1992 VOLKSWAGEN CARAVELLE engine oil

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GENERAL
MAINTENANCE
Arduous
operating
conditions
ne vehicle construction and equipment is
resigned for normal operating conditions.
his also applies to the frequency and the
extent of the maintenance laid down in the
service
Schedule.
f the vehicle is used in arduous operating
conditions (e.g. continuous trailer towing,
exceptionally high or low ambient tempera-

:ures,
very dusty conditions, poor quality

ruel,
etc.) it may be necessary to carry out
special
technical preparations, such as ;hanging the oil to the appropriate viscosity, ^stalling special air cleaners, modifying the
ignition timing etc. Furthermore, the main­
tenance must also be matched to the oper­
ating conditions - see also page 93.
Driving
abroad

If the vehicle is to be taken abroad, the fol­
lowing must also be borne in mind:
• If the vehicle has a catalytic converter, one must ensure
that
unleaded petrol will be available during the journey - see
page 86.The automobile clubs offer infor­ mation about the unleaded filling station
network.
• Although there are more than 10 000
Volkswagen
dealers all over the world to
service
Volkswagen vehicles there are
countries in which only a limited amount of

service
is available or none at all.
• In certain countries it is also possible
that
your vehicle model is not soid so
that
certain
spare
parts will not be available or
that
the

Volkswagen
personnel are not familiar
with
the repair procedure should anything go
wrong.
The Volkswagen
Sales
Centres in Germany or the
Importer
concerned will be only too
pleased
to give advice on the necessary
technical preparation of the vehicle, on the maintenance required and on the repair

possibilities.

The addresses are given in the vehicle 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
areas on the headlight lenses must be masked - see page 129.

Driving
on
holiday

Before starting off note the following
points:
• The roadworthiness and driving safety are particularly important when on holiday-

see
page 78.
• With a fully laden vehicle and/or roof rack, the handling changes. The driving
style must be adapted to the different condi­
tions - more information on loading is given
on page 28.
The
tyre
pressures must be checked - see
page147.

• When a trailer is to be towed, there are many special points to note - see page 81.
• If an oil change or an Inspection Service
is
probably going to become necessary dur­
ing the
trip,
it is advisable to have this work
done before going on holiday if possible.

115
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GENERAL
MAINTENANCE

Winter
driving
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In winter the following points should be
noted:
• Winter weather is particularly hard on the
battery
and it should therefore be
checked,
preferably by a Volkswagen
dealer, before the onset of cold weather. If the vehicle is not driven for several weeks
when the temperatures are very low, the
battery
should be taken out - for
further
in­
formation see page 107.
• On a vehicle
with
a Diesel engine, winter
Diesel
must be used at temperatures below
0 degrees C - see page 87.
• The water should be drained out of the
Diesel
fuel
filter
before the onset of
winter.

This
operation is also included in the Lubri­ cation
Service.

• The anti-freeze in the cooling system should be checked before the cold
season
starts - see page 101.
• The engine oil viscosity must be correct for the ambient temperature - see page 99.
• Particularly in
winter,
frequent washing and waxing of the vehicle is the best way to protect it against harmful environmental in­

fluences.
• In winter the windscreen washer
sys­

tem should always be filled
with
a window
cleaning solution containing an anti-freeze
additive.
• To remove snow and ice
from
the win­ dows and mirrors, a plastic scraper should be used - see page 90.
• The road holding and handling can be im­ proved in winter road conditions by the use
of winter or All-weather tyres - see pages 114and146.
• When driving in mountainous districts in winter it is advisable to take snow chains

with
you. On some such roads, snow chains
are obligatory - see also page 114.
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DO-IT-YOURSELF
- Wind jack arm up by turning the crank handle
until
the jack
just
goes under the

vehicle.

- The claw of the jack must fit round the vertical rib on the side member so
that

the jack cannot slip when vehicle is
lifted

- see illustration.
- If the ground is soft, place a large strong
piece
of packing under the jack base
plate.
- Align jack and at same time wind claw up
further
until
it contacts the vertical rib on
side
member. •
Lift
vehicle
until
the defective wheel is

clear
of ground.
• Remove wheel bolts and place them on
a
clean surface (hub cap, cloth, paper) next
to the jack and take the wheel off.
• Fit spare wheel and lightly tighten all bolts. The wheel bolts must be clean and

easy
to
turn
- do not under any circum­

stances
use grease or oil!
• Lowervehicleand fully tighten bolts indi- agonal sequence.
• Refit the wheel trim.
•
Place
defective wheel in spare wheel carrier and secure it - see page 119.

Notes

• Pay attention to the following after changing a wheel:
- Check the
tyre
pressure immediately on the spare wheel which has been fitted.
- Have the tightening torque of the wheel bolts checked
with
a torque wrench as

soon
as possible. The torque for steel
and alloy wheels is 160 Nm. If it has been established when changing
the wheel
that
wheel bolts are corroded and hard to screw in, they must be renewed be­
fore checking the tightening torque.
Until these checks have been carried out
one should, for safety reasons, only drive at

a
moderate
speed.

• The defective wheel should be repaired
as
soon as possible.

