Volkswagen Caddy 2004 Instruction sheet

The 2004 Caddy
Self-study programme 328
Service Training

2
Important
Note
N W
The self-study programme shows the design and
function of new developments.
The contents will not be updated.
For current testing, adjustment and repair instructions,
refer to the relevant service literature.
The 2004 Caddy is built on the same platform as the 2004 Golf. Compared ith the previous
model based on the Polo platform, e have improved the technology and comfort considerably.
The 2004 Caddy ill thus take a leading position among its rivals.
Unlike its predecessor, the 2004 Caddy no comes in three different versions.
The Caddy Van, Caddy Shuttle and Caddy Life cover a ide range of needs.
In addition to, increased payload, more space and also improved functionality, the 2004 Caddy
has a boarder engine range that no also offers greater performance.
Furthermore no shortcuts have been taken in crash safety.
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Contents
In brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ngines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
lectrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heating and air-conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Radio, telephone and navigation. . . . . . . . . . . . . . . . . . . . . . . . 66
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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In Brief
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The 2004 Caddy
Where is the 2004 Caddy built?
In 1993, a joint venture as set-up bet een the
Polish car manufacturer FSR
(in Polish = Fabryka Samochodó
Rolniczych,
English = Factory for Agricultural
Automobiles)
and Volks agen Group.
Volks agen Poznan GmbH has been a
100-percent subsidiary of Volks agen
Commercial Vehicles since 1997.
With the launch of the 2004 Transporter, the plant no has its very o n product for the first time. All
2004 Transporters ith open superstructures are produced in Poznan. The 2004 Transporter Kombi also
rolls off the assembly line in Poznan.
No Poznan has another product of its o n - the 2004 Caddy.
Major investments include the set-up of a ne
paint shop, a ne body plant and ne assembly
lines for the 2004 Transporter and the 2004
Caddy.
The result is a complete automobile plant ith its
o n logistics services, quality assurance
department and all associated areas. Among
others, the latest laser elding and soldering
techniques are being used for the ne models.
The plant in Poznan
The original business concept behind Volks agen Poznan GmbH as to assemble light commercial
vehicles from kits. Kits from the different Volks agen Group brands ere delivered to Poznan for
complete assembly. Operations ere expanded constantly over the next years. Around 3,400 members
of staff currently ork at the plant.
Paint shop

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The Competitors
The diagram sho s the field of competitors facing the 2004 Caddy. Only one version of each vehicle is
sho n to represent the respective range.
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Ford Tourneo Connect
Opel Combo
Fiat Doblò
Mercedes Vaneo
Renault Kangoo
Citroën Berlingo
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2004 Caddy Van
2004 Caddy Shuttle/Life
Immediate rivals
Competition

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In Brief
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•Electromechanical po er
steering
•Crash-optimised pedals and
crash-optimised steering
column
•ABS - MK70 system (Conti Teves)
•Sliding door on right and left (optional),
Sliding door opens ide to 700 mm
•Rear axle ith leaf springs
•Clear glass headlamps ith H1/H7 bulbs
•Navigation/preparation
for telephone (optional)
•Payload up to 750 kg
•To ing up to 1,500 kg
•Loading capacity up to 3.2 m3
•Airbag system ith
front side airbags
•Generous storage compartments in the
doors and cab roof ceiling of driver’s cab
Technical highlights in the 2004 Caddy
The 2004 Caddy is setting ne standards ith the Caddy Van, Caddy Shuttle and Caddy Life versions.
It features a modern design ith smooth outer surfaces all-round.
Here is an overvie of the highlights:
Caddy Van
•Glazed load compartment,
same as Shuttle (optional)

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•Removable and locking to bar
on Caddy Shuttle/Caddy Life
•Tipping 1st seat ro in passenger
compartment on Caddy Shuttle/Caddy Life
•Up to 7 seats in the
Caddy Shuttle/Caddy Life
•Rear vent ings (optional)
on Caddy Shuttle/Caddy Life
•2nd seat ro in passenger compart-
ment (optional) in form of folding and
removable double bench
•Generous storage facilities in
Caddy Life passenger compartment
Caddy Shuttle/Caddy Life
The Shuttle version of the 2004 Caddy, offering further highlights compared ith the Caddy Van, comes
in 2 versions:
– Caddy Shuttle is the “Basic” version and
– Caddy Life is the “Comfort” version
•ESP (optional)
MK60 system (Conti Teves)
•Sliding indo s in
sliding doors

