Volkswagen Caddy 2004 Self-Study Programme
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Volkswagen Caddy 2004 Self-Study Programme

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The 2004 Caddy

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  • Page 1 Service Training Self-study programme 328 The 2004 Caddy...
  • Page 2 S328_001 The 2004 Caddy is built on the same platform as the 2004 Golf. Compared with the previous model based on the Polo platform, we have improved the technology and comfort considerably. The 2004 Caddy will thus take a leading position among its rivals. Unlike its predecessor, the 2004 Caddy now comes in three different versions.

  • Page 3: Table Of Contents

    Contents In brief ..........4 Body .

  • Page 4: In Brief

    The original business concept behind Volkswagen Poznan GmbH was to assemble light commercial vehicles from kits. Kits from the different Volkswagen Group brands were delivered to Poznan for complete assembly. Operations were expanded constantly over the next years. Around 3,400 members of staff currently work at the plant.
  • Page 5 The Competitors The diagram shows the field of competitors facing the 2004 Caddy. Only one version of each vehicle is shown to represent the respective range. 2004 Caddy Van S328_096 Fiat Doblò Citroën Berlingo Opel Combo Mercedes Vaneo Renault Kangoo S328_162 Ford Tourneo Connect Immediate rivals...
  • Page 6 In Brief Technical highlights in the 2004 Caddy The 2004 Caddy is setting new standards with the Caddy Van, Caddy Shuttle and Caddy Life versions. It features a modern design with smooth outer surfaces all-round. Here is an overview of the highlights: Caddy Van •...
  • Page 7 Caddy Shuttle/Caddy Life The Shuttle version of the 2004 Caddy, offering further highlights compared with the Caddy Van, comes in 2 versions: – Caddy Shuttle is the “Basic” version and – Caddy Life is the “Comfort” version • Up to 7 seats in the •...

  • Page 8: Technical Data

    In Brief Technical data Caddy Van S328_005 S328_006 S328_094 Dimensions Length 4,405 mm Height of load sill 587 mm Length with tow bar 4,505 mm Ground clearance 154 mm Width 1,802 mm Wheelbase 2,682 mm Width with mirrors 2,062 mm Track width at front 1,537 mm Height...
  • Page 9 Caddy Shuttle/Caddy Life S328_095 The Caddy Van, Caddy Shuttle and Caddy Life look the same from the front. The outside dimensions of the different Caddy versions are the same. They only differ in equipment and weight. S328_007 Weight Caddy Van Caddy Shuttle/Caddy Life 5-seater 7-seater...
  • Page 10 In Brief Interior dimensions Caddy Van S328_008b S328_008a Load compartment dimensions Opening width - 1,181 mm rear door/tailgate Opening height - 1,116 mm rear door/tailgate Loading height up to 1,257 mm Opening width - 700 mm sliding door S328_009 Loading length up to 1,781 mm Loading width 1,172 to 1,558 mm...
  • Page 11 Caddy Shuttle/Caddy Life S328_010a S328_010b Luggage compartment -dimensions Opening width - 1,181 mm rear door/tailgate Opening height - 1,116 mm rear door/tailgate Loading height up to 1,238 mm Opening width - 700 mm sliding door S328_011 Luggage compartment up to 1,354 mm length Luggage compartment 1,170 to 1,340 mm...
  • Page 12 In Brief Overview of doors Caddy Van … with tailgate … with rear … with rear wing doors wing doors and “ladder flap” S328_012...
  • Page 13 Caddy Shuttle/Caddy Life … with tailgate … with rear … with rear wing doors wing doors and “ladder flap” S328_013 The 2004 Caddy comes in a wide range of The picture shows the complete Caddy versions. The variable equipment with sliding range.

