Volkswagen The Caddy 2021 Manuallines
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Volkswagen The Caddy 2021 Manuallines

Volkswagen The Caddy 2021 Manuallines

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Converter guidelines
August 2024 edition
Converter guidelines
The Caddy
(from model year 2021)
Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition
The Caddy – Page 1 of 163

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Summary of Contents for Volkswagen The Caddy 2021

  • Page 1 Converter guidelines August 2024 edition Converter guidelines The Caddy (from model year 2021) Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 1 of 163...

  • Page 2: Table Of Contents

    1.2.1 Product and vehicle information for converters ........................10 1.2.1.1 Contact in Germany ....................................10 1.2.1.2 International contact ....................................10 1.2.1.3 Electronic repair and workshop information from Volkswagen AG (erWin*) ..................11 1.2.1.4 Genuine Parts Online Ordering Portal* ..............................11 1.2.1.5 Online Owner’s Manual ..................................11 1.2.1.6 Homologation ......................................
  • Page 3 2.5.2.7 Current and signal take-off of vehicle electrical system potentials ...................... 61 2.5.3 Electrical interface for special vehicles ..........................62 2.5.3.1 General notes on the interfaces ................................62 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 3 of 163...
  • Page 4 3.1.2 Subsequent installation of windows ........................... 110 3.1.3 Roof cut-outs ..................................111 3.1.4 Modifications to the roof of the Caddy Cargo / Caddy ......................113 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 4 of 163...
  • Page 5 8.2.1 Permissible aerodynamic changes and min./max. weights apply to the following variants: ..........155 8.2.2 Permissible aerodynamic changes and max. dimensions ..................... 156 9 Listings....................................... 157 9.1 List of changes ..................................... 157 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 5 of 163...

  • Page 6: General Information

    Therefore, Volkswagen AG does not accept any liability for accidents or injuries arising from changes of this kind made to its vehicles, especially if the changes have a negative effect on the vehicle as a whole.

  • Page 7: Means Of Representation

    This note draws your attention to the risk of possible damage to the vehicle, as well as to regulations and provisions to be observed. Information This note indicates additional information. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 7 of 163...

  • Page 8: Vehicle Safety

    We recommend that you use parts, mechanical units, conversion parts or accessories that have been tested by Volkswagen AG for the corresponding vehicle type. Have the vehicle’s safety checked immediately if non-recommended parts, mechanical units, conversion parts or accessories are used.

  • Page 9: Operational Safety

    The texts, pictures and data contained in these converter guidelines are subject to copyright. This also applies to editions on CD-ROM, DVD or other media. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 9 of 163...

  • Page 10: General Notes

    Country-specific features can vary. 1.2.1 Product and vehicle information for converters 1.2.1.1 Contact in Germany If you have questions concerning vehicle models from Volkswagen Commercial Vehicles, you can contact us online on the Volkswagen AG portals (https://www.customized-solution.com)

  • Page 11: Electronic Repair And Workshop Information From Volkswagen Ag (Erwin*)

    *Information system from Volkswagen AG, subject to payment 1.2.1.4 Genuine Parts Online Ordering Portal* For the purchase of spare parts and for the research of Volkswagen Genuine Parts, our latest parts catalogues are available on the Internet on the Genuine Parts Online Ordering Portal: https://www.partslink24.com...

  • Page 12: Homologation

    Further information on this topic can be found in chapter 8 “Notes on homologation of modifications and conversions”. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 12 of 163...

  • Page 13: European Type Approval And Ec Certificate Of Conformity

    The Volkswagen type approval can be used for the multi-stage type approval for vehicles with conversions or add-ons that remain within the ISC parameters / maximum technical specifications for add-on parts. If the add-on or conversion is outside the ISC parameters / maximum technical specifications defined by the manufacturer for add-on parts, the converter must demonstrate compliance with the exhaust gas emissions requirements / electric range.

  • Page 14: Manufacturer's Declaration

    As a result, Volkswagen AG recommends that all work should be carried out on the base vehicle and the body in accordance with the current Volkswagen converter guidelines applicable to the vehicle in question.
  • Page 15 Safety is only provided if the design, production and installation are carried out by the converter performing the modifications in accordance with the state of the art and in accordance with the applicable converter guidelines of Volkswagen AG – and assuming any deviations from these guidelines have been declared to be technically safe.

  • Page 16: Application For The Letter Of Non-Objection

    There is no legal entitlement for a letter of non-objection to be issued. Due to ongoing technical development and the information derived from this, Volkswagen AG is entitled to refuse a letter of non-objection even if a comparable certificate had been issued formerly.

  • Page 17: Warranty And Product Liability Of The Converter

    No general legal entitlement for the approval of a body modification exists, even if such approval was previously granted. If bodies comply with the present guidelines, no additional approval by Volkswagen AG is required for the presentation of the vehicle at the relevant authority examining roadworthiness.

