1992 VOLKSWAGEN CARAVELLE clutch

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CONTROLS
AND EQUIPMENT

-andbrake

~: ;:dy the handbrake pull lever up
firmly.

Zr - s the
1
st gear or
with
automatic gear- :ne parking lock should also be en-

r'zz^z.
The handbrake should always be

ace
53 so
firmly
that
it is not possible to
zr .9 nadvertently
with
the handbrake on.

~T"
handbrake is applied
with
the ignition
• :_e brake warning lamp comes on.
~: "e ease handbrake, pull lever up slightly,
: r;s locking knob in and push lever
right
Manual
gearbox

Note

When driving you shot z ' z: est .: ~ E~ :
on the gear lever. The press^-e z~ .:„'-="
is
transmitted to the selectc ~z'-~ - ~T
gearbox and can cause pren-a:_"5 .-, ~z' z~
the forks.
Gear
gate

• All forward gears are baulk synchro­
nised.
The synchronising hubs enable easy
noise-free selection of the forward gears.
• Only engage reverse gear when vehicle
is
stationary. When engine is running, de­

press
clutch
fully
and
wait
a few seconds
before moving gear lever, to prevent grating

noises.

When reverse gear is engaged
with
ignition
on,
the reversing lights come on.

3'
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CONTROLS AND
EQUIPMENT

Automatic
gearbox4

The vehicle is equipped with an electroni­ cally controlled 4-speed automatic gear­
box.

The gearbox has a lock-up clutch which eliminates the system-inherent converter
slip in 4th gear, and in certain driving
condi­

tions also in 3rd gear.
This
significantly im­ proves the efficiency of the gearbox in
these two gears and reduces the fuel
con­
sumption.

Depending
on driving style the lock-up
clutch can cause more frequent gear shift­
ing.
This
is normal and no cause for concern.
Programme
switch

The programme switch in the instrument panel can be used to select a sports
pro­

gramme for a sporty type of driving (S -
warning lamp lights up) or for normal driving (warning lamp out).
The programme selection can be made by pressing the switch
(arrow)
when vehicle is
stationary or on the move.
Normal
driving

The programme by changing up early and changing down late, makes economical
driving possible.
S -
Sport
programme
For a sporty style of
driving,
this programme
should be selected. By changing up later full use can be made of the engine's power re­
serve. Changing down is effected at higher
engine speeds than in the normal driving range.

Note

The programme which has been selected remains engaged even after the engine has
been switched off.
This
means that a
change of programme can only be effected
by operating the switch.
32
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CONTROLS AND EQUIPMENT

Starting
the
engine

General
hints
Attention

When
starting
the
engine
in con­

fined
spaces
there
is a
danger
of poisoning.
• Before starting, move gear lever to neu- ml
(with
automatic gearbox, selector lever -
"P"
or "N" position) and apply handbrake
I 'mly.
• On vehicles
with
a manual gearbox de-
:"9ss
the clutch pedal when operating

=:arter
so
that
starter only has to
turn
en­
gine.

• As soon as engine starts, release the gnition key so
that
starter can disengage.
• After starting a cold engine it may sound
_oisy
for a moment or two because the oil pressure has to build up in the hydraulic
tappets
first.
This is normal and no cause for
a
arm. Do not
warm
engine
up by run-
W>
ning
it
with
vehicle
stationary.
Drive
off
straight
away.

Do
not overrev or use
full
throttle
until the
engine has reached the normal operating
Temperature. • On vehicles
with
a
catalytic
con­

verter
the
engine
must
not be

started
by
towing
the
vehicle
in ex­

cess
of 50 m.
Otherwise
unburnt

fuel
can pass
into
the
converter
and
lead
to
damage.

•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see
page
130.
Petrol
engines

These
engines are equipped
with
a cer: ~-
jection system
that
automatically s^c; es the correct fuel/air mixture at ail anc e~:
temperatures.

When
engine is cold or at
operating

temperature
do not accelerate before or
during the starting procedure.
Applicable to all engines:
If the engine does not start at once, stop

using
the starter after 10
sees,
wait about
half a minute and then try again. If the engine still does not start, the electric
fuel pump fuse may have blown - see page
122.

