1992 VOLKSWAGEN CARAVELLE Owners Manual

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GENERAL
MAINTENANCE

Engine
compartment

Page

Windscreen
washer
container
.. 108
Power
assisted
steering

fluid
reservoir*
100
Engine
oil filler
opening
97

Engine
oil
dipstick
97

Coolant
expansion
tank 102
Brake
fluid
reservoir
104

Battery
106 Attention
Particular care should be
taken

when working in the engine
com­
partment!

•
Switch off engine, remove ignition key.

•
Pull handbrake on firmly.

•
Move gear lever into neutral or
"P"
position.

•
Allow engine to cool off.

•
As long as the engine is at op­
erating temperature:

-
Do not put your hand into the radiator fan, it could switch on

suddenly.

-
Do not open the radiator cap be­
cause
the cooling system is

under
pressure.

•
Avoid causing short circuits in
the electrical system - particular­ ly at the
battery
-.
•
If tests have to be
carried
out

with
the engine running,
there
is
an additional danger
present

from rotating parts - e.g.
V-belts,
generator, radiator fan etc. - and
from the high voltage ignition
system.

Attention must be paid to the warnings given in this Instruc­
tion Manual and to the generally
applicable
safety regulations.
When topping up fluids one
should
ensure
that
they are not mistaken,

one
for the other, under any
circum­

stances,
otherwise serious
func­

tional defects
will
result.
So
that
leaks
are quickly de­
tected
the ground underneath
the vehicle should be checked
reg­

ularly.
If spots as caused by oil or

other
operating fluids can be seen, the vehicle should be
taken
to the
workshop for checking.
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GENERAL
MAINTENANCE
Engine oil
T

Viscosity and
specification

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

climates.

As
a good engine oil is a prerequisite for
trouble free operation and long engine ser­

vice
life, only a correspondingly high quality oil may be used for topping up and at oil

changes.

The specifications shown on this page must be marked either separately or together

with
other specifications, on the containers.
When topping-up, the oils can be mixed

with
one another.
The viscosity class of the oil must be se­ lected in accordance
with
the illustration. If
the ambient temperature exceeds the given range briefly, the oil does not need to be

changed.

Important
note

Quite naturally engine oils are also being
continually developed. For this reason the statements in this Instruction Manual are
only in line
with
the current state at the time
of going to press.

Volkswagen
dealers are kept up-to-date by the factory regarding changes. For this
rea­
son
the oil change should preferably be
done by a Volkswagen dealer. F
100

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60-
40-
20 0

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Petrol
engines

A
- Multigrade - improved lubricity engine
oils,
specification VW 500 00

B
- Multigrade oils, specification VW 501 01
- Multigrade oils, specification
API-SF^orSG11
Diesel
engines

A
- Multigrade-improved lubricity oils specification VW 500 00 (not for turbo-

diesel
engines)

B
- Multigrade engine oils, specification
VW
505 00 (suitable for all diesel en­gines)
- Multigrade oils, specification
API-CD
(with
turbo-diesel only for topping-up
in an emergency)
- Multigrade oils-specification VW 501 0': (not for turbo-diesel engines)
Oil
characteristics
Multigrade
oils to VW
Standard
501
01 are reasonably priced oils
with
the fol­ lowing properties:
- All year round use in temperate climate
areas.

- Excellent cleaning capability.
- Efficient lubrication at all engine tem­ peratures and load conditions.
- High resistance to ageing.
11 These oils may only be used if the approved engine oils are not available.
96
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GENERAL
MAINTENANCE
The
multigrade-improved
lubricity
oils as per VW
Specification
500 00 m/e in addition the following advantages:

-
All year round use at practically all tem­ peratures.

-
Low frictional
losses
in the engine.

-
Best possible starting even at very low temperatures.
»Jotes
I
Single
grade
oils. Due to their limited
i-scosity
ranges these oils are not generally
j_::eptable for all year round use. "erefore these oils should only be used in

-
:reme climatic
zones.

•
When using SAE 5 W-30 multigrade oil, xntinuous high engine speeds and engine

seeding
should be avoided. This restriction
::es
not apply to multigrade-improved lu-
r city oils.
Checking
oil
level

Every
engine uses a certain amount of oil.

The
oil
consumption
can be up to 1.0
litres per 1000 km - see also page 80. The
engine oil level must therefore be checked
at regular intervals, preferably when filling
the tank and before a long journey.

The
location of the dipstick is shown in the illustration.

The
vehicle must be on a level surface when
checking
the oil level. After stopping engine
wait a few minutes for the oil to drain back
to the sump.

Then
pull the dipstick out, wipe it
with
a
clean
cloth and insert again.

Then
pull dipstick out again and check the oil
level:
A
- Oil
must
be topped-L.c.
Afterwards it suffices v.-5-:_e : e e
is
somewhere in area B.

B
- Oil can be topped-up. It can then happen
that
the c e.e s -

area
C.

C
- Oil
must
not be topped-up.