  • Page 18: Ensuring Traceability

    1.2.5 Trademarks VW badges and VW emblem are trademarks of Volkswagen AG. VW badges and VW emblems are not allowed to be removed without authorisation, or to be attached in a different location. 1.2.5.1 Positions on rear of the vehicle VW badges and VW emblems which are enclosed in the delivery must be fitted in the location intended by Volkswagen.
  • Page 19 Do not disconnect the battery! Information You can find further information about vehicle storage in the following documents: − Owner’s Manual − Vehicle care programme Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 19 of 163...

  • Page 20: Compliance With Environmental Rules And Regulations

    − All plastic parts shall be identified according to the VDA material sheet 260 (“Components of motor vehicles; Identification of materials”), e.g. “PP-GF30R”. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 20 of 163...

  • Page 21: Recommendations For Inspection, Maintenance And Repair

    Please observe the Volkswagen AG owner’s manual for the inspection, maintenance and repair of base vehicles. Please only use brake fluids and engine oils approved by Volkswagen for your vehicle.

  • Page 22: Quality System

    The requirements of a quality management system of this kind are described in DIN EN ISO 9001. For the reasons stated above, Volkswagen AG strongly recommends that all converters should set up and maintain a quality management system with the following minimum requirements: −...

  • Page 23: Planning Bodies

    You can find more information on the available body versions from the relevant department (see chapter 1.2.1 “Product and vehicle information for converters”) Information On the Volkswagen AG homepage you can put your vehicle together using the configurator and view the available optional equipment: https://www.volkswagen-...

  • Page 24: Vehicle Modifications

    EU directives or UN R regulations with the same corresponding content. Practical note Sufficient space must be provided in order to guarantee the function and operating safety of the components. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 24 of 163...

  • Page 25: Vehicle Acceptance

    The officially recognised appraiser or tester from the converter must be informed about modifications to the vehicle. Practical note Country-specific laws, directives and approval regulations shall be observed! Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 25 of 163...

  • Page 26: Optional Equipment

    PR number for optimum adaptation of the body to the vehicle. You can obtain information on special equipment provided by Volkswagen under PR numbers from your authorised repairer or in your contact options for product and vehicle information for converters (see chapter 1.2.1 “Product and vehicle information for converters”).

  • Page 27: Technical Data For Planning

    2.1.1 Vehicle dimensions Fig. 1: Vehicle dimensions for Caddy (acc. to DIN 70020, T1) Fig. 2: Vehicle dimensions for Caddy (acc. to DIN 70020, T1) Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 27 of 163...

  • Page 28: Basic Data Of Caddy Cargo

    Track width at rear: With wheel offset depth 47 1606 1606 With wheel offset depth 48 1604 1604 With wheel offset depth 49 1603 1602 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 28 of 163...
  • Page 29 Body opening height with rear lid 1130 1130 Body opening height with wing door 1122 1122 W206 Largest width of rear opening 1234 1234 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 29 of 163...

  • Page 30: Basic Data Of Caddy

    With wheel offset depth 48 with high-level running gear 1605 1605 With wheel offset depth 49 1603 1603 With wheel offset depth 49 with high-level running gear 1603 1603 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 30 of 163...
  • Page 31 Luggage compartment length, without seats in vehicle interior, 1913 2265 measured on floor L212-2 Luggage compartment floor length, 2nd row of seats 1100 1452 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 31 of 163...
  • Page 32 For additional technical data, especially dimensional drawings and weight information on the Caddy / Caddy Maxi according to the engine and equipment variant, please search online. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 32 of 163...

  • Page 33: Ramp Angle And Breakover Angle

    (A-117) in the basic data tables (see sections 2.1.1.1 and 2.1.1.2). * The values for the overhang angle A116 may differ for petrol and diesel engines due to different exhaust systems. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 33 of 163...

  • Page 34: Vehicle Centre Of Gravity

    The driving properties of vehicles with a high body or with an elevated overall centre of gravity can be expected to be restricted (see also chapter 2.2.6 “Brake system and brake control system ESC”). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 34 of 163...

  • Page 35: Determining The Centre Of Gravity

    2 Technical data for planning 2.1.5 Determining the centre of gravity Volkswagen recommends having the centre of gravity determined by a recognised test institution with experience in this field (e.g., DEKRA, TÜV or others). For the converter to determine the centre of gravity, we recommend following the procedures described under 6.1 “Determining the centre of gravity”.

  • Page 36: Running Gear

    Furthermore, the overload can lead to damage to load bearing parts and to the running gear. This may result in the driver losing control of the vehicle and causing an accident. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 36 of 163...

  • Page 37: One-Sided Weight Distribution

    See chapter 2.1.1 “Vehicle dimensions”. 2.2.3 Authorised tyre sizes The Volkswagen Owner’s Manual provides information about the wheel/tyre combinations authorised by Volkswagen AG in conjunction with snow chains (for tyre sizes see also section 2.1.1 “Vehicle dimensions”). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition...

  • Page 38: Modifications To Axles

    − If the air inflow and outflow to and from disc brakes are modified. Exceptions shall be approved by Volkswagen AG prior to the conversion, and shall be documented with an independent brake approval report. Please contact us before starting your conversion (see chapter 1.2.1, “Product and vehicle information for converters”).

