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T3 Caravelle 1980
User Manual
132 pgs18.62 Mb0

Volkswagen T3 Caravelle 1980 User Manual

Instruction
Manual
Volkswagen
Transporter
Volkswagen Caravelle
jk
Congratulations on
your
new Volkswagen Transporter/Volkswagen Caravelle You have made a
wise
decision
The Transporter I Caravelle is a versatile, million-fold proven vehicle. But, you have not
only
opted
for an outstanding vehicle
with
modern, low maintenance technical components,
you have also chosen
quality.
A quality ensured by the
most
up-to-date production technology, careful selection of materials and conscientious
work
by all involved.
And
with
the Transporter/Caravelle you have also chosen one of the largest and
most
efficient Service
Organizations.
In Europe alone there are around 7,000 V.A.G dealerships.
We
wish
you pleasant motoring: Your V0LKS WA G EN WER
KA
KTIEN
GESELLSCHAFT
INTR0DUCT10
INDEX
This
instruction manual is valid for all Transporter/Cara­velle models, including vehicles with four-wheel drive and exhaust emission control systems.
The manual contains many important instructions
on
using
your vehicle.
You
should therefore read
it
before driving
the
car
so
that
you get to
know your vehicle quickly
and
know
how
to
drive
it and
look after
it
properly.
Special attention
is
drawn
to the
chapter Driving tips:
These
tell
you how you can drive
safely, economically and environ-
ment-conscious.
However
the other chapters
are
also important because
the
correct
treatment
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
the upholding
of
warranty claims.
Further information
on
warranty
is
given
in the
service schedule. Here you will also find important data on the servic­ing
of
your
car and
exact details when the various services
are due.
Please note that items
of
equipment marked with a *are
only standard
on
certain models
or are
only available
as
options
on
certain models. Such equipment
is
not always
available
in all
export markets.
INSTRUMENT PANEL
2
OPERATION
4
DRIVING
TIPS
53
OPERATING
INSTRUCTIONS
~63
CARE
AND
MAINTENANCE
85
DO-IT-YOURSELF
91
TECHNICAL
DESCRIPTION
104
TECHNICAL
DATA
108
IDENTIFICATION
DATA
124
ALPHABETICAL
INDEX
1~26
1
f
NSTRUMENT
PANE
INSTRUMENT
PANEL
Page
1 - Air vents 40
2
— Air vents 40
3
— Light switch and instrument
lighting regulator 36
4 - Brake warning
light
33
5
— Speedometer 34 6 — Warning lamps 32 7 —
Fuel
gauge and coolant temperature gauge 35 Clock
or rev counter 34 8 - Heated rear window switch 36 9 — Emergency
light
switch ... 36
Page
10 - Fog light/rear fog
light
switch 36
11-
Air vents 40
12-
Ashtray 51
13-
Loud speaker opening
14 —
Fuse
box 94
15—
Turn signal and dip switch . 38 16 - Horn control 17 - Digital clock 34 18-
Steering lock/starter switch 28
19—
Auxiliary heater switch ... 43 20 -
Cold
starting aid
(diesel
engine) 30
Page
21 — Blower switch for
passenger
compartment
heat exchanger 42
22 — Windscreen wiper and
washer
lever 39
23
- Blower switch and levers
for ventilation
and
heating 40
24 —
Radio11
or cover plate
25
- Socket/cigarette lighter ... 51
26 - Air vents 40 27 - Shelf 51
Knobs
and warning lamps for the differential locks and
the manually controlled four wheel drive on Transporter/Caravelle syncro
- see page .... 23/25
Please
note
that
some of the items of
equipment listed are only
fitted
on certain
models
or are optional extras.
" For vehicles
with
a factory
fitted
radio, an
operating instruction leaflet
is
also
enclosed.
See
remarks on page 101 of "Do-it-yourself"
section
when service installing a radio. 3
OPERATION
KEYS
Up
to six keys are supplied
with
the
vehicle:
• two keys A
• two keys B*
• two keys D*
Key A
This
key
fits
all locks except:
• lockable glove box
• sliding door and rear flap
with
safety
locks
Key B
This
key
fits
the lockable glove box*
Key C
This
key
fits
the safety locks in sliding door and rear flap. It can only be withdrawn when the sliding door or rear flap is locked.
Tag E
On
this tag is the number for key A. The
tag should be kept safety and separately
(in your wallet for example) so
that
no
unauthorized person can order a key.
The numbers of keys B and C are stamp-
ed
on the key itself.
