economically and ecologically
.'arious
factors determine the fuel
con­

sumption,
the burden on the environment

and
the wear on the engine, brakes and

lyres.

The personal style of driving
Determines
to a great extent the economi-
:al
aspect and the exhaust and noise
devel­

opment:

jOp
Do not
warm
up the
engine
with

W» the
vehicle
stationary.
At idling speed it takes a very long
time
until
the engine becomes operationally
warm. However, in the warm-up phase,
wear and the discharge of pollutants is
oarticularly high. For
this
reason, drive
off immediately the engine has started
and avoid
high
engine speeds.

f
h Avoid
full
throttle
acceleration.

of only is the
fuel
consumption reduced

considerably
if one accelerates
with
feel­
ing, but the disturbance to the environ­

ment
and the wear are also reduced.

rflri
Do not
drive
with
unnecessarily
high
engine
revs
-
change
up as
soon as possible,
only
change
down
when
the
engine
no
longer
runs

smoothly.

The
fuel
consumption is for example
more
than
twice as
high
in 2nd gear
than
it is in top
gear.
At the same
time,
the re­ duced engine speed means a reduction
in engine noise.
On vehicles
with
an automatic gearbox
the economy programme should be se­
lected.

c^p
Try not to
drive
at
maximum
TO
speed.

The
fuel
consumption, exhaust pollution
and noise increase disproportionately at

high
speeds. If approximately only 3
quarters of top speed is utilised, the
fuel

consumption
will
be reduced by about
half.
Experience has shown
that
the loss in
time
is only marginal.

c
j-,
Drive
as
smoothly
as possible and
look
well
ahead.

Unnecessary
acceleration and braking

must
be paid for
with
higher
fuel
con­
sumption and more disturbance to the environment.

Switch
the
engine
off
during

traffic
hold-ups. The individual
operating
condi­
tions

Naturally
also
affect fuel consumption.

The
following factors for instance are not fa­

vourable
to good fuel consumption:

•
High traffic density, particularly large
.towns with numerous traffic lights.

•
Frequent stop/start driving, always re­starting and warming up the engine.

•
Driving in heavy, slow moving traffic in
low
gear so that the engine speed is
rela­

tively high in relation to the distance cov­
ered.
CQ~, One
should,
therefore,
plan
trips
in
advance
and try to
avoid
local

traffic
and
overcrowded
motor­
ways.

Obviously
the fuel consumption is
also
af­

fected
by factors over which the driver has
no
control. It is for example normal for the

consumption
to increase in the winter or in

arduous
conditions (bad roads, trailer tow­ ing etc.).

79
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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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