1992 VOLKSWAGEN CARAVELLE brake

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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

Moving
radiator
forwards
For certain operations in the engine
com­

partment e.g. changing plugs or to reach the
V-belt it may be necessary to move the
radi­
ator forwards.
To do this
first
remove the four securing
screws
(left
illustration).
Then
lift the radiator and move it forward.
When work in the engine compartment is
finished the radiator must be moved back to
the normal position and secured with the screws.
Brake
fluid

The brake fluid reservoir is in the engine compartment.

Note
On
vehicles with righthand drive the reser­
voir is on the other side of the engine
com­
partment.
104
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GENERAL
MAINTENANCE
'necking fluid level
Pe :orrect fluid level is essential to the sat-
:~=
:tory operation of the brake system. The
fc. Z level must always be between the
AX"
and "MIN" marks.
~- a "evel of fluid tends to sink slightly when
"a vehicle is used due to the automatic ad- ::ment of brake linings. This is quite nor-
-rwever, if the level sinks noticeably in a
srorttime or drops below the "MIN" mark
re system may be leaking. A low fluid level " the reservoir is indicated by the brake
w.arning lamp lighting up (see page 48 also), .nen this happens take car to a Volks­
wagen dealer immediately and have the
cake system checked. Renewing brake fluid
Brake fluid absorbs moisture. In the course
of time it takes in water from the ambient
air. Too high a content of water in the brake
fluid can in time cause corrosion damage in
the system. Furthermore the boiling point of
the brake fluid is reduced considerably. For
this reason the brake fluid must be renewed every two years.
Attention
When the brake fluid becomes
too old vapour bubbles can form in the brake system when the
brakes are used hard. The
effi­

ciency of the brakes and thus the
vehicle safety is then seriously

affected.
Only use our genuine brake fluio (see: - ra­
tion to US standard FMVSS 116 DO~-
.
~-e
fluid must be new.
Attention Brake fluid is poisonous!
It must therefore only be stored in the closed original container
out of reach of children.
Remember also that brake fluid will
attack the paintwork. Because of the disposal
prob­

lems,
the special tools necessary
and the specialist knowledge re­
quired,
the brake fluid changing
should preferably be done by a
Volk­
swagen
dealer.

It is advisable to have the fluid change car­
ried out during an Inspection Service.
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GENERAL
MAINTENANCE

•
Knowing
the
tyre
lettering and its
meaning
makes
the
selection
of the correct

tyres
easier.
Radial
ply tyres
have
the
fol­
lowing
lettering on the
sidewall:

e.g.:
195 / 70 R 15 97 S reinforced
195 =
Tyre
width in mm
70 = Height/width ratio in %

R
=
Radial
construction
code
letter
=
Radial

15 =
Wheel
diameter in
inches

97 =
Carrying
capability
code

S
=
Speed
code
letter
rein =
Reinforced
version

The manufacturing date is
also
to be
seen
on the tyre wall
(possibly
only on inner

side
of
wheel):

DOT
... 120 ...
means
that the tyre was
pro­

duced
in the 12th
week
of 1990.
Attention

Tyres
which are more than 6 years old should only be used in
an emergency and then
with
a particularly careful style of driv­

ing.
If you wish to fit your car
with
non­
standard wheels or tyres please note:
Attention

•
For technical reasons it is not normally possible to use wheels
from other vehicles - in certain
circumstances
not even wheels
from the same vehicle model!

•
Wheels and wheel bolts are matched to one another.

On
changing to a different type
of wheel (e.g. alloy wheels or
wheels
with
winter
tyres) the cor­ rect bolt
with
the proper length
and conical shape must be
used.
The security of the wheels and
the functioning of the brake
sys­

tem depend on this!

•
Using types of wheel and or
tyres which have not been ap­

proved
by us for your vehicle
model can be detrimental tc thi
safety of the vehicle. It can also
affect the vehicle under the
Con­

struction and Use regulations.

•
If wheel
trim
discs
are
subse­
quently installed it is essential to
ensure
that
the air flow remains
adequate to cool the brakes.

