VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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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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TECHNICAL
DESCRIPTION

Body
• Unitary construction body/ chassis • Floor frame reinforced by side and cross members
• Long term body protection
with
special high-quality materials-this makes possible
the long warranty period for paint defects
and
rust penetration (see Service Schedule)
Environment
compatibil­

ity Protection of the environment played a de­

cisive
role in the construction, selection of materials and manufacture. Amongst other
things special attention was given to the fol­ lowing points:

Constructive
measures
for econ­
omic recycling
• Disassembly-friendly design of joints
•
Easier
disassembly by modular
con­
struction methods
• Improved
purity
of materials
• All larger plastic parts marked in accord­
ance
with
VDA recommendation 260.

Selection
of
material

• Refrigerant for air conditioner*
CFC
free
• Materials which can be recycled are
used
as far as possible
• Use of similar plastic
within
an assembly group
• Use of materials which have been re­
cycled

• PVC not
used,
when possible to use an alternative material
• No Cadmium
• No Asbestos
• No leaded paint
• Reduction in vapours emitted by plastics
Manufacture

• Recycled material used for the manufac­
ture
of plastic parts
• Solvents abandoned for the cavity
seal­
ing
• Use of water based paints
• Solvent free transport preservation • Use of solvent free bonding agents
•
CFCs
abandoned as far as possible dur­ ing manufacture
• Surplus material recycled as far as
poss­
ible to gain energy and manufacturing sup­

port
materials
• The water required during manufacture
is
reprocessed.
140
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TECHNICAL DATA

General information
Where
not
otherwise indicated
or
listed separately,
all the
following
technical data
is for
standard
ve­
hicles
in
Germany. For special vehicles
and
vehicles
for

other countries these figures
may be

different.
Please note that
the
details
in the

official vehicle documents
can be

taken
as the
correct figures. Which engine
is
fitted
in
your
ve­

hicle
can be
found
in the
vehicle
data
in the
Service Schedule
or in

the official vehicle paperwork.
ENGINE DATA
Output11

kW
(BHP)
at
rpm
Maximum

torque

Nm
at rpm
Num­

ber
of

cylin­
ders
Ca­

pacity

cm3
Stroke

mm
Bore

mm
Com­

pres­
sion
Fuel2'

Petrol engines
with regulated
catalyst 62 (84)
/
4300

159/2200
4

1968
95.5
81.0

8.5
91
RON
unleaded
Petrol engines
with regulated
catalyst
81
(110)/4500

190/2200
5
2461
95.5
81.0

8.5
91
RON
unleaded
Diesel engines 45 (61)/3700

127/1700-2500
4

1896
95.5 79.5
22.5
Diesel

Diesel engines

503>
(68)
/
3700
140/2000-3000
4
1896

95.5 79.5
22.5
Diesel

Diesel engines
57 (78)/3700
164/1800-2200
5
2370
95.5
79.5 22.5
Diesel

Petrol engines
without cata­
lyst41
62 (84)
/
4300
1 59/2200 4
1968

95.5
81.0

8.5
91
RON
unleaded/leaded

11 According to EC or DIN regulations. Due to different methods of measuring, slight
deviations are possible. 21 For further details -
31 With catalyst see page 86.
4) Only for some export countries
141
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TECHNICAL DATA

Performance

Maximum
speed flaps,
very
wide
tyres
etc. which affect the

in
km/h performance.
The performance figures were measured
without the vehicle being fitted with any
equipment
such as air conditioner, mud
Caravelle, Kombi,
Multivan,

Delivery van
Pick-up

High
roof Kombi,

High
roof Delivery van
Double
cab

Petrol
engines
with
catalytic
converter

62 kW Manual gearbox 144 128
137 132
81 kW Manual gearbox 158 142
151 146

Automatic
154
138 147 142

Diesel
engines

45 kW Manual gearbox 128 115
122 117
50 kW Manual gearbox 132 119
126 121
57 kW Manual gearbox 137 124
131 126

Automatic
133 120
127 122

Petrol
engines
without
catalytic
converter

62 kW Manual gearbox 144
128 137
132
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TECHNICAL DATA
Fuel
consumption

Passenger
vehicle
models

The consumption figures are determined
according to EC guideline 80/1268 EEC.
Three different conditions are used for the
test:
• The measurements for 90 km/h (56 mph) and • 120 km/h (75 mph) are carried out at

a
constant test
speed.

• For the
urban
measurement normal town
traffic
driving is simulated. Depending on driving style, road and
traffic

conditions, environmental influences and
vehicle condition, the figures obtained in actual practice may differ from those given.

