1992 VOLKSWAGEN CARAVELLE maintenance

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GENERAL
MAINTENANCE

Winter
tyres
In winter conditions winter tyres will dis­
tinctly improve the vehicle's handling. This
applies
in particular to vehicles that are
equipped
with wide tyres.
Because
of their
construction (width, rubber mixture, tread
formation etc.) these tyres provide
less
trac­
tion on ice and snow.

When
fitting
winter tyres note the follow­

ing:

• Only radial ply winter tyres may be fitted.
The
factory recommended tyre
sizes
are
givenonpagel
46.
• To obtain the best possible handling
characteristics,
winter tyres must be
fitted

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 also be used in­
stead
of winter tyres.
• If you have a
flat
tyre the remarks on
using
the spare wheel on page 112 should

be
noted.
• Do not leave winter tyres
fitted
for an un­
necessary
long period because when the

roads
are free of snow and ice the handling
with summer tyres is better.
For
environmental
reasons

summer
tyres
should
be
fitted

again
as soon as possible
because
normally
they
are
quieter
in
running,
tyre
wear
is
reduced
and the
fuel

consumption is
lower.
Snow chains
Snow chains may only be
fitted
on
the
front
wheels.

Snow
chains must not be
fitted
on 215/65 F
16
tyres. When
necessary
the vehicle mus:

be
equipped with smaller tyres - see

Wheels,page146.

Only
use thin chains which do not stanc

clear
more than 15 mm (including ten-

sioner).

When
using snow chains wheel
trim
plates
and
trim
rings must be taken off. For safet
reasons
the wheel bolts must then be f ittec
with caps which are available from
Volks­

wagen
dealers.

When
driving over roads which are free of
snowyou
must remove the
chains.
On such
roads
they are detrimental to vehicle handl­

ing,
damage the tyres and wear out quickly.
In Germany, the maximum permissible

speed
with snow chains is 50 km/h.
114
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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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Accessories,
modifications
and
renewal
of
parts

The Caravelle/Transporter is
built
in accord­
ance
with
the most modern principles of
safety technology and offers therefore a nigh degree of active and passive safety. To
ensure
that
this remains so the vehicle as supplied by the factory may not be modified
without
careful thought. The following
points must be noted if the vehicle is to be subsequently
fitted
with
accessories,
technically modified or have parts renewed ater on:
• Always consult a Volkswagen dealer be­
fore
purchasing accessories and
before
any modifications are carried out because
through close cooperation
with
us the Volk­
swagen
Organisation is particularly com-
oetent in such matters.

Attention
In
your
own
interests
we recom­

mend
that
only
genuine
acces­
sories or
only
expressly
approved

Volkswagen
accessories1 and
Genuine
Volkswagen
Parts
are used on
your
Caravelle/Trans­

porter.
The
reliability,
safety
and

suitability
of
these
accessories
and
these
parts
has
been

specially
determined
for the Ca­
ravelle/Transporter.
•
Despite
continuous
market
ob­

servation
we
cannot
assess or ac­

cept
responsibility
for
other

products
even
though
in some
cases
approval
has
been
given
by
a
legally
appointed
test
centre
or
an
official
permit
has
been
given.
• Approved Volkswagen accessories and
Genuine
Volkswagen Parts can be obtained
from Volkswagen dealers who will of
course
carry out the
fitting
correctly.
• Additionally connected electric
con­
sumers
e.g. cold box, horns, fans etc. must
correspond to the electromagnetic com­patibility as per DIN VDE 40 839. Otherwise
functional defects can occur in the vehicle.
• If technical modifications are to be
made,
our guidelines must be observed.

This
is to ensure
that
no damage occurs to
the vehicle, the
traffic
and operating safety
is
retained and
that
the modifications are

permissible.
Volkswagen dealers will also
carry out this work correctly or will recom­ mend a specialist workshop.
GENERAL
MAINTENANCE

Mobile
telephones
and
two way
radios

Mobile
telephones
CT.-.-5:
:5 -
not be operated ms ;e:"f .r' : ; ~ :•_

a
separate external aer a
When transmitting,
tress
azz a:5s ate high frequency energy. :a~
for physical reasons nana \; ' sheet metal body and are
'e~e::5;
~s :•
the body.

Attention
Mobile
telephones
and
two-way

radios
operated
inside
the ve­

hicle
without
a
separate
external

aerial
can be
injurious
to
healthl

Notes

• The
high
frequency
transmitting
energy
radiated
inside
the
vehicle

can
interfere
with
the
functioning
of
the
vehicle
electronics.

For
these reasons and to avc z "55" :: ~z
the operating range of the rroc
e:5er:"a

or two-way radio, a specie
external
:•. :
must be
fitted
to the vehicle.
Not available in all Export markets.
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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

Attention
Due to high temperatures which
can occur in the catalytic
con­

verter in very unfavourable conditions, the vehicle should not be parked so that the catalyt­
ic converter can come into
con­

tact with inflammable materials.
If whilst driving, the engine mis­
fires, loses power and runs uneven­ ly,
this
could be due to a fault in the ignition system. In a
case
like this,
unburnt fuel can enter the exhaust
system and then escape to atmos­
phere.
Furthermore, the catalytic
converter could become damaged
due to overheating. The vehicle
speed must be reduced immediately
and the defect should be eliminated
at the nearest Volkswagen dealer.
Note
Even
in the
case
of a
perfectly working
ex­

haust emission control system there can, under certain engine operating conditions,
be
a
sulphur-type exhaust
smell.

This
depends upon
the
sulphur content
in
the fuel being
used.
Quite often this can
be
remedied
by
select­
ing another brand
of
fuel
or,
filling
up
with

unleaded premium petrol.
50
kW
Diesel
engine

An
oxidation catalytic converter
is
fitted
in

the exhaust system
of
this Diesel engine.
It
consists
of
a steel-cased ceramic body
con­

taining
a
multitude
of
longitudinal
passages

which are vapour coated
with
platinum. The catalytic converter largely eliminates
the
unpleasant smelling hydrocarbons
and

turns carbon monoxide
into
carbon dioxide.
In addition
an
exhaust
gas
turbocharger
forces
air
into
the
cylinder, causing
the
en­
gine
to
operate
with
a high
excess
of
air. The
fuel which is then injected in is so complete­ ly
burnt,
that
under
full
load soot is no longer
visible
in the
exhaust.

As
the
diesel engine catalytic converter
does
not get
hotter than
a
conventional
ex­
haust system, under normal conditions
there
is
nothing special
to be
noted, this

applies
also
to
parking.
The system does
not
require any additional

care
or
maintenance.
Activated
charcoal
filter*

Vehicles
with
a
regulated catalytic
con­

verter,
in
Germany
and
other export countries, have
a
fuel system which
in­

cludes
an activated charcoal
filter
(petrol va­pour accumulator).
The activated charcoal
filter
prevents
the

fuel vapour escaping
into
the
atmosphere.

These
vapours
pass
into
a
container filled

with
activated charcoal and, when
the en­
gine
is
stationary they
are
accumulated
in

the activated charcoal. When
the
engine
is
running,
the
container
is
automatically
ventilated
by
opening
a
valve
and the
fuel
vapour
is fed
into
the
engine
for
combus­
tion.
The system works completely automati­

cally
and
is
maintenance-free.
138
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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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