  • Page 39: Vehicle Stability And Esc

    Please check whether ESC* is required in the intended country of registration for the envisaged type of the completed vehicle. *Electronic Stability Control Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 39 of 163...

  • Page 40: Influence Of Vehicle Conversions On The Function Of Esc* Brake Regulation System

    *Electronic Stability Control Exceptions shall be approved by Volkswagen AG prior to the conversion, and shall be documented with an independent brake approval report. Please contact us before starting your conversion (see chapter 1.2.1, “Product and vehicle information for converters”).

  • Page 41: Routing Additional Lines Along The Brake Hoses/Brake Lines

    The spring rates are never allowed to be modified. We recommend using optimally matching springs from the Volkswagen delivery range for the vehicle with body. Modifications to the springs must be assessed by a test centre/monitoring organisation/technical service responsible for this function, and can result in invalidation of the operating permit.

  • Page 42: Wheel Alignment Settings

    UC5, must be replaced by standard equipment. Otherwise, the driving properties might be negatively impaired. 2.2.8 Wheel alignment settings Changes to wheel alignment parameters are not permitted! Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 42 of 163...

  • Page 43: Body-In-White

    During vehicle conversions and installation of bodies, it is not permitted to make any modifications which impair the function and freedom of movement of the suspension (e.g. for maintenance and inspection work) or the accessibility to the same. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 43 of 163...

  • Page 44: Screw Connections

    When attaching components to the base vehicle using screws, make sure that no panels or other components of the base vehicle are bent or damaged. The use of Volkswagen tightening torques assumes that the total coefficient of friction is in the range μtot = 0.08 to 0.14 for the particular items being bolted together.

  • Page 45: Welding Work

    Avoid making more than three welds at any one point. − Avoid welding in work-hardened areas. − Spot welds and stitch welding should be offset. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 45 of 163...

  • Page 46: Selection Of Welding Process

    In order to avoid damage to the molten core, the specified distances from the edge of the panel must be maintained (L = 3e + 2 mm). Ratio between panel thickness and distance from edge e - Panel thickness L - Distance from the edge of the panel Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 46 of 163...

  • Page 47: Shielding Gas Hole Spot Welding

    The mechanical quality can additionally be improved by using slots (l = 2 × b). Ratio between width and length of elongated holes b - Width of elongated hole I - Length of elongated hole Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 47 of 163...

  • Page 48: Tacking

    Following conversion and installation work on the vehicle, surface and corrosion protection shall be applied to the affected points. Practical note Only the corrosion protection agents tested and approved by Volkswagen are allowed to be used for all corrosion protection measures. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition...

  • Page 49: Planning Measures

    2 - Insulating sleeve Contact corrosion can be avoided by using electrical insulation such as washers, sleeves or tubes. Avoid welding work on inaccessible cavities. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 49 of 163...

  • Page 50: Component Design Measures

    Apply a primer to all bare metal parts, and paint them. − Apply a wax-based corrosion protection agent to cavities. − Carry out corrosion protection measures on the underbody and frame components. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 50 of 163...

  • Page 51: Interior

    − If the current load compartment does not have standard anchors for seats and seat belts already installed, then retrofitting, and therefore equipping the load compartment with original Volkswagen seats or rows of seats is not possible. − When retrofitting original Volkswagen seats, (side) airbags, belt tensioners, seat occupancy detection, and belt fastening detection, must all be re-coded by the customer service workshop.

  • Page 52: Belt Anchors

    Specialists such as the manufacturer and suppliers of acoustic material should be contacted for advice on achieving the optimum acoustic protection for bodies. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 52 of 163...

  • Page 53: Electrics/Electronics

    Comply with the country-specific registration provisions with regard to the complete lighting devices (lighting and turn indicator devices). Note the basic setting for the headlight (see vehicle wallet). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 53 of 163...

  • Page 54: Mounting Special Lights

    PWM (pulse-width modulation signal). No additional wires may be connected to the existing lighting wiring fitted by Volkswagen AG. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition...

  • Page 55: Vehicle Electrical System

    This can lead to a failure of components/functions (S) or safety- relevant parts and consequently to accidents or damage to the vehicle. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 55 of 163...

  • Page 56: Additional Circuits

    >150 V in the vehicle electrical system. For conversions, suitable measures must be taken to ensure this (e.g. by using protection diodes). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 56 of 163...

  • Page 57: Retrofitting Electrical Devices

    2.5.4.1 “Installation of additional battery”. − If the electrical power requirement is higher, the alternators approved by Volkswagen for the vehicle shall be used. − No further electrical equipment is allowed to be connected to assigned fuses.

  • Page 58: Electromagnetic Compatibility

    Active systems in the surrounding area are not disrupted nor is the system itself impaired. Electrical interference in motor vehicle electrical systems is caused by the different consumers. At Volkswagen, the factory-fitted electric and electronic components have been checked for their electromagnetic compatibility in the vehicle. If modifications are made later on, reductions in comfort (e.g.

