Volkswagen T3 Caravelle 1987 User Manual

Volkswagen Transporter

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Volkswagen Caravelle

Instruction Manual

Congratulations on

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your

new Volkswagen Transporter/Volkswagen Caravelle You have made a

The Transporter I Caravelle is a versatile, million-fold proven vehicle.

wise

decision

But, you have not

you have also chosen A quality ensured by the

work

by all involved.

And

with

the Transporter/Caravelle you have also chosen one of the largest and

Organizations.

In Europe alone there are around 7,000 V.A.G dealerships.

We

wish

you pleasant motoring: Your V0LKS WA G EN WER

only

KA

opted

quality.

most

KTIEN

for an outstanding vehicle

up-to-date production technology, careful selection of materials and conscientious

GESELLSCHAFT

with

modern, low maintenance technical components,

most

efficient Service

Volkswagen

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Transporter

Volkswagen

Instruction

Caravelle Combi

Van

Pick-up

Double Cab

With

Manual

petrol engines (including catalytic converter), Diesel engines,

and Automatic gearboxes and Four wheel drive (syncro)

Manual

Caravelle

This

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Instruction Transporter/Caravelle modeis available ex-factory.

Certain vehicle models such as, for example

Multivan, Ambulance, Special bodies and additional items (e.g. radio sets, air conditioner) are not described in this manual but are dealt

cial separate manuals.

This

manual contains many important structions should therefore read cause cles

and maintenance of

the

one

of warranty Special

Driving tips:

drive

ment-conscious.

In

addition any supplements which sary,

vehicle

the Service a

Dealers

on

the

serves

vehicle and

of the

attention

safely, economically and environ-

to

the

following also belong

list

of act,

Manual is valid for all

with

in spe-

using

your

vehicle.

it

correct treatment

- in

addition

- to

stipulations

claims.

is in

is

These

drawn

tel!

this Instruction Manual and

carefully

of the

to

regular care

maintain

many cases also

for the

you how you can

may be

<le

•f

the

upholding

to

the chapter

neces-

to

V.A.

You

be-

vehi-

value

your

In the Service Schedule you

-

the

main identrication data

vehicle

-

the

Inspection

vals

-

the

operations which

at the Inspection

-

important

in-

In the

list

you will find phone numbers

rope details Service.

If you

the publications, please consult V.A.G Dealer.

Please

in this with tain options equipment

all

export

of addre3 ss

and

overseas

concerning

have

note thattjc items

Instructi

a * are or ' ily

models

on ce3

marlt

and Oil

detail;

the i '

of V ' \.G

any qit

on

or i are

is n' 9ot

ets.

djus

about Warranty.

; ind

th e

estions

rtain models. Such

always available

will find

for

your

change inter-

are

carried

(V.A.G

'resses

Dealers

also important

V.A.G Emergency

in

of

equipment

Manual marked

standard

only available

Service)

and

tele-

in Eu-

respect

your

on

cer-

out

of

as

in

Accessories, renewal of parts and technical modifications

Accessories, the vehicle

parts which have us can cause damage be detrimental

safety reasons therefore only

V.A.G Volkswagen parts. These

been designed proved safety aspects.

have

our liability V.A.G accessories, Genuine Volkswagen

parts and the associated qualified advice can

be for Volkswagen Commercial vehicles. They

correctly the permissible technical modifications.

Please liability approved cations - particularly with regard

stallations, sions - which When modifying

particular attention pertaining Volkswagen

parts

to be

fitted

in

and

unsuitable replacement

not

been approved

to the

to

driving safety.

accessories

accessories and these parts have

by us,

conditions.

obtained from

will also

appreciate that

for

your

particularly with regard

This

backing

and are

by us and by

in

respect

carry

out the

fully informed about

damage caused

attachments

are not

your

to

AG.

to the

bodywork" published

vehicle

you

should

and

vehicle

means that

of the

all V.A.G

we

can accept

by

technical modifi-

and

permissible.

vehicle, please

"Regulations

on by

and

For

use

Genuine

and ap-

to

they

legal

Dealers

installation

no

parts

not

to in-

conver-

pay

by

Warning lamps 6

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Handbrake, gear and selector

Keys,

doors, flaps 7,9,10 Windows, mirrors 11,12 Seat

belts, head restraints . }. . . 13,15

Seats

16

Stowing luggage 22 Warning lamps

Running-in and afterwards 56 environment-conscious 58

Fuel,

filling

Engine

tank

oil, gear oil

.

68, 74,75 Brake system, pedals 81,83

E

First aid kit, warning triangle

Vehicle

tools

Engine

da* 119

levers 23,24,28 Differential locks 25 Steering lock/ignition switch, Starting engine 30

Driving safely, economically and

Power

assisted steering 76

Cooling

70 Windscreen washer 80

99

Fuses,

99 Headlights 105

system 77

Care

of car 93

Maintenance, Inspection intervals ... 97

Spare

wheel, changing wheels . . 100.101

bulbs 102. 104

Vehicle

description 110

Functional description 117

Fuel

consumption, performance . . . 120 Weigh'

Spark

plugs, vee belts 125 Dimt

Wheels,

tyre

pressures 126

Instruments 37 Switches 39 Turn signals, windscreen wipers . . 41,43 Cruise

control system 42

Heating, ventilation, auxiliary heater. 44, 47

34

Sliding

roof,

sun roof 52

Trailer towing 60

Driving a four-wheel drive vehicle .... 63

Battery 84 Wheels

86 Emission Difficult

Lifting vehicle 98

Windscreen wiper blades 109 Emergency starting, towing, tow starting 111, 112

Iden

control system 90

operating conditions 91

liter

., :ities 131,134

i

•:

vy

ghtf

127,130

• 135

There

is a

detailed

alphabetical

index

at the end of

this

manual

INSTRUMENT

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PANEL

INSTRUMENT

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PANEL

Page

1 - Air vents 44 2

- Air vents 44

3

- Light switch and instrument lighting regulator 39

4 - Brake warning 5

- Speedometer 37

light

36

6 - Warning lamps 34 7 -

Fuel

gauge and coolant temperature gauge 38 Clock

or rev counter 37 8 - Heated rear window switch . . 39 9 - Emergency

light

switch .... 39

10 - Fog light/rear fog 11 - Air vents 44 12 - Ashtray 54 13

- Loudspeaker opening

14 -

Fuse

box 112

15

- Turn signal and dip switch ... 41 16 - Horn control 17 - Digital clock 37 18 - Steering lock/starter switch . . 30 19

- Auxiliary heater switch 47 20 -

Cold

starting aid

(diesel

engine) 32

light

switch . 40

Page

21 - Blower switch for passenger

compartment heat exchanger . 46

22 - Windscreen wiper and washer

lever

43

23

- Blower switch and levers for ventilation and heating 44

24 - Radio') or cover plate 25

- Socket/cigarette lighter .... 54

26 - Air vents 44 27 - Shelf 55

Knobs

and warning lamps for the ential locks on Transporter/Caravelle syncro

- see page 26.

Note

Some

of the items of equipment listed

are only

fitted

on certain models or are

optional extras.

') For vehicles

ating instruction leaflet is also See

section

with

a factory

remarks on page 110 of "Do-it-yourself"

when service installing a radio.

fitted

radio, an oper-

enclosed.

Page

differ-

INSTRUMENT

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PANEL

WARNING

Symbol

m

(®) 889

A

ffl

io

H

LAMPS

Turn signals

Generator Glow Engine Headlight high beams Coolant Brake Anti-locking brake system (ABS) Emergency

Rear

Fog

Differential locks (syncro)

plugs-Diesel

oil pressure '®

temperature/coolant level ©

system ©

light

system

window heating

lights/rear fog

light

Page

35

35 34 35 35 36 36 39 39 40 26

Notes

• If one of the lamps marked

comes

on when driving, stop at once

and

switch engine off. Details can be

found on the pages given.

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

On the other hand

lamps

which are not listed here because

they

are installed on so few vehicles.

with!{jP'

there

are

KEYS

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OPERATION

Up

to six keys are supplied

vehicle:

\

• two keys A

• two keys B*

• two keys C*

Key A

This

key

fits

all locks except:

• lockable glove box

• sliding door and rear flap 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.

with

the

safety

Tag D

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 stamped

on the key itself.

With the aid of the number, a replacement key can be ordered from a V.A.G Workshop.

Caution When

-

even

key

with

leaving

the

only

briefly - always

you.

vehicle

unattended

take

the

Note

On

four wheel drive vehicles there is

an extra key for the lockable tank cap.

D

|B2S~4S0

OPERATION

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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.

b

To unlock the tailgate insert key and turn it to right (c). Hold in this position and press

button in. If the key is withdrawn in the horizontal

position (a), 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 (b) and tailgate closed, it will be locked all the time. The tailgate can then only be unlocked with the key.

Note

if the central locking system shoul: develop a fault, all the locks can be operated normally, see next page.

The sliding door can be secured al released separately with the safety catc

DOORS

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Cab doors

From

outside

locked

and unlocked unlocking the locking knobs go up, when locking they go down.

The

front from outside 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

pressing 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 the door can be opened from outside in an emergency.

both cab doors can be

with

the key. When

passenger's door can be locked

without

the door can be locked by

down the locking knobs. As

using the key: Just

that

Sliding door

From

outside

locked

and unlocked

fully open the door is held by a hook.

To close sliding door

Press

the door handle down to release the hook and slide the door wards.

The sliding door can also be locked from outside locking catch in and close door.

From

inside

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 so

that

outside in an emergency.

the sliding door can be

with

the key. When

from

outside.

firmly

without

the door can be opened from

using the key:

the sliding door is locked

left

in the upper position

-

for-

Press

Child-proof

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

position.

catch

the locking catch in the up

on sliding door*

9

OPERATION

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TAILGATE

To open the tailgate when key hole is

horizontal, lift

tailgate.

Note

The with

To

close tailgate pull it down and slam

it to gently.

After on it perly could open suddenly moving turned

Do not exhaust the

vehicle

Opening

On

vehicles hind the cab and seats in rear compartment, the tailgate can be opened from inside cap gate. right

press the lock cylinder and

lock cylinder can also be pressed in

the key.

closing the

briefly

closed -

even

in lock. drive

gases are

from

in an emergency. To do this the

must be taken off the lock in tail-

Then press release lever to the

and open tailgate.

tailgate

to

make

otherwise

though

with

the

interior.

always

sure

that

the

when

the key has

tailgate

then

able

inside*

with

a full-width partition be-

pull it is pro tailgate

vehicle

been

open as

to

enter

up

is

ENGINE COMPARTMENT COVER

The

cover is in the luggage compartment. To remove cover catches

On panel.

to the

left.

the Pick-up, the flap is in the rear

turn

the two

10

WINDOWS

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'IjH.fM'KI'

Vent wings*

To open - Press button in fastener and

swing fastener forwards.

To close - Press window against seal at front and turn fastener to the rear until

button engages.

Sliding windows*

To open, press catch down and slide dow along.

win-

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 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

dows. When leaving the vehicle always

take the keys with you.

trim.

win-

11

OPERATION

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MIRRORS

The rear view mirror should always be ad-

justed properly before moving off so that good vision to the rear is obtained.

Note for vehicles with convex outside mirror*

Convex (curved outwards) mirrors enlarge the field of view but they make objects look smaller. These mirrors make it cult to estimate how far the vehicle behind is away.

Adjusting mirrors Normal exterior mirrors are adjusted by

moving the mirror housing.

diffi-

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.

Mirror heating

The electrically operated exterior mirrors are heated when the heated rear window is switched on.

Ant-dazzle interior mirror*

With this lever the mirror can be set :z\ the anti-dazzle position:

Lever forward - Normal setting Lever to rear - Anti-dazzle setting

It is important when setting the ensure that the lever on lower edge mirror is pointing forward.

mirror-jj

12

SEAT

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OPERATION

BELTS

It has been proved good protection in accidents. It most countries belts

Put your also in

All vehicle occupants should also always those on the

Even wear point type).

The tance

How

on

therefore

is required by law.

belt

town

wear

the

pregnant women should always

a seat belt (preferably the three

routing of the belt is of major impor-

to the protective effect of the belt.

the belt should be worn is described

the next pages1).

on

before

traffic.

seat

rear

seats.

that

the

belts

seat

belts

wearing

every

journey

- including

of

give

seat

-

Safety

for children

Children under 12 years old should nor-

mally

be carried on the

velle

and Combi) and should, depending on age, be secured childs

restraint

belt.

•

Children up to about 6 years of age

should,

depending on

a

reclining safety seat or a child's seat.

•

Children above 6 years of age can

also

use a lap belt.

•

Babies

also

be carried on the front passengers

seat

in a restraint system specially

approved

•

Larger children may use three point

belts

provided that the belt

over

centre of shoulder and not against the child's neck - see illustration on next page.

If

necessary,

can

be

used.

The

installation restraint accordance manufacturer

system or the existing

up to about 8 months old can

for this purpose.

systems must be done in

with

concerned.

rear

seat

(Cara-

there

with

a

size

be carried in

passes

a safety seat cushion

and use of child

instructions of the

General notes

Only

one person is to be secured with

each

belt. Never secure two people

(even

children)

On vehicles seats,

always

underneath

The

belt should not be worn over hard or

breakable

key

rings, pipes, etc.)

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

The

slot for the belt tongue must not be

blocked

wise The

wise perly section).

with paper or anything as other-

the tongue cannot engage properly.

belts must be kept clean as other-

the retractors may not work pro-

(see

with one belt.

with

armrests* for the

ensure

the armrests.

articles

also

that

(glasses,

because

edges.

"Care

and Maintenance"

the

ball

belt

this can

runs

pens,

In some export countries the belts fitted may

differ from the belts described

here.

13

OPERATION

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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

seating

positions with belts of belts should

service installed

on

at

the factory.

be

done

vehicles

The

by a V.A.G

for all

not

fitted

installation

workshop because these workshops have

the

information necessary

job

properly.

to do

Note

On the Van there are no belt anchorages in

the

load compartment.

|B25-

521

Three-point inertia reel belts*

The inertia reel belt gives complete freedom

of Sudden braking belt

The retractor mechanism will also lock the belt when accelerating, driving down steep gradients

Putting

Pull across into tongue engages audibly

The shoulder part of the belt must run roughly across the centre of the shoulder as shown - on no account against contact

movement when pulled slowly.

to

lock.

however

or

will cause

cornering hard.

belt on

the

tongue slowly

your

the

chest and hips

lock part fitted

and

on the

(pull

smoothly

seat until

to

the neck - and be firmly in

with

the body.

the

push

it

check).

On

the

front

seats

the shoulder belt can a

belt anchorage height adapter.

be

altered

routing

by

installing

of fe

The lap part of belt must always • tightly

across the lap. Pull belt

tight

1

necessary. Particularly in the case of pregnar-

women

the lap part of the belt should be

as

low across the lap as possible s:

that no pressure is exerted on the abdomen.

The belt must not be twisted. The backrest of the front seats mus"

not be inclined too far to the rear as otherwise the belts are no longer

effec-

tive.

Taking

belt off

To release coloured button will

then spring

Pass hand belt

up

the

tongue towards

so

that

the

properly.

belt, press

in the

lock.

out.

retractor

the

The

the

can

orange-

tongue

door

b.

roll

the

HEAD

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RESTRAINTS*

RATION

Belt height adjustment

Two anchorage points the

cab for the

This

makes

body

Lap

belt*

The buckle is used in the same way as the three-point inertia reel belts.

The belt must always fit the lap.

To lengthen belt

angles to belt and pull belt through to the

required length.

The belt cap

are

To shorten belt it is

pull

the

The surplus belt length

moving

it

size.

possible

is

easier

pressed together.

free end

the

plastic slide.

are

upper belt attachment.

hold the tongue

to

adjust

of

belt.

provided

to

adapt belt

tightly

if

tongue and

only necessary

is

taken

in to

on

across

at

right

to

up by

Two-point inertia reel belts*

The individual seats*

compartment inertia

reel belts. freedom ly but sudden braking the belts to lock. The automatic retractor mechanism driving down steep gradients ing

hard.

Putting

Pull

the

across

the hips and push part fitted engages audibly

The belt must not be twisted. The belt

must

always fit

slightly if necessary.

Taking

To release coloured button will

then spring

Pass

the tongue across

the retractor can roll the belt up properly.

are

of

movement when pulled slow-

will also lock

belt on

tongue slowly

on the

belt off

the

out.

in the

fitted with

They

however

seat until tongue

(pull

to

tightly,

belt press in the

passenger two

give

complete

will

the

belt when

or

and

smoothly

it

into the lock

check).

pull belt up

the

lock.

The

by

hand

point

cause

corner-

orange

tongue

so

that

The head restraints must be adjusted properly to suit the body size. Only correctly adjusted head restraints, together effective protection.

with

the seat belts, provide

Adjusting height

Grip

at up be

Removing

Push

in backrest with a small lift head restraint

To

the guide rings of clip restraint rods into engage audibly.

Note:

The spring clips need

on vehicles which have a rear seat/fully reclining

It is ing rear, removed.

sides with both hands

or

push down. The upper edge should

roughly

at eye

level.

and installing

spring clips

install,

first press the spring clips into

is at the

seat bench.

quite sufficient

spring clip extensions back

to

enable the head restraints

out.

so

rear.

out of

screwdriver and

that

the

Then

the

guides until

not be

to

push

and

pull

slotted rings

straight part

push head

they

taken

out

the

protrud-

to the

to be

SEATS

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Individual

ger

To

Lift seat. further

IN CAB

driver's

and

front

passen-

seats

move

seats back

lever (1) on outside of seat and move

Then release lever and move seat

so

that

or

forward

catch engages.

