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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

Summary of Contents for Caddy 2004

Page 1: ...The 2004 Caddy Self study programme 328 Service Training ...

Page 2: ...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 boarde...

Page 3: ...3 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 ...

Page 4: ...e in Poznan Now Poznan has another product of its own the 2004 Caddy 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...

Page 5: ... 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 Caddy Shuttle Life Immediate rivals Competition ...

Page 6: ... telephone optional Payload up to 750 kg Towing up to 1 500 kg Loading capacity up to 3 2 m3 Airbag system with 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 new standards with the Caddy Van Caddy Shuttle and Caddy Life versions It features a modern design with smooth outer surface...

Page 7: ...e 2nd seat row 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 with the Caddy Van comes in 2 versions Caddy Shuttle is the Basic version and Caddy Life is the Comfort version ESP optional MK60 system Con...

Page 8: ...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 width at front 1 537 mm Track width at rear 1 531 mm Tank capacity 60 l S328_005 S328_094 S328_006 ...

Page 9: ... 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 1 513 1 597 kg Shuttle 1 558 1 642 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...

Page 10: ... 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 Load compartment dimensions Colour Volumes Name Volumes Load compartment volumes up to 3 200 l Load compartment Volume The pictures show the Caddy Van with wing doors A tailgate is also available as an option ...

Page 11: ...340 mm Luggage compartment volume Luggage compartment dimensions The pictures show the Caddy Shuttle with tailgate It can also be equipped with optional wing doors Colour partial volume Name Volume Sum of partial volume Caddy Shuttle Caddy Life Volume closed luggage compartment behind 1st seat row in passenger compartment up to 626 l up to 560 l Volume open luggage compartment behind 1st seat row ...

Page 12: ...view of doors In Brief S328_012 Right hand sliding door Left hand sliding door Sliding doors on both sides Without sliding door with tailgate with rear wing doors with rear wing doors and ladder flap Caddy Van ...

Page 13: ...ors 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 The ladder flap will be available later on with tailgate with rear wing doors with rear wing doors and ladder flap Caddy Shuttle Caddy Life ...

Page 14: ...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 load...

Page 15: ...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 qualities ...

Page 16: ...s 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...

Page 17: ... 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 the...

Page 18: ...ding 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 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 S328_129 S328_130 ...

Page 19: ... stability 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 Refer to the operating manual for information on fitting the base carrier The base carrier is secured with the supplied screws and seals The seals prevent water leaking into the body The sealing screws should be kept and fitted again when the base carr...

Page 20: ...en hold A4 binders thanks to the width 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 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 under...

Page 21: ...21 S328_151 Bulkhead Jack and tool set mounted without cover Lashing rings on floor ...

Page 22: ...hed 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 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 ...

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: ...s longer and comes as standard in the Caddy Life and is an option in the Caddy Shuttle Body Dash panel The 2004 Caddy has an all new dash panel There are two versions that mainly differ in the centre console equipment Centre console Caddy Shuttle Life Armrest with storage compartment Cup holder Storage Storage Centre console Caddy Van Shuttle Cup holder 2 x 2 cup holders Ashtray Socket 12 V Furthe...

Page 25: ...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 without lid Left hand storage compartment on top of dash panel with lid and document holder Caddy Life ...

Page 26: ...seat optional Head restraint height and tilt adjustable Drawer under seat optional Seat height adjustable Backrest folds forward when there is only one sliding door always on the opposite side of the vehicle Side airbag Drawer storage Head restraints Height adjustment Adjustment of backrest tilt Handle for folding seat Longitudinal adjustment 2nd seat row in passenger compartment 1st seat row in p...

Page 27: ...t sections can be secured in position with folding struts so that they do not move on the road S328_148 S328_150 1st row of seats in passenger compartment individual seat tipped 1st row of seats in passenger compartment tipped completely S328_032 2nd row of seats in passenger compartment folded Strut Gas filled struts Screw fastening Strut Loop for releasing backrest Floor latch Loop for folding L...

Page 28: ... backrest to roll up the belt The Isofix child restraint system is integrated on the two outside seats of the first seat row Occupant protection A key switch in the glove compartment allows you to disable the front passenger airbag in the 2004 Caddy S328_036 Occupant protection The 2004 Caddy is equipped with the proven occupant protection systems the airbag system the belt system and a child rest...

Page 29: ...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 driver Front passenger side airbag module ...

Page 30: ...ion coils Non return fuel system Air filter integrated in the engine cover Engines Engine code BCA Type 4 cylinder in line engine Displacement 1 390 cm3 Bore 76 5 mm Stroke 75 6 mm Valves per cylinder 4 Compression ratio 10 5 1 Maximum output 55 kW at 5 000 rpm Maximum torque 126 Nm at 3 800 rpm Engine management ME 7 5 10 Fuel Super unleaded RON 95 normal unleaded at RON 91 with reduction in perf...

