Volkswagen Caddy 2004 User Manual
Service Training
Self-study programme 328
The 2004 Caddy
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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.
The Caddy Van, Caddy Shuttle and Caddy Life cover a wide range of needs.
In addition to, increased payload, more space and also improved functionality, the 2004 Caddy
has a boarder engine range that now also offers greater performance.
Furthermore no shortcuts have been taken in crash safety.
The self-study programme shows the design and
function of new developments.
The contents will not be updated.
2
NEW
For current testing, adjustment and repair instructions,
refer to the relevant service literature.
Important
Note
Contents
In brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heating and air-conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Radio, telephone and navigation. . . . . . . . . . . . . . . . . . . . . . . . 66
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3
In Brief
The 2004 Caddy
Where is the 2004 Caddy built?
In 1993, a joint venture was set-up between the
Polish car manufacturer FSR
(in Polish = Fabryka Samochodów
Rolniczych,
English = Factory for Agricultural
Automobiles)
and Volkswagen Group.
Volkswagen Poznan GmbH has been a
100-percent subsidiary of Volkswagen
Commercial Vehicles since 1997.
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.
The plant in Poznan
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Major investments include the set-up of a new
paint shop, a new body plant and new assembly
lines for the 2004 Transporter and the 2004
Caddy.
The result is a complete automobile plant with its
own logistics services, quality assurance
department and all associated areas. Among
others, the latest laser welding and soldering
techniques are being used for the new models.
With the launch of the 2004 Transporter, the plant now has its very own product for the first time. All
2004 Transporters with open superstructures are produced in Poznan. The 2004 Transporter Kombi also
rolls off the assembly line in Poznan.
Now Poznan has another product of its own - the 2004 Caddy.
Paint shop
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4
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
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Fiat Doblò
Opel Combo
Immediate rivals
Competition
Renault Kangoo
Ford Tourneo Connect
Citroën Berlingo
Mercedes Vaneo
2004 Caddy Shuttle/Life
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5
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
• Payload up to 750 kg
• Towing up to 1,500 kg
• Loading capacity up to 3.2 m
• Sliding door on right and left (optional),
Sliding door opens wide to 700 mm
3
• Clear glass headlamps with H1/H7 bulbs
• Electromechanical power
steering
• Navigation/preparation
for telephone (optional)
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• Rear axle with leaf springs
• ABS - MK70 system (Conti Teves)
• Generous storage compartments in the
doors and cab roof ceiling of driver’s cab
6
• Crash-optimised pedals and
crash-optimised steering
column
• Airbag system with
front side airbags
• Glazed load compartment,
same as Shuttle (optional)
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
Caddy Shuttle/Caddy Life
• Rear vent wings (optional)
on Caddy Shuttle/Caddy Life
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• ESP (optional)
MK60 system (Conti Teves)
• Tipping 1st seat row in passenger
compartment on Caddy Shuttle/Caddy Life
• Generous storage facilities in
Caddy Life passenger compartment
• Removable and locking tow bar
on Caddy Shuttle/Caddy Life
• 2nd seat row in passenger compartment (optional) in form of folding and
removable double bench
• Sliding windows in
sliding doors
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In Brief
Technical data
Caddy Van
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Dimensions
Length 4,405 mm
Length with tow bar 4,505 mm
Width 1,802 mm
Width with mirrors 2,062 mm
Height 1,833 mm
Overhang length at front 880 mm
Overhang length at rear 843 mm
Height of load sill 587 mm
Ground clearance 154 mm
Wheelbase 2,682 mm
Track width at front 1,537 mm
Track width at rear 1,531 mm
Tank capacity 60 l
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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
weight.
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Weight
Caddy Van Caddy Shuttle/Caddy Life
5-seater 7-seater
Curb weight including driver* 1,400 – 1,481 kg 1,476–1,560 kg (Shuttle)
1,521 – 1,605 kg (Life)
Maximum weight* 2,150 – 2,235 kg 2,000 – 2,124 kg 2,165 – 2,250 kg
Braked towing capacity* 1,200 – 1,500 kg 1,200 – 1,500 kg 1,035 – 1,350 kg
Load without driver* up to 750 kg 503 - 653 kg (Shuttle)
479 - 608 kg (Life)
Roof load 100 kg
* Depending on engine and equipment
1,513-1,597 kg (Shuttle)
1,558 –1,642 kg (Life)
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In Brief
Interior dimensions
Caddy Van
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Load compartment dimensions
1 Opening width -
rear door/tailgate
2 Opening height -
rear door/tailgate
3 Loading height up to 1,257 mm
4 Opening width -
sliding door
5 Loading length up to 1,781 mm
6 Loading width 1,172 to 1,558 mm
1,181 mm
1,116 mm
700 mm
Load compartment – Volume
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The pictures show the Caddy Van with
wing doors. A tailgate is also available
as an option.
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Colour Volumes
Name Volumes
Load compartment volumes up to 3,200 l
Caddy Shuttle/Caddy Life
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Luggage compartment -dimensions
1 Opening width -
rear door/tailgate
2 Opening height -
rear door/tailgate
3 Loading height up to 1,238 mm
4 Opening width -
sliding door
5 Luggage compartment
length
6 Luggage compartment
width (Shuttle)
Luggage compartment
width (Life)
1,181 mm
1,116 mm
700 mm
up to 1,354 mm
1,170 to 1,340 mm
1,120 to 1,340 mm
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The pictures show the Caddy Shuttle
with tailgate. It can also be equipped
with optional wing doors.