  • Page 59: Mobile Communication Systems

    Communication with the control unit can be carried out using ODIS (Offboard Diagnostic Information System) and the software that has been developed for this purpose. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 59 of 163...
  • Page 60 *NFC = Near Field Communication (contactless data transmission using radio frequency identification (RFID) technology), *NAD = Network Access Device (telephone module) Information Your Volkswagen customer service department can provide you with further information. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 60 of 163...

  • Page 61: Current And Signal Take-Off Of Vehicle Electrical System Potentials

    Behind the glove compartment on right-hand drive models The exact position and description can be found in the Owner’s Manual of your vehicle. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 61 of 163...

  • Page 62: Electrical Interface For Special Vehicles

    Inappropriate interventions can result in damage to the vehicle and breakdowns, and may also invalidate the operating permit. − The parameters of the special vehicle control unit are only allowed to be set in consultation with Volkswagen. − Connections must be made properly (see section 2.5.2.1 “Electrical wiring/fuses”).
  • Page 63 The interfaces are located on the right-hand side of the vehicle above the wheel housing in the area of the rear gate. Fig. 1 Coupling point position, viewed from above Fig. 2 Coupling point on right rear gate Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 63 of 163...

  • Page 64: Dc/Ac Converter (Pr No. 9Z3, 9Z6)

    Installation position on the Caddy Fig. 2: 1 - Location of DC/AC converter, left seat box 2 - Installation position of socket 3 - Direction of travel Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 64 of 163...
  • Page 65 The voltage on the socket is switched on by a mechanism integrated in the socket which only switches on the DC/AC converter when a plug is inserted. − When the engine is stopped, the 230 V socket continues operating for up to 10 minutes. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 65 of 163...

  • Page 66: Customer-Specific Functional Control Unit (Cfcu)

    If additional electrical consumers are installed, in particular factory-fitted optional equipment that use the second battery preparation, a positive overall charging balance shall be ensured by the converter. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 66 of 163...
  • Page 67 CFCU, in order to minimise this risk. CAN* Controller Area Network FMS** Fleet Management System Fig. 1.: View of customer-specific functional control unit Interfaces CIA447 J1939 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 67 of 163...
  • Page 68 You must register on the Customised Solution Portal in order to access this. The configuration of the customer- specific functional control unit (CFCU) can be ordered via the CS portal. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 68 of 163...

  • Page 69: Vehicle Battery

    You can order a preparation for second battery including energy management for the Caddy ex-works using PR number: 8FV. (Not for Caddy PHEV) Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 69 of 163...
  • Page 70 200-A fuse, as protection between the second battery and the vehicle. CFCU or CFCU preparation required Activation of the customer-specific functional control unit (CFCU) can be requested after the conversion from the Volkswagen Commercial Vehicle Partner for the following battery capacities by means of the after sales PR numbers:...
  • Page 71 Permanent deactivation of the start/stop functions and brake energy recuperation is unauthorised. * Customer-specific function control unit Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 71 of 163...
  • Page 72 Only then should you disconnect the positive cables. Short-circuits could occur if this is not observed. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 72 of 163...

  • Page 73: Intelligent External Charging Control

    If this is not done, the isolation relay may prematurely fail. Solar charging modules must not be connected to the first battery! Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 73 of 163...

  • Page 74: Parameterised* Reactions On Reaching Certain Second Battery Charge Levels With Second Battery Monitoring

    2.5.4.3 Parameterised* reactions on reaching certain second battery charge levels with second battery monitoring Note: Only for retrofitted second battery from the second battery preparation (PR no. 8FV Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 74 of 163...
  • Page 75 The warning and shut-off stage of the second battery has no effect on the base vehicle. It must be made available for the connected additional electrical equipment using customised calibration of the CFCU. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 75 of 163...

  • Page 76: Retrofitting Of Alternators

    − The cable cross-section should be dimensioned according to the current drawn (see chapter 2.5.2.1 “Electrical wiring/fuses”). − The higher power requirement can make it necessary to replace the starter/alternator warning harness. We recommend Volkswagen genuine parts for this. −...
  • Page 77 Electrical system) on the Internet at erWin* (Electronic Repair and Workshop Information from Volkswagen AG): http://erwin.volkswagen.de/erwin/showHome.do *Information system from Volkswagen AG, subject to payment Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 77 of 163...

  • Page 78: General Overview

    Modifications can result in these systems no longer working correctly and failing. This may result in the driver losing control of the vehicle and causing an accident. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 78 of 163...

  • Page 79: Electronic Stability Control (Esc)

    This may result in the driver losing control of the vehicle and causing an accident. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 79 of 163...

  • Page 80: Tyre Pressure Monitoring System (Tpms)

    The Tyre Pressure Monitoring System control unit J502 with the Tyre Pressure Monitoring System aerial R175 is located on the cross panel of the body. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 80 of 163...
  • Page 81 Furthermore the vehicle can in some cases no longer meet the registration requirements. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 81 of 163...