With the aid of the number, a replace-
ment key can be ordered from a V.A.G
Workshop.
Caution
When
leaving
the
vehicle
unattended
-
even
only
briefly - always
take
the
key
with
you.
D
JB25-450
4
OPERATION
CENTRAL
LOCKING SYSTEM*
With this system
all the
doors,
and - depending
on the
position
of the
tailgate
lock — also
the
tailgate
can be
locked
and unlocked.
The system
is
operated from the
driver's
door,
and
front
passenger door — from
outside with
the key,
from inside with
the locking knob.
Note
The central locking system
can
only function correctly when the driver's and front
passenger doors
are
properly
closed. When locking,
the
locking knobs
on all doors must move down. If the knob on one door does not move at any time, open the door concerned
and
close
it
properly.
Caution When
the locking knobs in the driver's
and
front
passenger doors are pressed down all the doors are locked. Children should
therefore not be left on their
own in the car
because
when the doors
are
locked it would be difficult to help
in an emergency. Sliding
door and tailgate
can
be
locked
or unlocked separately with
the key.
To unlock the tailgate insert key and
turn
it
to
right. Hold in this position and press
button
in.
If
the
key
ist withdrawn
in the
horizontal
position,
locking
of the
tailgate will
be
controlled
by
the central locking system
when
it is
closed again.
When the key is withdrawn in the vertical position
and
tailgate closed,
it
will
be
locked
all the time. The tailgate can then
only
be
unlocked with
the key.
The sliding door
can be
secured
or
released
separately with the safety catch.
Note
If the
central locking system should
develop a fault,
all the
locks
can be
operated normally,
see
next
page.
5
OPERATION
DOORS Cab doors
From
outside
both cab doors can be
locked
and unlocked
with
the key. When unlocking the locking knobs go up, when locking they go down.
The
front
passenger's door can be locked
from outside
without
using the key: Just
press
locking knob down and close door.
The driver's door cannot be locked when
open by pressing the locking knob and closing
door. This prevents you from
leaving the key in the car and forgetting it.
From
inside
the door can be locked by
pressing
down the locking knobs. As long as the knobs are pressed down the doors cannot be opened from inside or outside.
We
advise you not to press the knobs
down when vehicle is in motion so
that the door can be opened from outside in an emergency.
Sliding door
From
outside
the sliding door can be
locked
and unlocked
with
the key. When
fully open the door is held by a hook.
To close sliding door
from
outside.
-
Press
the door handle down to release
the hook and slide the door
firmly
for-
wards.
From
inside
the sliding door is locked by pushing down the locking catch near the door opening lever.
As
long as the catch is in the lower po­sition the door cannot be opened from inside or outside.
When the vehicle is in motion, the door must always be properly closed but when carrying passengers the locking catch should be
left
in the upper position
so
that
the door can be opened from
outside in an emergency.
Child-proof
catch
on sliding door*
When the child-proof catch is engaged ­lever on door lock turned upwards - the inner lock release lever is inoperative. The door can only be opened from out­side
with
the locking catch in the up
position.
TAILGATE
ENGINE COMPARTMENT COVER
To open the tailgate when key hole is
horizental,
press the lock cylinder and
lift
tailgate.
Note
The
lock cylinder can also be pressed in
with
the key.
To
close tailgate pull it down and slam
it to gently.
After
closing the
tailgate
always
pull
up
on it
briefly
to
make
sure
that
it is pro-
perly
closed -
otherwise
the
tailgate
could open suddenly
when
vehicle
is
moving
even
though
the key has
been
turned
in lock.
Do not
drive
with
the
tailgate
open as
exhaust
gases are
then
able
to
enter
the
vehicle
interior.
The
cover is in the luggage compart-
ment. To remove cover
turn
the two
catches
to the
left.
On
the Pick-up, the flap is in the rear
panel.
OPERATION
WINDOWS
Vent wings*
To open -
Press button
in
fastener
and
swing
fastener clear.
To close -
Press window against seal
at
front
and
turn
fastener until button
en-
gages.
Sliding
windows
To open, press catch down and slide win-
dow along.
Door windows
These
windows
are
opened
and
closed
with
the
crank
in the
door
trim.
Electrical control*
When
the
ignition
is on the
windows
can
be
opened and closed electrically.
The switch
is in the
door
trim.
The window
in the
passengers door can
be controlled from
the
driver's side.
Caution Careless
and uncontrolled closing of the windows can cause injuries. Take care
therefore when closing the win­dows. When leaving the vehicle always take
the keys
with
you.