Luggage compartment – volume
Colour partial volume
Name Volume
Volume, closed luggage compartment,
behind 1st seat row in passenger compartment
Volume, open luggage compartment,
behind 1st seat row in passenger compartment
Volume, open luggage compartment,
behind front seats with tipped 1st seat row
Sum of partial volume
Caddy Shuttle Caddy Life
up to 626 l up to 560 l
up to 1,266 l up to 1,200 l
up to 2,305 l up to 2,239 l
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In Brief
Overview of doors
Caddy Van
… with tailgate … with rear
Right-hand sliding doorLeft-hand sliding doorSliding doors on both sidesWithout sliding door
wing doors
… with rear
wing doors and
“ladder flap”
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Caddy Shuttle/Caddy Life
… with tailgate … with rear
wing doors
… with rear
wing doors and
“ladder flap”
The 2004 Caddy comes in a wide range of
versions. The variable equipment with sliding
doors, rear wing doors, tailgates or a ladder
flap.
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The picture shows the complete Caddy
range.
The assignment of left-hand and righthand drive vehicles can be found in the
current sales literature.
The ladder flap will be available later
on.
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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.
The 2004 Caddy has a torsionally stiff and low
weight two-shell body structure (inside/outside
body shell). The following structural features can
be distinguished in terms of function:
– Floor pan with frame structure,
with tailored blanks at front (different sheet
thicknesses, welded before shaping)
– inner body shell,
with 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
Floor pan - front
with tailored blanks
Longitudinal member - front
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Floor - front
increasing sheet thickness
Longitudinal member - front
Roof reinforcements
The pictures show the body
in white of the Caddy Van.
Cross member
Reinforcing element
Floor panel - rear
Floor panel - front
Normal-strength sheet
Higher strength sheets
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Side section (one-piece)
Mounted partsSheet qualities
Doors
Side impact elements
High-strength sheets
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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.
Inside handle
Outside handle
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Locking lever
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The left-hand wing 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 wing door. Wing doors lock at a 90° angle when opened. If the door
latches are detached, the wing doors will open to approx. 170° due to a stop in the hinge.
Tailgate
The Caddy Shuttle and Caddy Life come with a tailgate with rear window as standard. The Caddy Van
can also be fitted with a tailgate. The tailgate can be opened with an outside handle. A draw loop is
provided to help pull it down.
Draw loop
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Outside
handle
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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.
Only the Caddy Van with a glazed load
compartment can be equipped with a sliding
door.
The Caddy Shuttle and Caddy Life have sliding
doors a with windows.
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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 when the door is slid backwards, the
2004 Caddy has a locking unit when equipped
with a sliding door on the left-hand side.
Function
When the tank filler flap is open, a Bowden
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 outwards so that the sliding door hits it
and cannot be pushed back any further.
Blocking latch
Blocking unit
Bowden cable
on tank filler flap
Bowden cable
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Rotating bolt
Blocking latch
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Connect to
tank filler flap
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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.
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Vent windows
Optional manual vent windows are also
available for the Caddy Shuttle and Caddy Life.
Both sides will be equipped with vent windows
when this option is chosen.
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Roof rack
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.
Base carrier
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4 screws with rubber seals are fitted on the
vehicle roof. These screws need to be removed
together with the seal to fit the base carrier.
The sealing screws should be kept and
fitted again when the base carrier is
removed to seal the roof.
The base carrier is secured with the supplied
screws and seals.
Screw with
seal
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Screw
The seals prevent water leaking into the
body.
Refer to the operating manual for information on fitting the base carrier.
Foot
Seal
Protective
film
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Body
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
width of 1000 mm, depth of 400 mm and height
of up to 250 mm.
Overhead storage
The cargo is safely secured by the lashing rings
and the bulkhead between 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 with an optional rubber mat.
The side panels underneath the windows in the
load compartment are protected with noncoated hardboard. There are no additional
storage compartments here.
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Storage in driver’s door
Bulkhead
Jack and tool set,
mounted without cover
Lashing rings on floor
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Body
Caddy Shuttle/Caddy Life
The Shuttle version of the 2004 Caddy comes in
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. Four lashing rings on the floor allow
safe anchoring of loads.
The side panels of the passenger compartment
are made from varnished hardboard. They do
not have storage compartments. The ceiling is
is also lined with varnished hardboard.
There are two storage compartments with
removable lids in the footwell in front of the first
row of seats in the passenger compartment.
The jack and tool set are mounted on the side
wall without a cover.
The picture shows a Caddy Life.
The Caddy Life has additional features
compared with the Caddy Shuttle. The side
panels are moulded sections with integrated
storage bins.
Attachment rings are mounted above the
windows for an optional net partition.
A further option is storage nets with hooks for
hanging items. The Caddy Life comes with a
luggage area cover as standard (not shown
here).
The jack and tool set are stowed away behind a
cover in the side panelling.
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Compartment in floor
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