  • Page 14: Body

    Body Body in white A sturdy body in white has a decisive influence on the stability and thus also on the driving safety of a vehicle. This particularly important for vehicles that are mainly used as fast commercial vehicles. The driving comfort also benefits from a good body design. That is a plus for the Caddy Shuttle and the Caddy Life when used as a family and leisure vehicle.
  • Page 15 Roof reinforcements The pictures show the body in white of the Caddy Van. Cross member Reinforcing element Floor panel - rear Floor panel - front S328_014 Side section (one-piece) Sheet qualities Mounted parts Normal-strength sheet Doors Side impact elements Higher strength sheets High-strength sheets...
  • Page 16 Body Wing doors The Van version of the 2004 Caddy comes with glazed wing doors split in the ratio 2/3 to 1/3. The windows in the wing doors can be covered with an optional dark opaque film. The Caddy Shuttle/ Caddy Life can be optionally fitted with the wing doors.

  • Page 17: Sliding Door

    Sliding door The 2004 Caddy is equipped with a sliding door reaching up to the roof on the passenger side. The drivers side can also be fitted with an optional sliding door. The sliding door opens to a maximum width of 70 cm.
  • Page 18 Body Window Sliding window The version of the Caddy Van with glazed load compartment can be optionally fitted with a sliding window in the sliding door. The Caddy Shuttle can also be equipped with an optional sliding window in the sliding door. The Caddy Life comes with the sliding window as standard.

  • Page 19: Roof Rack

    Roof rack Base carrier A system with a bolt-on base carrier is used for the roof rack on the 2004 Caddy. There are special accessories allowing you to attach a roof box, bicycles, skis, surfboards or boats on the base carrier. The bolt-on base carrier guarantees a high level of stability.
  • Page 20 Body Interior concept Caddy Van Overhead storage The equipment provided in the Caddy Van is mainly directed at commercial vehicle applications. Storage compartments in the side doors and an overhead compartment have been provided for the driver and front passenger –...
  • Page 21 Bulkhead Jack and tool set, mounted without cover S328_151 Lashing rings on floor...
  • Page 22 Body Caddy Shuttle/Caddy Life The Shuttle version of the 2004 Caddy comes in The picture shows a Caddy Life. the equipment derivatives – Caddy Shuttle as the “Basic” version and – Caddy Life as the “Comfort” version. In the Caddy Shuttle, the floor of the passenger compartment is fitted with carpet (Dilours) as standard.
  • Page 23 Hooks for net partition and storage net Jack and tool set behind panel S328_152 Storage between C and D-pillar Sliding door storage...
  • Page 24 Body Dash panel The 2004 Caddy has an all-new dash panel. There are two versions that mainly differ in the centre console equipment. Centre console type with Centre console type with – open storage – Compartment for a CD changer under the –...
  • Page 25 Left-hand storage compartment on Left-hand storage compartment on top of dash panel top of dash panel - with lid and (Caddy Van and Caddy Shuttle) document holder (Caddy Life) Right-hand storage compartment on top of dash panel -without lid S328_153 Storage compartment on passenger side Ashtray and cigarette...
  • Page 26 Body Seats The driver and front passenger seats in the Seats (example Caddy - 7-seater) 2004 Caddy are individual seats. The first row of seats in the Caddy Shuttle/Life is a 3-seat bench split 1/3-2/3. An optional double bench can be fitted in the second row.
  • Page 27 Seats in passenger compartment 1st row of seats in passenger compartment - individual seat tipped The three-seat bench in the first seat row of the passenger compartment is split into a 1/3 seat and a 2/3 seat. The bench is permanently screwed to the floor and cannot be removed.

  • Page 28: Occupant Protection

    Occupant protection Occupant protection The 2004 Caddy is equipped with the proven occupant protection systems, the airbag system, the belt system and a child restraint system (Isofix) depending on the vehicle version. The complete airbag system includes: – Driver airbag –...
  • Page 29 The picture shows the Caddy Life. Three-point seat belt, Front passenger integrated in seat side airbag module S328_037 Three-point seat belt with rack and pinion belt tensioner, fixed to body Driver side airbag Side airbag module for driver Front airbag for driver Side airbag crash sensor, in cab under driver’s/front...

