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.