1992 VOLKSWAGEN CARAVELLE service

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DO-IT-YOURSELF

Masking
headlights

When the vehicle is used in a country which drives on the opposite side
of
the road to the
home country,
the
asymmetric dipped neadlights
will
dazzle oncoming
traffic.

To prevent this,
the
wedge-shaped sector on the headlight lenses must be covered
up

with
an
opaque adhesive strip.
The illustration shows
the
strip installed
for

the change
from
right
hand
to
left
hand
traffic.
Installing
radio

When service installing
a
radio
or
replacing
a
set
installed
by the
factory
the
following points should
be
noted:
•
The
connection*
in the
vehicle
is for
Genuine
Volkswagen radios11
from
Model

Year
1988. The supply plug has the following
wire colours and connections:
Red/white Permanent positive
(+)

Brown Negative
(-)
vehicle earth
Grey/blue
Instrument
panel lighting
Brown/red* Control wire
for
"Ignition
key" switching radio
on/

off. On no account use this
connection
for
operating
voltage supply.
Blue/white*
Speed
signal
for
automatic volume control
•
Radios
with
other connections must
be
connected
with
an adapter cable which can

also
be obtained
from
a Volkswagen dealer.
11 Not available
in all
export markets
Attention

On
no account cut wires off and
leave
them
without
insulation. If

necessary
use a proper adapter.
Otherwise the wiring can be
overloaded or short circuits can
occur
- Fire danger!
Apart from this important elec­
tronic components can be damaged or the functioning impaired. If for
example the speed signal is
dis­

turbed this can lead to
faulty
man­ agement of engine, automatic gear­box, ABS etc.

Even
connecting the speed signal to
radio sets
with
speed dependent
vol­
ume control from other manufac­
turers can cause
such
faults.
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DO-IT-YOURSELF
• The radios from the Genuine Volks­ wagen Accessory Programme11 are similar
to those used in the factory and ensure
trouble-free installation. These sets are in keeping
with
the advanced technology and
well-planned easy-to-operate design. In
Germany
there is also an Exchange Service
for these radios so
that
even after years of
use
a set requiring repair can be exchanged

cheaply
for a completely reconditioned,

good-as-new
set by a Volkswagen dealer.
• Loudspeakers,
fitting
parts, aerials and
suppression
kits should also be taken from
the Genuine Volkswagen Accessory
Pro­

gramme11. These parts have all been

specially
developed for each vehicle model. • When installing the aerial it is essential to
ensure
that
the hole provided by the factory
where the aerial enters the body is sealed
very carefully. In addition the aerial cable,
the connecting wires and the loudspeaker
wires must be routed so
that
they cannot
chafe,
rattle
or get tangled up
with
moving parts (e.g. pedals, steering, heating controls
etc.). Otherwise the operation of the
con­

trols may be affected or vehicle safety im­
paired.

In
cases
of doubt, exact information can be
obtained from Volkswagen dealers.
Emergency
starting

|B43-
174[

A
- Flat battery
B
- Boosting battery
The battery is located in the engine com­ partment.
If the engine will not start because the ba:-
tery is
flat,
jumper
cables can be
con­
nected to the battery of another vehicle tc
start the engine. The following points
should be noted:
• Both batteries must be of the 12 Volt var­ iety and the capacity (Ah) of the booster bat­
tery must be approximately the same as

that
of the
flat
battery.
• The jumper cables must be heav enough to carry the load. Note cable manu­
facturer's data.
Not available in all export markets
130
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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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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
Vehicles
with 4
cylinder
engines
(Figures
for 5
cylinder
engine
in
brackets)
Reduced
payload

(K800)

(in
kg)
Wheelbase

in
mm
Permissible

GVW
Unladen

weight
(with
driver)
Payload

Permissible

front
axle load
Perm,

rear axle load
Perm,

roof

load21

Van
2920
2320 (2395) 1520 (1595)
800 (800) 1200 (1280) 1200 100

Kombi
2920
2320 (2395)

152011
(1595)11 800 (800) 1280 (1350) 1200 100

Notes

• Other model versions
and
optional
ex­
tras
-
e.g.
air
conditioner, automatic gear­box, sliding
roof,
towing bracket
etc. and

service
installation
of
accessories
in­

creases
the unladen weight and the payload
has
to be
reduced
by
this amount.
•
The
load must
be
stowed
so
that
it
can­
not slide about
or fly
forward when
the

brakes
are
applied.
If
necessary
use the
lashing eyes provided. • When carrying heavy loads,
the
load

should,
in
the
interests
of
good handling,
be
placed,
where possible, between
the
axles.
The permissible axle
and
gross vehicle weights must
not be
exceeded
on any
ac­
count. Bear
in
mind also
that
the
load will
alter
the
vehicle handling. Driving style
and
speed
must therefore
be
adapted
to
suit. Without driver