  • Page 82: Front Camera For Driver Assist Systems

    Otherwise the camera can no longer function correctly and may fail. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 82 of 163...

  • Page 83: Rain/Light Sensor

    “Park Assist” park assist steering and Park Distance Control at the front and rear 7X5 At Volkswagen, the parking aid ensures compliance with UNECE R 158 (reverse travel equipment). For this reason, each vehicle is always fitted with Park Distance Control ex works. Only incomplete vehicles can be ordered without Park Distance Control.
  • Page 84 This could damage the CDP coat and it can no longer be applied later on. Chemical or mechanical reworking is also not permitted. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 84 of 163...

  • Page 85: Lane Departure Warning "Lane Assist

    The control units required for the correct functioning of Front Assist, or ACC may not be removed, nor may their function be impaired in any way. (See table “Required control units”). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 85 of 163...
  • Page 86 The road traffic regulations in the countries of registration must be observed and coordinated with the responsible test centre or technical service. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 86 of 163...

  • Page 87: Earth Points

    2 Technical data for planning 2.5.7 Earth points Use the earth points provided by Volkswagen for subsequent electrical add-ons or installations to ensure an optimum earth connection to the base vehicle. Warning note The use of other earth points can lead to malfunctions in safety systems.

  • Page 88: Engine Peripherals/Drive Train

    Information Volkswagen Commercial Vehicles does not support adaptation of the fuel gauge to the modified fuel system. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 88 of 163...
  • Page 89 Internet at erWin* (Electronic Repair and Workshop Information from Volkswagen AG): http://erwin.volkswagen.de/erwin/showHome.do *Information system from Volkswagen AG, subject to payment Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 89 of 163...

  • Page 90: Cng* Fuel System

    Special care must be taken when working on the body near the vehicle floor and the filling openings to prevent damage to the gas tanks, gas pipes, sensors and electrical supply lines. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 90 of 163...

  • Page 91: Exhaust System

    Country-related regulations and guidelines shall be complied with Exceptions require the approval of Volkswagen AG before the conversion, and shall be documented in a registration report detailing the modifications and adjustments made. Please contact us before starting a conversion (see chapter 1.2.1, “Product and vehicle information for converters”).
  • Page 92 1 - Emission control 2 - Damper element 3 - Converter 4 - Converter 5 - Exhaust control flap 6 - Front and rear silencers Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 92 of 163...
  • Page 93 When working on lines carrying AdBlue®, comply with the workshop manuals from Volkswagen AG. Otherwise, AdBlue® could crystallise and lead to damage to system components. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 93 of 163...

  • Page 94: Hybrid Powertrain Exhaust System (Phev)

    If a modification to the exhaust system due to body design, removal or conversion is required, this can have consequences relevant to registration. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 94 of 163...

  • Page 95: Scr System (Eu6)

    (see chapter 2.6.4 “Exhaust system”). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 95 of 163...

  • Page 96: Filling The Adblue® Tank

    Comply with the laws and regulations of the country in question regarding correct storage and disposal. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 96 of 163...
  • Page 97 More information and safety instructions for the SCR system can be found in the Owner’s Manual for your vehicle and the Workshop Manuals of Volkswagen AG on the Internet: http://erwin.volkswagen.de/erwin/showHome.do Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 97 of 163...

  • Page 98: Engine Power Take-Off Systems

    Fig. 2: Schematic diagram: poly V-belt drive 1 - Alternator 2 - Belt tensioner 3 - Poly V-belt 4 - Air conditioner compressor Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 98 of 163...

  • Page 99: Compatibility With Base Vehicle

    Practical note In vehicles without an air conditioning system, conversion using the measures code is also required when an additional unit is retrofitted. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 99 of 163...
  • Page 100 Fig. 1: Detail U – Drive pulley for refrigerant compressor (example DENSO 7SAS17) Please observe the installation and removal regulations from Volkswagen AG when performing conversions. Information For detailed instructions about the installation and removal,...

  • Page 101: Retrofitting Air Conditioning System

    Compatibility with the base vehicle must be observed without fail (see chapter 2.7.1 “Compatibility with base vehicle” and chapter 2.7.4 “Specifications of genuine refrigerant compressor”). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 101 of 163...

  • Page 102: Specifications Of Genuine Refrigerant Compressor

    4360 EA211 MPI 1.6 l MAHLE 6CVC140c 5Q0 816 803 J 4418 EU 4 / EU 5 PHEV Hanon Gen3.8.4EU 5QE.816.803 H 5976 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 102 of 163...

  • Page 103: Pulley Diameter Of The Refrigerant Compressor

    2.7.4.5 Connection dimensions of genuine refrigerant compressor Information The exterior and connection dimensions of the ancillaries can be found in the manufacturer’s data sheets. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 103 of 163...

  • Page 104: Add-Ons/Units

    There are 4 mounting points in the roof on each side on the Caddy Maxi as standard (see Fig. 2). Various roof carriers are available ex-works as special equipment. For more information, refer to the sales documents of Volkswagen AG. Fig. 1: Caddy mounting points Fig.