Caution

• For

safety

only

be

stationary.

To

adjust

Take

weight off backrest, press lever (2)

on

right move backrest to desired position by moving upper part of body then release lever.

reasons the

adjusted

backrest

side of seat frame down and

when

rake

seats

vehicle

should

is

|B25-548|

Caution

• Do not when belts

lower

on the

are

then

the

move

no

longer

backrest

because the

fully

too far

effective.

seat

Armrests*

The armrests on the hinged up if they are not required.

The angle of the armrests can be adjusted

as

required

neath the armrest.

with

front

seats can be

a knurled knob under-

To

take

seat

out

• Slide seat forward tion.

•

Lift

hook (3) against spring-loac -; at the same time pull lever (1), he : I and slide seat past stop.

•

Release

seat

forward out of runners.

• The hook need not be putting lever lifted, can stop.

Seat

Seat seat

can be heated electrically whe-

ignition is on. Further details are give unce

"Switches",

Head

The head restraints must be adjusted :: body

hook and lever and p.r

seat back as the seat,

heating*

cushion and backrest of drive's

page 40.

restraints*

size

- see page 15.

into 1 st latch c: :-

lifted

just

be pushed past ~^

w-a

with

rm

SEATS IN PASSENGER COMPARTMENT*

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OPERATION

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 driver's 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.

Removing and installing centre seat bench

The centre seat is pushed into two ners and secured with four screws. To take seat out the floor covering must be lifted and the screws removed. The seat can then be pulled out of the runners sideways through the opened sliding door.

Note

On vehicles with floor carpeting, the securing strip in the sill area must be taken off first and the carpet then lifted carefully. Take care when doing this to ensure that the carpet does not tear at the cut-outs.

run-

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.

INDIVIDUAL SEATS IN PASSENGER COMPARTMENT*

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Centre seats

The centre seats

backrest angle adjusted.

can be

turned

and the

Turning

Lift lever the desired position and again.

It

the

necessary

seat

(see

backrest

to

can be

illustration), turn seat

is

very

raise

it

turned.

slightly before

let

lever engage

low, it may be

the

Adjusting backrest angle

Take weight

to

down

to

the

part

of

Removing

Lift

the

seat

out.

The base which remains can be removec

when carpet

Caution When sure that base

properly.

off

(see

desired position

body

lever used

the

backrest and press lever

illustration). Adjust backrest

and

release lever.

to

turn seat

is

lifted.

seats

are

installed again

and

seats

by

moving upper

and

are

secured

take

en-

OPERATION

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Rear

seats

The height, seat angle and backrest angle of the rear seats can be adjusted.

Mechanical

Adjusting

Press

lever B to position of seat as required by moving body weight.

Adjusting

Press

lever B alternately at rear and by moving weight of body to front

and rear

adjustment

seat

angle

front

seat

height

lift

or lower the seat.

or rear and adjust

front

and

Adjusting

Take A

at side of backrest.

Caution When must as

otherwise

fully

backrest

weight off backrest and

vehicle

not be

effective.

is in

motion,

inclined

the

belts

angle

turn

the

too far to the

backrests

are no

knob

rear

longer

19

OPERATION

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1

Electrical adjustment*

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.

|B25-382

Caution When vehicle is in motion, the back-

rests should not be inclined too far to

the rear otherwise the seat belts are no

longer fully effective.

20

OPERATION

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REAR SEAT/FULLY

The rear seat/reclining seat bench can

be converted

Before doing this, the backrests of the center row of seats must be tipped ward. The latching levers are located on the outsides of the

backrests.

To

convert

• Remove head restraints* -

see

page 15.

• Unlatch the backrest grip on the reverse side of the backrest, and fold the backrest forwards.

into

reclining

RECLINING

a large sleeping area.

right

and

seat

bench

with

SEAT BENCH*

for-

left

hand

the release

| &25-^05 \

• By pulling the release grip towards the bench are pulles in a forward direction.

• Finally, fold the seat backrest the rear to

Returning position

• Pull the seat backrest upwards out of the horizontal position.

• Slide the seat bench, together backrest to the rear again.

•

Push

tion.

front,

the backrest and seat

form a flat

seat

bench

backrest back

sleeping area.

to

into

further

original

locking

fully

with

posi-

to

• Pull the seat belts out again between backrest and seat, so position for use.

•

Install

see

The space underneath the seat bench can

For bench slightly at the in the located on the side,

head restraints* -

page 15.

be used as a storage compartment. this, it is necessary to

lifted

position when the

is swung upwards.

that

they are in a

lift

front.

left

on the sliding door

the seat

It

will

remain

strut,

21

OPERATION

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LUGGAGE

COMPARTMENT/

LOAD SURFACE To

enlarge

•

Release

• Fold backrest down to seat The backrest locks automatically when

hinged to the rear. Instructions on using the rear/reclining

seat*

Notes ment

or the

• The load must be stowed so cannot slip or even fly forward when the brakes are applied.

• In the interests of good handling the load

should, between the loads

and the permissible gross vehicle weight should on no account be ed.

• Ensure rear window is not damaged by articles rubbing against it.

Never

ment

not

haust

luggage

space*

backrest by pulling loop

are given on page 21.

on using the

load

wherever

axles.

that

drive

with

properly

gas can be

luggage

surface

possible,

The permissible axle

the heater element in the

the

luggage

closed

drawn

otherwise

into

compart-

that

it

be carried

exceed-

compart-

ex-

the body.

FOLDING

LUGGAGE

COMPARTMENT COVER*

The folding cover can be pushed together to together.

When the the rear or the rear part to the appropriate rod must be jerked out of the retainers. When the rear rod is pushed fully forward it engages.

Notes Only

placed cover.

Ensure

• The cover is correctly located in its

mountings when vehicle is moving.

• No items of luggage can fly forward if

brakes are applied sharply.

• The heater element in the rear window is not damaged by articles rubbing against it.

• Vision through rear window is not obstructed otherwise a second outside mirror must be fitted.

light

on the

that:

front

or rear or taken out all

front

part is to be pushed to

articles

of

clothing

luggage

compartment

front

the

may be

ROOF RACK

When a roof rack is to be following:

• Only use roof racks which are supported in the rain channel

• Distribute load uniformly.

Do

not exceed permissible roof load o-

permissible gross vehicle weight.

Further details on pages 127-129.

• When carrying heavy or large objects on the

roof,

bear in mind handling changes due to the alteratioin centre of gravity and the increase:

area

exposed to the wind. Driving style and speed must be modified to allovs for this.

used,

that

the vehicla

note th

22

OPERATION

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COVER* (Pick-up)

The cover must be secured properly be-

hind 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 ed

When the cover and rails have been re-

moved, ing to ensure properly in the rain channel (if necessary renew seal).

left

and

right

to the canopy frame.

care should be taken when

that

hand ends are bolt-

the foam

seal

refitt-

is stuck

DROPSIDES (Pick-up)

To

drop side boards - pull handle outwards to release locking pin und swing down to

On tailboard, be down.

lift

vehicles

placed

hook.

with

not

more

on the

support

than

tailboard

cables for the

150 kg should

when

it is

HANDBRAKE

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

it is not possible to drive off accidentally

with

handbrake slightly on.

When handbrake is applied

ignition on, the brake warning lamp* comes

on.

To

release handbrake, pull lever up

slightly, press locking knob in and push lever

right

down.

firmly

with

that

the

MANUAL GEARBOX

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.

|B25-452

1B25-453

|

B25-454

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.

4 + G

gearbox

(syncro)

Engaging crawler gear (G) on syncro

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.

24

DIFFERENTIAL LOCKS*

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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 differentials have a distinct characteristic: As soon as one wheel on an axle commences 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 obtained.

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 (syncro) have selectable

mechanical locks in front and rear differ-

entials.

Limited slip differential*

(Rear wheel drive) The locking effect is obtained by means

of plates which are arranged in the differential as 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 steer-

ing behaviour on the road, particularly in

sharp curves, remains almost un-

changed. The effective locking force is dependent

on the speed difference of the two driv-

ing 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 curv-

es.

This is due to the fact that a slight

locking effect is always present.

Furthermore in isolated borderline ditions 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.

con-

Gear oil

The oil level does not need checking be-

tween the intervals given in the Service

Schedule. The oil also does not need

changing.

V.A.G workshop should be contacted

because the gearbox must be filled with a special oil.

To top up or fill after a repair a

25

Selectable

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(syncro)

With the selectable differential locks, the wheels

gether (100%). As no compensation takes dling and steerability are affected - particularly in the tial lock.

Attention The

differential under described on the

differential

on one axle are fully locked to-

place when cornering, the han-

case

the

locks may

limited

locks*

of the

front

differen-

only

specific conditions

following

be used

pages.

Engaging the

The

differential locks are engaged and disengaged centre of the instrument panel vehicle

stationary or moving.

Left

knob

The

knob for the

secured

tentionally. The knob must therefore be turned to the

Right

knob - Rear

differential

with

the knobs shown in the

- Front axle differential lock front

so

that

it cannot be pulled unin-

right

before it is pulled out.

axle differential lock

locks

with

differential lock is

When

the knobs are pulled/pushe

engagement or disengagement is onselected. can ing at different train is under strain, e.g. with even gage throttle and ahead slightly to enable the lock to engage' disengage.

The

indicate the operational condition of tha locks:

• If the been lamp flashes. As soon as the lock am

gages

• The

tors the function of the rear axle diffe--

ential lock. It does not flash when the lock has been selected but only light; up once the lock has engaged proper!;.

The actual shifting process

be delayed. If the wheels are rota?]

differential lock engaged, it could

happen

or disengage at all. In such a

application should be reduce

the vehicle should be driven straigr

while moving steering wheel

warning

selected, the

the lamp lights up continuously

right

speeds,

that

lamps

front

axle differential lock has

hand warning lamp monH

or if the drivq

tight

the lock will not er-

above the knotsi

left

hand warning

corne-

case

26

•

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Both warning lamps

once

the

and If

after selecting and after driving some distance, warning lamps cal should

Attention

The differential locks influence

steerability with gaged, able. erential offroad conditions and then only speeds. fore driving

knobs have been pushed

the

locks have actually disengaged.

the

do

system

be

checked

the

front

the

For

this reason, the

lock must only

Always disengage

not light up, the electri-

and the

of the

axle differential lock

vehicle

on

metalled road surfaces.

go out

differential locks,

locks themselves

at a

V.A.G workshop.

vehicle.

is no

be

In

particular,

longer steer-

front

axle diff-

used under

at low

the

lock

again

in

the

en-

be-

When may the differential locks not

be engaged?

•

Neither differential driving along metalled road surfaces.

Locking makes

When locked, the

two effect This also being stances train.

For this reason, engaged under off-road conditions an

assistance when moving

See

"Driving Tips"

the

front

locks may be engaged when

the

on the

leads

to

steered.

front

vehicle unsteerable.

rear axle differential

the

rigid connection between

rear wheels

to

increased

"jerking" when

it may

nor the

axle differential

has a

tyres

when cornering.

tyre

In

even damage

the

certain circum-

locks may only

on

page 65 also.

rear axle

is

scrubbing

wear

and

vehicle

off.

the

is

drive

be

or

as

•

When a wheel example This tyre drive train acceleration. ing standstill are engaged.

•

see

• namometer, local

the

would

wear

wheel must first

When

page 112 also.

When testing

authorities

vehicle

not

but it

and

For this reason, the spinn-

before

the

vehicle

e.g.

OPERATION

is

spinning,

is

only lead

could also damage lead

when being tested

- see

stuck

to

uncontrollable

be

the

brought

differential locks

is

being towed

vehicle

page 67 also.

if for

in

snow.

increased

on a dy-

the

to a

-

by

27

AUTOMATIC GEARBOX

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Selector lever P - Parking lock

The driving wheels

cally.

The parking lock when vehicle

lever into and

safety catch

pressed.

Depending may also

lector lever safety catch. then only when

the

the knob

positions

are

may

is

out of the

in

on

vehicle version, there

be an be

moved

brake pedal

in the

only

standing lever handle must

additional electrical

out of the P

is

selector lever pressed.

locked mechani-

be

engaged

still.

To

"P" position

The

depressed

move

lever

position

the

be

se-

can

and

R - Reverse gear

The reverse gear must also ed when vehicle engine idling. Before "R" can be engaged the safety catch

pressed.

N - Neutral D - Normal driving position

The three forward gears and down automatically according throttle opening

2 - Position

The 1st and 2nd gears are shifted up down automatically according opening

is braking effect.

The road speed must not exceed 90 km/h

(56 mph).

The lever

"2" However place immediately this must only

done

and

not

used. This increases

can be

with accelerator pedal depressed.

as the

at

speeds below

is

stationary

in

lever handle must

and

road speed.

for

hilly stretches

road speed.

moved from

shift into 2nd gear takes

be

engag-

and the

are

shifted

to

throttle

The 3rd

the

engine

"D"

85 km/h.

be

up to

and

gear

into

be

1 - Position

To engage this gear,

handle must mains

are

not sible engine braking effect. speed must

mph).

The lever can with accelerator pedal depressed. How-

ever

as the

place immediately this must only

done

at

for

steep hills

the

catch

in

be

in 1st

used. This gives maximum pos-

speeds below

pressed.

gear and

not

exceed

be

moved from "2" into

shift into

The

2nd and 3rd

50 km/h (30

1st

45 km/h.

lever

vehicle

gears

The

road

gear takes

re-

"1"

be

Kick-down device

The kick-down device gives maximum

acceleration. When dal

is

pressed right down past

throttle position, depending

speed

and shift box changes down into gear.

engine speed, either

is

delayed (forced throttle)

the

accelerator

the

pe-

the

full

on

road

the up-

or the

next lower

28

OPERATION

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Notes on driving

Starting

The

engine selector "Starting

Selecting

Before selecting a gear stationary and engine running, always operate footbrake. This also applies when moving lever from "P" to "N".

Depending may

also

lector then when the

knob in the

Particularly when the idling speed is high cessary handbrake.

This

is matic is

not

speed

can only be started when

lever

is at "N" or

engine"

a driving range

be an additional

lever

only be

the brake pedal is

(after

to hold the vehicle

necessary gearbox completely

- the

on

page

on

vehicle

safety

moved

selector

starting from cold) it is ne-

the

vehicle

version,

catch.

The

out of the P position

depressed

lever

because

transmission

stopped

tends to

"P".

See

31.

with

vehicle

electrical

lever

pressed.

with

with an

of

even

at idling

"creep".

also

there

se-

can and

the

auto-

power

When selecting a gear tionary, do not depress accelerator.

When a driving range is selected the vehicle stationary, the on

no account be opened (e.g. by hand from engine compartment). The vehicle will

otherwise move immediately -

possibly Before working on the engine when it is

running, apply handbrake.

If the lever is moved accidentally into "N" and let the engine speed drop to idling before selecting a forward gear again.

Driving downhill in Before driving down a long slippery

gradient hicle that idle at normal speed. Otherwise the engine braking effect accelerator pedal is released and gentle braking on the slippery surface be possible.

even

with

place selector lever at "P" and

when driving, release accelerator

after

with

engine is warmed up enough to

starting from cold in a ve-

a carburetor engine, ensure

with

vehicle sta-

will

with

must

not

throttle

handbrake applied.

winter

will

be limited when

Stopping

To

stop traffic apply move however

Parking

On apply handbrake and will is easier

Tow starting

On

the

or

When

started cle "Emergency

Towing

If the time, the

vehicle

lights, all that is

the

lever

only be running at idling

level

ground all you

the

then the parking

ensure

not too

to

disengage.

vehicles

engine

pushing

battery is flat, the

from the battery of another

by

using

vehicle

you must

section

temporarily

brakes.

handbrake.

should

heavily

It is not

to "N". The

be

that the

loaded

with an automatic

cannot

the

be started by towing

vehicle.

a jumper

starting",

has to be towed at any

read

"Towing"

such

necessary

engine

need

On a gradient the

applied

lock

engaged.

locking

and

engine

cable.

page

the instructions in on

page

as at

is to

to

should

speed.

do is to

firmly first

makes

gearbox

can be

112.

This lock

vehi-

See

mechanism

111.

OPERATION

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STEERING

LOCK/IGNITION

SWITCH

Petrol

engine

1 -

Ignition

locked.

2 -

Ignition

3 -

Starting

Diesel

1 - Fuel supply cut off -

can be locked

2 - Glow and

While

heavy be

3 -

Starting

off -

Steering

on

engine

drive

glow plugs are on, no other

current consumers should

switched on.

engine

position

can be

Steering

For all vehicles:

Position 1:

To

lock the steering wheel withdraw key

and

turn

engage.

Caution

Do not

stationary.

Position 2:

If the key is difficult to cannot be turned to this position at all, the steering wheel must be turned to and

Position 3:

In this position the headlights, the windscreen rear window^ are switched off.

Before

the key must be turned back to position 1. The

prevents the starter from being operated when engine is running as this could damage

wheel until you hear the pin

withdraw

fro slightly to release the locking pin.

wipers, the blower and the heated

the starter can be operated again

non-repeat lock in the ignition switch

the starter.

key

until

vehicle

turn

in the lock or

is

STARTING THE ENGINE

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General

• Be in a confined space. ing.

• Check

(On vehicles Selector handbrake firmly before starting.

• Depress the clutch pedal on vehicles with that gine.

• As soon as the engine starts, release the ignition key so disengage.