8
MIRRORS
Normal exterior mirror
The mirror
is
adjusted
by
moving
the
mirror housing.
Electrically adjustable mirrors
are
set by
moving the lever in the driver's
door
trim.
Turning
the
knob from
L to R
switches
control from left
to
right mirror.
If
the
electrical control
of the
mirror fails
at
any
time
the
mirrors
can be
adjusted
by hand
by
pressing
on the
edge
of the
mirror surface.
The electrically operated exterior mirrors are heated when the heated rear window
is switched
on.
Anti-dazzle interior mirror*
Mirror
in
normal position
Mirror
in
anti-dazzle position
- Lever to front
- Lever to rear
SEAT BELTS
Seat belts are only beneficial if they are worn at all times - also in town traffic.
For this reason all vehicle occupants should always wear the seat belts - in­cluding those on the rear seats.
With the three-point belts it is essential to ensure that the shoulder part of belt runs roughly over the centre of the shoulder, as shown in Fig. on next page -
on no account against the neck.
On the front seats the belts can be made to fit properly with the aid of the adjust­able belt anchorage (see next page). Contact your V.A.G workshop if necess­ary.
Safety for children
Children under 12 years old should be carried on the rear seat (Caravelle and Combi) and should, depending on age,
be secured there with a childs restraint system or the existing belt.
Very small children should, depending
on size be carried in a reclining safety seat or a child's seat.
Children above 6 years of age can also use a lap belt.
Larger children may use three point belts provided that the belt passes over centre of shoulder and not against
the child's neck - see illustration on next
page.
If necessary, a safety seat cushion
can be used.
The installation and use of child restraint
systems must be done in accordance
with instructions of the manufacturer
concerned.
General notes
Only one person is to be secured with each belt. Never secure two people (even children) with one belt.
On vehicles with armrests*for the seats, always ensure that the belt runs under­neath the armrests.
The belt should not be worn over hard or
breakable articles (glasses, ball pens, key rings, pipes, etc.) because this can cause injury to the body.
Loose, bulky clothing (e.g. overcoats over jackets) affects the fit and function of the belts.
The belt must not be jammed anywhere
or rub on any sharp edges.
The slot for the belt tongue must not be
blocked with paper or anything as other-
wise the tongue cannot engage properly. The belts must be kept clean as other-
wise the retractors may not work pro-
perly (see also "Care and Maintenance" section).
Seat belts which are damaged or have been stressed in an accident and stretch­ed must be replaced - preferably by a V.A.G workshop. The anchorages should also be checked.
Belts can be service installed for all seating positions on vehicles not fitted
with belts at the factory. The installation
of belts should be done by a V.A.G
workshop because these workshops
have the information necessary to do
the job properly.
On the Van there are no belt anchorages in the load compartment.
10
OPERATION
Belt height adjustment
Two anchorage points
are
provided
in
the
cab for the
upper belt attachment.
This
makes
it
possible
to
adapt belt
to
body
size.
I
B33-518
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 retractor mechanism will also lock the belt when accelerating, driving down steep gradients
or
cornering hard.
Putting
belt on
Pull
the
tongue slowly
and
smoothly
across
your
chest and hips and push
it
into
the
lock part fitted
on the
seat until
tongue engages audibly
(pull
to
check).
The shoulder part of the 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 lap part of belt must always fit
tightly
across the lap. Pull belt
tight
if
necessary. The belt must not be twisted. The backrest of the front seats must
not be inclined too far to the rear as otherwise the belts are no longer effec­tive.
Belt warning device*
The belt
for
the
driver
has a warning
de-
vice.
When the ignition is switched on, a buzzer sounds
to
remind
you to put the
belt
on.
The
buzzer stops after about
5 se-
conds
or
when belt
has
been
put on.
Taking
belt off
To release
the
belt, press
the
orange-
coloured button
in the
lock.
The
tongue
will
then spring
out
Pass
the
tongue towards
the
door
by
hand
so
that
the
retractor
can
roll
the
belt
up
properly.
OPERATION
Lap
belt*
The
buckle is used in the same way as on
the three-point inertia reel belts.
The
belt
must
always
fit
tightly.
To
lengthen
belt
hold the tongue at
right
angles
to belt and pull belt through to the
required length.
The
belt is easier to adjust if tongue and
cap
are pressed together.
To
shorten
belt
it is only necessary to
pull the free end of belt.
The
surplus belt length is taken up by
moving the plastic slide.