  • Page 105: Rear Luggage Carrier/Rear Ladders

    The test of dimensions and angles shall be undertaken with suitable length and/or angle measuring instruments. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 105 of 163...
  • Page 106 Clearance according to the height of the coupling ball as per UN-R 55 (side view) 1 – Clearance 2 – Vertical plane through end points of the total length of the vehicle 3 – Floor Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 106 of 163...
  • Page 107 Clearance of the coupling ball according to UN-R 55 (top view) 1 – Clearance 2 – Vertical plane through end points of the total length of the vehicle Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 107 of 163...

  • Page 108: Raising The Vehicle

    With a jack See the owner’s manual for the procedure and jacking points on all vehicle variants. Fig. 1: Positions for jack (schematic diagram) Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 108 of 163...

  • Page 109: Modifications To Closed Bodies

    For further information about body assembly work, refer to the Internet under erWin (Electronic Repair and Workshop Information of Volkswagen AG): http://erwin.volkswagen.de/erwin/showHome.do *Information system from Volkswagen AG, subject to payment Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 109 of 163...

  • Page 110: Subsequent Installation Of Windows

    3 Modifications to closed bodies 3.1.2 Subsequent installation of windows Retrofitting windows is complicated and costly. Therefore Volkswagen Commercial Vehicles recommends ordering the required windows ex-works. If windows are to be retrofitted, proceed in accordance with the Workshop Manual for Caddy 2011> (body assembly instructions, exterior, section 64 –...

  • Page 111: Roof Cut-Outs

    1 - Front roof frame 2 - Areas for roof cut-outs 3 - Rear roof frame 4 - Roof cross strut 5 - Roof frame right/left Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 111 of 163...
  • Page 112 For further information about body assembly work, refer to the Internet under erWin (Electronic Repair and Workshop Information of Volkswagen AG): http://erwin.volkswagen.de/erwin/showHome.do *Information system from Volkswagen AG, subject to payment Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 112 of 163...

  • Page 113: Modifications To The Roof Of The Caddy Cargo / Caddy

    For further information about body assembly work, refer to the Internet under erWin (Electronic Repair and Workshop Information of Volkswagen AG): http://erwin.volkswagen.de/erwin/showHome.do *Information system from Volkswagen AG, subject to payment Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 113 of 163...

  • Page 114: Modifying The Partition Wall/Forced Ventilation

    When installing non-factory partitions, make sure that the vehicle body is not completely sealed off. It must be ensured that air can flow between the driver’s compartment and the load compartment. You can obtain more information on special equipment depending on the vehicle model from your Volkswagen customer service and from the website.
  • Page 115 Otherwise, the passengers on the outer seats are no longer protected in the event of a side impact. You will find further information on the standard contact points as well as installing and removing the standard partition in the Volkswagen AG Workshop Manuals.

  • Page 116: Partition Connection Points

    3– 6x M6 round weld nuts 4– 2x speed buts M6x23.8x16 mm Installation sequence: − Partition bracket − Partition bottom part − Partition top part Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 116 of 163...

  • Page 117: Interior

    Modifications to the floor structure in the area of the airbag control unit or the satellite sensors are also unauthorised. For information about the deployment zones of the airbags, refer to the owner's manual of the vehicle. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 117 of 163...

  • Page 118: Ecall Emergency System

    Retrofitting seats with standard seats in the 3rd seat row is only possible in the Caddy if the seat preparation with PR no. 3NR was taken into account when ordering the vehicle. Please refer to chapter 1.3.1 “Selection of the base vehicle” in this regard. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 118 of 163...

  • Page 119: Add-Ons

    3 Modifications to closed bodies 3.3 Add-ons 3.3.1 Accessories An extensive range of accessories for the Caddy/Caddy Maxi can be obtained from Volkswagen Accessories. Information For more information about this topic, refer to: http://www.volkswagen-zubehoer.de/ Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition...

  • Page 120: Implementations Of Special Bodies

    4.1 Motor vehicles for the transport of persons with disabilities (KMP) A wide range of driving aids for disabled persons, catering to persons with various disabilities, is available as optional equipment from Volkswagen AG. For more information, please contact your Volkswagen dealership. Information For more information about this topic, refer to: https://www.volkswagen-...

  • Page 121: Selection Of Steering Rack For Conversions For People With Disabilities

    Volkswagen Commercial Vehicles dealership by specifying the vehicle identification number. They will also help you with the ordering process. Your importer or Volkswagen Commercial Vehicles dealership will then send your manufacturer’s declaration and the fully completed order form for retrofitting the KMP running gear to the NSC**.
  • Page 122 (see chapter 2.6.4 “Exhaust system”) *KMP: motor vehicle for people with restricted mobility ** NSC: Commercial Vehicles service centre *** ETKA: Electronic parts catalogue for After Sales Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 122 of 163...

