1992 VOLKSWAGEN CARAVELLE engine overheat

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CONTROLS AND EQUIPMENT

3edals
• e ~ cvement of the pedals must not be re-
:: :~is reason, do not put articles in the
—•".•.ell which could roll or slide underneath

—-E-
zedals.

•Vr^-d the pedal area there should not be •r. -;otmatsorotheradditionalfloorcover- •: -aterials:
• In the
case
of defects on the brake sys-
r~
3 greater pedal travel may be
necess-

• : should always be possible to depress
~3
: _tch and accelerator pedals fully.
• - pedals must be able to return, unhin-
z-z'^z.
to their rest positions,
""•e'efore, the only
foot
mats which may be
are those which leave the pedal area
::—oletely free and which are prevented . " slipping. Brakes
The following points are of particular import­
ance
to the safe operation of the brakes.
• New brake linings must also be run in and do not have the optimum
friction
prop­
erties during the
first
200 km. The slightly reduced braking effect can be compen­
sated for by more pressure on the brake

pedal.
This also applies when new linings have been fitted.
• 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 Volkswagen dealer but be prepared to use more pressure on the pedal
and allow for longer braking distances on
the way.
• The brake
fluid
level must be checked regularly-see page 105.
The brake warning lamp
will
come on to indi­ cate
that
the brake
fluid
level is too low (see

also
page 48).
• Brake lining wear depends to a large ex­
tent
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 by a Volkswagen dealer in between the in­
tervals given in the Service Schedule.
• Change down in good time when driving downhill, in orderto make use of the engine braking effect. This relieves strain on the
brake system. When the brakes are applied do not keep them on con::rjc_s , =" .
and release alternately.
• Under certain operating conditions, *c example after driving through water, a^e' 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 out
first
by applying
the footbrake.
The
full
braking effect may also be delayed when vehicle has been driven for some time
on heavily salted roads
without
using the
brakes,
because the layer of salt on discs
and pads has to be removed
first.

Attention
If a
front
spoiler,
full
size
wheel

trims
etc., is
retrofitted,
it is necessary to
ensure
that
the
flow

of air to the
front
brakes
is not re­

stricted
-
otherwise
the
brakes

can
overheat.
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CONTROLS AND
EQUIPMENT

Emergency
programme
~.~:;ional defects occur in the electronic
. ;:e~ the gearbox can, amongst other ' "is. carry on operating in two emergency
: ::_s~imes:
• Tre gearbox continues to change up and x ••- automatically as before but hard
shift
- 3 are however noticeable. The vehicle •<:- 3 be taken to a Volkswagen dealer.

~e
gearbox no longer changes up and - automatically.
"•= rearbox can then be shifted manually
:- tie selector lever positions "D", "3"
;': 2" only the 3rd gear is available.
- selector lever positions "1" and "R", the =: and reverse gears are available as nor-
-: .vever, the converter must, due to the ab-

;-s~ce
of 2nd gear
work
harder, and under
:e~ain
circumstances this
causes
the con- r~er to overheat. In a
case
such as this the
•eiide should be taken, as soon as
poss-
: e, to a Volkswagen dealer.
Selector
lever
lock

In positions "P" and "N"
with
the ignition
switch on the selector lever is locked. To move the selector lever out of these
posi­

tions the brake pedal must be depressed
and the selector lever
button
pushed-in.

This
prevents a gear being engaged inadver­

tently
and the vehicle unintentionally mov­ ing off.

A
delay circuit prevents the selector lever

from
locking when it is moved quickly past
the "N" position (for instance
from
"R" to
"D").
This enables for example the vehicle
to be "rocked" out of a "bogged down" position. The
shift
lock only locks the
selec­

tor lever if it is
left
in the "N" position for more than about
1
second
without
the brake
pedal being depressed.
At speeds above 5 km/h the selector lever lock is automatically switched-off in
posi­

tion
"N". In the dash panel there is a display tra:

shows
the currently selected selects' eve' position.

Selector
lever
positions

P -
Parking
lock

The driving wheels are locked mechanics .
The parking lock may only be engagec
the vehicle is stationary. Before mov -g :_e lever in or out of the "P" position tre" ::•

button
in the selector lever handle r-_s: re­

pressed.
Before moving the
se!e:::"

out of the "P" position, the ca-e ;e:s must also be depressed when 're z~;z~ ;
switched on.
11 Depending upon the rrc~e ~._e : s; = :;~
also
be
fitted
in the Cc~: e":
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CONTROLS AND EQUIPMENT

2
-
Coolant temperature
—
~~s
gauge starts
to
work
when ignition
is
=
.vitched on,
but it
takes some time before
~e needle reaches
its
final position.
-en ignition
is
switched
on the
warning
c~ip flashes
for a few
seconds
as a
func-

•
:nal check.