Page 31: ...on Non return fuel system Secondary air system S328_041 Engine code BGU Type 4 cylinder in line engine Displacement 1 595 cm3 Bore 81 0 mm Stroke 77 4 mm Valves per cylinder 2 Compression ratio 10 3 1 Maximum output 75 kW at 5 600 rpm Maximum torque 148 Nm at 3 800 rpm Engine management Simos 7 1 Fuel Super unleaded RON 95 normal unleaded at RON 91 with reduction in performance Exhaust gas treatme...

Page 32: ...s recirculation Electrical intake manifold flap Engines S328_045 Engine code BJB Type 4 cylinder in line engine Displacement 1 896 cm3 Bore 79 5 mm Stroke 95 5 mm Valves per cylinder 2 Compression ratio 19 1 Maximum output 77 kW at 4 000 rpm Maximum torque 250 Nm at 1 900 rpm Engine management EDC 16 Fuel Diesel min 51 CN Exhaust gas treatment Exhaust gas recirculation and oxidation catalytic conv...

Page 33: ... Exhaust gas recirculation Electrical intake manifold flap S328_043 Engine code BDJ Type 4 cylinder in line engine Displacement 1 968 cm3 Bore 81 0 mm Stroke 95 5 mm Valves per cylinder 2 Compression ratio 19 1 Maximum output 51 kW at 4 200 rpm Maximum torque 140 Nm at 2 200 2 400 rpm Engine management EDC 16 Fuel Diesel min 51 CN Exhaust gas treatment Exhaust gas recirculation and oxidation catal...

Page 34: ... a further development of the 02T manual gearbox as already used in the Polo for example The gearbox has 5 gears and can transmit torques of up to 200 Nm It is used with the petrol engines and the SDI engine The gearbox is a further development of the 02J manual gearbox The construction has been specially reinforced for the greater torque to be transferred and is already used in the 2004 Golf The ...

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: ...the 2004 Golf and provides optimum comfort with good driving dynamics The standing height has been increased especially for use in the 2004 Caddy Technical features are Aluminium assembly carrier Wishbones Decoupled spring and damper connection by rubber metal bearings for the struts 3rd generation wheel bearings Active speed sensor the sender wheel is integrated in the wheel bearing seal S328_048...

Page 37: ...arrier are made from aluminium The assembly carrier is bolted rigidly to the body at six points This stiffens the front section of the body This connection and the optimum configuration of the rubber metal bearings in the traverse link and the strut bearing allow good driving dyna mics and body acoustics S328_102 S328_098 Left console Subframe Right console Connection to body Subframe Right consol...

Page 38: ...es the driving comfort and vehicle acoustics The bearing is stiff in the transverse direction This has a positive effect on the driving dynamics and the steering response 3rd generation wheel bearings A compact third generation wheel bearing unit is used The wheel bearing wheel hub and mounting form a unit that is screwed to the wheel bearing housing The pretensioning forces for setting the bearin...

Page 39: ...it consisting of the wheel bearing and wheel hub The magnetic track for the active speed sensor is on the front side of the wheel bearing no sender wheel in wheel bearing seal Rear axle The 2004 Caddy has a rigid axle with leaf spring suspension It is a new design and is characterised by both its simplicity and robustness S328_166 S328_167 Wheel hub with magnetic track for active speed sensor Inst...

Page 40: ... the steering is exchanged via the drive CAN data bus Chassis Advantages of this steering system are Simpler packaging no need for traditional components like a power steering fluid pump hoses fluid reservoir and hydraulic fluid Lower fuel consumption 0 15 l 100 km Speed related steering assist Servotronic No risk of pollution as no oil is required Good straight line stability due to active return...

Page 41: ...power of the electric motor flanged on parallel to the rack and pinion is transferred to the rack via a second pinion input pinion This pinion meshes in the steering rack and transfers the assist power You will find detailed information in the self study program 317 The Electromechanical Power Steering with Dual Pinion S328_085 Sender for steering moment Control unit Electric motor Input pinion Ra...

Page 42: ...ection the steering column and universal joint shaft are designed to slide inside each other This means the steering column and steering wheel cannot be pushed towards the driver when the front section of the car is deformed in a collision The steering column is connected to the dash panel module carrier with a mounting made from diecast aluminium The mounting is screwed to the steering column con...

