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Volkswagen Caddy 2004 Self-study Programme

Summary of Caddy 2004

  • Page 1

    The 2004 caddy self-study programme 328 service training.

  • Page 2

    2 important note new 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. Compare...

  • Page 3

    3 contents in brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4

    4 in brief s328_002 s328_004 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 1...

  • Page 5

    5 the competitors the diagram shows the field of competitors facing the 2004 caddy. Only one version of each vehicle is shown to represent the respective range. S328_096 ford tourneo connect opel combo fiat doblò mercedes vaneo renault kangoo citroën berlingo s328_097 s328_162 2004 caddy van 2004 ca...

  • Page 6

    6 in brief s328_096 • electromechanical power steering • crash-optimised pedals and crash-optimised steering column • abs - mk70 system (conti teves) • sliding door on right and left (optional), sliding door opens wide to 700 mm • rear axle with leaf springs • clear glass headlamps with h1/h7 bulbs ...

  • Page 7

    7 s328_097 • removable and locking tow bar on caddy shuttle/caddy life • tipping 1st seat row in passenger compartment on caddy shuttle/caddy life • up to 7 seats in the caddy shuttle/caddy life • rear vent wings (optional) on caddy shuttle/caddy life • 2nd seat row in passenger compart- ment (optio...

  • Page 8

    8 technical data in brief 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 dimensions caddy van height of load sill 587 mm ground clearance 154 mm wheelbase 2,682 mm track width at f...

  • Page 9

    9 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 weight. Caddy van caddy shuttle/caddy life 5-seater 7-seater curb weight including driver...

  • Page 10

    10 in brief interior dimensions caddy van s328_008a s328_009 s328_008b 1 opening width - 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 width - sliding door 700 mm 5 loading length up to 1,781 mm 6 loading width 1,172 to 1,558 mm ...

  • Page 11

    11 caddy shuttle/caddy life s328_010a s328_011 s328_010b 1 opening width - 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 width - sliding door 700 mm 5 luggage compartment length up to 1,354 mm 6 luggage compartment width (shuttle...

  • Page 12

    12 overview of doors in brief s328_012 right-hand sliding door left-hand sliding door sliding doors on both sides w ithout sliding door … with tailgate … with rear wing doors … with rear wing doors and “ladder flap” caddy van.

  • Page 13

    13 s328_013 the 2004 caddy comes in a wide range of versions. The variable equipment with sliding doors, rear wing doors, tailgates or a ladder flap. The picture shows the complete caddy range. The assignment of left-hand and right- hand drive vehicles can be found in the current sales literature. T...

  • Page 14

    14 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...

  • Page 15

    15 s328_014 the pictures show the body in white 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 parts sheet qual...

  • Page 16

    16 body wing doors the van version of the 2004 caddy comes with glazed wing doors split in the ratio 2/3 to 1/3. The windows in the wing doors can be covered with an optional dark opaque film. The caddy shuttle/ caddy life can be optionally fitted with the wing doors. S328_087 s328_088 s328_089 s328...

  • Page 17

    17 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 ...

  • Page 18

    18 body window sliding window the version of the caddy van with glazed load compartment can be optionally fitted with a sliding window in the sliding door. The caddy shuttle can also be equipped with an optional sliding window in the sliding door. The caddy life comes with the sliding window as stan...

  • Page 19

    19 s328_017 s328_104 s328_105 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 stab...

  • Page 20

    20 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 ...

  • Page 21

    21 s328_151 bulkhead jack and tool set, mounted without cover lashing rings on floor.

  • Page 22

    22 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 lashin...

  • Page 23

    23 s328_152 sliding door storage storage between c and d-pillar hooks for net partition and storage net jack and tool set behind panel.

  • Page 24

    24 centre console type with – open storage – cup holders – ashtray in passenger compartment fitted as standard in the caddy van and caddy shuttle. Centre console type with – compartment for a cd changer under the armrest lid – air-conditioning vents – fold-out cup holder – 12 v socket this centre co...

  • Page 25

    25 s328_153 storage compartment on passenger side containing key switch for front passenger airbag left-hand storage compartment on top of dash panel (caddy van and caddy shuttle) key switch for front passenger airbag ashtray and cigarette lighter right-hand storage compartment on top of dash panel ...