When
the engine is
very
hot it may be
necessary
to accelerate slightly after the
engine has started.
37
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CONTROLS AND
EQUIPMENT

Cruise
control
system* : "elieve the
foot
on the accelerator pedal

~ -
s system can hold any speed aboveabout output

is'mits.

Attention

The
cruise
control
system
should not be used in
dense
traffic
and

poor
road
conditions
(slippery

surfaces,
aquaplaning,
gravel).

iVhen
system
is
switched
on do not

•nove
into
neutral
without
depres­

sing the
clutch
pedal,
otherwise
the

engine
will
race
and can,
under
cer­

tain
circumstances,
become
dam­
aged.
B
A
|B
33
- 696[
The
system
is
operated
with
the sliding switch A and the press
button
B on the
turn

signal lever.
The system is
switched
on by moving switch A to I.
When the speed to be maintained has been reached the press
button
B (FIX) must be

pressed
briefly. The
foot
can then be taken
off the accelerator pedal.
The programmed speed can also be in­

creased
without
pressing the accelerator
pedal.
The
button
B need only be pressed

until
the desired speed has been reached.
The speed can also be increased in the nor­ mal way
with
the accelerator pedal. When
the pedal is then released the previously programmed speed is resumed. The system is
temporarily
switched

off when brake or clutch pedals sre _se; : •
when speed is considerably bee.', z'z- grammed speed i.e. when driving _c =
steep gradient in too high a gear.
To resume speed previously programmed
when brake or clutch pedals are releasee or at end of gradient, push switch A to the
left
(AUFN).

Attention

The
programmed
speed
must
only
be
resumed
when
it is not
too
high
for the
existing
traffic
conditions.

The system is
completely
switched
off by moving the switch A to the
right
(0) or -
when vehicle is stationary - by switching
the ignition off.
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DO-IT-YOURSELF
Fuse
layout

<*'om
left
to
right)

No.
Component
A11
' - Dipped beam
left,
headlight range control
left
10
I- Dipped beam
right,
headlight range control
right
10
3-
Instrument
and number plate lighting 10
--
Rear
wiper, seat heating 15

5-
Windscreen wiper,
windscreen and rear window

washer/elec.
heated

washer
jets 15

5-
Blower, air conditioner 30
/- Tail and side
light
right,
engine compartment
light
10

3-
Tail and side
light
left
10
9-
Rear
window heating, mirror heating 20

10-
Fog lights, rear fog
light
15
II- High beam
left,
high beam
warning lamp 10

12-
High beam
right
10

13-
Horn, radiator fan (run-on) 10
1 Ampere No.
Component
A

14-
Reversing lights, electric outside mirrors, sliding/tilting
roof,
shift pattern auto, gearbox,

cruise
control system
(cancel contacts on the brake
and clutch pedal) 10

15-
Engine electronics 10

16-
Warning lamps,
dash
panel insert,
glove box
light
15

17-
Turn signals 10

18-
Electric fuel pump,

Lambda
probe 20

19-
Radiator fan, air conditioner 30

20-
Brake lights 10

21-
Interior
and luggage compartment lights, make-up mirror
light,

clock,
radio,
central locking 15

22-
Cigarette lighter 10
Additional
fuses
(in separate holders)
• above the relays A11

Fuse
for electric windows 20
• In the engine compartment on the bulk­
head
above the brake servo:

Glow
plugs21 50
• Under the driver's seat

Fuse
for additional water heater 10

Fuse
for heater blower .30

Fuse
for water heater
glow plug 20
Fuse
for auxiliary heater3' 25
Fuse colour code:

Red:
10 Ampere

Blue:
15 Ampere

Yellow:
20 Ampere

Green:
30 Ampere
21 This fuse should only be renewed by
a
Volks­
wagen dealer.
31 On vehicles
with
swivelling seats this fuse
can
be found in the side
trim
behind the
driver's seat.

123
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DO-IT-YOURSELF
Tow
starting/towing

General
notes

• "owing eyes are provided on the
right
under
front
and rear bumpers.

Tow-ropes
or bars should be attached at

these
points only.

On
vehicles
with
a factory
fitted
towing bracket a towing eye is not fitted. On those

vehicles
the towing bracket can be used for
towing.
• The tow-rope should be slightly elastic to reduce the risk of damage to both ve­
hicles.
It is advisable to use synthetic fibre

ropes,
or ropes of similar elastic material. It
is
however
safer
to use a
tow-bar!