  • Page 123: Notes On Installing Manual Operating Devices For The Foot Brake

    (with entry in the driving licence), if there is insufficient distance to the steering wheel or if a smaller steering wheel for wheelchair users is fitted (self-drive) and no airbag can be installed. For more information, please contact your Volkswagen customer service.
  • Page 124 2.5.4 “Vehicle battery” − 2.5.5 “Subsequent installation of generators” − 3.1 “Body-in-white” − 2.6.3 “Fuel system” − 2.6.4 “Exhaust system” − 3.2.1 “Safety features” Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 124 of 163...

  • Page 125: Refrigerated Vehicles

    2.5.5 “Subsequent installation of generators” − 2.7. “Engine auxiliary drives” − 3.1 “Structure/body” − 3.1.4 “Modifications to the roof of the Caddy Cargo/Caddy” Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 125 of 163...

  • Page 126: Shelf Installation/Workshop Vehicles

    “sufficient”. Usually from the front and above (roof) to the rear bottom (floor, side panel at bottom). Warning note All applicable safety regulations for handling gas cylinders must be complied with. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 126 of 163...
  • Page 127 PR number UC5, must be replaced by standard equipment. Otherwise, the driving properties might be negatively impaired. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 127 of 163...

  • Page 128: Emergency Vehicles

    Information For more information on this topic, visit: http://www.Industry solutions and conversions | Volkswagen Commercial Vehicles (volkswagen- nutzfahrzeuge.de) Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 128 of 163...

  • Page 129: Preparation For Taxis And Private Hire Cars

    Signal Pin no. Signal MFA_21 MFA_20 MFA_4 MFA_5 Pin no. MFA_22 MFA_3 MFA_8 MFA_7 Signal CFCU pin assignment: Taxis and private hire cars Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 129 of 163...
  • Page 130 MFE_05: Taxi roof sign button (only for taxi preparation PR number F4E) − MFE_21: Signal from taximeter: Roof sign control (only for taxi preparation PR no. F4E) − MFE_23: Signal from end device: fare Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 130 of 163...

  • Page 131: Function Description

    (see 1.2.1.1 “Contact in Germany” and 1.2.1.2 “International contact”). You will also find information on this in the owner’s manual for your vehicle, on the Volkswagen Commercial Vehicles homepage under “Industry Solutions and Commercial Customers/Industry Solutions/Commercial Vehicles Passenger Transport/Taxi” or at your Volkswagen Commercial Vehicles Partner.
  • Page 132 Time-controlled switching off the voltage supply and at low charge level of the battery Provision of data for the taximeter − Output of a distance signal via the MFA 14 output Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 132 of 163...

  • Page 133: Programming According To Customer Requirements

    The configuration of the customer- specific functional control unit (CFCU) can be ordered via the CS portal. *CFCU: customer-specific functional control unit, see also chapter 2.5.3.3 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 133 of 163...

  • Page 134: Leisure Vehicles

    Information For more information about this topic, refer to the Volkswagen Commercial Vehicles website at: https://www.volkswagen- nutzfahrzeuge.de/de/modelle/nutzfahrzeugkategorien-im- ueberblick/california-reisemobile.html Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 134 of 163...

  • Page 135: Vehicles For Local And Public Authorities

    Further information on this topic can be found on the Volkswagen Commercial Vehicles website at: http://www.Local and public authorities | Volkswagen Commercial Vehicles (volkswagen-nutzfahrzeuge.de) Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 135 of 163...

  • Page 136: Vehicles For Couriers And Logistics

    When there is a door arrester with an additional buffer, the opening angle of the doors is reduced by approx. 6 degrees! The third position is not reached! Fig. 1: Schematic diagram, door with buffered door arrester 1 - Additional buffer Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 136 of 163...

  • Page 137: Plug-In Hybrid Electric Vehicle (Phev)

    5 – Charging socket 1 for high-voltage battery charging 6 - Power and control electronics for electric drive 7 – Charging unit 1 for high-voltage battery 8 - Three-phase current drive Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 137 of 163...

  • Page 138: Power And Control Electronics For Electric Drive

    Fastenings on the vehicle floor that protrude into the area of the high-voltage battery or permanently restrict accessibility to the battery − Exterior conversions that project into the area of the high-voltage battery or permanently restrict accessibility to the battery. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 138 of 163...
  • Page 139 Fig. 2: Bottom view of high-voltage battery location, short wheelbase 1 – lithium-ion high-voltage battery 2 – underbody cladding 3 – Fuel tank Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 139 of 163...
  • Page 140 Warning note Changes to the electrical drive system can lead to the system ceasing to function properly. Control of the vehicle may be lost. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 140 of 163...
  • Page 141 Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 141 of 163...

  • Page 142: 12-V Vehicle Electrical System

    Fig. 1: Starter battery with cover in the rear right luggage compartment, above the wheel arch A sound generator is mounted on the front right longitudinal member to generate driving noises during electric vehicle operation. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 142 of 163...

  • Page 143: Technical Data

    Please refer to our build dimension drawings for the dimensions of the new Caddy and Caddy Maxi. They are available for download in DXF, TIFF and PDF format at the Customised Solution Portal of Volkswagen AG. All files (except PDFs) are packed as Zip archives.