Use
only
the
roof load carrying system
ap­

proved
by us.
Distribute load evenly.
Do not

exceed
permissible roof load including roof rack
- and
permissible vehicle weight.
For

further
details see page
75

On
vehicles
with
a
pop-up roof
the
unladen
weight
is
increased
by 60 kg
and which corre­
spondingly reduces
the
payload.
150
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ALPHABETICAL
INDEX

S

Safety
for children 18

Seat
adjustment 20

Seat
belts 15

Seat
heating 51
Seat
stop 21

Seats
20

Selector
lever 33

Service
address list 2

Service
Schedule 2

Side
lights 50

Sleeping
surface 26

Sliding
door 9

Sliding
window 13
Sliding/tilting roof "71

Snow
chains 114
Spare
wheel 119

Spark
plugs 145
Speedometer
40
Starting the engine 37
Steering/starter lock 36
Stopping engine 39

Sun
roof 70

Sun
visors 73

Switches
50
T Tachograph 45 Tailgate 10
Tank capacity 153
Technical
Data 141

Technical
description 136 Telephone 117
Tilting roof 70, 71
Timer 65, 68

Tools
118 Tow starting 133
Tow-bar weight 151 Towing 133
Trailer socket 81
Trailer towing 81
Trailer weights 151
Tread depth 111 Trip recorder 40
Trolley jack 134 Turn signal lever 52
Turn signals 48, 125
Two way radios 117
Type plate 154 Tyre pressures 147

Tyres
110 - Condition 111
-
Inflation
pressure 110 - Pressures 147
u

Unbalanced
wheels 111
Undercoating 92
Unladen
weight 148

Unleaded
fuel 86
V

V-belts
145
Vehicle
data sticker 154

Vehicle
identification data 154

Vehicle
identification number 154

Vehicle
lift
134

Vehicle
literature
2

Vehicle
tools 118
Ventilation 55, 56, 57
w
Warning and control lights 6 Warning lamps 6, 47
Warning triangle 118
Warranty 2

Washing
88 Weights 148

Wheelbase
148

Wheels
110, 146
Windows 12
- De-icing 90
- Defrosting 56, 58

Windscreen
washer system 108
Windscreen
wiper 54

Windscreen
wiper blades 109
Wing doors 11 Winter driving 116
Winter tyres 114

Wipe/washer
system 54
159
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You
can enter the most
important
data
for
your
vehicle here.

If
you have any questions, any Volkswagen Dealer
will
be
pleased
to
help.

Vehicle
identification
number1'
Model
Engine
oil
specifications2'

• To Volkswagen Standard 501
01

• To Volkswagen Standard 500
00

• To Volkswagen Standard 505
00

Engine
output11
kW
Engine
code
letters1'
Engine
oil
specifications2'

• To Volkswagen Standard 501
01

• To Volkswagen Standard 500
00

• To Volkswagen Standard 505
00

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres.
Engine
oil
specifications2'

• To Volkswagen Standard 501
01

• To Volkswagen Standard 500
00

• To Volkswagen Standard 505
00

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres.

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres.

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres.

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres.
Tyre
pressures4'
(in bar)
front
rear

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres. With half load

Mixture
preparation2'

•
Injection
•
Diesel
• With catalyst
Fuel2'
• Regular unleaded31 91 RON • Diesel 1) This data can be found
in the
Service

Schedule.

21 Mark
with
cross
31 Leaded also for engines
without
catalytic con­
verter.
4) Factory
fitted
tyres. With
full
load

VOLKSWAGEN
AG is working continuously on the development
of
all models.
Please
appreciate
that
we must reserve the
right

to change our models
in
shape, equpment and technology
at
any time.No legal commitment is therefore implied by the details, illustrations and descriptions
in
this manual.
Reprinting, reproducing
or
translation,
in
whole
or
in
part,
is
not permitted
without
written
permission
from
VOLKSWAGEN
AG.

All
rights are reserved expressly by
VOLKSWAGEN
AG. Subject
to
modification
without
notice.
Produced
in
Germany
.© 1992
VOLKSWAGEN
AG
TO
This paper was manufactured
from
pulp bleached
without
using chlorine
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