• After starting a cold engine it may sound sure pets^

for alarm.

notes

careful

manual gearbox when starting so

the starter only has to

noisy briefly because the oil pres-

has to build up in the hydraulic tap-

first.

when

running

Danger

that

gear lever is in neutral.

with

lever at "P" or "N") and apply

This is normal and no cause

automatic gearbox:

that

the

engine

of poison-

turn

the en-

the starter can

• Do not warm engine up by running it with

vehicle stationary. Drive off straight

away.

• Do not overrev or use until the engine has reached the normal operating temperature.

• On vehicles

er the

engine catalytic perature distance as can get be

into

burned

44 and 57 kW

Starting

The

carburetor is

choke

which is actuated the accelerator engine is cold.

• Depress accelerator pedal slowly

once

(twice

release

it.

• Start engine - do not use accelera-

tor.

• If the engine does not start at once,

stop using starter after 10 seconds, wait

about half a minute and then try again.

with a catalytic

must converter by

towing

there

not be

is at

otherwise the

the

catalytic

- see also

carburetor

a cold

engine

fitted

pedal is depressed when

when

it is

full

started

operating

vehicle

unburnt

converter

page

engines

with

an automatic

first

freezing)

throttle

convert-

when

tem-

a long

petrol

and

83.

time the

and then

• The increase in the idling speed which takes

place as engine starts to warm up

can

be reduced by

erator pedal briefly.

On vehicles

the engine should be run at fast idling speed

for about one minute after start-

ing when it is very cold.

The

pedal should then be tapped so the speed drops and a gear can be selected

Starting a warm

• Depress pedal slowly ing starter and hold it in the position - do not pump the pedal!

• starts.

at normal idling

Release

just

tapping the

with

an

automatic

speed.

or hot

engine

while

pedal as soon as engine

gearbox

operat-

full

throttle

accel-

that

31

OPERATION

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Fuel

injection

The

engine is

system

which automatically supplies the correct fuel/air mixture for all operating conditions. The starting procedure described

here is applicable regardless of

ambient or engine temperature:

• Start engine - do not depress accel-

erator.

• Only if the engine does not start the first

time, should the accelerator pedal

be

depressed slowly during the next

attempt

release

to start. When engine starts

accelerator pedal immediately.

engines

fitted

with

a fuel injection

Diesel

engines

Glow

plugs

The

engine is time the plugs are on is indicated by a lamp which is controlled by the coolant temperature - see page 33.

Cold

starting

To

faciliate starting from

cold

starting device in the injection

pump.

The

cold starting device is actuated

when the knob on the

ing column is pulled out fully.

Starting

• The knob of the cold starting device should ing starter regardless of the ambient temperature.

• Turn ignition key to position 2, glow

plug lamp commes on. It goes out when the ignition temperature is reached (see page

30).

fitted

aid

a cold

engine

be pulled out

with

glow plugs. The

cold,

there is a

right

of the steer-

fully

before operat-

If the warning lamp does not come on when engine is fect in the glow plug system - get expert assistance.

To

avoid ily, do not rent

consumers on

are on.

• As soon as a~c goes out. start en-

gine.

Do ro: oecress aoceierator while

starting

If engine on,;, - -es "eg., arly, continue

to opera:e

(15

seccncs

runs under :s c.v cower. If enghe ::es ~z: s:a~t. switch glow

pugs

age" a~o :-y s:arting it again

cold,

draining

switch

s:a~e-

a: ~a>

there may be a de-

battery

any

a fev. seconds longer

: :es not start the fuse ;s

unnecessar-

other

heavy

while

glow

until

~av nave blown -

cur-

plugs

engine

•

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Push

the knob of cold starting aid in fully as soon as the engine has reached normal operating temperature.

Starting a warm

The

glow plug warning lamp does not

come

on - the engine can be started

straight away. Do

not pull cold starting aid knob and do

not depress accelerator pedal.

engine

STOPPING ENGINE

•

When for a soon as you stop. Let it minutes

• When engine is hot, the fan may tinue to run when engine has been stopped when ignition has been switched off.

vehicle

while

to cool it

or it may switch on suddenly - even

do not

has

been

switch down

driven

engine

idle

for

slightly.

hard

off as

about

con-

2

OPERATION

I

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OPERATION

WARNING

The

layout of the warning lamps depends on the model and the engine fitted. The symbols actual warning lamps.

This

warning lamp flashes when the igni-

tion

is switched on. After the engine has

started, the lamp must go out again. If the warning lamp does not go out, or

flashes speed sounds - stop

gine

off. Check the oil level and if ne-

cessary,

If the lamp comes on despite the oil level being correct,

case, at idling speed - call in expert

Note:

The oil pressure warning lamp is not

oil level indicator.

LAMPS

shown here are also on the

-

Engine oil pressure

when driving - at an engine

of approx. 2000 rpm a buzzer then

add oil - see page 74.

the

do not drive

engine must

|

at

once and switch

on.

not

be run,

assistance.

en-

In such a

even

an

-

Generator

Petrol engines

This

lamp comes on when the ignition is switched on and should go out when the engine is started.

If the lamp comes on when driving,

at once, switch engine

vee

belt.

If the belt is broken do not drive because longer being driven. Fit a new belt. (For belt

If the warning lamp comes on although

the belt is not broken one can normally

drive on to next However

ing continuously, all electrical components which are not absolutely essential

should be switched off.

the coolant pump is then no

sizes

see "Technical data".)

V.A.G

as the battery is then discharg-

off and check

workshop.

stop

further

.......

Diesel

engine

This

lamp comes on when the ignition is switched on and should go out when the engine is started.

If the lamp comes on at once, switch engine off and check the vee

belts for generator and coolant

pump. If the belt for the coolant pump is broken,

do not drive for belt

If the belt for the generator is broken the vehicle V.A.G

workshop but the battery discharge graph.

If the belts are not broken one can normally drive on to the next V.A.G workshop.

As the battery

continuously, all electrical components

which are not absolutely essential should

be switched off.

further.

size

see "Technical data".

can still be driven to the next

continuously - see next para-

when

driving,

Renew the belt -

will

be discharging

will

stop

then

34

-

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Glow

(Diesel

engine only)

When

engine is

comes

on when key is turned to drive

position

If the warning lamp does not come on, there may be a defect in the glow plug system

- get expert assistance.

When

the lamp goes out, start engine

immediately - see page 32. When

engine is warm the glow plug lamp

does

not come on - the engine can be

started straight away.

00 -

Turn

The

warning lamp flashes when

nals

are switched on. If a

the warning lamp flashes twice as fast.

(Not when towing a trailer). Further de-

tails are on page 41.

01 -

High

The

warning lamp comes on when high

beams

are on or headlight flasher is

used.

plugs

(ignition

signals

beams

cold,

the warning lamp

on).

turn

signal fails,

sig-

-

Coolant

~~

coolant

This

lamp flashes for a few seconds as

a

functional check when ignition is

switched on.

If the lamp does not go out afterwards or flashes when driving, either the coolant

temperature is too high or the coolant

level

is too low.

Stop

at once,

check

if the radiator fan is running (by listening). The fan is at the the radiator grille. If the fan is not running,

check fuse and replace if

sary

- see page 102.

If the fan is in order, check coolant level

and

top up if necessary.

Caution. removing down.

For

If the warning lamp does not go out even

though the coolant in order, do not assistance.

Danger

the cap, let

further

temperature/

level

switch

details see page 78.

drive

engine

front

of scalding.

engine

level,

and fan fuse are

further

- get expert

off and

behind neces-

Before

cool

OPERATION

If the trouble is only caused by the fan and

assuming coolant level is in order

and

warning lamp is out - one can drive on to the next to make a good use of the air stream for cooling very slowly.

Trailer

The

warning lamp flashes when signals

are switched on when towing a

trailer.

If a

turn

the warning lamp does not flash.

Differential

Warning lamps for the differential locks on four wheel drive models - see page

26.

V.A.G

workshop. In order

do not let engine idle or drive

turn

signals*

turn

signal fails on trailer or vehicle,

locks*

35

OPERATION

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INSTRUMENTS

(©) -

Brake

system

The warning lamp* comes on when

• the handbrake is applied

• the fluid level is low

If the

lamp

brake

is

driving, the

released

fluid too low. If at the free

travel

does not go out

hydraulic You can

workshop pressures and

increases, one of the two

circuits

drive

on to the

but

allow

longer

or comes on

level

same

may

in

reservoir

time

have

nearest

for

higher

braking

when

the

failed.

distan-

hand-

when pedal

V.A.G

pedal

ces on the way.

(@) - Anti-Locking

Brake

(ABS)*

The warning lamp comes on when the

ignition is switched on. It goes out, when engine has been started and the generator warning lamp has gone out. (When a vehicle speed of approx. 6 km/h has been

is

reached, an automatic check se-

quence

takes place. During the check a

pump motor noise may be heard.) If the lamp does not go out, or if it

comes

on while driving the system is not in order. The vehicle can then only be braked

with and should be taken to a soon

as possible.

the normal brake system

V.A.G

Further detail on ABS is given on page

83.

System

dealer as

The arrangement of the instruments

depends

the engine

panel",

on the model concerned and

fitted

- see also

"Instrument

page 4.

Speedometer

The permissible maximum speeds in the gears

during the running-in period are

given on page 56.

Mileage

recorder

1

The last figure of the mileage recorder or

trip

recorder*

indicates 100 m or

1/10 mile.

The

trip

zero

recorder can be set back to

by pressing the knob in the speedo-

meter dial.

36

OPERATION

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Clock*

Normal

To dial and

Digital

The right

hours and the

• If pressed briefly, preferably ball pen, the time changes one hour or on minute.

• If pressed continuously the hours or minutes change continuously.

With the minute button the clock can be

• before time to be set.

the seconds indicator of an accurate

clock

time signal is heard on the radio.

clock

set the time, press knob in centre of

turn

hands.

clock

time is set

of dial. The

set exactly to the second.

Press

•

Press

shows a

with

buttons on

left

right

button until time is one minute

button at the moment when

button is for the

one for the minutes:

full

minute or when the

left

with

and

a

Rev

counter*

The

dotted zone on the scale shows the maximum engine speed permitted briefly when engine has been run in and is warm.

It is advisable to change up or

reduce

engine speed at the latest by the

time the needle reaches this zone.

Changing up in good fuel

and

keeps

Always

change down to the next lower

gear

before the engine starts labouring,

(no longer pulls smoothly). The

green or green shaded area on the scale

shows the speed at which the engine is developing its most favourable torque.

The

permissible engine speeds during

the running-in period are given on page

56.

time

the noise down.

helps to save

Tachograph*

In many European countries the installation and use of a tachograph is obligatory for certain vehicles.

Details

of the regulations can be obtained from local vehicle licensing authorities.

The

operation of the tachograph is described tachograph manufacturers.

in a special leaflet from the

_L

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- Coolant

temperature

gauge

The

gauge starts to work when ignition

is

switched on, but it takes a

before the needle reaches the final po-

sition. When

ignition is switched on the warn-

ing lamp (c) flashes for a few seconds

as

a functional check.

a

- Cold

Avoid work engine too hard yet.

zone

high engine speeds and do not

little

time

b -

Normal

When needle

When bient temperature is high, the needle may

move well over to the

This is not serious as long as the ing

lamp

c - Warning If the lamp flashes when driving either

the coolant temperature is too high or the coolant level is too low. Stop at once, the cause of the trouble - see page 35.

zone

vehicle is driven normally the

should settle down in this

engine is working hard and am-

(c) does not flash.

lamp

switch engine off and try to find

zone.

right.

warn-

fllj

- Fuel

The

fuel gauge needle starts to move when the ignition is switched on but it takes

a few seconds to reach its final

position. The

tank holds about 60 litres (syncro 70

litres).

When the reserve mark (R) there are about 10

litres of fuel

gauge

the needle reaches the start of

left

in the tank.

38

SWITCHES

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3 - Heated rear window*

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 ele-

ment off. The reduced current consumption helps to reduce the fuel consumption - see also "Driving economically".

On vehicles with electrically adjusted exterior mirrors the mirror surface is heated whenever the rear window heating is switched on.

1 - Lighting switch

First detent - side lights1)

Second detent - headlight high or low

beams

The headlights only work when the tion is on. When the engine is being started,

the headlights are switched off

igni-

2 - Emergency lights

When the emergency lights are on, a warning lamp in the switch flashes as well.

The system also works when the ignition

is switched off.

automatically. When the lights are on, the level of the

instrument lighting can be regulated by turning the knurled disc* below the switch.

Dipping and flashing headlights - see page 41.

On vehicles with additional headlights in the radiator grille*, these come on together with the high beams.

I On vehicles for Great Britain (depending on

model) the headlights also come on with reduced brightness (Dim-dip lighting) at the

first detent when the ignition is switched on.

4 - Fog lights*

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rear fog light*

First detent - fog lights Second detent - front and rear fog lights,

or only rear fog light.

At the second position a warning lamp in

the switch comes on.

The fog lights work only 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.

Note

The use of the lighting described at 1, 2

and 4 is subject to local regulations.

Knurled disc for seat heating*

The cushion and backrest of the driver's seat can be heated electrically when the ignition is on.

The heating is switched on and regulated with the knurled disc.

To switch heating off, turn knurled disc to the detent position.

^JiiiiTilJiH

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TURN SIGNAL AND DIP LEVER

To signal a lane change

Move lever up or down to pressure point and hold in position - the warning lamp must also be flashing.

To dip headlights

Pull lever past pressure point towards steering wheel. When high beams are on1),

a warning lamp in the dash lights

up.

Headlight flasher

Pull lever towards steering wheel to pres-

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

Right turn signals Left turn signals -

When turn signals are working the warn-

ing lamp flashes as page 35.

On vehicles with additional headlights in

the radiator grille*, these come on to-

gether with the high beams.

When a turn signal fails, the warning

lamp flashes roughly twice as fast.

The turn signals cancel automatically

after making a

- lever up lever down

turn.

well.

See also

igni-

sure point - the high beam warning lamp lights up.

Parking lights*

The parking lights only work when tion key is removed.

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

i On vehicles for Great Britain (depending on

model) the headlights also come on with reduced brightness (Dim-dip lighting) at the first detent when the ignition is switched on.

igni-

41

OPERATION

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CRUISE CONTROL SYSTEM*

B

A

B

33-511

With this system any desired speed from about

35 km/h can be

(insofar This

to keep pressed

as

engine output permits).

means that the

the on

long journeys.

accelerator constantly

held constant

driver

does not have

de-

Caution

•

The cruise control system should not be used in dense traffic and poor road conditions aquaplaning,

•

When system is switched on do not

(slippery

gravel).

surfaces,

move into neutral at speeds above 30 km/h

without

pedal

as otherwise engine

and

can be

depressing the clutch

will

damaged.

race

The system

button A and

turn

signal lever.

The system

button When

been reached be pressed briefly. taken

The programmed speed

increased tor

pedal.

be pressed until

is operated

the

with

press button

the

is switched on by

A to EIN.

the

speed

to be

maintained

press button B must

The

foot can then

pedal.

off the

the

accelerator

can

without pressing the accelera-

The

press button B need only

the

desired speed

been reached.

The speed can also

normal

way

the

with

pedal

When

be

increased

the

accelerator

is

then released previously programmed speed sumed.

sliding

B on the

moving

has

be

also

be

has

in the

pedal.

the

is re-

The system when brake when speed grammed steep gradient

is temporarily switched off

or

clutch pedals are used

is

considerably below pro-

speed

i. e.

in too

when driving

high a gear.

up a

or

To resume speed previously programmed are released button

when brake

or at

A to the

end

left

(AUFN).

or

clutch pedals

of

gradient, push

Caution The programmed speed must only be resumed

when it is not too high for the

existing traffic conditions.

The system by moving or

by

is completely switched off

the

switch

switching

the

to the

ignition

right

off.

(AUS)

42

WINDSCREEN

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WIPER

AND WASHER SYSTEM

Wipers

and washers only work when

ignition is switched on.

When

it is freezing, check

blades

are not frozen to the glass before

switching wipers on for the

that

the wiper

first

time.

Windscreen

Brief

wipe:

fore stop 1.

Wiper Wiper

Windscreen

Pull

lever towards steering wheel - the system this position.

Automatic

Pull

wipers and washer work.

Release

The on for about 4

Lever

The

(intermittent

Lift lever to pressure point be-

slow: Lever at position 1. fast:

Lever at position 2.

washer

works as long as lever is held in

wash/wipe

lever towards steering wheel -

lever.

washer stops and the wipers carry

seconds.

at detent 3

wipers work about every 6

wipe)

facility*

seconds,

Rear

window

Automatic

Press wheel - the wiper works about every 6 seconds

lever

Press and

hold in position -

The

wiper and washer work as long as

lever

Release The

washer stops and the wiper carries

on for about 4

Headlight

When

are washed every time the windscreen

is

washed.

At regular intervals such as when filling

the tank, caked on

should

Filling

wash/wipe*

lever briefly away from steering

(intermittent

briefly again switches the wiper off.

lever away from steering wheel,

is held in position.

lever -

seconds.

washer

the headlights are on, the lenses

be removed.

washer container, see page 80.

wipe).

Pressing

system*

dirt

and insects

OPERATION

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HEATING AND

VENTILATION

B25-568

Controls

Levers A and C

Lever

A to

right

Lever

C to vents in passenger compartment* are opened.

