technical data VOLKSWAGEN CARAVELLE 1992 T4 / 4.G Owners Manual

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CONTENTS
DASHBOARD AND

CONTROLS

Layout
4
i\='-:ng
lamps 6

CONTROLS
AND

EQUIPMENT

•
e.s. Central locking system 7, 8
I:cs, Tailgate 9, 10
I'I
~g doors 11

..
-^ows, Mirrors 12, 13
Sea: belts 15 5re:y for children 18
-ead restraints 19

Seats
20 _:ariing/sleeping surface 26

__ggage
compartment cover 27 __cgage compartment/load surface ... 28
-edals, Brakes 29 Vanual gearbox 31
--tomatic gearbox 32
gnition
lock 36
Starting / Stopping the engine .... 37, 38 "struments 40

.'.
arning lamps 47
Switches 50
~yn signal and dip lever 52

3'uise
control system 53 .'.'indscreen wiper 54
-eating and ventilation 55

Air
conditioner 57
Recirculating air switch 61
Auxiliary heater 63
Additional
water heater 67
Sun roof, Sliding/tilting roof 70, 71
nterior lights, Sun visors 72, 73
Ashtray, Cigarette lighter 73
-oof
rack 75
DRIVING
TIPS

The first 1500 km - and afterwards ... 76 Driving safely 78
Driving economically and

ecologically
79
Trailer towing 81

GENERAL
MAINTENANCE
Filling the tank, Fuel 85, 86
Care of car, Maintenance 88, 93 Bonnet, Engine compartment 94, 95
Engine oil, Gearbox oil 96, 99

Air
cleaner 100 Power assisted steering 100

Cooling
system 101
Brake fluid 104
Battery 106
Windscreen washer system 108
Wheels 110
Arduous operating conditions 115
Winter driving 116
Accessories, modifications and
renewal of parts 117
Mobile
telephones and two way
radios 117

DO-IT-YOURSELF

First
aid kit, Warning triangle 118
Vehicle tools 118 Spare wheel/changing wheel ... 119, 120
Fuses
122

Changing
bulbs 124
Adjusting/masking headlights .. 128,129
Headlights 129
Installing radio 129
Emergency starting 130
Tow starting/towing 132
Lifting vehicle 134
TECHNICAL
DESCRIPTION

Engine 136
Emission control system 137
Activated charcoal filter '38 Power flow '39
Steering, Axles 139 Brakes, Body -139,
1
AC
Environment compatibility 140

TECHNICAL
DATA
Engine 141
Performance 142
Fuel consumption 143
Spark plugs 145
V-belts 145
Wheels,
Tyre
pressures 146, 147

Weights,
Trailer weights 148, 151 Dimensions 152
Capacities 153
Vehicle identification data 154

SPECIAL
INFORMATION

Adjusting the brake pressure regulator 155

ALPHABETICAL
INDEX

Alphabetical index 156

CHECKS
WHEN
FILLING

THE TANK
Overview 160
3
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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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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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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
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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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Vehicles
with 4
cylinder engines
(Figures
for 5
cylinder engines
in
brackets)
Increased
payload
Wheelbase

Permissible
Unladen

Payload
Permissible
Perm. Perm.

(in
kg)
in
mm
GVW
weight
(with

front
axle
rear

roof
driver)
load
axle
load2'

load

Caravelle
2920
2650
(2700)

15651)
(1640)11
1085
(10.60)
1350
(1520)

1460
100

3320
2750
(2800)
166511
(1740)1'

1085
(1060)
1430
(1520)

1460
100

Kombi
2920
2700
(2775)

15201'
(1595)1' 1180(1180)
1430
(1430)

1460
100

3320
2750
(2800)
157011
(1645)11 1180(1155)

1430
(1430)
1460
100

High-roofed
Kombi
3320

2750
(2800)
162011
(1695)1) 1130(1105)
1430
(1520)

1460

-

Van
2920
2700
(2775)
1520
(1595) 1180(1180)

1350
(1430)
1460
100

3320
2750
(2800)
1570
(1645) 1180(1155)
1430
(1430)

1460
100

High-roofed
Van
3320
2750
(2800)
1620
(1695) 1130(1105)

1430
(1430)
1460

-

Pick-up
2920
2650
(2725)
1470
(1545) 1180(1180)

1280
(1350)
1460

50

3320
2700
(2775)
1520
(1595) 1180(1180)
1350
(1430)

1460
50

Low
loader
3320
2700
(2775)
1520
(1595)
1180(1
180)
1350
(1430)

1460
50

Chassis
and cab
2920
2650
(2725)
1315
(1390)
-
1280
(1350)

1460
50

3320
2700
(2775)

1340
(1415)
-
1350
(1430)

1460
50

Remarks
and
footnotes
- see
page
150

149
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