All
figures were measured
with
standard
tyres. On vehicles
with
other tyres the fig­ ures will vary accordingly.
Consumption in litres per 100 km
Caravelle,
Kombi, Multivan
90 km/h 120 km/h Urban 90 km/h High roof Kombi
120 km/h Urban

Petrol
engines
with
catalytic
converter

62 kW Man. gearbox 9.1 13.7
14.4 10.1
15.2 14.9
81 kW Man. gearbox 9.4 13.4 15.9
10.4
14.9 10.4
Automatic
10.5
14.1
15.9
11.5
15.9

11.5

Diesel
engines

45
kW Man. gearbox 6.5
— 9.1
7.3
— 9.4
50 kW Man. gearbox 2)
2) 2)
2)
2!
2)
57 kW Man. gearbox 7.5 10.8 10.7
8.4
12.5
10.4
Automatic 8.6 12.7

11.5
9.6
—
11.5

Petrol
engines
without
catalytic
converter

62 kW Man. gaerbox 9.1
13.7 14.4
10.1 15.2
14.9

Only
applies to vehicles which have a top

speed
in
excess
of 130 km/h (81 mph). 21 The figures were not available at time of going
to
print.

143
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TECHNICAL DATA

Commercial
vehicle
models

These consumption figures were deter-
Tiined
in accordance with DIN 70030 Part 2
(July 1978 Edition) with half payload at a
constant 3/4 of top speed (but not more
than 80 km/h) plus 10 %. Depending on driving style, road and traffic
conditions, environmental influences and
vehicle condition, the figures obtained in
actual practice may differ from those given. All figures were measured with standarc

tyres.
On vehicles with other tyres the
fig­

ures will vary accordingly.
Figures ttr./l 00 km Delivery van
High roof Delivery
van Pick-up
Double cab

Petrol engines with catalytic converter

62 kW Manual gearbox 13.5 13.2
13.5 15.9
81 kW Manual gearbox 15.0 14.8
13.2 15.6
Automatic gearbox 14.7
14.6 15.5 15.6

Diesel engines

45 kW Manual gearbox 7.9 8.2 9.4
8.7
50 kW Manual gearbox ii
D
D
57 kW Manual gearbox 9.4 10.4
10.7 10.7
Automatic gearbox 10.8 11.9
12.3 1.3

Petrol engines without catalytic converter

62 kW Manual gearbox 13.5 13.2
13.5 15.9
31 The figures were not available at time of going to print.
144
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Spark
plugs

V-belts

The
spark plugs are renewed during the

Volkswagen
Inspection Service If the spark plugs have to be renewed be­
tween the Inspection
Services,
the follow­ ing should be noted:
• Engine, spark plugs and ignition system are matched to one another. To avoid faulty
operation and even engine damage only the
Genuine
Volkswagen spark plugs for the en­
gine concerned should be
used.
Important,

among other things, are the number of elec­
trodes, the heat value and if necessary the radio suppression.
• The plugs may be, for technical reasons,
changed
at short notice during the current model year. It is therefore advisable to ob­
tain plugs only from Volkswagen dealers -
they have the latest information

Engine
Genuine
Part
Number

62 kW 101 000 026AA/N 9 BMC
81 kW 101 000 001
AE/14-8
DTU
101 000 005
AE/W8
DTC
101 000 007AB/N7 BYC
101 000 027
AB/BP
5 ET • The V-belts are among the most severe­
ly stressed parts of a vehicle. The belts
must therefore be subjected to very high
quality requirements.
• When renewing a belt it is not sufficient to use
just
any belt of the same
size.
For
safe
operation only the special Genuine

Volkswagen
belt for the vehicle concerned
should
be
used.
The correct belts can be ob­
tained from Volkswagen dealers under the
Genuine
Part number given.
• The V-belts may be, for technical
rea­
sons,
changed at short notice during the
current model year. It is therefore advisable
to obtain V-belts only from Volkswagen
dealers
- they have the latest information.
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TECHNICAL DATA

Wheels

The tyre/wheel combinations in the table are valid for steel and alloy wheels. Details
on whether other tyres or wheels can be
used
can be obtained from Volkswagen

dealers.

For
winter tyres the most suitable tyre/
wheel combination is given. The winter
tyre
recommendation applies also to All-
weather tyres. Further remarks on the use of winter tyres are given on page 114.
Attention

If you
wish
to fit
your
car
with

non-standard
wheels
or
tyres

(e.g.
alloy
wheels
or
wheels
with

winter
tyres),
you
must
read
the

appropriate
notes
in the
centre

and
right
hand
columns on
page
113.
Snow
chains

Snow
chains may only be
fitted
on the
front

wheels.