  • Page 30: Engines

    Engines 1.4l/55 kW petrol engine The 1.4l/55 kW petrol engine has already proven itself in the Golf and now features in the 2004 Caddy. Technical features – 4-valve technology – 2 hollow overhead camshafts – Reduced-weight crankshaft – Lightweight piston –...
  • Page 31 1.6l/75 kW petrol engine The 1.6l/75 kW petrol engine has already been used in the Golf and Touran and is now being mounted in the 2004 Caddy. Technical features – An assembled camshaft – Roller rocker arm – SIMOS 7.1 engine management –...
  • Page 32 Engines 1.9l/77 kW TDI engine The 1.9l/77 kW TDI engine has already proven itself in the Golf and now features in the 2004 Caddy. Technical features – Diesel engine with exhaust-gas turbocharger – Unit injector system – Overhead camshaft – EDC 16 engine management –...
  • Page 33 2.0l/51 kW SDI engine The 2.0l/51 kW SDI engine with unit injector technology is a further development of the 1.9l/ 74 kW TDI engine used in the Touran. Technical features – Naturally aspirated diesel engine – Unit injector system – Overhead camshaft –...

  • Page 34: Transmission

    Transmission Gearbox Two mechanical manual gearboxes conceived for transverse installation feature in the 2004 Caddy. The gearboxes are based on the proven group manual gearboxes. They have been further developed with the following changes. Changes: – Shaft spacing increased – Axle drive reinforced –...
  • Page 35 Engine-gearbox combinations Engine 5-speed 5-speed manual gearbox manual gearbox 1.4l/55 kW petrol engine 1.6l/75 kW petrol engine 1.9l/77 kW TDI engine 2.0l/51 kW SDI engine...

  • Page 36: Chassis

    Chassis Front axle The 2004 Caddy has an optimised McPherson front axle with lower wishbones and MacPherson struts. The axle is basically the same as the front axle on the 2004 Golf and provides optimum comfort with good driving dynamics. The standing height has been increased especially for use in the 2004 Caddy. Technical features are: –...
  • Page 37 Assembly carrier Left console The assembly carrier holds the traverse link, anti- roll bar and steering rack. It is made up of three parts and has a central Right console subframe to which consoles are connected on the left and right. The components of the assem- bly carrier are made from aluminium.
  • Page 38 Chassis Strut bearing The strut bearing is a rubber/metal bearing. The connection of the springs and the damper to the Rubber element body are uncoupled from each other. The spring force is thus channelled separately into the body and tensioning of the damper bearing is avoided.

  • Page 39: Rear Axle

    Rear axle The 2004 Caddy has a rigid axle with leaf-spring suspension. It is a new design and is characterised by both its simplicity and robustness. Technical features are: – Single-layer leaf spring for Caddy Van and – Dampers position at an angle towards the Caddy Shuttle front to guarantee the through-loading width –...

  • Page 40: Electromechanical Power Steering

    Chassis Electromechanical power steering The 2004 Caddy is equipped with a Advantages of this steering system are: electromechanical power steering system (manufacturer ZF), which is made up of the – Simpler packaging (no need for traditional following main components components like a power steering fluid pump, hoses, fluid reservoir and hydraulic fluid).
  • Page 41 Function The electromechanical power steering is an The assist power of the electric motor flanged on active system. It operates in relation to parallel to the rack and pinion is transferred to the rack via a second pinion (input pinion). This –...

  • Page 42: Steering Column

    Chassis Steering column The steering column is mechanically height and length adjusted. For optimum adaptation to the needs of the driver, the height can be adjusted by 40 mm and the length by 50 mm. Moving the adjustment lever, releases and locks the plate clamp for height and reach adjustment of the steering column. The steering column is connected to the dash panel module carrier with a mounting made from diecast aluminium.
  • Page 43 Brake servo Brakes ABS or ESP unit ABS system The MK70 ABS system from Conti Teves is used as standard in the 2004 Caddy. It has the following technical features: – Anti-lock brake system (ABS) with – electronic brake pressure distribution (EBD). The traction control system (TCS) and engine S328_052 braking control (EBC) are controlled by the...
  • Page 44 Chassis Brake servo The 2004 Caddy uses a 10" brake servo from Conti-Teves. This brake servo has one essential new feature called the “dual rate characteristic curve”. This means that the brake assist works according to a two-step curve. A modified inside structure of the brake servo leads to a progressive curve following a so- called “dual-rate characteristic curve”.