Lever B -

To

right

To

left

44

left

Heat

- increases

- decreases

distribution

vents 1 and 2 are opened vents 4 and footwell

output

air

Lever D - Roof compartment*

To

right

To

Note:

To levers, and

Switch

The

- fresh air decreases

left

- fresh air increases

distinguish better from the other

there are small knobs on levers B

D which can be distinctly

E -

blower has 3 speeds.

vents

Blower

in passenger Air

felt.

vents

Depending heated or unheated fresh air flows fror all

vents.

The

closed knurled disc downwards - vent opened knurled disc upwards - vent closed By

swinging the complete outlet grille q

vents 3 the air flow can be moved vert-

cally.

When

and laterally.

on the position of the lever

vents 3 can also be opened an:

separately:

the lever in the grille is moved tc

fro, the air flow direction is alterec

Warm

or

fresh

Defrosting

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windows

• Move all levers fully to the right.

• Switch blower to stage 2 with switch E.

• Switch off blower of additional heat exchanger*.

Demisting

windows

When air

humidity, e.g. when it is raining, we

recommend

• Move levers A, C and D fully to the

right.

• Move lever B slightly to the right into the heating range, if necessary.

• Blower switch E to stage 2 or 3.

•

Close

Heating possible

• Levers A, B + D fully to the right

• Lever C fully to the

•

Close

• Switch blower to stage 2 with switch E.

windscreen and side

the windows mist up due to high

the following settings:

vents 3.

interior

vents 3

as quickly as

left

Heating

When desired we recommend the following settings:

• Lever A to the

• Lever B to the desired heat output

• Lever C to the

• Blower switch E at stage 1

Ventilation

When all vents 3.

interior

the windows are clear and the

temperature has been reached,

heating is off, fresh air flows from

vents. When heating is on, only from

normally

left

Notes

• In order to ensure that the heating and

ventilation works properly, the blow-

er

should always be switched on when

driving slowly.

• To prevent contaminated air from getting into the vehicle, move lever A fully to

left

right. The vents 3 must also be

• The heat depends on the engine temperature - the full heat output is there-

fore only available when engine is warm.

• All controls except blower switch E can

be set to any intermediate position.

• Depending on vehicle model the

stale

in the rear

side windows.

The

slots in the

opened

and levers C and D fully to

air can escape either through slots

front

doors or through slots in the

front

or closed by means of

doors can be

closed.

slides.

45

Additional heat exchanger* for the

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passenger compartment

The additional heat exchanger is located under the rear seat. The blower is trolled by a 3 stage switch on the dash panel - see left hand illustration.

To obtain warm air from the heat exchanger, the valve on the heat exchanger must be fully open.

To close or open the valve the trim un-

der the rear seat must be removed.

con-

To do this, grip trim on the left side and

pull it out. Then move valve lever as shown above.

Lever upwards - opened (Winter

tion)

Lever to rear - closed (Summer

tion)

In the warm season the blower of the heat exchanger can be used to circulate

the air. When used in this way the valve

on the heat exchanger should be closed.

This will prevent unnecessary heat radiation reaching the footwell when the weather is warm.

posi-

AUXILIARY AIR HEATER*

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OPERATION

The heater is switched on and off with the knob (see Fig.) in the dash on the

right of the steering column. This switch

also regulates the amount of heat.

Depending on model concerned the

warm air flows from the footwell vents

in the passenger compartment and/or from a controllable vent under the driver's seat. The air distribution cannot

be regulated. The heater can be used all the time

when vehicle is moving. When engine is not running the heater switches off automatically after about 15 minutes to avoid draining the battery.

The heater is supplied with fuel from the vehicle tank. It can use up to one litre per

hour according to operating conditions. The heat output is about 7 kw (6000

kcal/h).

0

Switch positions

0 - Heater off 0 to 1 - Heating with engine not

running 2 - Heating when driving 2 to 3 - Regulates amount of heat

Heating with engine not running

(Ignition off) To switch heater on Press switch knob in at position 0 and

turn it clockwise towards 1 (warning lamp lights up). The knob springs out again when released.

The amount of heat can be regulated between 2 and 3 as required.

Note On vehicles with Diesel engine it takes about 40 seconds before the heat can be felt.

To switch heater off The clockwork in the temperature regu-

lating switch switches the heater off automatically after about 15 minutes and the lamp goes out.

To switch heater off before clockwork

has run down: turn knob anti-clockwise

to 0. The lamp goes out and clockwork

runs down.

OPERATION

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Heating

To Turn switch knob clockwise to position 2

(warning lamp in knob comes on)

The

between 2 and 3 as required. Note

On about 40 felt.

To

Turn switch knob anti-clockwise to tion 0 (warning lamp goes out)

when

driving

switch heater on -

amount of heat can be regulated

vehicles

switch heater off -

with

seconds

Diesel

engine it takes

before the heat can be

posi-

Notes

• Every time the heater is switched off, the warm air and combustion air blowers

continue running briefly to cool the

heater down quicker.

• To avoid draining the battery, do not run the heater repeatedly when the engine is not running.

• When the heater is running on the clockwork time switch, it must be switched

off by hand before attemptrng to start the engine at low temperatures so the

full

turn

• In enclosed spaces and the switched

Due to the not be used instance

battery capacity is available to

the engine.

the

when

heater is

fuel

tank,

the

of

fire

vehicle

heater

off.

risk

when

on dry grass or leaves.

filling

must

parked

that

be

for

Maintenance

When

driving through mud and snow the exhaust pipe may tend to get blocked.

Have a look at it occasionally to see

that

it is clear.

According to tion:

The

heat exchanger in the heater is only to be used for 10 years. After this period the heat exchanger must be replaced in a

V.A.G heater is ed

on the nameplate on the heater.

The

V.A.G workshop must then put the date of the repair on the plate on the heat exchanger.

offical

workshop. The year in which the

first

put into operation is mark-

German

regula-

48

The heater on vehicles with a petrol

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engine has a safety switch which is located under the dash on the left near the steering column. If the heater does not start, or starts and then stops again, wait 3 minutes and then operate the red lever on the safety switch.

If the heater still does not work or if the safety switch stops it again, there is a defect in the heater which can only be repaired by a V.A.G workshop.

OPERATION

If the heater on vehicles with a Diesel

engine will not start or stops after oper-

ating for a while, an automatic cut-out

switches the heater off. If the heater

cannot be started by switching the rotary switch off and on, the heater is defective and must be repaired in a V.A.G workshop.

Fuses

See page 102.

49

OPERATION

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AUXILIARY

The auxiliary heater heats the coolant the heating circuit and supplies the heat exchanger in the normal heating system and

the the passenger compartment heating with heated coolant. of

the

The system switch-on time preselected a

switch and indicator unit located on the

left

(or

Air distribution with

the

and ventilation system The auxiliary heater

vehicle stationary When vehicle only runs in order also

switches

coolant temperature When

below 70° C the switched

WATER HEATER*

additional heat exchanger*

The

engine

the

is not

is

switched

right)

unter the instrument

and

controls

for a

to

on

of the

or

is

stationary,

maximum

avoid draining

off

automatically when

coolant temperature drops

heater

again.

coolant circuit

heated.

off

and on

by

regulation

normal heating

(see

page 44).

can be

when

of

used with

it is

the

of

30 minutes

the

80° C is

is

automatically

(syncro)

or

means

panel.

is

done

moving.

heater

battery.

reached.

in

for

the

of

It a

The heater

vehicle tank per hour.

(4000

The

kcal/h).

is

supplied with fuel from

and

uses

up to

heat output is about

half a litre

4.5

the

A - Buttons

kw

selected

B - Indicator lamp C - Preselected time D - Display E - Actual time F - Heater on/off G - Warning lamp

time.

for

setting time

for

preselected

(heater

on)

and

pre-

time

50

Setting

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•

• Set clock The

is

display

preselected,

for 2

To

When lamp G lights up. The heater can only work if the lever for the heat output is

electrical

Preselecting

(stationary operation, ignition off)

With buttons C two different switch-on times can be selected within 24 hours.

• priate figure 1 or 2 appears in display.

The

the

time

Press

pressed.

• This is done by pressing button F.

pushed

Press

and hold clock button E.

with

buttons A.

display lights up as long as button

When button is released the

goes out or, if a time has been

the selected time lights up

seconds.

switch

heater

heater is switched on the warning

fully to the

contact.

and hold button. The appro-

ready-for-action lamp lights up.

on or off

right.

starting

This

time

closes

for

heater

an

• Set required switch-on time buttons A. The display remains on for about 20 seconds after releasing button C.

In order to ensure

up at the selected time, the lever for the heat output must be pushed fully over to the

right. must be switched to stage 1. On account of the higher current consumption, a

higher stage should only be selected in isolated

Switching

• The preselected time can be switched

button C. The ready-for-action lamp and

the figure in display then go out.

Fuses

See

cases.

preselected

off by briefly pressing the appropriate

page 102.

that

the heater starts

In addition to this the blower

time

with

off

Notes

• Every time the heater is switched off, the warm air and combustion air blowers

continue running briefly to cool the

heater down quicker.

• To avoid draining the battery, do not run the heater repeatedly when the engine is not running.

When

driving through mud and snow, the exhaust pipe may tend to get blocked. Have

a look at it occasionally to see

it is clear.

According to tions:

The

heat exchanger in the heater is only to be used for 10 years. After this period the heat exchanger must be replaced in a

V.A.G

heater is

ed

on the nameplate on the heater.

The

V.A.G workshop must then put the date of the repair on the plate on the

heat exchanger.

• In enclosed spaces and the

fuel

switched

official

workshop. The year in which the

first

put into operation is mark-

tank,

off.

the

German

when

heater

regula-

must

that

filling

be

OPERATION

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SLIDING

The crank above the driver's seat:

To

open - Fold crank down and to the again. To

close - Fold crank down and to the it back until it can be folded into the recess.

Caution For

always

ROOF*

roof is opened and closed

left,

then fold crank into recess

right

as far as it will go then

safety

reasons, the

be in the recess.

crank

with

the

turn

it

turn

it

turn

should

SUN ROOF*

The

roof is opened and closed knurled disc in the headlining above the front

seats.

The

roof can be desired

Raising

Turn knurled disc clockwise.

Lowering

Turn knurled disc anti-clockwise.

or taken out altogether.

tilted

at the rear as

with

the

To

take

out

• Turn retaining screw (A) in centre knurled disc one quarter (e.g.

with

a coin)

• Then raise roof and press it up.

•

Press

• Detach roof.

• Lift roof from outside and pull it oM

to the rear.

To put

• Slide roof back into the hinges anil

let it drop lightly into the retainers.

Caution Ensure

ed front,

The vehicle

locking lever (B) up.

back

that

into

the two

and locked at the

roof

must

is

with

the

roof

retaining

only

stationary.

turn

roof

is

be unlocked

clockw

closed.

properly

hinges at the

rear.

inser

wheJ

Note

If the roof becomes hard to operate after a while, the runners should be cleaned

52

and greased - see page 94.

OPERATIO

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INTERIOR

Light

Switch positions:

1 - Light on continuously 0 - Off 2

- Door contact position,

Step

The step door is opened. It goes out a few onds after the sliding door has been closed.

Table

Switch positions:

To

front

To

rear - Off

LIGHTS

above

on when cab doors are open.

light*

driver's

light

comes on when sliding

- On

seat

light

comes

sec-

Reading

The reading lamps have separate

switches and can be moved about as required.

Switch positions: Ring Ring

The reading lamp on the

lights up continuously when the sliding door is opened. When the sliding door is

closed it goes out in the off position

together

of a few

lamps*

turned to turned to

with seconds.

right

- On

left

- Off

the step

right

light

after a delay

at the rear

Reading seat*

Switch positions:

Up Down - On

Luggage

The luggage compartment lights come on

when the rear flap is opened.

Note

When leaving the vehicle ensure

lights are switched off so is

not run down if the vehicle is

stationary for some time.

light

- Off

compartment

in

front

of passenger

lights*

that

the battery

all

left

53

OPERATION

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SUN VISORS

Both sun visors can be lifted out of their brackets and swung round towards the doors.

An illuminated make-up mirror* is fitted at the back of the passenger's sun visor.

To switch light on - move switch to left. When the sun visor is moved up, the

mirror illumination goes out automatically.

Note

When leaving the vehicle always ensure that the light is switched off so that the battery is not run down when vehicle is left standing for some time.

ASHTRAYS Ashtray in dash

To take out: Grip the strip on opened lid and lift at

one side to take out. To insert: Press ashtray into opening with lid

closed.

Ashtray in passenger compartment

To take out: Open ashtray, press down and take out. To insert: Insert at top first then push in fully.

On vehicles with individual seats:

To take ashtray out: Lift one side of the handle of the opened

lid.

To insert ashtray:

Push ashtray into opening with lid closed.

CIGARETTE LIGHTER/SOCKET*

The cigarette lighter is switched on by pushing in the element.

When the heating element glows, the lighter springs out automatically - pull it out immediately.

The socket can be used for a cigarette

lighter or other electrical accessories with a capacity of up to 100 watts. When the engine is not running this will how-

ever soon discharge the battery.

Caution

Cigarette lighter and socket also work

when the ignition key has been taken out.

Children should therefore never be left

alone in the car.

54

OPERATION

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GLOVE

Vehicles with a lockable glove an

To open together.

Caution

For safety reasons the lid* should always be closed when the vehicle is in motion.

BOX

additional key - see also page

the

lid,

squeeze both buttons

box

have

7.

CURTAINS*

The curtains which vehicles with seats/reclining seat bench are stored underneath

bench.

They surrounds tain

behind

can

the

by

be

front

can be

are secured

press studs. A further cur-

press-studded

seats.

supplied

the

rear seat

to

the window

in

position

for

EXTENDING

On vehicles with individual seats passenger compartment there tending

The table

retainers and folded down

tion).

Caution For safety reasons the table must be

pushed

TABLE*

in the

is

table

on the

can

in when vehicle is in motion.

be

left side.

pulled

up out of its

(see

an

illustra-

ex-

THE

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FIRST

1500 KM - AND AFTERWARDS

During the engine internal friction is higher than later on when all the moving parts have bedded process able driven during the

first

few operating hours the

down. How well this running in

is done depends to a consider-

extent on the way the vehicle is

first

1500 km.

Up to 1000 km do not use

Furthermore the following speeds in km/h should not be exceeded in the gears:

Petrol

Manual gearbox

1st gear 2nd gear 40 40 3rd gear 70 60 4th gear 5th gear

Automatic gearbox

Driving range 1 Driving range 2 Driving range D 110

full

engines

4 speed gearbox

throttle

0-1000 km

20

105

-

at all.

5

speed gearbox

20

85

105

0-1000 km

35 75

Diesel

engines

0-1000 km

5

4 speed gearbox

1st gear 2nd gear 40 3rd gear 4th gear 5th gear

The

maximum

during the The

speeds given here must however

not be exceeded.

From

1000-1500

the speed can gradually be increased to the road or engine maximum.

After

the

on vehicles should

change at the latest by the time the red warning zone

is reached.

The

maximum permissible engine

speeds

for continuous operation are:

Petrol

engines about 5400 rpm

Diesel

engines about 4600 rpm

Turbo Diesel engines . . about 4800 rpm

20 65 55

95 85

—

permissible engine speed

first

1000 km is 4000 rpm.

km

running-in

with

a rev counter one

into

the next higher gear

speed gearbox

20

35

95

period

In isolated overtaking the needle may move briefly into

the dotted or shaded zone on the

rev counter scale - see also page 37.

A

speed limiter prevents extremely high

engine speeds.

Important

• Do not overrev the engine when cold

- either in neutral or in the gears. All speeds engine is properly warm.

• Do not drive unnecessarily helps

• Do not let engine labour - change

down when engine no longer runs smoothly.

• New tyres must also be "run in" because sion

at the start. This must be taken

account

first

100 km.

cases,

for example when

notes

and revs are only valid when

with

to save fuel and reduces noise.

high - changing up early

they do not have maximum adhe-

by driving carefully during the

the engine speed

into

56

RIVING

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TIPS

DRIVING

The

cle So

before moving off, always check the

following points:

• Lights and

• Brakes

•

Amount

•

Mirror

• Cleanliness of

and

Also

•

Tyre

86-89,

• Engine oil

The oil time conditions or daily

• Coolant

•

Brake

• Fluid

page

• Condition of

blades - page 109.

Furthermore compliance fied Inspection intervals - in particular the brake fluid changing - is of great importance for driving safety - pages 82,

97.

SAFELY

operational

is essential to safe driving.

windows

check at regular intervals:

condition and pressures - page

126.

level

fuel

level

80

condition of your vehi-

turn

signals

of

fuel

settings

tank

level

fluid

headlights,

level

- page 74

should be checked

is

filled,

full

throttle

- page 77

level

- page 82

in

windscreen

or in

operation,

washer

with

the

lenses

every

difficult

-

wiper

speci-

Safety

on the

extent on the personal attitude and style of driving.

To

be on the safe side you should:

•

Always

ing off -

In many countries the wearing of seat

belts is compulsory anyway.

• Ensure including wearing

Passengers

ger

not only themselves, but also the

driver.

•

Adjust

The

upper edge of head restraint must

be

approximately at eye

Ensure

that

operation

road

depends to a large

put

seat

belt

on

even

in

town

that

all your passengers -

those

their

on the

belts

- page 13.

without seat belts can endan-

head

restraints

no

articles

of pedals - page 89.

before

traffic

- page 13.

rear

seat

to body size.

level.

interfere

mov-

- are

with

•

Stow

page

on the

• Do not

Stop ing for two hours.

•

Never

impaired

Not only alcohol but also drugs and many medicines can be very detrimental

to your reactions.