Attention
If the
vehicle
is to be
subsequent­
ly
fitted
with
wheels
or
tyres

which
differ
from
those
fitted
by
the
factory,
it is
essential
to
read

the
remarks
in the
centre
and
right
hand
columns on
page
113.
121
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DO-IT-YOURSELF

Adjusting
headlights
I he setting of the headlights is very import­
ant to traffic safety. The adjustment should
tnerefore only be done
with
a special
appliance.
Note official regulations when
setting headlights.
On vehicles
with
beam
control* the
knurled disc on the instrument panel must

be
in the
basic
position (-).
Both illustrations show the adjustment on
the
right
hand headlight. On the
left
hand headlight the adjustment is symmetrically

opposite.

Main
headlights

The
headlights are adjusted from the
front

with
a suitable Phillips screwdriver
(from
ve­
hicle
tools). The bonnet must be released or

open..

A
- Vertical adjustment
Turning clockwise lowers the headlights.
B
- Lateral adjustment
PIPS
|B7Q-
)55|

Fog
lights*

The
front
foglights are adjusted by a knurled
wheel mounted on the foglight behind the bumper. To adjust, push the
flat
end of a
screwdriver through the opening adjacent
to the foglight (see Fig.) and rotate knurled

wheel.

On
vehicles without a spoiler the knurled
wheel can also be turned by hand.

To
reduce the beam range,
turn
screwtothe
left.

128
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DO-IT-YOURSELF
Tow
starting

The
following
points
must
be
noted
when
tow
starting:

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

burnt
fuel
can pass
into
the con­

verter
and cause
damage.

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

gearbox
is not possible.
Towing

When
towing
vehicles
with
an
auto­

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

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

gears
in the automatic gearbox then
turn
at

such
high speeds
that
the gearbox will be

severely
damaged in a short time.

Does
not apply to 50 kW Diesel engine
with

catalytic converter

133
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TECHNICAL
DESCRIPTION

Engine
• 4 stroke petrol/Diesel engine, trans­
verse
installation
• 4/5 cylinders in-line
• Cast-iron cylinder block
• 5/6 bearing crankshaft
• Sheet metal sump
• Alloy cylinder head
• Valves operated via toothed belt and overhead camshaft
• Maintenance free valve gear
with
hy­ draulic tappets
• Cooling system filled for life of vehicle
• Radiator
with
separate expansion tank • Electric radiator fan controlled by ther-
moswitch
• Maintenance free electronic ignition
• Long-life spark plugs
• Optical and acoustic oil pressure warn­ ing
• Low maintenance battery
with
high starting capacity
• Long-life low maintenance V-belts
• Thermostatically controlled intake air preheating
• Dry air cleaner
with
paper element • Fuel
injection
engines
have fully
electronic engine management (combined
control of injection and ignition systems).
• Emission control system
with
Lambda probe on petrol engines (not in all Export
markets)
•
Diesel
engines
with
distributor injec­
tion
pump
with
cold start aid,
filter
preheat­
ing,
self-bleeding fuel system
• Long life exhaust system.
'36
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TECHNICAL
DESCRIPTION

Emission
control
system<122>

The exhaust emission control system effec­
tively reduces
the
amount
of
pollutants
in

the exhaust gas.
Petrol
engines

The main parts
of the
emission control
sys­

tem
are

•
a
mixture formation system which guar­ antees very exact composition
of
the air/pe­

trol
mixture
at all
engine speeds
•
the
catalytic converter
•
the
Lambda probe1'
The
catalytic
converter
is
installed
in

the exhaust system.
It
consists
of a
steel-
cased
ceramic
or
metal body containing
a
multitude
of
longitudinal
passages
which
are vapour coated
with
a
thin
layer
of
plati­
num
or
rhodium.
The exhaust gas flows through
the
catalytic converter
and
reacts
with
an
afterburning
process
when
it
contacts
the
precious
metal coating.

Lambda
=
Air/petrol relationship
)B19-
129
In
this process three pollutants (three-way
catalytic converter)
are
converted
as
fol­
lows.

• Carbon monoxide
to
carbon dioxide
• Hydrocarbons
to
water
• Nitrogen oxide
to
nitrogen
(four
fifths
of
the
air we
breathe
is
nitrogen).

A
stipulation
for the
proper functioning
of

the catalytic converter, however,
is
that
the
exhaust gas has
a
certain specific composi­

tion
and
minimum temperature when
it

enters
the
catalytic converter. To obtain this
composition, exact regulation
of the
fuel/air mixture
is
required. Avery exact regulation

is
obtained
with
a
Lambda probe. The Lambda
probe*
is
fitted
in the ex­

haust pipe where
it
measures
the
exhaust

gas
composition continuously. The informa­

tion
signal
is
fed
to
an electronic control
unit

which
in
turn
regulates
the
mixture forma­

tion
system so
that
the
mixture
is
kept
con­

stantly correct.
The exhaust emission control system tech­ nology
is so
well developed
that
no
addi­
tional maintenance whatsoever
is
required.

To
maintain
the
effectiveness
of the
emission
control system,
the
following
must
be
noted:
• Only
fill
up
with
unleaded petrol
- see
page
86.

• Never
run
tank completely empty
-
see page
85.

•
Do not
overfill engine
oil -
see page
98.

•
Do not
switch
off
ignition whilst driving - see page
39.

•
Do not tow
start vehicle
for
more than 50 m-see page 133.
137
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TECHNICAL
DESCRIPTION

Power
flow

Manual
gearbox

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

Automatic
gearbox*

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

Steering

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

Front
axle

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

Rear
axle

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

sorbers.
Brakes

• Hydraulic dual circuit brakes
•
Disc
brakes at
front

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