  • Page 26

    26 body s328_030 s328_093 seats (example caddy - 7-seater) seats the driver and front passenger seats in the 2004 caddy are individual seats. The first row of seats in the caddy shuttle/life is a 3-seat bench split 1/3-2/3. An optional double bench can be fitted in the second row. Features on driver...

  • Page 27

    27 seats in passenger compartment the three-seat bench in the first seat row of the passenger compartment is split into a 1/3 seat and a 2/3 seat. The bench is permanently screwed to the floor and cannot be removed. The backrests of each seat section can be folded forward separately and lock into a ...

  • Page 28

    28 the complete airbag system includes: – driver airbag – front passenger airbag – single-stage* – front side airbags* * optional for caddy van the belt system includes: – three-point safety belts with belt tensioners and belt pressure limits on the driver’s and front passenger seat – three-point sa...

  • Page 29

    29 the picture shows the caddy life. S328_037 three-point seat belt, integrated in seat three-point seat belt with rack and pinion belt tensioner, fixed to body driver side airbag module side airbag for driver side airbag crash sensor, in cab under driver’s/front passenger’s seat front airbag for dr...

  • Page 30

    30 1.4l/55 kw petrol engine the 1.4l/55 kw petrol engine has already proven itself in the golf and now features in the 2004 caddy. Technical features – 4-valve technology – 2 hollow overhead camshafts – reduced-weight crankshaft – lightweight piston – me 7.5.10 engine management – aluminium sump wit...

  • Page 31

    31 1.6l/75 kw petrol engine the 1.6l/75 kw petrol engine has already been used in the golf and touran and is now being mounted in the 2004 caddy. Technical features – an assembled camshaft – roller rocker arm – simos 7.1 engine management – aluminium sump with oil level sensor – electronic power con...

  • Page 32

    32 1.9l/77 kw tdi engine the 1.9l/77 kw tdi engine has already proven itself in the golf and now features in the 2004 caddy. Technical features – diesel engine with exhaust-gas turbocharger – unit injector system – overhead camshaft – edc 16 engine management – electronic power control with contact-...

  • Page 33

    33 2.0l/51 kw sdi engine the 2.0l/51 kw sdi engine with unit injector technology is a further development of the 1.9l/ 74 kw tdi engine used in the touran. Technical features – naturally aspirated diesel engine – unit injector system – overhead camshaft – edc 16 engine management – electronic power ...

  • Page 34

    34 transmission gearbox two mechanical manual gearboxes conceived for transverse installation feature in the 2004 caddy. The gearboxes are based on the proven group manual gearboxes. They have been further developed with the following changes. Changes: – shaft spacing increased – axle drive reinforc...

  • Page 35

    35 engine-gearbox combinations engine 5-speed manual gearbox 0ah 5-speed manual gearbox 0a4 1.4l/55 kw petrol engine bca 1.6l/75 kw petrol engine bgu 2.0l/51 kw sdi engine bdj 1.9l/77 kw tdi engine bjb.

  • Page 36

    36 chassis – anti-roll bar with 1 : 1 connection. The anti-roll bar is connected directly to the strut via a coupling rod and thus ensures good stability. – opening at front in subframe for gearbox pendulum support front axle the 2004 caddy has an optimised mcpherson front axle with lower wishbones ...

  • Page 37

    37 assembly carrier the assembly carrier holds the traverse link, anti- roll bar and steering rack. It is made up of three parts and has a central subframe to which consoles are connected on the left and right. The components of the assem- bly carrier are made from aluminium. The assembly carrier is...

  • Page 38

    38 chassis strut bearing the strut bearing is a rubber/metal bearing. The connection of the springs and the damper to the body are uncoupled from each other. The spring force is thus channelled separately into the body and tensioning of the damper bearing is avoided. This improves the ride comfort a...

  • Page 39

    39 technical features are: – single-layer leaf spring for caddy van and caddy shuttle – two-layer leaf spring for the caddy life (increased comfort) – bump stop (“additional spring” made of polyurethane) – dampers position at an angle towards the front to guarantee the through-loading width under th...

  • Page 40

    40 electromechanical power steering the 2004 caddy is equipped with a electromechanical power steering system (manufacturer zf), which is made up of the following main components – the steering wheel and – the electric motor with integrated control unit. The steering system is mounted on the subfram...

