catalytic converter VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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CONTROLS AND EQUIPMENT

Starting
the
engine

General
hints
Attention

When
starting
the
engine
in con­

fined
spaces
there
is a
danger
of poisoning.
• Before starting, move gear lever to neu- ml
(with
automatic gearbox, selector lever -
"P"
or "N" position) and apply handbrake
I 'mly.
• On vehicles
with
a manual gearbox de-
:"9ss
the clutch pedal when operating

=:arter
so
that
starter only has to
turn
en­
gine.

• As soon as engine starts, release the gnition key so
that
starter can disengage.
• After starting a cold engine it may sound
_oisy
for a moment or two because the oil pressure has to build up in the hydraulic
tappets
first.
This is normal and no cause for
a
arm. Do not
warm
engine
up by run-
W>
ning
it
with
vehicle
stationary.
Drive
off
straight
away.

Do
not overrev or use
full
throttle
until the
engine has reached the normal operating
Temperature. • On vehicles
with
a
catalytic
con­

verter
the
engine
must
not be

started
by
towing
the
vehicle
in ex­

cess
of 50 m.
Otherwise
unburnt

fuel
can pass
into
the
converter
and
lead
to
damage.

•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see
page
130.
Petrol
engines

These
engines are equipped
with
a cer: ~-
jection system
that
automatically s^c; es the correct fuel/air mixture at ail anc e~:
temperatures.

When
engine is cold or at
operating

temperature
do not accelerate before or
during the starting procedure.
Applicable to all engines:
If the engine does not start at once, stop

using
the starter after 10
sees,
wait about
half a minute and then try again. If the engine still does not start, the electric
fuel pump fuse may have blown - see page
122.

When
the engine is
very
hot it may be
necessary
to accelerate slightly after the
engine has started.
37
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CONTROLS
AND EQUIPMENT

Stopping engine
•
Applies to all engines: I*I"en engine has been running fast

•:'
a long time, let it idle for about
2 —inutes so
that
it can
cool
down
:
ghtly before being switched off.
Attention
After the engine has been

stopped
the fan can continue
running for a
while
(up to about 10 minutes)
with
the ignition
switched off. It can also
start
to
run again suddenly
after
a short

time
if

-
the coolant temperature in­
creases
due to
heat
build-up

-
when engine is hot and the en­ gine compartment is heated
additionally by strong
sun­
light.

Special
care must therefore be
taken when working in the en­ gine compartment.
•
Applicable to vehicles
with
cata­
lytic converter *:

The
ignition must not be switched off as long as the vehicle is rolling

with
a gear engaged, otherwise, un- burnt fuel can
pass
into the catalytic
converter and cause damage.
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DRIVING
TIPS

The technical
prerequisites

"or
a low fuel consumption and efficiency were "built in" at the factory. Particular im­
portance was placed on the lowest possible

disturbance
to the environment. To retain

and
make the best possible use of these
characteristics
attention should be paid to
the following points:

Vehicles
fitted
with
a
catalytic

converter
may
only
be
driven
on

unleaded
petrol.

Even
those
vehicles
which
do
not
have
a
catalytic
converter

should
be
driven
on
unleaded
petrol
for the
sake
of the
environment.

The
prescribed
maintenance

operations
should
be
carried
out

exactly
as
specified
in the
Service
Schedule - see
also
page
93.
Having your vehicle regularly serviced by
a Volkswagen dealer not
only
ensures
that
it is always operationally fit, but it
also ensures economy, lowest possible burden on the environment and a long
service
life.
Check the
tyre
pressures
every
4

weeks.

Low
tyre
pressures increase the rolling

resistance.
This not
only
increases the

fuel
consumption and
tyre
wear,
but the
handling is also impaired.
Do not
carry
unnecessary
ballast

in the
luggage
boot

Particularly in
town
traffic
when one has to accelerate
often,
weight
has a
great
in­
fluence on the
fuel
consumption. As a

rule
of
thumb:
For every 100 kg of
weight

the consumption increases by approxi­
mately
litre
per 100 km.

Remove
roof
rack
immediately

after
use
Particularly at
high
speeds the increased
air resistance makes
itself
felt
consider­

ably.

gCK
Electrical
consumers
should
only
be
switched
on
when
they

are
actually
required

Heated rear windows, additional driving

lights
and heater blower consume a con­
siderable amount of
current.
The higher
alternator
load
also increases the
fuel

consumption. For instance, over a period of 10 hours, the heated rear window
will

increase
the
fuel
consumption by ap­
proximately 1
litre.
Check the
fuel
consumption
reg­

ularly

The
fuel
consumption should be checked
each
time
the
tank
is
filled
up. By doing
this
inconsistencies on the vehicle which
lead to an increased
fuel
consumption
can be discovered sooner.
• Check the
engine
oil
level
each
time
the
tank
is
filled
up

The
oil consumption depends to a great ex­

tent
on the engine load and
speed.
Depend­
ing on the style of driving the consumption

can
be as much as 1.0 litres/1000 km.
It is normal for the oil consumption of a new

engine
to reach its lowest level after a cer­
tain mileage has been covered. The
con­
sumption cannot be properly
assessed
until
the vehicle has run approx. 5000 km.