Two-point
inertia
reel
belts
The
individual seats* in the passenger
compartment are
fitted
with
two point inertia reel belts. They give complete freedom of movement when pulled slow­ly but sudden braking however will cause the belts to lock. The automatic retractor mechanism
will also lock the belt when driving down steep gradients or corner­ing hard.
Putting
belt
on
Pull
the tongue slowly and smoothly
across
the hips and push it into the lock
part
fitted
on the seat until tongue eng-
ages
audibly (pull to check).
The
belt
must
not be
twisted.
The
belt
must
always
fit
tightly,
pull
belt
up
slightly
if necessary.
Taking
belt
off
To
release the belt press the orange
col­oured button in the lock. The lock will then spring out.
Pass
the tongue across by hand so
that
the retractor can roll the belt up properly.
HEAD RESTRAINTS* Adjusting
height
Grip
at sides
with
both hands and pull up or push down. The upper edge should be
roughly at eye level.
Removing and
installing
Push
spring clips out of slotted rings
in backrest
with
a small screwdriver and
lift
head restraint out
To
install,
first
press the spring clips
into the guide rings so
that
the straight part of clip is at the rear. Then push head
restraint into the guides until it
engages.
Note:
The
spring clips need not be taken out on
vehicles
which have a rear seat/fully re-
clining seat bench. It is quite sufficient to push the protrud-
ing spring clip extensions back to the rear, to enable the head restraints to be removed.
12
SEATS
IN CAB
Caution
• For
safety
reasons the
seats
should
only
be
adjusted
when
vehicle
is sta-
tionary.
• Do not
lower
the
backrest
too far
when
on the
move
because the
seat
belts
are
then
no
longer
fully
effective.
|B25-396
Individual
driver's
and
front
passen-
ger
seats
To
move
seats back
or
forward
Lift
lever (1) on outside of seat and move
seat.
Then release lever and move seat
further
so
that
catch engages.
To
adjust
backrest
rake
Take
weight off backrest, press lever (2)
on
right
side of seat frame down and move backrest to desired position by moving upper part of body then release lever.
Armrests*
The armrests on the
front
seats can be
hinged up if they are not required.
[B25-397
To
take
seat
out
• Slide seat forward
into 1 st latch
posi-
tion.
•
Lift
hook (3) against spring-loading, at the same time pull lever (1), hold it and slide seat past stop.
•
Release
hook and lever and push
seat
forward out of runners.
• The hook need not be
lifted
when
putting
seat back as the seat,
with
the
lever lifted, can
just
be pushed past the
stop.
SEATS IN PASSENGER COMPARTMENT*
Two seater bench*
The seat is moved back or forward in same way as the single seats. The lever is at the front of seat.
When seat is moved, the backrest rake is also altered.
To remove
Remove in same way as the single seats. Bolts on right and left of backrest must be removed.
Swivelling seats*
On vehicles with swivelling seats the passenger's seat can be turned 180° to the right and the drivers seat 90° to the left. To turn seats, push them forward slightly or open door, and pull the release lever. The handbrake must be released
before turning driver's seat. (Engage a
gear to prevent vehicle from rolling away.)
The swivelling seats must always be facing forward when vehicle is in mo­tion.
Seat heating*
Seat cushion and backrest of front seats can be heated electrically when ignition
is on. Further details are given under "switches", page 27.
Removing and installing centre bench seat
Remove four wing bolts under seat. When putting seat back again ensure
that the runners are clean.
Head restraints*
The head restraints must be adjusted to body size - see page 12.
Removing and installing rear bench seat
The rear seat cushion is bolted to the side panels on each side with one bolt under the upholstery. Remove bolts and take lower part of seat out.
The seat backrest is secured at each side with two bolts. The bolts between seats and backrests also serve as seat belt anchorages.
When refitting the seat and backrest, ensure that the seat belt is also correct­ly installed.
14
INDIVIDUAL SEATS IN PASSENGER COMPARTMENT*
Centre seats
The centre seats
can be
turned
and the
backrest angle adjusted.
Turning
Lift lever
(see
illustration), turn seat
to
the desired position and
let
lever engage
again.
If
the
backrest
is
very
low, it may be ne-
cessary
to
raise
it
slightly before the seat
can
be
turned.
Adjusting backrest angle
Take weight
off
backrest and press lever
down
(see
illustration). Adjust backrest
to
the
desired position
by
moving upper
part
of
body
and
release lever.
Removing
Lift
the
lever used
to
turn seat
and
take
seat
out.
The base which remains can
be
removed
when carpet
is
lifted.
Caution When
the
seats
are
installed again
en-
sure that base
and
seats
are
secured
properly.