When
the engine is working hard sue as -
sustained
high-speed motorway cruising in
summer, when towing a trailer or :re~
climbing mountain
passes,
the c: e.e
should
be kept at area C (not
above

Note

If the dipstick does not have a- c"ee: -

measuring
area,
the upper and lows- e~zi
of the etched area form the MAX.
a~
z '.'
marks.
The oil level must be betv.ee- re
two marks. If it has dropped to 're '.' ". mark, oil must be added,
however
on no

account
above
the MAX.
mark.
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GENERAL
MAINTENANCE

Topping
up
engine
oil Unscrew the cap from oil filler opening and
pour oil in 0.5 litres at a time. Then check
level with the dipstick.
On no account must the oil level be
above area C. Otherwise oil can be drawn into the engine via the crankcase breather
and escape into the atmosphere via the ex­ haust system. On vehicles fitted with a
catalytic converter, the oil could burn inside
the converter causing it damage. Attention
When topping up the oil, do not spill it onto hot engine compo­nents - danger of fire.
Carefully close the filler cap and push the oil
dipstick in as far as possible, this will pre­
vent oil spill when the engine is running.

Changing engine
oil Not only does the engine oil deteriorate due
to use when the engine is running, but also to ageing. The engine oil change intervals depend therefore on the mileage and also
on the time elapsed.
Petrol engines
Change engine oil every 15 000 km or every 12 months (whichever comes first).
Diesel engines
Change engine oil every 7500 km or every 12 months (whichever comes first).
For further details, see Service Schedule. For petrol and Diesel engines
If the vehicle is used continuously in ar­
duous conditions, the engine oil must be
changed at shorter intervals - see also page

93.

Recommended oil and viscosity classes -
see page 96.
Attention
Old oil must be stored out of reach of children until it is dis­
posed of in the correct manner.

ojfcj
On no account must oil be
earth.

Because of the disposal
problems,
the necessary special tools anc
specialist knowledge required the engine oil and filter changing shoulc
preferably be done by a Volkswagen
dealer.

Engine
oil
additives

No additives should be mixed with
the engine oil.
Any damage caused by the use o
such additives will not be coverec by the warranty.
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GENERAL
MAINTENANCE

Gearbox
oil
Specifications

Manual
gearbox
and
final
drive

•
Gear
oil,
API-GL
4, SAE 80 or
•
Gear
oil, G 50, SAE 75 W-90

Automatic
gearbox

• Final drive:
Gear
oil, G 50, SAE 75 W-90 I Gearbox part: ATF Dexron®
Checking oil
level
rVith
a
manual
gearbox
and
final

drive
the oil level does not need checking.
'.ith the
automatic
gearbox
the oil

•e.
el in the final drive does not need check- *g either.

"he
ATF
level
in
gearbox
part
must ": .'/ever be checked in between the inter-

•BS
given in Service Schedule. To do this
ire vehicle must be standing on a level sur-
fe:e.
The
level must only be checked when
He ATF is
warm.
(Approximately 10 km

Irrer
starting from
cold,
the ATF has re­
tted the required temperature.) If fluid is
l:: :: or too hot the reading will be incorrect.
1
he engine must be running at idling
speed,

the handbrake must be applied and the se­ lector lever at "N".

To
check, pull dipstick (see Fig.) out, wipe
with a clean lint-free rag and then insert it
fully
again.

Pull
the dipstick out and check ATF
level.

When
the ATF is
warm
the
level
must
be
between
the two
marks
- other­

wise
the vehicle must be taken to a
Volks­
wagen
dealer without delay so that they can
find the reason for the incorrect
level.
It is not sufficient to merely top up or drain off

ATF.
Changing oil

For
the manual
gearbox
with
final

drive
the oil does not need changing.
For the
automatic
gearbox
the :
the final drive does not need
chariC-g

either. The ATF in gearbox part must how­

ever
be changed at the intervals given in
Service
Schedule.
Because of the disposal
prob­

lems,
the
special
tools
necessary
and the
specialist
knowledge
re­
quired,
the ATF
changing
should

preferably
be
done
by a
Volkswagen
dealer.

Notes

•
When
there
is no
lubricant
in the
manual
or
automatic
gearbox,
the

engine
must
not be
started
and the
vehicle may only be
towed
with
the

driving
wheels
lifted.

• No
additives
may be
mixed
with
the lubricants.
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GENERAL
MAINTENANCE
Air
cleaner
Power
assisted
steering

The
paper
filter
element in the air cleaner is normally renewed as detailed in the Service

Schedule.
In very dusty conditions the el­
ement must be cleaned or renewed at
shorter intervals.
To clean or
renew
element

•
Release
clip (1 ) •
Press
locking handle ( 2 ) down and un­ hook it.
• Take
filter
housing out upwards.
• Take
filter
element out. •
Clean
element
with
compressed air or renew it.