5
- Cold

-. Did
high
engine speeds and
do not
work

r-gine
too
hard
yet.

:
- Normal

nen
the
vehicle
is
driven normally
the

~eedle
should settle
down
in
this zone.
-en engine
is
working hard and the ambi-

r~t
temperature
is
high,
the
needle
may
-ove
a
long
way up. This is not serious as long as the
warning lamp does not flash.
Warning lamp
If
the lamp flashes when driving, check first
the indicated coolant temperature.

If the
needle
is in the
normal zone,
top the

coolant
up at the
next
opportunity.

If
the reading
is
in the upper zone, either the
coolant level
is too low or the
coolant tem­
perature
is too
high.
Stop,
switch
en­
gine off
and
try to
find cause
of
trouble
-

see
page 47.

Notes

•
Additional
lights
in
front
of the cooling air intake interfere
with
the

flow
of cooling air. At
high
ambient
temperatures and
full
throttle
there is a danger that the engine
will
then
overheat.
3
-
Digital clock
*

To
set the
time there
are two
buttons
on
lower left
of
instrument cluster.
The
hours
are
set
with
the
upper button
(h) and the
minutes
with
the
lower one
(min):

•
If
pressed briefly, preferably
with
a ball
pen,
the time changes one hour
or
one min­

ute.
•
If
pressed continuously the hours
or
min­
utes
change continuously.

With
the minute button the clock can be set exactly
to the
second:

•
Press button until time shown
by
clock
is
one minute before time
to be set.

•
Press button
at the
moment when
the
seconds
indicator
of an
accurate clock
shows a full minute
or
when the time signal
is
heard
on the
radio.
41
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CONTROLS AND EQUIPMENT

Auxiliary
heater*
To
switch heater on
•
Press
rocker switch D on rent.
• Select desired heat
with
knee -
The
green heater in-operatior. =~~" _
comes
on.
Regulating
heat

The
heat is infinitely adjustable
with
:~e knob A.
After heater has been switched on it takes

a
little
time before heat can be
felt.

When
the set temperature is reached, the green in-operation lamp becomes darker.

The
temperature is then held fairly constant by the heater thermostatically.
w-^
=
jxiliary heater works independently of
me .ehicle heating. It is supplied
with
fuel
I: rr the vehicle tank.
He suxiliary heater can be used continu­

es
. when on the move or stationary.
|r~? current is supplied from a 2nd battery.

r~T
air flows from the outlets behind the p*.er's seat.
k- the summer the heater blower can be

(sed
to circulate the air in the vehicle with-
it.: heat.
5v. itching on and off and regulating the aux-
tey heater are done from the control panel
r the dash panel.
-
a
timer* is
fitted
(see page 65) the control

panel
is located on the roof cross member I the passenger compartment.
A
BCD

[J70~-T971

Control
elements

A
- Regulating heat output
B
- Overheating indicator (red)

C
- Heater in-operation lamp (green)
D
-
Rocker
switch for switching heater on
and
off and operating blower without heat.
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CONTROLS
AND EQUIPMENT
To
switch
heater
off
• Move rocker switch D to centre position.
The
heater in-operation lamp C then goes out, but the biower continues to run for a
short time.

Note

The
warning lamp B flashes if the heater

overheats.
If this happens, check whether
the air intake or the warm air outlet are
blocked.
Switching
blower
on
without
heat

Press
rocker switch D on the
left.
The green
in-operation lamp C comes on.

Switching
off
• Move switch D to centre position. The in-operation lamp goes out.
Stipulation is
that
the heater is not being
controlled at the same time by the timer
(see
next page).

Attention

The
heater
must
be
switched
off in enclosed spaces and
when
fil­

ling
the
tank.

Notes

• Every time the heater is switched off the blower continues to run for a while to cool
the heater down quicker. When filling tank it is not necessary to wait to end of run-on.
• When driving cross-country or through mud or deep snow the heater exhaust pipe

can
become blocked. Before switching the heater on intheseconditions, check thatthe
pipe is clear. • The
following
official
regulation

is
applicable
in
Germany:

The
heat exchanger of the heater may be
used
for 10 years. After this period the heat

exchanger
must be replaced by a Genuine heat exchanger in a Volkswagen Dealer­

ship.
To enable this period of time to be monitored the year when the heater is taken
into use is marked on the maker's plate on
the heater (under vehicle floor).