Avoid
excessive towing
effort
and do not

jerk.
During towing operations on other than
surfaced
roads there is always the danger

that
the attachment points will be over­
loaded
and damaged.
•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see previous page. If the
vehicle
has to be tow
started

or
towed
at any
time,
the
following

must
be noted:
•
Check
whether there are any local traffic regulations concerning the towing of ve­

hicles.

• Both drivers must be familiar
with
tow­ ing procedures. Inexperienced drivers

should
not attempt to tow start or tow.
• When using a tow-rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
• The driver of the vehicle being towed must ensure
that
the tow-rope is always

taut.
• The emergency lights must be switchec
on on both vehicles - unless local regula­
tions differ.
• Turn ignition key to "Drive" position sc
that
the steering wheel is free and the
turr
signals,
horn, and, if necessary, the wind­

screen
wiper and washer can be
used.

• As the brake servo only works when the engine is running, considerably more pres­

sure
is required on the brake pedal when the
engine is not running.
• On vehicles
with
power assisted steer­ ing more force is required to
turn
steering
wheel when engine is not running.
• When there is no lubricant in the manua or automatic gearbox, the vehicle may only

be
towed
with
driving wheels lifted.
132
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DO-IT-YOURSELF
Tow
starting

The
following
points
must
be
noted
when
tow
starting:

•
Before
moving off, engage 2nd or 3rd gear.
• Switch ignition on.
• As soon as engine starts, depress clutch and move gear lever
into
neutral to avoid running
into
the towing vehicle.
• On
vehicles
with
a
catalytic
con­
verter
the
engine
must
not be
started
by
towing
the
vehicle
in ex­
cess of 50 m1. Because
then,
un-

burnt
fuel
can pass
into
the con­

verter
and cause
damage.

• For
technical
reasons tow
start­
ing a
vehicle
with
an
automatic

gearbox
is not possible.
Towing

When
towing
vehicles
with
an
auto­

matic
gearbox,
the following points must be noted in addition to the details on
the previous page:
• Selector lever at "N".
• Do not have the vehicle towed faster than 30 mph (50 km/h).
• To not tow
further
than 30 miles (50 kilo­ meters). If the vehicle has to be towed long distances
it must be
lifted
at the
front.

Reason:
When the engine is not running,
the gearbox oil pump is not working and the
gearbox is not adequately lubricated for high speeds or long distances.
• With a breakdown vehicle the vehicle may only be suspended at the
front.
Reason:
If given a rear suspended tow, the
drive shafts
turn
backwards. The planetary

gears
in the automatic gearbox then
turn
at

such
high speeds
that
the gearbox will be

severely
damaged in a short time.

Does
not apply to 50 kW Diesel engine
with

catalytic converter

133
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TECHNICAL
DESCRIPTION

Power
flow

Manual
gearbox

• Mechanically or hydraulically operated single plate dry clutch
• Baulk synchronized five speed manual gearbox and final drive in one housing.
• Common lubrication for gearbox and final drive. Permanent oil filling
• Front wheel drive

Automatic
gearbox*

• Hydro-dynamic torque converter
with
lock-up clutch to eliminate converter slip in
3rd speed (under certain driving conditions)
and (always) in 4th speed
• Planetary gearbox
with
4 forward gears
• Two electronically controlled selectable driving programmes
• Flanged on final drive
with
separate lubri­ cation and life-long oil filling
• Front wheel drive
Steering,
Axles

Steering

• Maintenance free rack and pinion steer­ ing
• Steering column
with
angled joints
• Steering pinion and column connected by angled shaft
with
two universal joints
• Hydraulically assisted steering
(PAS)*

Front
axle

• Independent wheel suspension
with
double wishbones, shock absorbers and
anti-roll bars
• Longitudinal mounted torsion bar

Rear
axle

• Independent suspension
with
diagonally trailing arms, coil springs and shock ab­

sorbers.
Brakes

• Hydraulic dual circuit brakes
•
Disc
brakes at
front

• Self adjusting drum brakes at rear
• Brake servo
• Pressure/load-sensitive brake pressure regulator for rear axle
• Mechanical handbrake effective on rear wheels
• Anti-locking brake system
(ABS)*
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