•

Adapt

road

Remember slippery roads the handling and braking also

is

On aquaplane can

Further instructions on safety are given

in the various chapters in this manual.

all

luggage

22

roof

rack

drive

for a break at the latest after driv-

drive

in any way.

vehicle

conditions.

that

on vehicles

limited by the adhesion of the tyres.

wet roads the

at high

then no longer be steered properly.

correctly

- page 22

when

you

when

your

speed to

particularly on smooth

with

four-wheel drive -

front

speeds.

in

boot

feel

tired.

reactions

traffic

wheels can

The vehicle

are

and

-

57

DRIVING

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TIPS

DRIVING

~re economy and the exhaust emissions and noise depend to a great extent on the

To

use as turb and keep wear of engine, brakes and tyres to the minimum, the following points should be noted:

• Do not run the

Drive off immediately after starting. Do not overrev.

• Avoid

The best consumption and least disturb-

ance engine speeds in the highest possible gear. Drive as often and as long as sible

The fuel consumption is for example twice as high in 2nd gear and 1.5 times as

high in 3rd gear as in 4th gear.

ECONOMICALLY AND ENVIRONMENT-CONSCIOUS

personal

the environment as

vehicle

of environment is obtained at low

in the highest gear.

style

of driving.

little

fuel as possible and dis-

engine

stationary.

full

throttle

high

engine

little

to

warm

acceleration.

speeds

as possible

it up

with

pos-

• Change longer

Depending on gearbox you can normally drive on the level in the highest gear at 40-60 km/h and still accelerate.

• Avoid speed.

•

Drive

look

Unnecessary must be paid for sumption and more disturbance of the environment.

•

Stop

runs

well

down

only

when

smoothly.

driving

as

ahead.

engine

continuously

smoothly

acceleration and braking

with

during

engine

as possible and

higher fuel

traffic

hold-ups.

no

at top

con-

The

individual

naturally also affect fuel consumption.

The following factors for instance are not favourable to fuel consumption:

• Traffic density, particularly large towns

with

• Frequent stop/start driving, particularly driving from house to house so engine is never properly warm.

• Driving in heavy, slow-moving in low gear so relatively high in relation to the distance covered.

One

should, therefore, plan trips in ad-

vance

to avoid unfavourable operating

conditions.

Obviously

affected by factors over which the driver

has

no influence. It is for example nor-

mal for the consumption to increase in

the winter or in arduous conditions (bad

roads,

trailer towing etc.).

operating

numerous

that

the engine speed is

the fuel consumption is also

conditions

traffic

lights.

that

traffic

58

DRIVING

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ECONOMICALLY AND ENVIRONMENT-CONSCIOUS

The economy and the exhaust emissions and noise depend to a great extent on

the

personal

To

use as

turb

the environment as and keep wear of engine, brakes and tyres to the minimum, the following points should be noted:

• Do not run the

vehicle

Drive off immediately after starting. Do not overrev.

• Avoid

The best consumption and least disturbance

of environment is obtained at low engine speeds in the highest possible gear. Drive as often and as long as sible

in the highest gear. The fuel consumption is for example

twice as high in 2nd gear and 1.5 times as

high in 3rd gear as in 4th gear.

style

of driving.

little

fuel as possible and dis-

engine

stationary.

full

throttle

high

engine

little

to

warm

acceleration.

speeds •

as possible

it up

with

pos-

• Change longer

Depending on gearbox you can normally drive on the level in the highest gear at 40-60 km/h and still accelerate.

• Avoid speed.

•

Drive

look

Unnecessary must be paid for sumption and more disturbance of the environment.

stop

runs

well

down

only

when

smoothly.

driving

as

ahead.

engine

continuously

smoothly

acceleration and braking

with

during

engine

as possible and

higher fuel

traffic

hold-ups.

no

at top

con-

The

individual

naturally also affect fuel consumption. The following factors for instance are not

favourable to fuel consumption:

• Traffic density, particularly large towns

with

• Frequent stop/start driving, particularly driving from house to house so engine is never properly warm.

• Driving in heavy, slow-moving in low gear so relatively high in relation to the distance covered.

One

should, therefore, plan trips in ad-

vance

to avoid unfavourable operating

conditions. Obviously

affected by factors over which the driver has

no influence. It is for example normal for the consumption to increase in the winter or in arduous conditions (bad roads,

trailer towing etc.).

operating

numerous

that

the engine speed is

the fuel consumption is also

conditions

traffic

lights.

that

traffic

DRIVING

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TIPS

TRAILER

The vehicle transportation

other loads

a

trailer.

Trailer towing

on

the

centration from

The vehicle must for trailer towing. and driving instructions on

must

vehicle,

be

noted.

TOWING

is

intended mainly

of

persons, luggage

but it

can also

not

only places more stress

it

also

calls

the

driver.

be

specially equipped

In

addition

be

for

the

used

for the

and

to tow

more con-

operating

Technical requirements

If

the vehicle ted towing bracket, and legally necessary have been taken into account. is

required

er

(e.g. lighting), socket

If

the vehicle with a towing bracket, must

be

•

The Only a bracket which has been designed and type-approved be used. brackets sories fitted tions supplied with these brackets have been approved

•

In weight must sticker

is

supplied with a factory-fit-

all

for

additional items

caravan refrigerator

the

terminal

must

be

subsequently connected.

is to be

noted:

towing bracket

advisable

the

are

factory.

by the

the

be

shown

rear

of the

for

V.A.G range

identical

maximum draw

It is

from

as

these

by the

Germany

at the

that

is

technically

trailer towing will

If

electricity

in the

and

54g in the

subsequently fitted

the

is a

safety part.

this vehicle

to use

The

to the

fitting instruc-

factory.

on a

clearly visible

towing vehicle.

trail-

interior

trailer

following

may

towing

of

acces-

ones

bar

•

The

properly vehicle. to

• A special warning lamp must within that

• bracket includes cooling when service installing a bracket. wise overheating may occur when engine is temperatures,

information about

ing duty should therefore

bracket must documents.

trailer socket must

to the

This

the

terminal 54g

the

trailer

As the

system, this should also

pulling hard (mountains, high ambient

•

V.A.G

brackets

cooling system.

•

In

Germany

electrical system

applies, where necessary

driver's range

turn

signals are working.

factory installation

the

heavy

Dealers have

the

and the

be

the

be

entered

be

connected

in the

socket.

of

vision

modification

trailer loads).

done

fitting

of a

all the

installation

fitting

The

necessary

of a

installation

by

them.

of a

in the

of the

be

fitted

to

show

towing

of the

be

done

Other-

of

tow-

heavy-

towing

vehicle

60

DRIVING

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TIPS

Operating

• If the traffic behind the trailer cannot

be

seen properly view mirrors, additional outside mirrors will be necessary. Both outside mirrors

must be justed to give a good view to the rear at all

times.

• Pitching movements between towing

vehicle

heavy-duty springs and shock absorbers

on the rear axle. If these springs and

shock fitted

cases,

Dealer.

• Pitching and snaking movements can also be

obtained from and

Dealers

instructions

with

the standard rear

fitted

on folding arms and ad-

and trailer can be reduced by

absorbers have not already been

at the factory, they can, in many

be service-installed by a V.A.G

be reduced by stabilizers which can

in most European countries.

fitted

by V.A.G

• The permissible trailer weight - see

page

130 - must not be exceeded on

any

account.

• When towing a trailer in mountainous regions, en

for gradients up to 10 or 12%. If the trail-

er mum a correspondingly steeper gradient can

• The given trailer weights are only applicable sea the climbing ability drops due to the decreasing weight of vehicle and trailer must also be reduced or part thereof.

• Where possible make maximum permissible drawbar weight on ball of the towing bracket - see page 130 - but do not exceed it.

• While observing the permissible trailer load are as near as possible to the axle. The objects must also be secured so they cannot slip about.

note

that

in the "Technical data" are only valid

weight is below the permissible maxi-

be climbed.

for altitudes up to 1000 m above

level.

As the engine output and thus

air density above 1000 m the

by 10% for each further 1000 m

and drawbar weight, distribute the

in the trailer so

the trailer weights giv-

full

use of the

that

heavy objects

that

• The trailer and drawbar load figures on the data plate of the towing bracket are for test certification only. The correct figures for the vehicle, which are lower than the above figures, are given in the vehicle

documents and in this manual.

• The towing bracket increases the un-

laden

weight of the towing vehicle and

the playload must be reduced to corre-

spond.

•

Check

ing vehicle and on the trailer.

• The headlight settings must be

checked moving off and altered as necessary.

the tyre pressures on the tow-

with

trailer attached before

61

DRIVING

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Driving

Tips

To

obtain the best possible handling of

vehicle

and trailer, the following should be

noted:

• Try to avoid driving

hicle

and a loaded trailer. If this cannot be avoided, unfavourable weight distribution.

• The regulations regarding trailer

weights and speeds when towing which

are valid in various countries must always be permissible 80 km/h.

For even speed

Furthermore, if the vehicle is registered

as

restrictions on driving and trailer towing on Sundays and public holidays.

only drive slowly to allow for the

observed. In Germany for example the

safety reasons do not drive faster

in countries where the permissible

is higher.

a commercial vehicle there may be

TIPS

with

an unladen ve-

speed when towing a trailer is

• As driving stability of vehicle and trailer decreases not drive at the maximum permissible top speed

wind conditions - particularly when going

downhill. In any

immediately the trailer shows the slightest

to stop the snaking by accelerating.

• Always try to brake in good time. If the trailer has an overrun brake apply brakes gently at avoid the trailer wheels. Change down before going down a steep hill so can

• The cooling effect of the radiator fan cannot be increased by changing down

because

pendent on the engine therefore not change down even when towing a trailer as long as the engine can cope

much.

when the speed increases do

in unfavourable road, weather and

case

the speed must be reduced

sign of snaking. On no account try

first

the jerking caused by the locking of

act as a brake.

without

then brake firmly. This will

that

the engine

the speed of the fan is not de-

vehicle speed dropping too

speed.

One should

Notes

• During the running-in period avoid

trailer towing as far as possible.

• It is advisable to have the vehicle ser-

viced

between the Inspection intervals if it

is

used frequently for towing a trailer.

62

DRIVING

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TIPS

DRIVING

The

Contrary to the normal type of selectable four-wheel drive, the four-wheel drive on the Transporter/Caravelle syncro is always in action. Only the amount of power being transmitted to the and rear wheels changes according to the requirements. This automatic distribution of the driving forces is attained through a wear resistant viscous coupling incorporated in the ensures, ing force sible, best possible traction is attained when required.

A FOUR-WHEEL

drive

concept

on the one hand,

losses

and on the other hand,

are kept as low as

front

DRIVE

axle. This

that

the driv that

VEHICLE*

front

pos-

the

1 - Front axle final drive

and viscous coupling

This

ingenious drive concept make the Volkswagen a

versatile, efficient road vehicle which proves itself on ice and snow and in offroad conditions.

Transporter/Caravelle syncro

2

- Propshaft

3 - Rear

axle final drive

63

DRIVING

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TIPS

Advantages The special

wagen when

compared

only

has a

tages

in

points:

The

traction

The traction is increased considerably by the permanently engaged four-wheel drive. This is of particular benefit on snow and ice, when moving off and when driving on

difficult

Driving in such conditions is ous

with

avelle syncro:

There is no longer any need to drive past obstacles at speeds on slippery uphill stretches, because one is afraid of becoming stuck, one can approach slowly, stop and then start off again.

The

acceleration

As

the driving force to be put onto the road goes to four wheels instead of two, the amount of slip is considerably reduced. tween

tyre by, the acceleration capabilities on slippery road surfaces.

of

four-wheel

drive

Transporter/Caravelle

respect

mountain roads.

the Volkswagen Transporter/Car-

This improves the adhesion be-

concept of the Volks-

with a vehicle

two-wheel

of the

and road surface and there-

drive,

drive

syncro,

which

has advan-

following

less

hazard-

The

handling

Decisive slippery roads - is the grip between the four wheels and the road surface.

On wheels can spin on slippery surfaces if too much acceleration is given. This is detrimental to the adhesion.

By wheels instead of two the lateral forces which can be transmitted are increased on the Volkswagen Transporter/Caravelle syncro. away.

Using

With the four-wheel drive the Volkswagen Transporter/Caravelle syncro has good traction in winter road conditions even with of winter or all-weather tyres is recommended on all four wheels to obtain even better handling and braking.

For be improved considerably tyres.

for the handling - particularly on

two-wheel drive vehicles the driving

distributing the driving forces to four

The vehicle is

winter

tyres

the standard tyres. However the use

cross country driving the traction can

less

likely to break

with

winter

Using

snow

chains

Snow

chains improve not only the traction in winter road conditions but also braking. For

this reason snow chains must also be

used

on vehicles

when snow chains are obligatory. Further

details about using snow chains are given on page 89.

Operation

Contrary to customary four-wheel drives,

the driver of a Volkswagen Transporter/

Caravelle or disengage the drive. The distribution of

the driving force to the

axles

ways matched to the existing road surface

conditions. Incorrect operation is thus excluded and

the driver can concentrate fully on the traffic.

Only engaged by hand in special operating conditions. Further details are given on the next two pages.

syncro does not need to engage

takes place automatically, and al-

the differential locks

with

four wheel drive

front

>K

have to be

and rear

DRIVING

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TIPS

Driving on dry roads

The

differential locks must not be en-

gaged.

They

tages

at

pair

the

Particularly if the lock is engaged, the vehicle is no longer steerable.

Important instructions locks

are to be

do not

all

on dry

vehicle's steerability.

provide

road surfaces,

front

axle differential

on the

found

on

page 27.

any

advan-

but im-

differential

Driving on wet, slippery roads

Due

to the power smooth

On wet surfaces

On

wet even with syncro to aquaplane

For this reason, one should avoid excessive speed and compatible to the road conditions. The differential

Important instructions locks

On slippery surfaces

On slippery surfaces erential moving lock

should then

The

front

be engaged.

Important instructions locks

four-wheel drive,

is

transferred even

road surface.

roads

one

the

it is

possible

locks*

are to be

lock may only

off, and at

axle differential lock must not

are to be

should also note that

Transporter/Caravelle

for

at

high speeds.

drive

must

found

on

the

be

very

be

disengaged again.

found

the

to a

the

front

at a speed

not be

on the

on

differential

page 27.

rear axle diff-

engaged when

low

speed.

differential

page 27.

engine

relatively

wheels

engaged.

The

Notes The style of driving must always be

adapted traffic conditions. The increased safety offered by this type of vehicle must not encourage one to take unnecessary risks.

In particular, one must always ber that the stopping ability is limited by the adhesion of the road surface. The braking capability of the vehicle is the normal reason, by the good acceleration capabilities, even on slippery road surfaces, into driving too fast.

to suit the road surface and

remem-

tyres

on the

same

two wheel

one should never be tempted

drive

as that of a

vehicle. For this

DRIVING

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TIPS

Drfnng cross

zrze

j-iving for the

: -.errain, it is advisable to make your-

=e: familiar

-oads,

and also under easier off-road conditions. For safe driving cross country, the following rules are of great im-

portance.

• Always wear your seat belt.

• Timely gear changing is better for the engine and prevents the vehicle from

bogging down.

• Never drive this leads to premature wear.

• The more uneven and creviced the

terrain, the lower the speed must be.

Pay

attention to the vehicle's ground

clearance.

• Do not drive over small embank-

ments or declines at excessive

This

can lead to bouncing during which it would be impossible to avoid any obstacle

which may suddenly appear. In

addition it could lead to vehicle damage.

• Drive down gradients in the same gear

as you would drive up.

country

first

time over diffi-

with

the vehicle on normal

with

the clutch slipping as

speed.

• Embankments, gradients and similar obstacles down at with

• If however one is forced to drive across tip, one should immediately steer directly

into

• Before driving through water, determine the depth - the

depth exceeded.

•

After

the following points are important:

- Disengage differential locksH<

-

Clean ment and underside of vehicle so moving and electrical and/or electronic parts can function properly.

-

Clean

examine tyres for foreign bodies in the treads and damage.

-Clean ber plate.

- Dry the brakes by driving a short dis-

tance This one side or braking effect being retarded.

should only be driven up or

right

the slope.

a slope and the vehicle tends to

the slope.

(see Technical Data)

with

will prevent brakes from pulling to

angles, i.e. directly in line

permissible

driving

excess

tyres and wheels roughly and

turn

through

dirt

signals, lights and the num-

the brake pedal depressed.

water

from engine compart-

must

wading

not be

or mud

that

all

-After going through dipstick out and check if there are drops of water on it or if the oil level has risen. If this is the

without

•

After

brakes must be checked and if cleaned. premature wear to the brake system.

• If, during cross vehicle sank deeply bottomed on an obstacle, the running gear, brake hoses and engine sump must be checked for damage.

Note

To the vehicle, the vehicle is equipped

protective plates in

and underneath the engine and gearbox and protective rails running along both

sides

case

delay.

driving

This will prevent damage and

prevent damage to the underside of

of the propshaft.

deep

water,

the oil must be changed

through

country

into

front

mud the

driving the

soft ground or

of the

front

pull

dirty,

with

axle

Note

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for vehicles

with

differential

lock(s)

Before

driving through a difficult cross country stretch (e.g. mud, snow

or steep gradients) it is advisable to

engage

the differential lock(s)>H at low

speed.

Important the

differential

pages 26 and 27.

instructions

locks are to be found on

sand,

regarding

water,

To

prevent the engine from drawing in water through the intake air preheater and

being damaged when wading, there

is

a valve in the engine compartment on the right behind the maintenance flap with which the intake air preheating can

be

closed.

ing it down and turning it to the right.