15
Rear seats
The height, seat angle and backrest angle of the rear seats can be adjusted.
Mechanical adjustment
Adjusting seat angle
Press lever B to front or rear and adjust position of seat as required by moving body weight.
Adjusting seat height
Press lever B alternately at front and rear and by moving weight of body to
front and rear lift or lower the seat.
Adjusting backrest angle
Take weight off backrest and turn knob A at side of backrest.
Caution
When vehicle is in motion, the backrests
must not be inclined too far to the rear as otherwise the belts are no longer
fully effective.
16
OPERATIO
B25-382
Electrical adjustments
Adjusting seat angle
Press switch A at front ­Front of seat is raised Press switch A at rear ­Front of seat is lowered
Press switch B at front ­Seat is raised at rear Press switch B at rear ­Seat is lowered at rear.
Adjusting seat height
Press switches A and B at front ­Seat is raised Press switches A and B at rear ­Seat is lowered
Adjusting backrest angle
Press switch C at front ­Backrest moves up Press switch C at rear ­Backrest moves down.
Caution When vehicle is in motion, the backrests
should not be inclined too far to the rear as otherwise the seat belts are no longer fully effective.
17
REAR SEAT/FULLY
RECLINING
SEAT BENCH*
The rear seat/reclining seat bench can
be converted
into
a large sleeping area.
Before doing this, the backrests of the
center row of seats must be tipped
for­wards. The latching levers are located on the outsides of the
right
and
left
hand
backrests.
To
convert
reclining
seat
bench
• Remove head restraints* ­see
page 12.
• Unlatch the backrest
with
the release grip on the reverse side of the backrest, and fold the backrest forwards.
• By pulling the release grip
further
to-
wards the
front,
the backrest and seat
bench are pulled in a forward direction.
• Finally, fold the seat backrest
fully
to
the rear to
form a flat
sleeping area.
Returning
seat
bench
to
original
position
• Pull the seat backrest upwards out of the horizontal position.
• Slide the seat bench, together
with
backrest to the rear again.
•
Push
backrest back
into
locking
posi-
tion.
• Pull the seat belts out again between backrest and seat, so
that
they are in a
position for use.
•
Install
head restraints*-see page 12.
The space underneath the seat bench can
be used as a storage compartment.
For
this, it is necessary to
lift
the seat
bench slightly at the
front.
It
will
remain
in the
lifted
position when the
strut,
lo-
cated on the
left
on the sliding door side,
is
swung upwards.
LUGGAGE
COMPARTMENT/
LOAD SURFACE
ROOF RACK
To
enlarge
luggage
space*
•
Release
backrest by pulling loop
• Fold backrest down to seat The backrest locks automatically when
hinged to the rear.
Instructions on using the rear/reclining
seat* are given on page 18.
Notes
on using the
luggage
compart-
ment
or the
load
surface
• The load must be stowed so
that
it
cannot slip or even fly forward when the
brakes are applied.
• In the interests of good handling the load should, wherever
possible,
be carried
between the
axles.
The permissible axle
loads and the permissible gross vehicle
weight should on no account be
exceed-
ed.
When a roof rack is to be
used,
note the
following:
• Only use roof racks which are sup­ported in the rain channel
• Distribute load uniformly. Do
not exceed permissible roof load or permissible gross vehicle weight. Further details on pages 117-119.
• When carrying heavy or large objects on the
roof,
bear in mind
that
the vehicle
handling can change due to the altera-
tsion in centre of gravity and the increas-
ed area exposed to the wind. Driving
style and speed must be modified to
allow for this.
OPERATION
COVER*
DROPSIDES
HANDBRAKE
Ensure
that
the cover is secured proper-
ly behind the cab.
The cover is correctly secured when the
rod incorporated in the cover engages in the rain channel at the rear of the cab and the
left
and
right
hand ends are bolt-
ed
to the canopy frame.
When the cover and rails have been re­moved,
care should be taken when
refitt-
ing to ensure
that
the foam
seal
is stuck properly in the rain channel (if necessary renew seal).
To
drop side boards - pull handle out-
wards to release locking pin und swing
down to
lift
hook.
On
vehicles
with
support
cables for the
tailboard,
not
more
than
150 kg should
be
placed
on the
tailboard
when
it is
down.
The handbrake is located between the front
seats.
To
apply the handbrake pull lever up firmly. On hilly roads the 1st gear or on automatic gearboxes the parking lock, should also be engaged. The handbrake should always be applied so
firmly
that it is not possible to drive off accidentally with
handbrake slightly on.