Volkswagen
dealers
have
a :ne
~e:e;5;~
information
about the
poss
;e :
~

of
wheels,
tyres and
wheel
trims.
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DO-IT-YOURSELF
Changing
wheels

Park
the vehicle as far as possible away
from the
traffic
flow, if necessary switch on emergency warning lights and place the
warning triangle in position - note legal re­
quirements.
• All vehicles occupants should leave the vehicle and move to a safe area (e.g. behind
the barrier).
• Apply handbrake firmly. If the car is on a
slope,
block one of the wheels on the oppo­
site side
with
a stone or some similar object.
• Take the tools out of the vehicle.
• Take spare wheel out of carrier at rear of vehicle - see previous page.
JB70
- 121J
•
Push
the wheel spanner as far as
poss­
ible onto the wheel bolt as shown and
turn

the spanner anti-clockwise. When doing this, grip the spanner as far as possible to­
wards the lever end.
If the bolts cannot be loosened, one can in
an emergency, carefully push the spanner
down
with
a
foot
on the end of the lever.
One
should ensure
that
one has a
firm

stance
and a good grip on the vehicle.

Loosen
wheel bolts about one turn. 8"" 1 •>!
•
Place
jack under vehicle: - Depressions in the side member at
front
and rear indicate the points at which the
jack must be
fitted
- see arrows in illus­
tration. On the sliding door side
ensure

that
the
claw
of the
jack
does not
fit
under
the sliding door.
- On the Pick-.up the jack is placed under the mounting of the trailing arm (triangu­lar mark) at the rear.
- If the
jack
is not
placed
at the
marked
points, the
vehicle
can be

damaged.

120
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DO-IT-YOURSELF
Fuse
layout

<*'om
left
to
right)

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

5-
Windscreen wiper,
windscreen and rear window

washer/elec.
heated

washer
jets 15

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

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

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

12-
High beam
right
10

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

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

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

15-
Engine electronics 10

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

17-
Turn signals 10

18-
Electric fuel pump,

Lambda
probe 20

19-
Radiator fan, air conditioner 30

20-
Brake lights 10

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

clock,
radio,
central locking 15

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

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

Glow
plugs21 50
• Under the driver's seat

Fuse
for additional water heater 10

Fuse
for heater blower .30

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

Red:
10 Ampere

Blue:
15 Ampere

Yellow:
20 Ampere

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

123
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DO-IT-YOURSELF
Changing bulbs

Before
starting to replace a bulb, switch off
the light concerned.

Do
not touch the glass part of the new bulb

with
bare fingers because the finger marks
left
on the glass evaporate when the bulb

becomes
hot, the vapour settles on the re­
flector and dims it.

Always
use the same type of bulb. The
des­

ignation is marked on the base of the bulb
or on the
glass.

It is advisable to always a carry a box of

spare
bulbs in the vehicle. These can be ob­
tained from Volkswagen dealers. It should contain at least the following bulbs which
are essential for traffic safety:
12 V 60/55 W Headlight (H4)

12V21W
Turn signal

12V21/5W
Brake
and tail light
12 V4W
Side
light

12V5W

Glass
base
Number
plate light
Headlights

The
headlight bulbs can be reached through
the opened bonnet.
• Pull off the connector.
• Pull cap off.
•
Squeeze
the spring clip of the bulb holder together and pull down.
• Take the bulb out and insert the new bulb
so
that
the locating lug on the bulb plate en­

gages
the recess in the reflector. The centre
of the three terminals on the bulb base is
then at the top.
• Fold the spring clip over bulb
base.
Squeeze
the clip together and engage it in
the retaining lugs.
•
Press
the cap back on.
• Attach the connector.
• Have the headlight beam alignment
checked.
Side
light
bulb

The
side light bulbs are located in the head­ light reflectors.
• Turn the bulb holder fully to the
left
and take it out of the reflector.
•
Press
the defective bulb into the holder,
turn
it to
left
and take it out.
• Insert the new bulb.
• Insert the bulb holder in the reflector and
turn
the holder fully to the
right.

124
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DO-IT-YOURSELF
Tow
starting/towing

General
notes

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

Tow-ropes
or bars should be attached at

these
points only.

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

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

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

Avoid
excessive towing
effort
and do not

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

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

or
towed
at any
time,
the
following

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

hicles.

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

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

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

screen
wiper and washer can be
used.

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

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

be
towed
with
driving wheels lifted.
132
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