The valve is closed by press-

Output

If the Transporter/Caravelle is to be output tested on a dynamometer, the propshaft must be removed.

Brake

For shaft must be removed. The differential locks

testing

test

stand

brake testing e.g at MOT, the prop-

must not be engaged.

OPERATING

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FUEL

INSTRUCTIONS

Petrol

engines

Vehicles fuel

Lead-free RON1) not

If regular petrol

with

injection

regular

lower

catalytic

converter

engines

petrol

than

91.

with

adequate anti-knock

70 kW

properties is not available, use premium petrol (lead-free or leaded) or a suitable mixture.

For ail vehicles Only

lead-free

these

vehicles.

The

use of leaded petrol is very detri-

with

catalytic

petrol

may be used in

converter

mental to the functioning of the emission control system because the lead is deposited in the catalytic converter.

Even one detract lytic

tankful

from

the

converter.

of

leaded

efficiency

petrol

will

of the cata-

Although lead-free fuel may again be used afterwards the original

efficiency of the catalytic converter is

never

fully attained.

On

vehicles

with

Lambda probe2) the mixture formation is also negatively affected.

Vehicles

and 57 kW Lead-free

not In the

free

lower

interests

petrol

without

catalytic

carburetor

or leaded

than

regular

91. of our

should be used

converter

engines

petrol

environment

whenever

44

RON1)

lead-

possible.

If regular petrol

with

adequate anti-knock properties is not available, use premium petrol (lead-free or leaded) or a suitable mixture.

82 kW

fuel

Leaded

premium

RON1) not

injection

lower

engine.

petrol

than

98.

Note

Lead-free 51607 and leaded petrol

petrol must comply

with

DIN3)

DIN 51600.

1)

Research

knock properties of the petrol.

Octane Number, indicates anti-

2) Lambda = Air/petrol relationship.

3) Standards issued by the German Standards

Institution.

Petrol

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additives

On

carburetor engines catalytic converters carburetor icing can occur

at ambient temperatures between

0° C and +15° C when the air humidity

is

high despite the automatically trolled intake air preheating. This can cause

the engines to stall occasionally

when idling in the warm-up phase.

Even

the anti-icing additives contained in

some

fuels in the cold season cannot entirely prevent carburetor icing. When a properly tuned engine stalls repeatedly in the conditions described above it is advisable

ditive

vents carburetor icing and also cleans the carburetor and protects it against

corrosion.

workshops in Germany and in many ex-

port No

with

to mix

with

the fuel. This additive pre-

It is obtainable from V.A.G

countries.

other fuel additives should be mixed

the petrol.

with

Volkswagen

and

petrol

without

con-

ad-

OPERATING

Diesel

engines

Diesel

fuel

CN1) not Driving

When

be

experienced at temperatures below

0° C because the fuel thickens due to

wax separation.

For

this reason, winter Diesel which is more resistant to cold is sold during the winter and works satisfactorily down to about -15° C.

In countries tions the Diesel fuels offered have a ferent temperature behaviour. Check with the country concerned regarding the availability of Diesel fuels.

When Diesel tures by mixing regular leaded or free petrol (not premium) Diesel.

to DIN 51601

lower

than

45

in

winter

using summer Diesel trouble may

with

different climatic condi-

V.A.G dealers or filling stations in

necessary summer and winter

can be used at lower tempera-

with

dif-

lead-

the

INSTRUCTIONS

As

this additive reduces the engine output, only the amount actually required should

be

used:

(max. 30%)

Temperature in 0 C

- Oto

- 5

- 5 to

-15

-25

This in Germany.

Due to the mixing be possible, the the

Mixing starts to separate because subsequent mixing is effective only in the tank but not in the rest of the fuel system.

Summer

Diesel

85%

70%

to

table is based on the fuels available

should, for

done

in the

tank

before

must take place before the wax

Petrol

-

inflammability

vehicle

petrol

the Diesel.

Winter-

Diesel

15%

30%

100%

-

safety

70%

of

reasons,

tank.

should be put

Petrol

petrol

Where

-

33

the

only

into

" Cetane Number, indicates the ignitability of

Diesel.

69

OPERATING

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IN

Filter

preheating*

If the vehicle is preheater, the fuel system will be kept operational down to -25° C if winter Diesel

fuel is preheated and

Dilution necessary.

Generally

It at temperatures below -25° C the fuel has that cient to place the vehicle in a warm room for a while.

Fuel similar

70 the Diesel fuel.

used. filter

hose connections (see Fig.).

with

applicable:

already waxed to such an extent

the engine will not start it is suffi-

additives (anti-waxing agents and

fluids) must not be mixed

fitted

with a filter

One can recognise the

by the additional valve

petrol is then no longer

with

FILLING

The of the vehicle.

Key tank cap* (on vehicles drive an extra key is supplied).

The

(Syncro

Trouble-free refueling calls for correct

use

• Insert nozzle fully into tank neck and do not

On

it should be noted smaller a

spring-loaded flap below the filler

opening.

petrol are correspondingly smaller in diameter and open the flap when inserted that the tank.

TANK

filler neck is on the

A = see page 4 -

fuel tank capacity is approx. 60 litres

70).

of filler nozzle.

tilt

it.

vehicles

into the filler neck. This is to ensure

only lead-free petrol can be put in

with

a factory

in diameter and is closed

Filler nozzles for lead-free

right

hand side

fits

the lockable

with

four wheel

that

fitted

the filler neck is

catalyst

with

• Do not try to otherwise the fuel (especially Diesel) will

foam and this may cause nozzle to switch

off too

soon.

As

soon as the correctly operated auto-

matic nozzle switches off for the

time, the tank is full. Do not try then to

put more fuel in because otherwise the expansion

the fuel can then overflow when it gets warm.

Note

Bleeding the

The when tank has been run dry - this takes

place

space in tank will be filled -

for vehicles

fuel system does not need bleeding

automatically while starting.

fuel

fill

tank too quickly,

with

Diesel

system

engine:

first

What to do when wrong fuel has

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been put into tank.

Premium petrol instead of regular

The engine can be run on premium fuel with no problems. A worthwhile reduction of fuel consumption or increase in output should however not be expected.

Regular petrol instead of premium.

In isolated cases the engine can also be run on regular petrol but the octane rating must not be under 91 RON. The vehicle must then only be driven at medium engine speeds and low engine loading. High engine loading with full throttle or high engine revs can cause engine damage. Fill

tank with 98 RON premium petrol as soon

as possible.

Lead-free premium petro! with 95 RON instead of leaded premium petrol

The engine can also be run as an ex-

ception on this of driving must adapted to the lower antiknock properties of this petrol - see previous paragraph.

Leaded petrol instead of lead-free

Vehicles with catalyst must not be driven on leaded petrol because otherwise the function of the emission control system is affected considerably - see also page

67.

The fuel system must be emptied, in accordance with environmental regulations - preferably by a V.A.G workshop.

fuel.

However the style

UUJEaUuLJkSU

Petrol instead of diesel

The engine can be run on a concentration of up to approx. 30% leaded or free regular petrol (not premium). However if premium petrol or a large quantity of regular petrol has been put in the tank accidentally, the engine must not be run otherwise damage will occur. The fuel system must be emptied bearing in mind environmental control regulations - preferably by a V.A.G workshop.

Diesel instead of petrol

The engine may not be run on fuel system must be emptied bearing in mind the environmental control regulations - preferably by a V.A.G workshop.

Diesel.

lead-

The

71

•»ij^:y^i.ifi:K»:m^ii

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LUBRICANTS

Petrol

engines

A

special very high quality oil is put in the engine at the factory and this can be used all the year round - except in very cold

cli-

mates.

As

a high quality engine oil is a prerequisite for trouble free operation and long engine service

life

only a correspondingly high quality oil may be used for topping up and at oil changes.

As

it has been established range of oils on sale quality, we strongly recommend

that

differ

considerably in

the wide that

only

the following mineral and synthetic oils,

which have been tested by us, are

used:

• Multigrade oils, specification VW 50101

or

• Improved lubricity oils, specification

VW

50000 or

• High performance engine oils, specifi-

cation VW 50000 and 50500. The specifications must be marked on the

container. When topping-up the oils can be mixed

with

one another.

Multigrade oils to VW Standard 50101 are reasonably priced oils

with

the following

properties:

- All year round use in temperate climate areas.

- Excellent cleaning ability.

- Efficient lubrication at all engine temperatures and load conditions.

- High resistance to ageing.

The improved lubricity and high perform-

ance

engine oils have in addition the fol-

lowing advantages:

- All year round use at practically all temperatures.

- Low frictional

losses

in engine.

- Best possible starting even at very low temperatures.

Only

if at some not available can a good quality oil the specification

time

the approved oils are

API-SF

(multigrade or

with

single grade) be used as a temporary exception.

VA.G

Dealers have all the details. The oil change should therefore preferably be done by a V.A.G Dealer.

°F

°c

40-

•100

30-

80

20-

•

60

10-

-40

0

• 20

10-

• 0

20

•20

30-

B25-

560

A

- High performance and improved lubricity oils, B - Multigrade oils, C - Single grade oils.

The viscosity

class

of the oil must be selected as shown in the Fig. The oil does not have to be changed when the ambient temperature is briefly above the range shown.

When using SAE 10 W single grade oil or SAE

5 W-20 or SAE 5 W-30 multi-grade

oils,

continuous high engine speeds and

engine loading should be avoided.

This

restriction does not apply when using high performance or improved lubricity oils.

OPERATING

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INSTRUCTIONS

Diesel engines

A

special very high quality oil is put in the

engine at the factory and this can be used

all

the year round - except in very cold

mates. For

topping up and changing, the follow-

ing mineral or synthetic oils are to be

used:

• Good quality oils, specification API-

CD

(only for topping up on the Turbo

Diesel

engines in an emergency) or

• Multigrade oils, specification VW50101

(not for Turbo Diesel engines) or

• Multigrade oils, specification VW

50500

or

• Improved libricity oils, specification VW

50000

(not for Turbo Diesel engines) or

• High performance engine oils, specifi-

cation VW 50000 and 50500. The

specifications must be marked on the container. When topping-up the oils can be

mixed

with

one another.

The

advantages of improved lubricity and high performance engine oils for petrol engines also

Diesel

mentioned on the previous page

apply when these oils are used in

engines.

cli-

C

°F

40

100

]

80

60

40

20

0

20

A

- High performance and Improved lubricity oils, B - Multigrade oils, C - Single grade oils.

The

viscosity class of the oil must be selected does ambient temperature is briefly above the range shown.

When not drive throttle

as shown in the Fig. The oil

not have to be changed when the

using SAE 10 W single grade oil do

for long periods.

J

o o

3

I

< <

II

u

with

high engine speeds and

full

Manual

•

Gear

Front

•

Automatic

• Final drive:

• Gearbox part: ATF Dexron®

Power

• ATF Dexron®

Lubricant

No

engine Any

additives ranty.

oil,

axle

Gear

oil,

assisted

additives

oil or the

damage

gearbox

and

API-GL

4, SAE 80

differential

API-GL

5, SAE 90

final

(syncro)

gearbox

Gear

oil,

API-GL

steering

additives

should be

other

caused by the use of such

will

not be covered by the

mixed

lubricants.

drive

5, SAE 90

with

the

war-

73

OPERATING

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INSTRUCTIONS

ENGINE OIL

Then

Checking oil

Every

engine

The

oil consumption can be up to 1.5 li-

tres per 1000 km.

The

engine oil level must therefore be checked when filling the tank. In arduous

ing conditions or ing

hard

fore

moving

The

dipstick and filler pipe can be reached number plate.

The

dipstick location is shown in the illustration:

The

vehicle must be on a level surface when checking oil engine wait a few minutes for the oil to

74 drain back to the sump.

level

uses

a certain amount of oil.

at regular intervals, preferably

when

it should be checked

engine

off.

through a flap behind the rear

level.

is

daily

After stopping

operat-

work-

be-

pull the dipstick out, wipe it

clean

cloth and insert again. Then pull dip-

stick out again and check the oil

The

level must be between the two

marks.

The

difference in quantity between the

min.

and max. marks is 1.0 litre.

When

the engine is working hard such as in sustained high-speed motorway cruising in summer, when towing a trailer or when climbing mountain level

should be kept up to the max. mark.

Topping up

Unscrew

extension pipe out fully. Add

oil.

Push

extension pipe in again and screw

the cap back on

Check

the level

should

engine

the cap from the oil filler and pull

tightly.

with

not be above the max. mark.

passes,

oil

the dipstick - the oil

with

level:

the oil

a

Changing

The to use when engine is running but also due to ageing. The engine oil changing times depend therefore on the mileage

and

Petrol

Engine every 12 months (whichever comes first).

Diesel engines

Engine 12 months (whichever comes first).

For

For all engines

• If the vehicle is used continuously in arduous conditions, the engine oil must be page

• Disposal of the old oil must be done in accordance regulations.

Recommended

- see page 72.

engine

engine oil deteriorates not only due

also the time

engines

oil change every 15000 km or

oil change every 7500 km or every

further detail, see Service Schedule.

changed at shorter intervals - see also

91.

oil

elapsed.

with

environmental protection

oils and viscosity

classes

GEARBOX

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OIL

Checking oil

With

the

differential (syncro) the oil level does not need

checking.

With

the

in the final drive also does not need checking.

The ATF

ever

be checked in between the intervals

given in service schedule. To

do this the vehicle must be standing

on a level surface. The level must only

be checked when the ATF is 10 km after starting from cold the ATF

is

at the correct temperature). If fluid is cold or too hot the reading will be incorrect. The engine must be running at

idle

speed,

applied and the selector lever at "P".

level

manual

automatic

level

gearbox

in

gearbox

the handbrake must be

and

gearbox

part

front

the oil level

must how-

warm

axle

(about

' "•

L_ - *

To

check, pull dipstick (see Fig.) out,

wipe

with

a clean lint-free rag and then

insert it fully again. Pull

dipstick out and check ATF level.

When the ATF is warm the

be

between

the vehicle must be taken to a V.A.G workshop find the reason for the incorrect level. It is not sufficient to merely top up or drain off ATF.

the two

without

marks

delay so

level

must

- otherwise

that

they can

Changing oil

With

the

axle

not need changing.

With

final drive also does not need changing. The ATF in gearbox part must however be

changed schedule. quired, the job knowledge necessary and the disposal problems, this should preferably be done by a V.A.G Dealer.

Note

When

ual or must may lifted.

manual

differential

the

automatic

at the intervals given in service

Due to the special tools re-

there

automatic

not be

only

be

(syncro)

is no

started

towed

gearbox

lubricant

gearbox

and the

with

driving

and

the oil does

front

the oil in the

in the

man-

the

engine

vehicle

wheels

POWER

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To system it is essential in reservoir is correct.

The reservoir is in the engine compartment on the ance

The check must only be done engine running and the wheels in straightahead

The "max" and "min" marks. When level has cropped to min. mark, ATF (Dexron®) should be added after removing the red

;=c in top of reservoir.

ASSISTED STEERING*

ensure satisfactory operation of the

that

the

fluid

level

right

flap.

position.

fluid

should always be between the

behind the mainten-

with

the

Note

If the power assisted steering fails at any

time

or when engine is not running (vehicle on tow) the vehicle can still be steered but more force

to

turn

the steering wheel.

will

be required

75

COOLING SYSTEM

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OPERATING

INSTRUCTIONS

Reservoir

The

cooling system is filled at the factory

with

a permanent coolant which is not changed. and

Glycol

" . as). This mixture not only gives the

• e: essary frost and corrosion protection :aiso :: -g point of the coolant. Should it

:^::~ie necessary at anytime to add

xxe

This coolant consists of water

our G11 additive (anti-freeze on

basis

with

anti-corrosion add-

prevents scaling and raises the

: : Hit or refill the system, only a mix-

of pure water and G11 or a coolant

Expansion

additive

774 A (note marking on the container) is

to be used - see also next page

"Topping up coolant".

Caution The

are poisonous.

The stored reach be

drained and also reused.

If the must environmental

tank - Petrol engines

with

the specification

coolant

additive

coolant

be disposed of in accordance

additive

must

in the

of children. If the

at

stored

therefore

original

anytime,

in a

safe

is not to be used

protection

and the

container

coolant

it

must

be

place

regulations.

TL-VW

coolant

only

be out of has to caught

until

it is

again

with

Expansion

In the engine compartment there is a reservoir

The

ed

in the reservoir. It only needs checking in the expansion tank if a large amount of coolant has been lost or if the warning lamp for coolant temperature/ coolant level lights up.

it

tank - Diesel engine

and an expansion tank.

coolant level is normally only check-

OPERATING

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INSTRUCTIONS

Checking

The

the satisfactory operation system.

Open should

when engine

max.

The

when

coolant level

correct coolant level

flap behind number plate. The level

be between min. and max. marks

is

can

cold

only

is not

mark when engine

level

engine

or

just

is

be

checked

running.

is

of

warm.

essential

cooling

above

properly

to

the

Coolant losses

In normal conditions is

almost maintenance-free.

Coolant in system workshop without delay. cient

In a water-tight system occur is

Overheating can occur

• the flow by a radiator (leaves, ing lights

• been see

• next page

loss normally indicates leakage

the

system.

should

to

merely add coolant.

if the

exceeded

the

next page "Topping

the

boiling point

as a

of

muff,

dust, insects)

in

front

boiling point

lowered

radiator fan

"Fan",

the

In

this

case

be

checked

losses

result

of

if:

cooling air is reduced, e.g.

very

dirty

or

of

radiator grille of the

by an

incorrect mixture

is not

or

cooling system

the

cooling

by a

It is not

of the

overheating.

additional driv-

up

working - see

V.A.G

suffi-

can only

coolant

radiator fins

coolant coolant".

has

-

• vehicle low a gear and

at very high ambient temperatures

see

the cause found dealer serious engine.