When handbrake is applied
with
the
ignition on, the brake warning lamp*
comes
on.
To
release handbrake, pull lever up
slightly, press locking knob in and push
lever
right
down.
-
PERATION
MANUAL GEARBOX
4 speed gearbox
Engaging reverse
Move lever in neutral to the left, press it down and move it further to the left stop and then push it forward.
Only engage reverse gear when vehicle is stationary.
When engine is running, depress clutch fully and wait a few seconds before mov-
ing gear lever, to prevent grating noises.
When reverse gear is engaged with
igni-
tion on, the reversing lights* come on.
5 speed gearbox
To engage 1st gear move lever past
pressure point to left stop and then pull
it back. One normally moves off in 1st gear but
on vehicles with the 44, 57 and 82 kW engine and 5 speed gearbox the rear
axle ratio is different so that one can
move off on the level with a light load in 2nd gear.
To engage reverse gear move lever past
pressure point to left stop, press it down
and push it to front.
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|B25-454
4+G gearbox (4 WD vehicles) Engaging crawler gear
Move lever in neutral to the left, press it down and move it further to the left stop and then pull it to the rear.
Note
When driving you should not rest your hand on the gear lever. The pressure of your hand is transmitted to the shift forks in the gearbox and can cause premature wear of the forks.
21
OPERATION
DIFFERENTIAL LOCKS*
22
When negotiating a curve, the wheels of a vehicle cover different distances. To balance out the differences in wheel speeds, differentials are incorporated in
the driving axles. However, these diffe-
rentials have a distinct characteristic: As soon as one wheel on an axle commen-
ces to spin on a slippery surface, only very little traction is available, even though the other wheel is on a hard
surface.
Using the differential locks the wheels of
one axle can be locked together and the
traction is once again abtained.
On the Transporter/Caravelle there are two different types of differential lock:
Vehicles with rear wheel drive have a
limited slip differential in the rear axle and 4 WD vehicles have selectable me-
chanical locks in front and rear different-
ials.
Limeted slip differential*
(Rear wheel drive) The locking effect is obtained by means
of plates which are arranged in the dif­ferential in a sort of multi-plate clutch. With this differential the locking effect is not 100% but only approx. 45%. Cont­rary to vehicles with 100% locking, the steering behaviour on the road, particul­arly in sharp curves, remains almost un­changed.
The effective locking force is dependent on the speed difference of the two driv­ing wheels. This means: the larger the difference, the larger is the locking force of the differential.
Driving tips
In normal conditions the vehicle can be driven just like every other vehicle. At the beginning it may take a bit of getting used to when driving through sharp curv­es.
This is due to the fact that a slight
locking effect is always present. Furthermore in isolated borderline
con­ditions where, on the one hand the fric­tional resistance of the driving wheels on the ground differs a great deal and, on the other hand, a large amount of power must be transmitted to move off, it may be found that the maximum pos-
sible locking effect is not obtained in the differential. One notices this because one wheel spins while the other' does not turn at all. In this case one should engage and disengage the clutch gently and repeatedly. This will prevent the differential from becoming overheated.
Gear oil
The oil level does not need checking be- tween the intervals given in the Service Schedule. The oil does also not need changing.
To top up or fill after a repair a V.A.G workshop should be contacted because the gearbox must be filled with a special oil.
OPERATION
Selectable
differential
locks*
(Four wheel drive) With the selectable differential locks, the wheels on one axle are fully locked together (100%). As no compensation takes place when cornering, the handling and the steerability is affected - parti­cularly in the
case
of the
front
differential
lock.
Attention The
differential
locks may
only
be used
under
the
limited
specific
conditions
described on the
following
pages.
HP
*
A
Q Q
I
USEES
Engaging the
differential
locks
The differential locks are engaged and disengaged
with
the knobs shown in the
centre of the instrument panel
with
vehicle stationary or moving.
Left knob - Front axle differential
lock
Right knob -
Rear
axle differential
lock
When
the knobs are
pulled/pushed
en-
gagement or disengagement is only se-
lected.
The actual shifting process can
be delayed. If the wheels are rotating at
different
speeds,
or if the drive
train
is
under strain, e.g.
tight
corner
with
differ-
ential lock engaged, it could even happen
that
the lock will not engage or diseng-
age
at all. In such a
case,
throttle
appli­cation should be reduced, or the vehicle should be driven straight-ahead to en­able the lock to engage/disengage.