  • Page 45: Front Brakes

    Front brakes Two different disc brake systems are used in the 2004 Caddy depending on the version or engine. They use ventilated brake discs. Up to an engine output of 55 kW, disc brakes with brake discs measuring Ø 280 mm x 22 mm are fitted.
  • Page 46 Chassis Pedal cluster Brake pedal Clutch pedal The crash-optimised pedal cluster has a modular structure and consists of – clutch pedal, – brake pedal and – accelerator pedal. The clutch pedal and the accelerator pedal have contact-free position sensors that recognise the pedal position.
  • Page 47 Senders for accelerator pedal position G79 and G185 The senders for the accelerator position work Evaluation electronics evaluate this movement according to the induction principle. and send a corresponding signal to the engine When the accelerator pedal is pressed, the control unit depending on the accelerator pedal angle movement is converted into straight-line position.

  • Page 48: Electrical System

    Electrical system Locations of onboard supply components Battery on left of engine compartment Battery The battery is located at the front left of the engine compartment. E-box The fuses and relays for the electrical components in the engine compartment are accommodated in the E-box.
  • Page 49 Fuse and relay box Relay carrier on left of engine compartment on left under dash panel S328_060 Relay carrier on control unit for onboard supply, on left under dash panel Fuse box on left under dash panel Pre-fuse box on left of engine compartment...
  • Page 50 Electrical system Networking concept Overview of network To enable data exchange between the control units, they are networked via different data bus systems. The diagnostic interface for data bus J533 (Gate- way) forms the interface for the following data buses: –...
  • Page 51 Legend Steering angle sender G273 Interior monitoring sensor G384 Vehicle inclination sender Horn for anti-theft alarm Heater control unit J104 ABS with EDL control unit J220 Motronic control unit J234 Airbag control unit J285 Control unit with display in dash panel insert J301 Air conditioning system control unit...
  • Page 52 Electrical system J519 onboard supply control unit Location The onboard supply control unit has been placed underneath the dash panel and forms a module with the relay carrier. S328_171 Variants The control unit for the onboard supply is available in the Basic and Highline variants. The Highline variant is built into vehicles with fog lights.
  • Page 53 Tasks: The onboard supply control unit activates and controls the following functions: • Terminal control, the onboard supply • Electrical load management control unit controls the following • Outside light control functions: – Terminal 75x via the relief relay for the •...
  • Page 54 Electrical system Electrical load management The electrical load management ensures that the The onboard supply control unit evaluates the battery has sufficient electrical energy to start the onboard supply load using this information and engine. the information on active high-power consumers with a short active period.
  • Page 55 Outside light control The onboard supply control unit evaluates the signals from the light switch directly. The information on switching on the turn signal, the main beam lights and use of the flasher lights is sent via the steering column electronics control unit J527 and the CAN convenience data bus. Functional diagram J519 Terminal 15...
  • Page 56 Electrical system Bulb monitoring The functioning of the bulbs is monitored constantly. They are monitored while switched off (cold monitoring) and switched on (hot monitoring). Cold monitoring The individual bulbs are switched on four times in short intervals of 500 ms when the ignition is turned on.
  • Page 57 Turn signal control When you tap turn light E2 briefly once, the turn lights will flash three times. If you tap again, the turn lights will flash a further three times. This function is called lane-change flash. Functional diagram First request Renewed request Request of the “Flash”...
  • Page 58 Electrical system Front windscreen wiper system Wiper control The wiper system uses one motor with a mechanical connection between the wipers. The operating rods for windscreen wiper switch E are transferred directly to the steering column electronics control unit J527 and then to the onboard supply control unit J519 via the CAN data bus convenience.
  • Page 59 Service and winter position If you move the windscreen wiper switch to the flick wiper position within 10 seconds after parking and turning off the ignition, the wipers will move to the top position. This function will not work when the bonnet is open.
  • Page 60 Electrical system Control unit with display in dash panel insert J285 The control unit with display manages all display elements, the analogue gauges and the warning lamps. Digital LED warning lamps display Dash panel insert S328_143 Speedometer Revolution counter Coolant temperature Fuel gauge The display comes in the following different versions:...
  • Page 61 Lights Side light Turn signal Headlights Main beam Dipped beam (H1 bulb) (H7 bulb) The headlight unit has a clear glass lens plus one reflector for dipped beam and one for main beam lights. The turn signal light is also integrated in the headlight unit.