Topping

Topping servoir

Do

not

The

excess

the system when engine gets

If the

the expansion tank must also ed

and filled

First down, turn

let pressure escape off.

Caution Do

not Danger System

is

driven

with

engine speed very high

"Fan".

of

and

as soon

only.

coolant

switch

then cover

cap one quarter

the overheating cannot be

eliminated, contact a V.A.G

as

damage

up

up is

fill

above

remove

of

scalding.

is

under

possible as otherwise

may be

coolant

normally done

the max.

coolant will be forced

warning

to

brim

the

engine

cap

pressure.

up a

long hill

done

lamp

if

necessary.

off

and

with a cloth

turn

to the

first.

Then take

when

engine

mark.

comes

be

in too

-

to the

in the re-

out of

hot.

on

check-

let it

cool

and

left

and cap

is hot.

78

OPERATING

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INSTRUCTIONS

In order to maintain the corrosion protection at all times and prevent the

system

from scaling up and the boiling point from being lowered the mixture should

not be altered

mer or in plain portion

freeze

C).

Screw cap on

The

gine running (at a fast idle). Take air in-

take grille off (see page 104), open vent

screw lever emerges, in reservoir and expansion tank.

warm

water:

system must then be bled

to "warm". As soon as coolant

the

should be at

protection

again

at top of radiator and set heater

close vent screw. Top level up

even

countries

coolant

least

down

to

tightly.

in the sum-

by

adding

additive

40%

(anti-

about

-25°

with

pro-

en-

Fan

The

fan is driven electrically and trolled by a thermoswitch which is actuated by the coolant temperature.

When

the engine is hot, the fan may

continue to run when the engine has

been

stopped or it may switch on

suddenly

Notes

• If the fan is not running although the coolant temperature is very high, the fuse should be checked and renewed if necessary

• The speed of the fan does not depend on engine

not therefore be increased by changing

down. As

a

gradient can be taken without a large drop in speed it is not necessary to change

- even when ignition is off.

- see page 103.

speed.

long as the engine runs smoothly and

down.

The cooling effect

con-

can-

Driving

The

tory provides frost protection down to about -25° C. To ensure tection is adequate, the coolant should be gins additive G11 or an additive specification

If greater protection against frost is required, can otherwise the anti-freeze protection is reduced effect is impaired.

Vehicles

usually

-35° C.

in

winter

mixture put in the system by the fac-

that

frost pro-

checked before the cold

and if necessary, undiluted coolant

TL-VW

the proportion of G 11 additive

be increased, but only up to 60%

and furthermore the cooling

for export to cold countries

have frost protection down to

774 A added.

season

with

be-

the

79

OPER

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WINDSCREEN WASHER SYSTEM

The filler opening of the container is

under the carpet on left hand side of front footwell. The container holds about

3.5 litres. On vehicles with a headlight washer the capacity is 6.5 litres.

80

On vehicles with rear window washer* there is an additional container on the

right in the luggage compartment This

container holds about 1 litre.

To fill container

Lift carpet, open flap and unscrew cap. Fill container to top with water and screw

cap on again. Switch ignition on and

check that washer is working.

It is advisable to add a window cleaner solution (with anti-freeze additive in ter) to the water because plain water is

not usually sufficient to clean the glass and headlight lenses quickly and tho-

roughly.

win-

Adjusting washer jets

When vehicle is stationary, the water should hit the windscreen at the follow-

ing points:

a = 490 mm c = 180 mm

b = 220 mm d = 350 mm The water jet for the rear window should

hit the window in the centre of the wiped area.

The jets can be adjusted with a needle. The jets for the headlight washer sys-

tem*can only be adjusted with a special tool.

When adjustment is necessary,

contact your V.A.G workshop.

OPERATING

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INSTRUCTIONS

BRAKE

The

SYSTEM

following points are of particular importance to the safe operation of the brakes.

• New brake linings must also be run in and

do not have the optimum friction

properties during the

first

200 km. The slightly reduced braking effect can be compensated sure

on the brake

for by slightly more pres-

pedal.

This also applies

when new linings have been fitted.

• On hills change down in good time to make

use of the braking effect of engine.

This

relieves strain on the brake system.

When

brakes are applied do not keep them on continuously, apply and release alternately.

• In certain operating conditions, for example

after driving through water,

after 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

first

by applying the footbrake.

The

full

braking force may also be re-

tarded when vehicle has been driven for

some

time on heavily salted roads without using the brakes because the layer of salt on moved

discs

first.

and pads has to be re-

Further details - particularly for vehicles with

four wheel drive - are given on page

66.

• Brake lining wear depends to a large extent 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 in a V.A.G workshop

in between the intervals given in

the service schedule.

• 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 be

prepared to use more pressure on

V.A.G

workshop but

the pedal and allow for longer braking distances

The

on the way.

failure of a brake circuit is shown by the lighting up of the brake warning lamp*

(see also page 36).

The

brake fluid level must be checked regularly - see next page.

Brake

servo

The

servo is operated by vacuum which

is

only available when engine is running.

Caution

For

this

be

ning.

When cause,

reason

allowed

the brake servo is not working be-

for example, the vehicle is being

to

the

roll

vehicle

with

should not

engine

not run-

towed or because a defect has occured on the brake servo, the brake pedal must be

pressed harder.

81

OPERATING

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INSTRUCTIONS

Brake

fluid

reservoir

The fluid reservoir is in the dash under the dash cover panel. The panel can be lifted

to

fill in the When installing insert the lower edge

Checking

the reservoir. To do this grip

recess

at the back of the cover.

first.

fluid

level

front

The correct fluid level is essential to the

satisfactory operation of the brake

system. The fluid level must always be between the "max" and "min" marks.

The level of fluid tends to sink slightly when the vehicle is used due to the automatic adjustment of brake lining wear. This

is quite normal.

However, if the level sinks noticeably in a

short time or drops below the "min" mark the system may be leaking. Take the vehicle to a and have the brake system

V.A.G

workshop at once

checked.

The failure of a brake circuit is shown by the lighting up of the brake warning lamp* (see also page 36). When this happens shop system

Brake

course

take the vehicle to a V.A.G

work-

immediately and have the brake

checked.

fluid

fluid absorbs moisture. In the

of time it takes up water from the ambient air. Too high a content of water in the brake fluid can cause corrosion damage

in the system in time. Furthermore the boiling point of the brake fluid is reduced considerably. This can then cause the formation of vapour bubbles in the fluid when the brakes are used hard. The efficiency of the brakes and thus the vehicle

safety is then seriously affected.

For

this

renewed

reason

every

the

brake

two years.

fluid

must

be

Use

only our genuine brake fluid (specifi-

cation to US standards

FMVSS

116 DOT

4). The fluid must be new.

Caution

Brake

fluid

is poisonous.

It

must closed children.

and the dash is

voir.

fluid.

V.A.G

therefore

original

Brake

fluid

plastic

spill any

cessary. Environmental

must

made.

fluid

Cover

be observed

Dealers have all the necessary in-

only

container

will

also

material

Take

when

area

round

protection

when

be

stored

out of

damage

great

topping

paintwork

of

which

care

up the

reservoir

regulations

disposing of the

in the

reach

the

not to

reser-

if ne-

of

formation and stock the specified brake fluid.

The renewal of the fluid should therefore

be carried out by a V.A.G Dealer, preferably during an Inspection

Service.

82

ING

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INSTRUCTIONS

ANTI-LOCKING

The ABS plays a major part in increasing the active safety of the vehicle. The big advantage of the ABS compared conventional brake system is when braking on slippery surfaces the wheels do not lock. The vehicle remains

steerable and the best possible driving stability is retained.

When the turning speed of a wheel

reaches hicle speed and it tends to lock, the brake pressure regulating process is of the brake pedal and is accompanied by warning to the driver in the locking range. The speed

mediately traffic

cannot The able

a level which is too low for the ve-

to this wheel is reduced. This

noises.

conditions.

Particularly

overcome

increased

must

risks

when

be

BRAKE SYSTEM*

with

the

that

even

felt

as a pulsation

This is deliberately done as a

on

not

driving.

that

adapted

slippery

the physical

amount

tempt

one

the wheels are

roads

safety

into

must

road

the ABS

limits.

avail-

taking

to the

of

im-

and

any

Every

time the engine is started the ABS

is

switched on automatically. The functioning of the ABS is indicated by a warning lamp - see page 36.

PEDALS

The movement of the pedals must not be restricted.

For

this reason, do not put articles in the

footwell which could roll or slide under-

neath the pedals.

Around the pedal area there should also be no

foot

covering materials:

• In the system, necessary.

• It should always be possible to depress fully.

• All pedals must be able to return, unhindered, to their rest positions.

For

foot

which leave the pedal area completely free and which are prevented from slip-

ping.

mats or other additional floor

case

a greater pedal travel may be

the clutch and accelerator pedals

these reasons therefore, the only

mats which may be

of defects on the brake

used,

are those

83

5A_ERY

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On vehicles with a petrol engine the battery is under the right hand seat. It can be reached when seat is pushed fully forward.

On vehicles with a Diesel engine the battery is on the right hand side of the engine compartment.

On vehicles with swivelling seats the seat must be turned 180° and pushed

fully forward.

2nd Battery*

The 2nd battery is under the left hand

seat. Access is gained by sliding the seat forwards as far as possible.

On vehicles equipped with ABS the 2nd battery is at the rear left hand side, inside the vehicle.

The 2nd battery supplies power for

tional fitments when the vehicle and engine are stationary. A cut-off relay between the 1st and 2nd batteries prevents the 1st battery from being run down as always sufficient power available for starting. move, the 2nd battery is charged up together with the 1st one.

well.

This ensures that here is

When the vehicle is on the

addi-

Checking acid level

In normal operating conditions the battery requires hardly any maintenance. At high ambient temperatures however it is advisable to check the acid level at regular intervals. It should always be between the min. and max. marks on the side of

the battery.

Caution Battery acid is corrosive and must not

get into the eyes or on to skin and clothes.

Any acid splashes must be washed off thoroughly with water. See a doctor if

necessary.

The level should therefore preferably be topped up in a V.A.G workshop.

Winter

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driving

Winter weather is particularly hard on the battery. Furthermore at low temperatures it has only a part of the capacity it has at normal temperatures. We recommend therefore checked before the onset of cold weather and charged necessary, and only result in quicker, more reliable starting but will help to prolong the life of the battery.

If the vehicle is not driven for several weeks the battery should be taken out and stored in a frost-free room, so not freeze up and become damaged.

Store To

two wires (see "Battery charging - Quick charging") and then remove retainer.

that

the battery should be

preferably in a V.A.G workshop

if necessary. At the same time, if

the terminals will be cleaned

special grease applied. This will not

when temperatures are very low,

that

it does

the battery out of reach of children.

take battery out,

first

disconnect the

OPE

Charging

When

with wires need normally not be taken off. The instructions from the charger manufacturer

Before with must be disconnected:

Disconnect wire.

A C. tery before it is given a quick charge as otherwise it may explode!

The be charger the battery terminals:

Red Black

Caution The gas

process is sources of ing battery.

battery

charging

a small charger) the connecting

must however be noted.

Quick charging,

a high current, both connecting wires

discharged battery can freeze at -10°

It is essential to thaw out a frozen bat-

mains wire of the charger should not

connected until after the clips of the

have been properly secured to

= plus (or positive)

= minus (or negative)

cigarettes

with

minus wire

given

off

highly

ignition

etc.)

a low current (e.g.

that

is charging

first,

then the plus

during

inflammable

(naked well

the charging

so

flames,

away

keep burn-

from

the

G

IN

When

connecting the battery to the vehi-

cle

system again note: Connect plus wire

first,

then the minus wire.

Caution Do not

reverse

count, as

tem

will

be seriously damaged.

Notes

•

Never

this

causes the

quickly and it may

• To

prevent circuiting, fore

doing any system. sufficient off.

• Never run the engine disconnected electrical

nents).

• Starting by connecting an additional

battery is described in the Do-it-yourself

section.

When

the

otherwise

short

detach

to

switch

system (electronic compo-

polarity

the

battery

burst.

any possibility of

battery

work

changing a bulb, it is

the

as this will damage the

electrical

terminals

to

heat

earth

on the

lamp

with

on any ac-

sys-

as

up

very

short

wire

be-

electrical

concerned

the battery

OPERATING

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WHEELS

INSTRUCTIONS

Wheels features. The wheels and tyres approved by us are specially matched to the model concerned excellent roadholding and safe driving characteristics.

If you standard

• For sible other not model.

• ed to one

On (e.g. tyres) length The functioning on

• Using which for tal to the

and tyres are important design

and contribute largely to the

wish

to fit

your

car

technical

in

every

vehicles

even

Wheels

changing

alloy

the

and conical

security

this.

have

your

vehicle

wheels

another.

wheels correct

types

safety

or

tyres

reasons it is not pos-

case to use

- in

certain

from

the

same

and

wheel

bolts

to a

different

or

wheels

bolt

with

of the

not

shape

brake

of

been

model

of the

must

wheels

system

wheel

approved

can be

vehicle.

please

type

with

non-

note:

wheels

and/or

from

conditions

vehicle

are

match-

of

wheel

with

winter

the

proper

be used.

and the

depend

tyre

by us

detrimen-

It can

also

affect

the

struction

• If

wheel installed, mains

adequate

V.A.G

workshops

about

the possible conversions of

tyres,

wheels

Many

V.A.G Dealers have an attractive

range of tyres and wheels for

General

• Check tyres for damage from time to time and remove any foreign bodies em-

bedded in treads.

• To avoid damage to tyres and wheels drive over curbs and similar obstacles very slowly and as nearly at as

possible.

If you

think

it must be checked by a

vehicle

and Use

trim

ensure

and

notes

that

discs are

under

regulations.

that

the air

to cool the

are

wheel

a wheel is damaged,

the Con-

subsequently

flow

brakes.

fully

informed

trims.

sale.

right

angles

V.A.G

workshop.

re-

• Keep grease, oil and fuel off the tyres.

• Replace missing dust caps as soon as possible.

• Mark wheels before taking them off so

that

they rotate in the same direction

when put back.

• When taken off, the tyres should be stored in a place. should be stored in a vertical position.

New

New straight away and should therefore be run in at moderate speeds and a careful style of driving for about the This longer.

cool,

Tyres which are not on wheels

tyres

tyres do not give maximum grip

will help to make the tyres last

dry and preferably dark

first

100 km.

86

yre

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wear

Tyre life depends to a considerable extent

on the following factors:

Inflation

Pressures shorten detrimental influence on vehicle handling.

At continuous high speeds a which the pressure is too low flexes more and heats up

cause out.

In addition low the fuel consumption.

The inflation pressures should therefore be checked twice a month and always before a long spare when tyres are cold. When warm, the pressure The pressures are given on page 126 and on

ninges.

pressure

which are too high or too low

tyre

life - quite apart from the

tyre

in

tread

wheel. Always check pressures

is higher but do not reduce.

left

excessively.

separation

tyre

pressures increase

trip,

not forgetting the

door pillar between the

and

This can

tyre

blow

OPERATING

Mode

of

driving

Fast

cornering, hard acceleration and

violent braking also increase

Incorrect

Incorrect wheel alignment not only causes wear but can also impair the car's safe handling. If unusual contact a

Wear

At the bottom of the tread of the original tyres there are 1.6 mm high "wear indicators"

Fig. according to make - evenly spaced round the the flanks of the letters "IWI" or triangles) show the locations of the wear indicators.

When tread depth is down to 1 mm measured at any point on the tread - the official permissible minimum tread depth has this figure may differ).

As surface

wheel

alignment

excessive, usually uneven

V.A.G

indicators

running across the tread - see

There are 6 - 8 of these indicators -

tyre

been reached (in export countries

worn

tyres

properly

tyre

workshop.

circumference. Marks on

tyre

(for example the

cannot

when

tyre

wear.

tyre

wear is noticed,

grip

the

driving

road

at

high

INSTRUCTIONS

speeds on wet tends

to able far.

aquaplane

not to let the

roads

and the

sooner, it is advis-

tyres

wear

vehicle

down

so

87

OPERATING

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INSTRUCTIONS

X >>

V J

I

B43 - 155~|

Changing

If the tyres are wearing unevenly, it is advisable to change them round as shown. about the same mileage.

When the wheels have been changed round it may be necessary to have the front

wheels

All the tyres

wheels balanced again.

round

will

then last for

Replacing

• For safety reasons the tyres should be replaced in pairs and not singly. The

tyres ways be on the

• Only radial ply tyres of the same type, size

and the same tread

combined.

• For safety reasons a new rubber valve should be less

tyre

• Tubes should only be used in tubeless

tyres in an emergency.

When this is done, ensure trapped between tube and

escape

• Repairing tyres calls for special equipment and knowledge and should there-

fore only be done by a specialist.

On the

following

All

four wheels must always be

with

tyres of the same pattern coupling does not engage the drive unnecessarily because of speed

tyres

with

the deepest tread should al-

front

wheels.

pattern

fitted

has been installed.

from

the valve.

Transporter/Caravelle

should also be

and make so

when a new tube-

that

noted:

size,

that

the viscous

may be

the air

tyre

can

syncro the

fitted

type, tread

front

axle

differences between the two axles. If the front

wheels have a noticeably smaller roll circumference than the rear wheels so

that

they

turn

faster, wind-up cur in the transmission and cause the tyres to wear quicker.