The
warning
lamps
above the knobs in­dicate the operational condition of the locks:
• If the
front
axle differential lock has
been
selected, the
left
hand warning lamp flashes. As soon as the lock en­gages
the lamp lights up continuously.
• The
right
hand warning lamp moni-
tors the function of the rear axle differ-
ential lock. It does not flash when the lock has been selected but only lights up once the lock has engaged properly.
OPERATION
•
Both
warning
lamps
go out
again
once
the
knobs
have
been
pushed
in
the
locks
have
actually
disengaged.
If after
selecting
the differential
locks,
and
after driving
some
distance,
the
warning
lamps
do not light
up,
the
electri-
cal
system
and the
locks
themselves
should
be
checked
at a
V.A.G
workshop.
Attention The
differential locks influence the
steerability of the
vehicle.
In particular,
with
the front axle differential lock en-
gaged,
the vehicle is no longer steera-
ble.
For this
reason,
the front axle diffe-
rential
lock
must only be
used
under off-
road
conditions and then only at low
speeds.
Always disengage the lock be-
fore driving on metalled road surfaces.
When may the differential locks not be engaged?
•
Neither the front nor the rear axle
differential
locks
may be
engaged
when
driving along metalled road surfaces. Locking
the front axle differential ma-
kes
the vehicle unsteerable.
When the rear axle differential
is
locked, the rigid connection between the two rear wheels has a scrubbing effect on the tyres when
cornering.
This leads to
increased
tyre
wear and also to
"jer-
king"
when the vehicle is being steered.
In certain circumstances it may even
damage the drive train.
For
this reason, the locks may only be
engaged
under
off-road
conditions
or
as
an assistance when moving off.
See
"Driving
Tips"
on page 60
also.
•
When a wheel is spinning, if for example the vehicle is stuck in snow. This
would not only lead to increased
tyre
wear but it could also damage the
drive
train
and lead to uncontrollable
acceleration.
For
this
reason,
the
spinn-
ing
wheel must first be brought to a
standstill before the differential locks
are engaged.
When the vehicle is being towed - see page 103
also.
When testing the vehicle on a dynamo­meter, e.g. when being tested by local authorities.
24
OPERATION
SELECTABLE
FOUR-WHEEL
DRIVE*
mm®
Vehicles
required for particularly arduous
operating conditions (e.g. predominantly
cross-country
work)
can be equipped
with
a manually controlled four-wheel
drive, as an optional extra. Under
normal driving conditions on dry
roads,
the vehicle should
only
be driven
by the rear axle.
When the road surface is wet, slippery, snow or ice covered, or when driving
under off-road conditions, one is advised
to engage the four-wheel drive. The drive can be engaged or disengaged
whilst the vehicle is in motion.
Engaging
four-wheel
drive
Pull
the knob
(arrow)
located in the
middle of the dash panel. When the knob is pulled/pushed, engage-
ment or disengagement is only selected. The actual shifting process can be delay­ed.
If the wheels are
rotating
at
different
speeds,
it could happen
that
the 4 WD cannot be engaged at all, or if the drive train
is under strain, e.g.
tight
corner
with differential lock engaged, it could even happen
that
the lock
will
not disengage.
In such a
case,
the accelerator should be released or the vehicle should be driven straight-ahead to enable the 4 WD to engage/disengage.
The warning lamp above the knob lights up or goes out only when the four-wheel drive has actually engaged or dis­engaged.
Notes
• When engaging the cross-country gear, the four-wheel drive is automatical­ly engaged.
• To keep the steering forces as low as possible,
the four-wheel drive should be
disengaged
when a
full
lock is required -
e.g.
when parking.
• Just how the differential locks are en­gaged,
and
important
instructions on their
use
are to be found on pages 23 and 24.
OPERATION
AUTOMATIC GEARBOX
p R
U
N
d 1
D 2
1
[B16 -150 |
Selector
lever
positions
P -
Parking
lock
The driving wheels are locked mechani-
cally.
The parking lock may only be engaged
when vehicle is standing still. To move lever
into
and out of the
"P"
position the safety catch in lever handle must be pressed.
R -
Reverse
gear
The reverse gear must also be engag­ed
when vehicle is stationary and the engine idling. Before "R" can be engaged the safety catch in lever handle must be pressed.
N -
Neutral
D -
Normal
driving
position
The three forward gears are shifted up
and down automatically according to
throttle
opening and road
speed.
2 - Position for
hilly
stretches
The 1 st and 2nd gears are shifted up and
down automatically according to
throttle
opening and road
speed.
The 3rd gear
is
not
used.
This increases the engine
braking effect.