Snow
chains
must
not be
fitted
to 215/65
R
15
size
tyres. If necessary smaller tyres
must be fitted.

Tyres
on
wheel
Winter
tyres/wheels

185
R14 C

99/97N
(or 99/97P)
5
1/2 J x14

185
R 14/5 1/2 Jx 14
195/70 R 15 97S reinforced 6 J x 15 205/65 R
1
5 / 6 J x 15
205/65 R 15 98S reinforced 6 Jx 15 205/65 R 15 / 6 J x 15
215/65 R 15 100T (or 102H) re­ inforced 7 J
x1
5
205/65 R
1
5 / 6 J x
1
5
146
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TECHNICAL DATA

Tyre
pressures
Attention

The
tyre
pressures
must
be
checked
at
least
once
a
month.

They
are
very
important
particu­
larly
at
high
speeds-see
page
110.
These
pressures are for cold tyres. When
tyres are warm the pressure is higher but do
not reduce it.
The inflation pressures are given on a sticker on the inside of the driver's door lock pillar. As the pressures may be altered at
short notice fortechnical reasons there may

Tyre
pressures
for
vehicles
with
a
permissible
axle
load11 on one
axle
of less
than
1285 kg
Tyres
Pressure
in bar
Front
Rear

Spare

185 R 14 C 97/99N (or 97/99P) 3.0 3.8
3.8
195/70 R 15 97 S reinforced 2.6 3.4
3.4
205/65 R 15 98 S reinforced 2.6 3.4
3.4
215/65 R 15 100 T (or 102H) reinforced 2.4 3.0
3.0

Tyre
pressures
for a
vehicle
with
a
permissible
axle
load11 on one
axle
of 1285 kg or
more

Tyres
Pressure
in bar
Front
Rear

Spare

185 R 14 C 97/99N (or 97/99P) 3.4
3.8 3.8
195/70 R 15 97 S reinforced 3.0 3.4 3.4
205/65 R 15 98 S reinforced 3.0 3.4 3.4
21 5/65 R 15 100 T (or 102H) reinforced 2.4
3.0 3.0 be differences between sticker and Instruc­

tion
Manual. If this should be the
case,
ask your Volkswagen dealer for the correct
pressures.

The permissible
front
and rear axle loads are givenonpage148.
147
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TECHNICAL
DATA

Weights

Vehicles
with
4
cylinder engines
(Figures for 5
cylinder engine
in
brackets)
Normal
payload
Wheelbase
Permissible Unladen weight
Payload
Permissible
Perm.
Perm.

(in
kg)
in
mm
GVW

(with
driver)
front
axle load rear axle
roof

(in
kg)

load
load2'

Caravelle
2920
2465
(2540)

156511
(1640)11
900
(900)

1350
(1430)
1300

100

3220
2565
(2640)
166511
(1740)1'

900
(900)
1430
(1520)
1300
100

lowered
suspension
2920
2365
(2440)

15651)(1640)1)
800
(800)
1280
(1350)
1200
100

Multivan31
2920
2500
(2540)
17051i(1780)l:'

800
(760)

1350
(1430)
1300

100

lowered
suspension31
2920

2430
(2505)
^os^mo)11
725
(725)
1350
(1430)
1200
100

Kombi
2920

2525
(2590)
15201,(1595)1»
995
(995)
1280
(1350)
1380
100

3320
2565
(2640)
15701'
(1645)1)

995
(995)
1350
(1430)
1380
100

High-roofed
Kombi
3320

2565
(2640)
16201,(1695)11

945
(945)
1350
(1430)

1380

-

Van
2920
2525
(2590)

1520
(1595)
995
(995)
1280
(1350)
1380
100

3320
2565
(2640)
1570
(1645)
995
(995)
1350
(1430)
1380
100

High-roofed
Van
3320

2565
(2640)
1620
(1695)
945
(945)

1350
(1430)
1380

-

Pick-up
2920

2465
(2540)
1470
(1545)

995
(995)
1200
(1280)

1380
50

3320
2525
(2590)
1520
(1595)

995
(995)
1280
(1350)
1380
50

Low
loader
3320

2525
(2590)
1520
(1595)

995
(995)
1280
(1350)
1380

50

Chassis
and cab
2920

2465
(2540)
1315
(1390)

-
1200
(1280)

1380
50

3320
2525
(2590)
1340
(1415)

-
1280
(1350)

1380
50

Double
cab
3320

2515
(2590)
1590
(1665)
925
(925)
1350
(1430)
1460
75

Chassis
with Double
Cab
3320

2515
(2590)
1460
(1535)

-
1350
(1430)

1460
75

Remarks
and
footnotes
- see
page
150
148
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