Balancing

The wheels on new vehicles are balanced.

However when vehicle is running,

various influences can cause wheels to

become unbalanced and this causes

steering vibration. As

imbalance also increases steering, suspension should be balanced again.

Furthermore a wheel should always be rebalanced when the paired or when a new

fitted.

wheels

and

tyre

wear the wheels

tyre

will

oc-

has been re-

has been

88

OPERATING

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INSTRUCTIONS

Winter

In winter conditions, the handling of the

vehicle

hicles

When

ing:

• Only radial ply winter tyres should be used. sizes

• With winter tyres, the PR figures on

the sidewalls should also be noted. The tyres must not be below the specified carcass

• To obtain the best possible handling

characteristics, ted on all four wheels.

• Winter tyres are no longer fully

effective when the tread has worn down

to a depth of 4 mm.

• All-weather tyres can be used instead

of winter tyres.

tyres

including four wheel drive ve-

- can be improved by winter tyres. fitting

winter tyres, note the follow-

The factory recommended tyre

are given on page 123.

strength.

winter tyres must be

fit-

Snow chains

Snow chains may be used on all the tyre

sizes

chains may be only. Only

stand clear more than 15 mm (including tensioner) should be

When of snow you should remove the chains. On

such roads they are detrimental to vehicle wear

In Germany the maximum permissible speed

The

following

Transporter/Caravelle

Snow fitted chains on the rear wheels.

On

vehicles chains wheels.

Further details about using snow chains

are given on page 64.

listed

thin

driving over roads which are free

handling, damage the tyres and

out quickly.

with

chains should, where possible, be on all four wheels. If only two

are available they must be

may only be

on

page

fitted

on the

chains which do not

used.

snow chains is 50 km/h.

should also be

with

16 inch wheels, snow

fitted

123. The

rear

wheels

syncro vehicles:

noted

fitted

on the rear

on

OPERATING

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INSTRUCTIONS

EMISSION

V.'-en

nothing

putting certain following served

•

Underbody sealant must not be applied exhaust pipes.

•

Due to the high temperatures which can verter in very unfavourable conditions, the vehicle should not be parked so that

the catalytic converter can come into contact materials.

CONTROL

vehicle

to the catalytic converter or the

is

special

lead-free petrol in the tank. In

exceptional

points

for

used

to be noted - apart from

should

safety

reasons:

occur

in the catalytic

with

SYSTEM*

normally

circumstances

however

easily inflammable

there is

the

be ob-

con-

To

ensure not ing

•

The vehicle must not be started when catalytic converter is at operating temperature by towing it a long tance.

•

The ignition must not be

as

long as vehicle is rolling

engaged.

•

If a defect system ed loss duced be eliminated in the shop.

In

these get burned

A

functional

control

that the damaged points must

when driving (can be recogniz-

by misfiring, uneven engine running,

of

power)

immediately. The defect should

conditions,

into the

there.

system

catalytic

by

overheating,

also

occurs

the speed must be re-

catalytic

description

unburnt petrol can

is

given

converter

the follow-

be

noted:

switched

with

in the ignition

converter

of the

on

page

and be

emission

117.

is

dis-

off

a gear

work-

90

OPERATING

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INSTRUCTIONS

DIFFICULT

The

vehicle construction and equipment

is

designed for normal operating ditions. This also applies to the frequency and

the extent of the maintenance laid

down in the maintenance schedule.

If the vehicle is used in ing conditions (e.g. continuous trailer towing, exceptionally high or low ambient temperatures, very dusty conditions, poor quality fuel, etc.) it may be sary

to carry out special technical preparations, such as using oil of the appropriate viscosity, installing special air cleaners ignition timing etc. Furthermore the maintenance must also be matched to the operating conditions.

OPERATING

(cyclone filters), modifying the

CONDITIONS

con-

difficult

operat-

neces-

Driving

If the vehicle is to be taken abroad, the

following must also be borne in mind:

• In many countries there is a large network of V.A.G workshops where your vehicle there are certain countries in which there is or even none at all.

• In certain countries it is also possible that certain spare parts are not available for your vehicle or is should

The

Republic

cerned vice tion

required and on the repair possibilities. The

wallet.

• When the vehicle is used in a country

which drives on the opposite side of the

road to the home country the wedge

shaped

must be masked - see page 109.

abroad

can be serviced. Despite this

only a limited amount of

your vehicle model is not sold so

not familiar

anything go wrong.

V.A.G

will be only too pleased to give ad on the necessary technical prepara of the vehicle, on the maintenance

addresses are given in the vehicle

areas on the headlight lenses

that

with

the repair procedure

Sales

of Germany or the

Centres in the Federal

the

V.A.G

Importer

service

personnel

con-

that

Driving

Before points:

• The roadworthiness and driving safety are particularly important when on holiday see

• If your vehicle has a catalytic converter, one must ensure - especialy when going abroad trol see information about the lead-free filling station network.

• With a fully loaded vehicle and/or roof

rack, the handling changes. The driving

style must be adapted to the changed conditions - more information on loading

is

The

• When a trailer is to be towed, there are many special points to note - see

page

• If an oil change or an Inspection vice

sary

this work done before going on holiday if

possible.

on

holiday

starting off note the following

page 57.

that

will be available during the journay -

page 67. The automobile clubs offer

given on page 127.

tyre

pressures must be

60.

is probably going to become

during the

trip,

it is advisable to have

lead-free pe-

checked.

neces-

Ser-

91

OPERATING

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INSTRUCTIONS

Z • , -g

• Winter weather is particularly hard on the battery and it should therefore be checked er, preferably by a V.A.G Dealer - see page 85.

If the vehicle is not driven for several weeks low, the battery should be taken out see

• On vehicles ter Diesel must be used at temperatures below 0° C - see page 69.

• The anti-freeze in the cooling system should be checked before the cold son

• The engine oil viscosity must be correct for the ambient temperature - see page 72.

• Particularly in winter, frequent washing and waxing of the vehicle is the best way to protect it against damage from environ-

mental influences.

in

winter

, -ter the following points should be

before the onset of cold weath-

when the temperatures are very

page 85.

with

a Diesel engine, win-

starts - see page 79.

sea-

• The windscreen washer system should always be filled cleaning solution tive in the winter - see page 80.

• To remove snow and ice from the windows and mirrors, a plastic scraper should be used - see page 94.

•

Even the roadholding and handling can be improved in winter road conditions by the use pages

• When driving in mountainous districts

it is advisable to take snow chains

you in the winter. On some such roads,

snow chains are obligatory - and this applies see

on vehicles

of winter or All-weather tyres - see

89 and 126.

also to four wheel drive vehicles -

pages 64 and 89.

with

anti-freeze addi-

with

four wheel drive

a window

with

92

CAR

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CARE

AND MAINTENANCE

Regular tain

Furthermore lations claims paint

Every suitable car care materials. The instructions for use on the container should be

followed.

Caution These

health out of

and

the

careful

value

it can be one of the stipu-

for the

should corrosion

defects

V.A.G

workshop carries stocks of

materials

if misused and should be

reach

of children.

care

of the

vehicle.

upholding

occur.

can be

helps

of

damage

injurious

to

main-

warranty

and

to

kept

Washing

The best protection against environmental influences is frequent washing and waxing. After the period when salt is put

on the roads, the underside of the vehicle

should always be washed thorough-

ly.

When the vehicle is washed in an auto-

matic wash plant nothing need be noted apart from the usual precautions. It is however advisable to fold the outside mir-

rors inwards. The longer

grime, insects and bird droppings etc.

are

left damage they are liable to do to the finish.

When the load compartment has been cleaned, side

When vehicle is washed not point the jet of water directly at the lock cylinders - otherwise they will freeze up in winter.

Tar

spots, traces of oil, industrial griime,

insects, by washing. As they damage the paint if left

on too long they should be removed as

soon as possible

preparation.

salt,

road dust, industrial

on the paintwork the more

the sliding door hinges or the

board hinges must be regreased.

with a hose,

etc. cannot always be removed

with

a suitable

do

Waxing

Wax

as often as possible. This will pre-

vent

dirt industrial grime from penetrating paint.

from sticking to the paint and

into

the

Polishing

Should

only be done if paint has lost its

shine and gloss cannot be brought back

with

wax. If the polish used does not

contain preservative compounds, the

paint must be waxed afterwards.

Matt

painted

not be treated

and

plastic

with

wax or polish.

parts

should

CARE

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Touching up

Small scratches

touched up immediately

(Volkswagen touch-up brushes or spray

cans)

However, should rust be found at any time it must be removed thoroughly and then the area treated

corrosion primer and then the correct

paint applied. You

by a The number of the original vehicle paint

is

given on the data sticker (see

page 132).

Windows

Remove and mirrors only To

avoid scratches due to glass, in one direction and not moved to and fro.

Traces can a

silicone remover.

The windows should also be cleaned on the inside at regular intervals.

AND MAINTENANCE

paint

damage

marks in the paint such as

or stone damage should be

before

can of course have this work done

V.A.G

the scraper should only be pushed

be removed

the metal starts to rust.

workshop.

snow and ice from windows

with

of rubber, oil, grease or silicone

with

paint

first

with

an anti-

a plastic scraper.

dirt

on the

window cleaner or

Do

not dry the windows

used

for the paintwork

paint cleaner will cause streaks to appear

on the

glass.

To

avoid damaging the

wires

in the rear window do not put

stickers over the wires on the inside.

Windscreen

To

prevent streaks from forming on the glass regularly When very the blades can be cleaned or brush. For safety reasons the wiper blades a

year. Wiper blades can be obtained

from all Changing

wiper

the wiper blades should be cleaned

with

a window cleaning solution.

dirty

and

should be renewed once or twice

V.A.G

Dealers.

wiper blades - see page 109.

with

the leather

because

heating

blades

full

of insect remains,

with

traces of

element

a sponge

Door,

lid and

The weatherstrips will remain flexible and last longer if they are rubbed lightly with

a rubber protective compound from time to time. This will also stop the weatherstrips freezing on in the winter.

Cleaning runners

In order to ensure continues to operate satisfactorily, it is ad-

visable

to clean the runners from time to

time, at least however once a year and

then to spray them cant.

Cleaning

If cleaning

washing is not sufficient, plastic parts

and leatherette may only be cleaned special

solvent-free plastic cleaners.

Cleaning

Upholstery cloth and similar materials must be cleaned

dry foam and a soft brush.

window

and

lubricating

plastic

with

a damp cloth or normal

cloth

upholstery

with

weatherstrips

sliding

that

the sliding

with

a silicone lubri-

special cleaners or

roof

roof*

with

94

CARE

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AND MAINTENANCE

Cleaning

and

care

of

leather

upholstery

A

damp cloth is normally all required to clean leather covered steering wheels and seats etc.

For

a more thorough cleaning job, it is best to use a sponge moistened lukewarm solution of a very mild detergent.

Do

not wet the leather too much other-

wise the water may seep through the

stitching. After cleaning, wipe dry If necessary the leather can be treated

with

a suitable leather care product. On no account should cleaners or sprays containing solvents be used - these could attack the colouring of the ma-

terial.

Care

of

chromed

Remove cleaner. can protection. Ensure parts are covered completely and uniformly

spots and marks

A chrome protective compound

be applied to give long-term

with

the compound.

with

parts

that

the chromed

that

with

a soft cloth.

with

a chrome

is

a

Cleaning

Keep retract properly if very

Dirty belts can be cleaned by washing with the belts out of the vehicle.

Do

not have the belts cleaned chemically

because damage the webbing material. Ensure that with

Inertia dry before they are allowed to roll up.

seat

belts

belts clean because they may not

a mild soap solution

the cleaning compounds

the belts do not come

corrosive fluids.

reel belts should be completely

dirty.

without

into

taking

contact

Steel

wheels

The wheels and the wheel trims should

be cleaned thoroughly at regular inter-

vals

when the vehicle is being washed.

This

will prevent brake dust,

road salt from accumulating on the

wheel.

Persistent, ingrained brake dust

can

be removed remover. Paint damage should be repaired before rust can form.

Alloy

wheels

In order to maintain the smart appear-

ance

of alloy wheels for a long period,

regular care is necessary. In particular,

salt and brake pad dust must be washed off thoroughly at least every two weeks

otherwise the surface of the alloy will be damaged.

should be treated

cleaner

three months it is necessary to give the wheels a good rubbing

damaged,

for alloy wheels. About every

Paint

polish or other abrasive solutions

must not be If the protective paint coat has been

aged

spots should be dealt

as

possible.

with

an industrial grime

After being

used.

e.g. by stone impact, the dam-

washed,

with

dirt

and

the wheels

an acid-free

with

hard wax.

with

as soon

95

CARE AND MAINTENANCE

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Cleaning ment

-articularly in quently

corrosion protection very important.

The complete engine compartment

should therefore before then given anti-corrosion treatment that fluence.

V.A.G dealers have stocks ing mended and have apply them.

and

anti-corrosion treat-

of

engine compartment

winter when vehicle

driven

on

salted roads

be

thoroughly cleaned

and

after

the

salting period

the

salt cannot have a damaging

and

preservation solutions recom-

by the

factory

the

equipment necessary

of the

for

this purpose

is

clean-

fre-

good

and

so

in-

to

Undercoating

The underside with a special compound from chemical

ences.

However, damaged when coating under

ing gear should

intervals - preferably before the winter season

made good. V.A.G workshops have stocks

rect compound, have

equipment and

cation procedure. fore

to

have

al coating done

Note

for

verter

Due

to the

cur

in the tional heat shields talytic converter. Underbody sealant

must

not be

the catalytic converter

pipes.

of the

as

this protective layer gets

the

vehicles with a catalytic con-

high temperatures which afterburning process,

applied

vehicle

and

mechanical

the

vehicle

body and

be

examined

- and any

are

patching

by a

the

familiar with

We

advice

up or

V.A.G workshop.

are

fitted ever

to

these shields,

or the

is

coated

to

protect

influ-

is in

use,

on the

runn-

at

certain

and

after

damage

of the

necessary

the

appli-

you

there-

addition-

addi-

the ca-

exhaust

it

the

cor-

oc-

96

MAINTENANCE

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As

the vehicle is maintenance technical components only a

small amount of regular servicing is required in order to maintain the roadworthiness,

The

selection made cial ning-in period. On vehicles engine a First Service must be carried out after 1000 km.

The V.A.G large extent the individual annual mileage covered as

is

30000

If a mileage of 15000 km (petrol engines) or 7500 km (Diesel engines) is reached before 12 months has elapsed, an Oil Change Service must be carried out. See Schedule.

The work is required at the Inspection and Oil

Change

economy and'reliability.

high manufacturing quality and the

of high-class materials have

it possible to dispense

service immediately after the run-

inspection service offered by the

workshop takes into account to a

and helps thus to keep the costs

low as possible. An

required every 12

km, whichever comes

also page 73 and the Service

Service Schedule also shows what

Services.

fitted

Inspection

months

with

modern low

with a spe-

with

first.

a Diesel

Service

or every

CARE

In difficult operating conditions, e.g. ex-

tremely low ambient temperatures, very

dusty conditions, buildings site work, etc. certain service operations should be carried out between the intervals given.

This

applies in particular to:

• Changing the engine oil

• Cleaning or changing the air cleaner element

• Draining water from or renewing the fuel

filter

on the Diesel engine.

• Lubricating the hinges of sliding and Double

Cab doors, dropsides, locker lid

and

rear doors.

The

service operations should be carried out in a V.A.G workshop because this work requires special knowledge, workshop

appliances and special tools. Fur-

thermore this work must be done in

accordance

The

disposal of old oil, used brake fluid,

dirty

coolant, old batteries or worn-out

tyres etc. must be done according to

environmental protection regulations.

with

our instructions.

AND MAINTENANCE

Complete workshop can be one of the stipulations

for the upholding of any warranty claims

during the one year warranty period.

Safety

place

repairs and adjustments to engine and

running gear parts which can be done by the owner. By tinkering affect the safety of the vehicle one can endanger

In addition, altering the settings of the carburetor or fuel injection system or the ignition, changes the emission ues sumption.

Caution

Special ing in the lar sources of (belt electrical gers, pressurized cooling system. The ings mal

proof of servicing by a V.A.G

regulations and anti-pollution laws

very strict limits on the amount of

with

parts which

oneself and other road users.

val-

and also increases the fuel

care

must

be

engine

pulleys,

system

high

given

valid

safety

danger

radiator

tension

in

this

taken

compartment!

are

rotating

fans

(short

ignition)

manual

rules

circuit

and the

must

con-

when

work-

Particu-

parts

etc.),

the

dan-

and the hot,

warn-

nor-

be heeded.

CARE

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AND MAINTENANCE

JFTiNG

Vehicle hoist

Before sure between

The

points

Trolley jack

The with a trolley jack at the points shown

here.

To a

suitable

packing.

On lifted rear axle or the

cause

Vehicle jack

Using ing

VEHICLE

driving over a vehicle hoist en-

that

there

hoist and low parts of vehicle.

vehicle

shown

vehicle

prevent

no account should the vehicle be

under the engine sump, gearbox,

serious damage.

the jack is

pages.

is sufficient clearance

may only be lifted at the

here.

should

damage

piece

also

only be lifted

it is

essential

of rubber or wooden

front

axle as this can

described

to use

on the follow-

Lifting points for hoist and trolley jack. Front Rear

At

the front jacking point At rear

cross

member

98