The road speed must not exceed 90 km/h
(56 mph). The lever can be moved from "D"
into
"2"
with
accelerator pedal depressed.
However as the shift
into
2nd gear takes
place
immediately this must
only
be
done
at speeds
below
85 km/h.
1 - Position for
steep
hills
To
engage this gear, the catch in lever
handle must be
pressed.
The vehicle re-
mains in 1st gear and 2nd and 3rd gears
are not
used.
This gives maximum
possi-
ble engine braking effect.
The road speed must not exceed 50 km/h
(30 mph).
The lever can be moved from "2"
into
"1"
with
accelerator pedal depressed. How-
ever
as the shift
into
1st gear takes
place
immediately this must
only
be
done
at speeds
below
45 km/h.
Kick-down
device
The kick-down device gives maximum
acceleration.
When the accelerator pe-
dal is pressed
right
down past the
full
throttle
position, depending on road
speed
and engine
speed,
either the up-
shift is delayed (forced
throttle)
or the
box changes down
into
the next lower
gear.
26
OPERATION
Notes on driving
Starting
The engine
can
only
be
started when
selector lever
is at
"N"
or
"P".
See
also
"Starting
engine"
on
page 29.
Selecting
a driving range
Before selecting a gear
with
vehicle stationary and engine running, operate footbrake or handbrake. This also app­lies when moving
lever
from
"P"
to "N".
Particularly when the idling speed is high
(after
starting from cold) it is ne-
cessary to hold the vehicle
with
the
handbrake.
This
is
necessary because with an auto-
matic
gearbox the transmission
of
power
is
not
completely stopped even
at
idling
speed
- the
vehicle tends
to
"creep".
When
selecting a gear
with
vehicle
sta-
tionary,
do not depress accelerator.
When a driving range is selected
with
the vehicle stationary,
the
throttle
must on no account be opened (e.g. by hand from engine compartment). The vehicle will
otherwise move immediately -
possibly even
with
handbrake applied.
Before working
on
the engine when it is
running, place selector
lever
at
"P"
and
apply handbrake. If the
lever
is moved accidentally
into
"N"
when driving, release accelerator
and
let the engine speed drop to idling
before selecting a
forward
gear again.
Driving downhill in
winter
Before driving down a long slippery gradient after starting
from
cold
in a
ve-
hicle
with
a carburetor engine, ensure that engine is warmed up enough to idle at
normal
speed.
Otherwise the
en-
gine braking effect
will
be limited when
accelerator
pedal
is
released
and
gentle
braking on the slippery surface
will
not
be possible. Stopping
To stop vehicle temporarily such
as at
traffic
lights,
all
that
is
necessary
is to
apply
the
brakes.
It is not
necessary
to
move lever
to
"N".
The
engine should
however
only
be
running
at
idling speed.
Parking
On level ground all
you
need
do
is
to
en-
gage
the
handbrake.
On a
gradient
the
handbrake should
be
applied firmly first
and then
the
parking lock engaged.
This
will
ensure that the locking mechanism
is
not
too
heavily loaded
and
makes lock
easier
to
disengage.
Emergency starting
The engine cannot
be
started
by
towing
or pushing
the
vehicle.
When battery
is
flat,
the
engine
can be
started from
the
battery
of
another
ve-
hicle
by
using a jumper
cable.
See "Emer-
gency starting", page 102.
Towing
If the
vehicle
has to be
towed
at any
time,
you
must read
the
instructions
in
the section "Towing"
on
page 103.
27
OPERATION
STEERING
LOCK/IGNITION
SWITCH
Petrol
engine
1 -
Ignition
off -
Steering
can be
locked.
2 -
Ignition
on
3 -
Starting
engine
Diesel
engine
1 - Fuel supply cut off -
Steering
can be locked
2 - Glow and
drive
position
While
glow plugs are on, no other
heavy
current consumers should
be
switched on.
3 -
Starting
engine
For all vehicles:
Position
1:
To
lock the steering wheel withdraw key
and
turn
wheel until you hear the pin
engage.
Caution Do not
withdraw
key
until
vehicle
is
stationary.
Position
2:
If the key is difficult to
turn
in the lock or cannot be turned to this position at all, the steering wheel must be turned to and
for slightly to release the locking pin.
Position
3:
In this position the headlights, the wind-
screen
wipers, the blower* and the
heated rear window* are switched off. Before
the starter can be operated again
the key must be turned back to position
1.
The
non-repeat lock in the ignition switch
prevents the starter from being operated
when engine is running as this could
damage
the starter.
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