  • Page 41

    41 function the electromechanical power steering is an active system. It operates in relation to – the driving speed, – steering moment and steering speed, – steering angle and – return forces. It therefore provides optimum steering assistance for the driver. The assist power of the electric motor f...

  • Page 42

    42 chassis s328_051 s328_110 steering column the steering column is mechanically height and length adjusted. For optimum adaptation to the needs of the driver, the height can be adjusted by 40 mm and the length by 50 mm. Moving the adjustment lever, releases and locks the plate clamp for height and ...

  • Page 43

    43 brakes abs system the mk70 abs system from conti teves is used as standard in the 2004 caddy. It has the following technical features: – anti-lock brake system (abs) with – electronic brake pressure distribution (ebd). The traction control system (tcs) and engine braking control (ebc) are control...

  • Page 44

    44 brake servo the 2004 caddy uses a 10" brake servo from conti-teves. This brake servo has one essential new feature called the “dual rate characteristic curve”. This means that the brake assist works according to a two-step curve. A modified inside structure of the brake servo leads to a progressi...

  • Page 45

    45 front brakes two different disc brake systems are used in the 2004 caddy depending on the version or engine. They use ventilated brake discs. Up to an engine output of 55 kw, disc brakes with brake discs measuring Ø 280 mm x 22 mm are fitted. The brake carrier is integrated in the wheel bearing h...

  • Page 46

    46 chassis pedal cluster the crash-optimised pedal cluster has a modular structure and consists of – clutch pedal, – brake pedal and – accelerator pedal. The clutch pedal and the accelerator pedal have contact-free position sensors that recognise the pedal position. Both pedals are made of plastic. ...

  • Page 47

    47 s328_111 metal plate accelerator pedal cover for circuit board evaluation electronics you will find detailed information on the design and function of the contact-free senders in the self-study programmes 316 “the 2.0l tdi engine” or 321 “the golf 2004 running gear”. Senders for accelerator pedal...

  • Page 48

    48 electrical system locations of onboard supply components battery the battery is located at the front left of the engine compartment. E-box the fuses and relays for the electrical components in the engine compartment are accommodated in the e-box. Relay carrier the relay carrier holds additional r...

  • Page 49

    49 s328_060 relay carrier on left under dash panel relay carrier on control unit for onboard supply, on left under dash panel fuse box on left under dash panel pre-fuse box on left of engine compartment fuse and relay box on left of engine compartment.

  • Page 50

    50 networking concept overview of network to enable data exchange between the control units, they are networked via different data bus systems. The diagnostic interface for data bus j533 (gate- way) forms the interface for the following data buses: – drivetrain can data bus – convenience can data bu...

  • Page 51

    51 s328_061 legend g85 steering angle sender g273 interior monitoring sensor g384 vehicle inclination sender h12 horn for anti-theft alarm j65 heater control unit j104 abs with edl control unit j220 motronic control unit j234 airbag control unit j285 control unit with display in dash panel insert j3...

  • Page 52

    52 j519 onboard supply control unit location the onboard supply control unit has been placed underneath the dash panel and forms a module with the relay carrier. Variants the control unit for the onboard supply is available in the basic and highline variants. The highline variant is built into vehic...

  • Page 53

    53 • terminal control, the onboard supply control unit controls the following functions: – terminal 75x via the relief relay for the x contact – terminal 15 via the relay for voltage supply terminal 15 in the e-box and on the relay carrier on the control unit for the onboard supply. – terminal 50 vi...

  • Page 54

    54 electrical load management the electrical load management ensures that the battery has sufficient electrical energy to start the engine. Electrical convenience consumers are switched off for this purpose. The technical safety is maintained. The onboard supply control unit evaluates the engine spe...

  • Page 55

    55 functional diagram s328_174 outside light control the onboard supply control unit evaluates the signals from the light switch directly. The information on switching on the turn signal, the main beam lights and use of the flasher lights is sent via the steering column electronics control unit j527...

  • Page 56

    56 cold monitoring the individual bulbs are switched on four times in short intervals of 500 ms when the ignition is turned on. The current value allows the onboard supply control unit to detect a faulty bulb. Hot monitoring the individual bulbs are controlled by semiconductor modules located in the...

