Gearbox VOLKSWAGEN CARAVELLE 1992 T4 / 4.G User Guide

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Fuse
layout

<*'om
left
to
right)

No.
Component
A11
' - Dipped beam
left,
headlight range control
left
10
I- Dipped beam
right,
headlight range control
right
10
3-
Instrument
and number plate lighting 10
--
Rear
wiper, seat heating 15

5-
Windscreen wiper,
windscreen and rear window

washer/elec.
heated

washer
jets 15

5-
Blower, air conditioner 30
/- Tail and side
light
right,
engine compartment
light
10

3-
Tail and side
light
left
10
9-
Rear
window heating, mirror heating 20

10-
Fog lights, rear fog
light
15
II- High beam
left,
high beam
warning lamp 10

12-
High beam
right
10

13-
Horn, radiator fan (run-on) 10
1 Ampere No.
Component
A

14-
Reversing lights, electric outside mirrors, sliding/tilting
roof,
shift pattern auto, gearbox,

cruise
control system
(cancel contacts on the brake
and clutch pedal) 10

15-
Engine electronics 10

16-
Warning lamps,
dash
panel insert,
glove box
light
15

17-
Turn signals 10

18-
Electric fuel pump,

Lambda
probe 20

19-
Radiator fan, air conditioner 30

20-
Brake lights 10

21-
Interior
and luggage compartment lights, make-up mirror
light,

clock,
radio,
central locking 15

22-
Cigarette lighter 10
Additional
fuses
(in separate holders)
• above the relays A11

Fuse
for electric windows 20
• In the engine compartment on the bulk­
head
above the brake servo:

Glow
plugs21 50
• Under the driver's seat

Fuse
for additional water heater 10

Fuse
for heater blower .30

Fuse
for water heater
glow plug 20
Fuse
for auxiliary heater3' 25
Fuse colour code:

Red:
10 Ampere

Blue:
15 Ampere

Yellow:
20 Ampere

Green:
30 Ampere
21 This fuse should only be renewed by
a
Volks­
wagen dealer.
31 On vehicles
with
swivelling seats this fuse
can
be found in the side
trim
behind the
driver's seat.

123
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Tow
starting/towing

General
notes

• "owing eyes are provided on the
right
under
front
and rear bumpers.

Tow-ropes
or bars should be attached at

these
points only.

On
vehicles
with
a factory
fitted
towing bracket a towing eye is not fitted. On those

vehicles
the towing bracket can be used for
towing.
• The tow-rope should be slightly elastic to reduce the risk of damage to both ve­
hicles.
It is advisable to use synthetic fibre

ropes,
or ropes of similar elastic material. It
is
however
safer
to use a
tow-bar!

Avoid
excessive towing
effort
and do not

jerk.
During towing operations on other than
surfaced
roads there is always the danger

that
the attachment points will be over­
loaded
and damaged.
•
Before
trying
to
start
engine
by
towing,
the
battery
from
another
ve­
hicle
should be used for
starting
if
possible - see previous page. If the
vehicle
has to be tow
started

or
towed
at any
time,
the
following

must
be noted:
•
Check
whether there are any local traffic regulations concerning the towing of ve­

hicles.

• Both drivers must be familiar
with
tow­ ing procedures. Inexperienced drivers

should
not attempt to tow start or tow.
• When using a tow-rope the driver of the towing vehicle must engage the clutch very gently when moving off and changing gear.
• The driver of the vehicle being towed must ensure
that
the tow-rope is always

taut.
• The emergency lights must be switchec
on on both vehicles - unless local regula­
tions differ.
• Turn ignition key to "Drive" position sc
that
the steering wheel is free and the
turr
signals,
horn, and, if necessary, the wind­

screen
wiper and washer can be
used.

• As the brake servo only works when the engine is running, considerably more pres­

sure
is required on the brake pedal when the
engine is not running.
• On vehicles
with
power assisted steer­ ing more force is required to
turn
steering
wheel when engine is not running.
• When there is no lubricant in the manua or automatic gearbox, the vehicle may only

be
towed
with
driving wheels lifted.
132
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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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Lifting
vehicle

Trolley
jack

To
prevent damage to the underside of the vehicle it is essential to use
a
suitable rubber

On
no account should the vehicle be
lifted
under the engine, gearbox,
rear axle or
front
axle as this can

cause
serious damage.
Attention
• With the vehicle
lifted
never start the engine - danger of
acci­

dent!
• If work has to be done under­ neath the vehicle, the vehicle
must be supported on suitable

stands.
Vehicle
lift

Before driving over the vehicle
lift,

ensure
that
there is adequate clear­

ance
between
lift
superstructure
and low parts on underside of ve­
hicle.

To
lift
the Caravelle/Transporter only
twin
column/pillar hoists
with
sufficiently long
support arms should be
used.

Only
as an exception - for short wheel base

vehicles
in unladen condition - can a single
column hoist be
used.

Hoists
with
fluid cushions (Repair reception hoists) must not be used
to
lift
this vehicle.
Lifting
points
for
workshop

hoist
and
trolley
jack

The vehicle may only be
lifted
at the poin:
shown here.
Front
At the
front
cross member (illustration) At

us

134
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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 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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Capacities
(in litres)
Fuel
tank
of
that
reserve about 80
about 10

Windscreen
washer

with
headlight washer about 5
about 7

Engine
oil
(with/without
filter
change)
4 Cylinder engines
5
Cylinder engines

The
oil level must be checked while topping up.
Do
not overfill (see page 97 )! about 5.0/4.5
about 5.5/5.0

Automatic
gearbox (ATF) about 3.0
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TECHNICAL DATA

Vehicle
identification
data

The
type
plate
is
secured to the
front
passenger's door lock
pillar.

Vehicles
for
certain export countries have no Type plate. 2
3

FAHRZG.
IDENT -NR.

VEHICLE
IDENT NO.

MOTORKB.
/ GtTR
-KB.
[
[NC.COM/TRANS.C0M
I

LACXNR./INNENAUSST.
[
PAINT
NO./
INTERIOR i

M-AUSST./

OPTIONS

8 17
183

The
vehicle
data
sticker
is
stuck underneath
the
instrument panel

near
the central electrics.
The sticker contains the following data: 1- Production control number

2-
Vehicle identification number

3-
Model code number

4-
Model explanation/engine
output
5-
Engine and gearbox code letters
6- Paint number/interior
trim
code
7- Optional extra number
The vehicle data 2-7 is also given in the
Ser­
vice
Schedule. The
vehicle
identification

number

(Chassis
number)

is
stamped on the outside on
right
below the

windscreen.

The
engine
number

is
stamped
in the
block below the cylinder

head
or is on a
sticker on
the
toothed belt

guard.

154
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