VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual
Manufacturer: VOLKSWAGEN, Model Year: 1992, Model line: CARAVELLE, Model: VOLKSWAGEN CARAVELLE 1992 T4 / 4.GPages: 164, PDF Size: 25 MB
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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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