  • Page 57

    57 legend e2 turn signal switch m5 front left turn signal bulb m6 rear right turn signal bulb m7 front right turn signal bulb m8 rear right turn signal bulb functional diagram s328_178 turn signal control when you tap turn light e2 briefly once, the turn lights will flash three times. If you tap aga...

  • Page 58

    58 front windscreen wiper system wiper control the wiper system uses one motor with a mechanical connection between the wipers. The operating rods for windscreen wiper switch e are transferred directly to the steering column electronics control unit j527 and then to the onboard supply control unit j...

  • Page 59

    59 service and winter position if you move the windscreen wiper switch to the flick wiper position within 10 seconds after parking and turning off the ignition, the wipers will move to the top position. This function will not work when the bonnet is open. Anti-block function the wiper system can det...

  • Page 60

    60 electrical system s328_143 control unit with display in dash panel insert j285 the control unit with display manages all display elements, the analogue gauges and the warning lamps. Revolution counter coolant temperature speedometer dash panel insert led warning lamps digital display fuel gauge l...

  • Page 61

    61 lights headlights the headlight unit has a clear glass lens plus one reflector for dipped beam and one for main beam lights. The turn signal light is also integrated in the headlight unit. The dipped beam light uses h7 bulbs, the main beam light h1 bulbs. The side light is integrated in the refle...

  • Page 62

    62 in the caddy van, there are only air vents for the driver and front passenger in the dash panel. The caddy life has additional vents at rear end of the centre console for the rear passengers, these are optional in the caddy shuttle. Furthermore vents are also fitted in the footwell of the caddy s...

  • Page 63

    63 manual heating the temperature and air distribution is set manually on the operating unit in the dash panel for the vehicle interior as a single climate zone. The temperature is not regulated. The rotary knob for the temperature and air distribution are connected the air-conditioning unit only me...

  • Page 64

    64 heating and air conditioning thermo top v auxiliary coolant heating the 2004 caddy can be optionally equipped with the thermo top v auxiliary coolant heating system. It has the following technical features: – the control unit for the auxiliary coolant heating is integrated in the heating unit. Th...

  • Page 65

    65 venturi injector the intake air is guided via a ceramic housing in the shape of a venturi injector. This leads to a knock-on effect that supports the fuel injection. S328_115 activating the thermo top v there are three possibilities for activating the thermo top v auxiliary coolant heating. The “...

  • Page 66

    66 s328_068 s328_069 radio systems two different radios are available for the 2004 caddy. Radio r 100 technical features – 2 loudspeaker channels (only at front, each 20 watt) – rds fm/am europa radio – control for an external 6-cd changer – telephone control (hands free) – gala speed-dependent volu...

  • Page 67

    67 s328_071 rns mfd-2 radio navigation system the 2004 caddy can also be equipped with a radio featuring an integrated navigation system. Technical features – multi-colour display (mfd) – dynamic traffic guidance (avoiding jams) – 2 or 4 loudspeaker channels (each 20 watt) – rds fm/am europa radio –...

  • Page 68

    68 radio aerials the 2004 caddy has different aerials fitted in the front windscreen depending on the equipment. Depending on the type of radio system, single aerials and diversity aerials are used. Radio, telephone and navigation s328_156 s328_155 s328_164 single aerial the r 100 radio has a single...

  • Page 69

    69 s328_159 telephone/navigation aerial the 2004 caddy can also be optionally equipped with an additional telephone/navigation aerial. The aerial is used in conjunction with the following optional components: – rns mfd-2 radio navigation system – telephone/preparation for telephone* – remote control...

  • Page 70

    70 s328_072 service diagnosis the vas 5051 vehicle diagnosis, measuring and information system and the vas 5052 vehicle diagnosis and service information system are available for the 2004 caddy. The “guided functions” mode is new. In this way, without a complete vehicle system test, you can quickly ...

  • Page 71

    71 notes.

  • Page 72

    328 © volkswagen ag, wolfsburg, vk-21 service training all rights and rights to make technical alterations reserved 000.2811.44.20 technical status 04/04 ❀ this paper was manufacturer from pulp that was bleached without the use of chlorine..