This
also
applies to the fuel consumption
and
the engine output.
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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
Fuel

Petrol
engines
Vehicles
with
catalyst

62 and 81 kW Fuel
injection
en­
gines
Unleaded
regular
petrol

RON11 not
lower
than
91

rQp
On
vehicles
with
catalytic
con-
<35
verter
only
unleaded
petrol
may
be
used.

The
use of leaded petrol is very detrimental
to the functioning of the emission control
system
because the lead is deposited in the
catalytic converter.
rijK
Even
one
tankful
of
leaded
pet-
®5
rol
will
detract
from
the
effi­

ciency
of the
catalytic
converter.

Although unleaded fuel may again be used
afterwards the original efficiency of the
catalytic converter is never fully attained.
On
vehicles
with
Lambda probe2' the mix­
ture formation is also negatively affected.
11
Octane
Number, indicates the ignitability of
Diesel

2) Lambda = Air/petrol relationship Vehicles
without
catalytic
con­

verter

62 kW
Carburettor
engine

unleaded
or leaded
regular
petrol

RON1) not
lower
than
91

i-Op
In the
interests
of our
environ-

ment
unleaded
petrol
should
be

used
whenever
possible.

Notes

• Unleaded petrol must comply
with
DIN3' 51 607 and leaded petrol
with
DIN 51 600.
• Only good quality petrol containing addi­ tives should be used - see also" Petrol addi­

tives"
next column.
• If in an emergency the octane rating of the available petrol is lower than
that
re­quired by the engine, only drive
with
me­
dium engine speeds and low engine load­
ing.
High
engine
loading
with
full

throttle
or
high
revs
can cause en­
gine
damage.
Fill tank
with
petrol of the
correct rating as soon as possible.
31 Standards issued by the German Standards Institution.
Petrol
additives

The
quality of the fuel has a decisive influ­
ence
upon the running behaviour, perform­

ance
and service life of the engine. The addi­
tives which are mixed into the petrol are of particular significance. One is advised
therefore only to use good
quality
pet­
rol
containing
additives.

If such fuel is not available, or if engine
troubles such as starting difficulties, stalling during idling, vibration and loss of power
occur,
the appropriate additives should be
mixed
with
the petrol when filling the tank.
At temperatures between about 0 and 15
degrees
C, these additives prevent possible icing up of the carburettor, have an anti-cor­
rosion effect, clean the fuel system and pre­
vent deposits building up in the engine.

Petrol
additives available in accessory
outlets have not all shown themselves to be
effective. Therefore additives which have

been
tested for
Volkswagen
engines are av­

ailable
from Volkswagen dealers in
Ger­
many and in many export countries. The

Volkswagen
dealers are also informed
with
regard to the use of additives, and they know what to do in
cases
where deposits

have
already built up.

SB
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GENERAL MAINTENANCE
ing should only
be
carried
out in a
workshop
or
filling
station.

Undercoating

The underside
of
the vehicle
is
coated with
a special compound
to
protect
it
from cor­ rosion and damage.
However,
as
this protective layer becomes
damagedwhen the vehicle is in use, the pro­
tective coating under
the
body and
on the
running gear should be examined at defined
intervals
-
preferably before
and
after
the

winter season
- and any
damage made
good.

Volkswagen dealers have stocks
of
the cor­ rect compound, have
the
necessary equip­
ment and
are
familiar with
the
application
procedure. We advise you therefore to have
the patching
up or
additional coating done by
a
Volkswagen dealer.
Note
for
vehicles
with
a
catalytic

converter

Due
to
the high temperatures which occur
in the afterburning process, additional heat
shields
are
fitted over
the
catalytic
con­

verter. Underbody sealant must
not be
applied
to
these shields,
the
catalytic
con­

verter
or
the exhaust pies. Removal
of the
heat shields
is
also
not
permissible.
Cavity preservation

All cavities
on the
vehicle which could
be
susceptible
to
corrosion
are
given perma­
nent protection
at
the factory.
This coating does not need checking or any subsequent treatment. Should
a
smal
amount of wax run out of the cavities at high
ambient temperatures
it can be
removec
with a plastic scraper and some white spirit

QCK
If the wax
which
has run out is
<35 removed with clean
petrol,
heed
the environmental protection
regu­

lations.
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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
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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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

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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