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Technical data
In Brief
Length 4,405 mm
Length ith to bar 4,505 mm
Width 1,802 mm
Width ith mirrors 2,062 mm
Height 1,833 mm
Overhang length at front 880 mm
Overhang length at rear 843 mm
Dimensions
Caddy Van
Height of load sill 587 mm
Ground clearance 154 mm
Wheelbase 2,682 mm
Track idth at front 1,537 mm
Track idth at rear 1,531 mm
Tank capacity 60 l
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Weight
Caddy Shuttle/Caddy Life
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
eight.
Caddy Van Caddy Shuttle/Caddy Life
5-seater 7-seater
Curb eight including driver* 1,400 – 1,481 kg 1,476–1,560 kg (Shuttle)
1,521 – 1,605 kg (Life)
1,513-1,597 kg (Shuttle)
1,558 –1,642 kg (Life)
Maximum eight* 2,150 – 2,235 kg 2,000 – 2,124 kg 2,165 – 2,250 kg
Braked to ing capacity* 1,200 – 1,500 kg 1,200 – 1,500 kg 1,035 – 1,350 kg
Load ithout driver* up to 750 kg 503 - 653 kg (Shuttle)
479 - 608 kg (Life)
Roof load 100 kg
* Depending on engine and equipment
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In Brief
Interior dimensions
Caddy Van
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1 Opening idth -
rear door/tailgate
1,181 mm
2 Opening height -
rear door/tailgate
1,116 mm
3 Loading height up to 1,257 mm
4 Opening idth -
sliding door
700 mm
5 Loading length up to 1,781 mm
6 Loading idth 1,172 to 1,558 mm
Load compartment dimensions
Colour -
Volumes
Name Volumes
Load compartment volumes up to 3,200 l
Load compartment – Volume
The pictures sho the Caddy Van ith
ing doors. A tailgate is also available
as an option.

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Caddy Shuttle/Caddy Life
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1 Opening idth -
rear door/tailgate
1,181 mm
2 Opening height -
rear door/tailgate
1,116 mm
3 Loading height up to 1,238 mm
4 Opening idth -
sliding door
700 mm
5 Luggage compartment
length
up to 1,354 mm
6 Luggage compartment
idth (Shuttle)
Luggage compartment
idth (Life)
1,170 to 1,340 mm
1,120 to 1,340 mm
Luggage compartment – volume
Luggage compartment -dimensions
The pictures sho the Caddy Shuttle
ith tailgate. It can also be equipped
ith optional ing doors.
Colour -
partial volume
Name Volume
Sum of partial volume
Caddy Shuttle Caddy Life
Volume, closed luggage compartment,
behind 1st seat ro in passenger compartment
up to 626 l up to 560 l
Volume, open luggage compartment,
behind 1st seat ro in passenger compartment
up to 1,266 l up to 1,200 l
Volume, open luggage compartment,
behind front seats ith tipped 1st seat ro
up to 2,305 l up to 2,239 l

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Overview of doors
In Brief
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Right-hand sliding doorLeft-hand sliding doorSliding doors on both sidesWithout sliding door
… ith tailgate … ith rear
ing doors
… ith rear
ing doors and
“ladder flap”
Caddy Van

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The 2004 Caddy comes in a ide range of
versions. The variable equipment ith sliding
doors, rear ing doors, tailgates or a ladder
flap.
The picture sho s the complete Caddy
range.
The assignment of left-hand and right-
hand drive vehicles can be found in the
current sales literature.
The ladder flap ill be available later
on.
… ith tailgate … ith rear
ing doors
… ith rear
ing doors and
“ladder flap”
Caddy Shuttle/Caddy Life

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Body in white
A sturdy body in hite 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 hen used as a family and leisure vehicle.
Body
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The 2004 Caddy has a torsionally stiff and lo
eight t o-shell body structure (inside/outside
body shell). The follo ing structural features can
be distinguished in terms of function:
– Floor pan ith frame structure,
ith tailored blanks at front (different sheet
thicknesses, elded before shaping)
– inner body shell,
ith reinforcement elements,
– outer body shell,
single-piece side section
– Roof reinforcements
– Use of different sheet qualities depending on
the loading of the respective body areas
– Reinforcement and impact elements for
improved occupant protection in the front
doors Longitudinal member - front
Floor pan - front
with tailored blanks
increasing sheet thickness
Longitudinal member - front
Floor - front