The
element must not be washed
with
pet­ rol or moistened
with
oil.
Installing

• Insert
filter
housing. Ensure
that
the
plastic
lug on the rearend of the elementfits
in the recess in the mounting.
• Secure clip (1 ).
• Pull locking handle ( 2 ) up until it en­
gages.

The
reservoir is located in the engine com­partment on the
right
looking forward.

The
power assisted steering is filled
with
our hydraulic oil G 002 000.

The
correct oil level in the reservoir is
essen­

tial for the satisfactory operation of the power assisted steering.

The
level can only be checked
with
the en­ gine at normal operating temperature but not running.
100
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GENERAL
MAINTENANCE
nere are two marks
with
which the oil level
:an be
checked.

• Outside on container (Fig.) • Inside on dipstick attached to the cap. ~he oil level should always be between the
MAX."
and "MIN" marks. When the level

"as
dropped down below the "MIN" mark

:^e
power assisted steering should be
:necked
at a Volkswagen dealer. It is not
sufficient merely to top up
with
hydraulic oil.

Note
f the power assisted steering fails at any
: me or when engine is not running (vehicle on tow) the vehicle remains fully steerable cut more force must be used to
turn
the
steering wheel. Cooling
system

Under
normal conditions the cooling
sys­

tem is almost maintenance-free.
The vehicle is
fitted
with
a hinged radiator
which can be folded forward when required
- see page 104.
The cooling system is filled at the factory
with
a permanent coolant which is not

changed.
The coolant consists of water and

a
40 % concentration of our coolant additive
G
11 V8B (anti-freeze on glycol basis
with

anti-corrosion additives). This mixture not
only gives the necessary frost protection
down to -25 degrees C but also protects the
alloy parts in the cooling system against cor­
rosion.
In addition it prevents scaling and ra­
ises
the boiling point of the coolant.
The concentration of the coolant therefore must not be reduced in the summer or in
warm countries, by topping up
with
plain
water. The
coolant
additive
propor­

tion
must
be at
least
40 %.
If greater protection against frost is re­
quired, the proportion of G 11 V8B additive

can
be increased, but only up to 60 % other­
wise the anti-freeze protection is reduced
and furthermore the cooling effect is im­
paired.
Vehicles
for export to cold countries -s~a .
have frost protection down to -35 decrees

C.

Only
our G 11 V8B or an additive v/rs :~e

specification
TL-VW 774 B (markea or
container) should be added to the coolant.
The additives can be obtained from
Volks­

wagen dealers.

Other
additives
can be
very
detri­

mental
to the
anti-corrosion
effect
in
particular.

The
subsequent
corrosion
damage
can
lead
to
coolant
loss
resulting
in

major
engine
damage.
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GENERAL
MAINTENANCE

Checking
coolant
level

The
expansion tank
is in the
engine
com­
partment on the bulkhead
-
see Fig.

The
correct coolant level
is
essential
to
the satisfactory operation
of
cooling system.
For
this reason, the coolant level should
be

checked
regularly,
and
this
is
best done
when refueling.

The
level
can
only
be
checked properly
when engine
is
not running.

The
coolant level must be between the MIN
and
MAX marks
on the
expansion tank
when engine
is
cold
and can be
slightly
above
the MAX mark when
it
is warm.
When
the
coolant level
is too low on ve­

hicles
with
an automatic coolant level moni­
toring device,
it is
indicated by the coolant
temperature/coolant level warning lamp
flashing continuously (see page 47).

Coolant
losses

Coolant
loss normally indicates leaks in the

system.
In
this
case
the
cooling system
should
be checked by a Volkswagen dealer

without
delay.
It is
not sufficient merely
to

add
coolant.
In
a
sealed system
losses
can only occur
if

the boiling point
of
the coolant is exceeded
as
a
result
of
overheating, and coolant
is

forced out
of
the system.
Overheating can occur
if:

• the flow
of
cooling air is reduced, e.g.
by
a
radiator
muff,
very
dirty
radiator fins
(leaves,
dust, insects)
or
additional driving
lights
in
front
of
the cooling air intake.
• the boiling point
of
the coolant has been lowered by an incorrect mixture
-
see previ­

ous
page.
•
the
radiator
fan is not
working
- see
"Fan"
on next page
-
or, • the vehicle
is
driven up
a
long hill
in too

low a gear
with
engine speed very high and
at very high ambient temperatures
-
see
"Fan"
on
next page.
If
the
cause
of the
overheating cannot
be

found
and
eliminated, contact
a
Volks­
wagen dealer
as
soon
as
possible other­

wise
serious damage may
be
done
to the
engine.

Topping
up
coolant
Switch
engine
off
and let
it
cool down. Then

cover
expansion tank cap
with
a
cloth and

turn
cap carefully
to
the
left
and remove.

Attention
Do
not
remove
expansion
tank

cap
when
engine
is
hot
-
Danger
of scalding.

System
is
under
pressure.

If, in an
emergency only water
can be

added,
the
correct mixture concentration must be restored
with
the specified coolant
additive (see previous page)
as
soon
as
possible.

•02
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