The
Volkswagen dealer enters the date of
replacement on the plate on the heater.
64
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DRIVING
TIPS

• As the factory installation of a towing bracket includes the modification of the

cooling
system, this should also be done
when service installing a bracket. Other­

wise
overheating may occur when the en­ gine is pulling hard (mountains, high ambi­
ent temperature, heavy trailer loads).

Certain
vehicle versions can be equipped

with
a heavy-duty cooling system ex fac­

tory,
even though the vehicle is delivered

without
a towing bracket. Details can be ob­
tained from Volkswagen dealers.
• Volkswagen dealers have all the
necess­
ary information on the installation of towing
brackets
and the
fitting
of a heavy-duty

cooling
system. The installation should
therefore be done by them.
• If, when towing a trailer for commercial
purposes,
the permissible
total
weight of

vehicle
and trailer - also
with
passenger
cars
- exceeds 3500 kg, it is necessary to in­
stall and use a tachograph in most European

countries.
Operations
instructions

• When inserting the 13 plug
into
the
socket
on the vehicle, the ribbed sleeve on
the plug must be turned fully to the
right.

The
lid of the socket then engages over the
boss
on the
sleeve.

• If the
traffic
behind the trailer cannot be
seen
properly
with
the standard rear view mirrors, additional outside mirrors will be

necessary.
Both outside mirrors must be

fitted
on folding arms and adjusted to give
a
good view to the rear at all times.
• Pitching movements between towing
vehicle
and trailer can be reduced by heavy-
duty springs and shock absorbers on the rear axle. If these springs and shock ab­

sorbers
have not already been
fitted
at the
factory, they can, in many
cases,
be servi­

ce-installed
by a Volkswagen dealer.
• Pitching and snaking movements can
also
be reduced by stabilizers which can be
obtained from and
fitted
by Volkswagen
dealers
in most European countries. • The permissible trailer weight11 - see

page
151 -must not be
exceeded
on any
ac­

count.
• When towing a trailer in mountainous re­
gions,
note
that
the trailer weights given ir
the "Technical data" are only valid for gradi­ ents up to 10 or 12 %. If the trailer weigh'
is
below the permissible maximum a corre­
spondingly steeper gradient can be

climbed.

• The given trailer weights are only appli­
cable
for altitudes up to 1000 m above see
level.
As the engine
output
and thus the
climbing ability drops due to the decreasing
air density, the weight of vehicle and trailer must also be reduced by 10 % for eacr

further
1000 m or part thereof.
1 The permissible vehicle/trailer weight
con­
sists
of the permissible
total
weight of tow­ing vehicle plus the permissible
total
weight
of trailer. If the permissible trailer load is to be
fully utilized it may be necessary to reduce
the weight of the towing vehicle appropriate­ ly. The towing vehicle must however not be
lighter than the trailer.
82
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GENERAL
MAINTENANCE
Filling the
tank

The
filler neck is on the left-hand side of the

vehicle.

The
tank holds about 80 litres. Trouble-free
refuelling
calls
for correct
use
of filler
nozzle.

•
Insert
nozzle
fully into tank neck and do not
tilt
it.

On
vehicles with a catalytic converter the

spring-loaded
flap below the filler opening
must be
pressed
open with the filler
nozzle.

This
should
also
be noted when using a pet­ rol can to
fill
the tank. As soon as the
correctly
oper­

ated
automatic
nozzle
switches

off for the
first
time,
the
tank
is
full.

Do not try
then
to put
more
fuel
in
because the expansion space in
tank
will
be
filled
- the
fuel
can
then
over­

flow
when
it becomes
warm.

After
filling tank, screw cap on tightly and
lock
it.

Note

•
Never
drive
until
the
fuel
tank
is completely
empty
on vehicles
with

a catalyst. The
irregular
fuel
supply
can cause misfiring. This
allows
un-
burnt
fuel
into
the exhaust system.
Which can cause
overheating
and damage to the catalyst.

•
When carrying a spare can of petrol on the vehicle, official regulations must be ob­
served.
For safety reasons we advise you not to carry a spare can of petrol. In an
acci­

dent the can could become damaged and petrol
escape.

55
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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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