  • Page 144: Diagrams (Foil Templates)

    All files are packed as Zip archives. The files can be unpacked using Winzip (PC) or ZipIt (MAC). Information Current diagrams are available for downloading from the Customised Solution Portal of Volkswagen AG under the “Foil templates” menu item. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 144 of 163...

  • Page 145: Current Flow Diagrams

    5 Technical data 5.3 Current flow diagrams For detailed information about this topic, refer to the workshop manuals and circuit diagrams of Volkswagen AG. Information Volkswagen AG workshop manuals and circuit diagrams can be downloaded from the Internet at erWin* (Electronic Repair and Workshop Information from Volkswagen AG): http://erwin.volkswagen.de/erwin/showHome.do...

  • Page 146: Cad Models

    The available 3D data can be found on the Customised Solution Portal of Volkswagen AG under menu option “Technical information/CAD data”*. *Registration required. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 146 of 163...

  • Page 147: Calculations

    The centre of gravity in the vehicle longitudinal direction is given in relation to a vehicle axle. The centre of gravity height is related to the wheel hub or related to the road. Volkswagen recommends having the centre of gravity determined by a recognised test institution with experience in this field (e.g., DEKRA, TÜV or others).
  • Page 148 This value is then used for calculating in accordance with the equations (3) and (4). Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 148 of 163...

  • Page 149: Determining The Centre Of Gravity In Z-Direction

    (for example, 600 mm, 700 mm and 800 mm). This also allows errors to be limited by averaging. The centre of gravity height results from the arithmetic average of the individual centre of gravity heights for each raising height. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 149 of 163...
  • Page 150 The practical determination of the centre of gravity height may only be performed by appropriately qualified personnel with the help of suitable and calibrated measuring systems and measuring tools. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 150 of 163...
  • Page 151 Fig. 2: Determining the location of the vehicle centre of gravity in z-direction Determining the overall centre of gravity S in z-direction: ℎ = ℎ + �� �� �� �������� Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 151 of 163...

  • Page 152: Weighing Equipment

    Centre of gravity height over road �� ℎ Centre of gravity height over centre of wheel �� ℎ′ Height by which the vehicle has been raised Weighing equipment Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 152 of 163...

  • Page 153: Weights (Masses)

    We recommend determining the definitive kerb weight of the entire vehicle by weighing before the conversion. For further questions, please contact your Volkswagen Commercial Vehicles dealer, your importer or our Customer Care (see chapter 1.2.1.1 “Contact in Germany”, 1.2.1.2 “International contact”).

  • Page 154: Notes On Homologation Of Modifications And Conversions

    WLTP calculator, please contact your responsible technical service department and check whether individual approval or multi- stage type approval is possible. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 154 of 163...

  • Page 155: Technical Specifications

    The new values for the 90 kW TDI MQ 4x4 and the 55 kW TDI MQ will be filled with the next version in CW 48/2024. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 155 of 163...

  • Page 156: Permissible Aerodynamic Changes And Max. Dimensions

    WLTP calculator, please contact your responsible technical service department and check whether individual approval or multi- stage type approval is possible. Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 156 of 163...

  • Page 157: Listings

    Non-Volkswagen badge 1.2.6 Recommendations for vehicle storage 1.2.7 Compliance with environmental rules and regulations 1.2.8 Recommendations for inspection, maintenance and repair 1.2.9 Accident prevention Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 157 of 163...
  • Page 158 2.3.1.1 Dynamic roof loads 2.3.2 Modifications to the body-in-white 2.3.2.1 Screw connections 2.3.2.2 Welding work 2.3.2.3 Welded connections 2.3.2.4 Selection of welding process Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 158 of 163...
  • Page 159 Parameterised* reactions on reaching certain second battery Chapter updated charge levels with second battery monitoring 2.5.5 Retrofitting alternators Chapter updated, see note updated Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 159 of 163...
  • Page 160 2.8.3.1 Maximum trailer weights 2.8.3.2 Retrofitting a trailer towing bracket 2.8.3.3 Clearance according to UN-R 55 Raising the vehicle Modifications to closed bodies Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 160 of 163...
  • Page 161 Plug-in hybrid electric vehicle (PHEV) Chapter added 4.9.1 High-voltage system Chapter added Technical data Build dimension drawings Diagrams (foil template) Current flow diagrams Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 161 of 163...
  • Page 162 Chapter added the following variants 8.2.2 Permissible aerodynamic changes and max. dimensions Chapter added Listings List of changes Last page Title, Brieffach, issue date Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 162 of 163...
  • Page 163 Converter guidelines The Caddy Converter guidelines Subject to change without notice August 2024 edition Internet: https://www.volkswagen-nutzfahrzeuge.de https://www.customized-solution.com Consulting for converters in Germany is available from the listed address. Volkswagen Commercial Vehicles Brieffach 2949 Postfach 21 05 80 D-30405 Hannover...

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