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The pictures sho the body
in hite of the Caddy Van.
Floor panel - rear
Side section (one-piece)
Cross member
Roof reinforcements
Reinforcing element
Floor panel - front
Side impact elements
Doors
Normal-strength sheet
High-strength sheets
Higher strength sheets
Mounted partsSheet qualities

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Body
Wing doors
The Van version of the 2004 Caddy comes ith glazed ing doors split in the ratio 2/3 to 1/3.
The indo s in the ing doors can be covered ith an optional dark opaque film. The Caddy Shuttle/
Caddy Life can be optionally fitted ith the ing doors.
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Outside handle
Inside handle
Locking lever
Outside
handle
Dra loop
The left-hand ing door needs to be opened first. The outside handle on the left-hand door is integrated
in the number plate light fitting. The locking level built into the bottom of the right-hand door can then be
used to open the right-hand ing door. Wing doors lock at a 90° angle hen opened. If the door
latches are detached, the ing doors ill open to approx. 170° due to a stop in the hinge.
Tailgate
The Caddy Shuttle and Caddy Life come ith a tailgate ith rear indo as standard. The Caddy Van
can also be fitted ith a tailgate. The tailgate can be opened ith an outside handle. A dra loop is
provided to help pull it do n.

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Sliding door
The 2004 Caddy is equipped ith a sliding door
reaching up to the roof on the passenger side.
The drivers side can also be fitted ith an
optional sliding door.
The sliding door opens to a maximum idth of
70 cm.
Only the Caddy Van ith a glazed load
compartment can be equipped ith a sliding
door.
The Caddy Shuttle and Caddy Life have sliding
doors a ith indo s.
Protection of the tank filler flap
The tank filler flap is located on the driver’s side
just in front of the D-pillar. To ensure that it is not
damaged hen the door is slid back ards, the
2004 Caddy has a locking unit hen equipped
ith a sliding door on the left-hand side.
Function
When the tank filler flap is open, a Bo den
cable attached to the tank filler flap activates a
rotating bolt in the locking unit. The blocking
latch connected to the rotating bolt is then
moved out ards so that the sliding door hits it
and cannot be pushed back any further.
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Blocking latch Bo den cable
on tank filler flap
Blocking unit Rotating bolt
Bo den cable
Blocking latch
Connect to
tank filler flap

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Body
Window
Sliding window
The version of the Caddy Van ith glazed load
compartment can be optionally fitted ith a
sliding indo in the sliding door.
The Caddy Shuttle can also be equipped ith an
optional sliding indo in the sliding door.
The Caddy Life comes ith the sliding indo as
standard.
Vent windows
Optional manual vent indo s are also
available for the Caddy Shuttle and Caddy Life.
Both sides ill be equipped ith vent indo s
hen this option is chosen.
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Roof rack
A system ith a bolt-on base carrier is used for
the roof rack on the 2004 Caddy.
There are special accessories allo ing 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.
4 scre s ith rubber seals are fitted on the
vehicle roof. These scre s need to be removed
together ith the seal to fit the base carrier.
Refer to the operating manual for information on fitting the base carrier.
The base carrier is secured ith the supplied
scre s and seals.
The seals prevent ater leaking into the
body.
The sealing scre s should be kept and
fitted again hen the base carrier is
removed to seal the roof.
Seal
Foot
Scre ith
seal
Scre
Protective
film
Base carrier

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Interior concept
Caddy Van
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
– in addition to the storage bins in the
– dash panel and centre console.
The generous overhead storage is particularly
useful. It can even hold A4 binders thanks to the
idth of 1000 mm, depth of 400 mm and height
of up to 250 mm.
The cargo is safely secured by the lashing rings
and the bulkhead bet een the cab and the load
compartment. The bottom half of the bulkhead is
made from a plastic surface and the top from a
plastic grille.
The floor of the load compartment can also be
covered ith an optional rubber mat.
The side panels underneath the indo s in the
load compartment are protected ith non-
coated hardboard. There are no additional
storage compartments here.
Body
Overhead storage
Storage in driver’s door