  • Page 62: Heating And Air-Conditioning

    Heating and air conditioning Climate control Two different systems are used in the In the Caddy Van, there are only air vents for the 2004 Caddy: driver and front passenger in the dash panel. The Caddy Life has additional vents at rear end –...
  • Page 63 Operating unit for manual heating Manual heating Immediate heat button Rear window heating The temperature and air distribution is set auxiliary coolant heating manually on the operating unit in the dash panel (optional) for the vehicle interior as a single climate zone. The temperature is not regulated.

  • Page 64: Heating And Air Conditioning

    Heating and air conditioning Thermo Top V auxiliary coolant heating The 2004 Caddy can be optionally equipped with the Thermo Top V auxiliary coolant heating system. It has the following technical features: – The control unit for the auxiliary coolant heating is integrated in the heating unit. The electrical contacts for the combustion air fan are mounted directly on the control unit.
  • Page 65 Venturi injector Combustion air intake The intake air is guided via a ceramic housing in the shape of a Venturi injector. Fuel intake This leads to a knock-on effect that supports the fuel injection. S328_115 Glow pencil fitting Activating the Thermo Top V There are three possibilities for activating the Thermo Top V auxiliary coolant heating.

  • Page 66: Radio, Telephone And Navigation

    Radio, telephone and navigation Radio systems Two different radios are available for the 2004 Caddy. Radio R 100 Technical features – 2 loudspeaker channels (only at front, each 20 Watt) – RDS FM/AM Europa radio – Control for an external 6-CD changer –...
  • Page 67 RNS MFD-2 radio navigation system The 2004 Caddy can also be equipped with a radio featuring an integrated navigation system. Technical features – Multi-colour display (MFD) – Dynamic traffic guidance (avoiding jams) – 2 or 4 loudspeaker channels (each 20 Watt) –...
  • Page 68 Radio, telephone and navigation Radio aerials The 2004 Caddy has different aerials fitted in the front windscreen depending on the equipment. Depending on the type of radio system, single aerials and Diversity aerials are used. Single aerial Single aerial Aerial amplifier Housing The R 100 radio has a single aerial in the front windscreen and an aerial amplifier.
  • Page 69 Telephone/navigation aerial The 2004 Caddy can also be optionally equipped with an additional telephone/navigation aerial. The aerial is used in conjunction with the following optional components: – RNS MFD-2 radio navigation system – Telephone/preparation for telephone* – Remote control for auxiliary coolant heating* * When the vehicle is equipped with a telephone/preparation for telephone and auxiliary coolant heating with remote control, the reception signals are split by a frequency divider.

  • Page 70: Service

    It is used from the basis CD V06.00.00 and the Volkswagen brand CD V06.42.00. The ”Vehicle self-diagnosis” mode can still be used, but there is no further ELSA information available.
  • Page 71 Notes...
  • Page 72 © VOLKSWAGEN AG, Wolfsburg, VK-21 Service Training All rights and rights to make technical alterations reserved 000.2811.44.20 Technical status 04/04 ❀ This paper was manufacturer from pulp that was bleached without the use of chlorine.

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