Page 43: ...ally available as an ESP system for the Caddy Shuttle Caddy Life from 75 kW Compared with the MK70 system it has the following additional technical features Electronic Stabilisation Program ESP with ESP button and ESP warning lamp Hydraulic brake assist BA Traction control system TCS S328_052 S328_053 S328_054 Please refer to self study program 204 ESP for further information on the electronic sta...

Page 44: ...pressure than is possible with conventional brake servos can be reached even with low pedal forces This also guarantees good dosing Dual rate characteristic curve When the brake pedal is pressed the brake pressure in the brake servo does not rise linearly over the whole range From a specific pedal force threshold value the brake pressure rises more than the pedal force and thus boosts the braking ...

Page 45: ...ng From an engine output of 75 kW and in the Caddy Shuttle Life with 7 seats a disc brake system with brake discs measuring Ø 288 mm x 25 mm is used The brake carrier is bolted to the wheel bearing housing Rear brakes The 2004 Caddy has disc brakes with solid brake discs measuring Ø 260 mm x 12 mm on the rear axle So called combi callipers are used for the brake callipers The brake pedal operates ...

Page 46: ...l from steel sheet G476 clutch position sender The clutch position sender is a Hall sender When the clutch is operated it recognises the pedal position and signals it to the engine control unit by means of a permanent magnet attached to the push rod The engine control unit switches off the speed control system On the diesel engines the injection amount is reduced briefly to avoid engine jolts upon...

Page 47: ...lerator pedal position G79 and G185 The senders for the accelerator position work according to the induction principle When the accelerator pedal is pressed the angle movement is converted into straight line movement to move a small metal plate back and forth Evaluation electronics evaluate this movement and send a corresponding signal to the engine control unit depending on the accelerator pedal ...

Page 48: ...ly control unit The following relays are located in the relay carrier on the onboard supply control unit Relay 2 for voltage supply terminal 30 J689 Relay for heated rear window J9 Horn relay J413 Relay 1 for double washer pump J729 Relay 2 for double washer pump J730 X contact relief relay J59 Fuse box The fuses for the electrical components in the vehicle are in the fuse box Battery on left of e...

Page 49: ...r 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: ...s Convenience CAN data bus Infotainment CAN data bus Combi instrument CAN data bus dash panel insert Diagnostics CAN data bus Electrical system In addition to the CAN data bus some electrical components are networked via the LIN data bus Control units connected to Drivetrain CAN data bus Convenience CAN data bus Infotainment CAN data bus Combi instrument CAN data bus Diagnostics CAN data bus LIN d...

Page 51: ... system control unit J345 Trailer detector control unit J362 Immobilizer control unit J386 Driver door control unit J387 Front passenger door control unit J393 Convenience system central control unit J400 Wiper motor control unit J412 Mobile telephone operating electronics control unit J500 Power steering control unit J503 Control unit with display for radio and navigation J519 Onboard supply cont...

Page 52: ...trol unit for the onboard supply is available in the Basic and Highline variants The Highline variant is built into vehicles with fog lights Fog lights can only be added if the Basic version of the control unit is replaced with the control unit for the Highline variant S328_172 Electrical system S328_171 Onboard supply control unit Relay carrier on onboard supply control unit ...

Page 53: ...supply control unit Once the engine has been started it is supplied via the engine control unit Alternator exciter The alternator is excited via the onboard supply control unit Electrical load management Outside light control Turn signal control Wipers front windscreen Forwarding of data bus signals to the wiper motor control unit Wipers rear windscreen Heated rear windscreen The heated rear winds...

Page 54: ...ply control unit can request a higher engine speed from the engine control unit on the basis of this information Furthermore convenience consumers can be switched off Three different operating modes are recognised for load management uncritical critical very critical Electrical system S328_173 Management not active Load management If the battery voltage is below 12 7 V for longer than 10 s Cancel ...

Page 55: ...1 Terminal RFL Terminal FL Terminal DDL Terminal 56 Terminal 58 Terminal 30 Terminal 15 Legend D Ignition switch terminal 15 E1 Light switch E4 Switch for headlight dipper and flasher E19 Parking light switch F Brake light switch F4 Reversing light switch J519 Onboard supply control unit J527 Steering column electronics control unit Term 56 Driving lights Term 58 Side lights Term RFL Rear fog ligh...

Page 56: ...ognise whether there is overloading a short circuit or an open circuit Fault detection In both monitoring types an entry is made in the fault memory and there is an indication in the dash panel insert when a fault is recognised A new bulb is recognised by the monitoring system the fault is deleted and the displayed indication cancelled Bulb monitoring The functioning of the bulbs is monitored cons...

Page 57: ...Turn signal control When you tap turn light E2 briefly once the turn lights will flash three times If you tap again the turn lights will flash a further three times This function is called lane change flash First request Renewed request Request of the Flash function by tapping the turn signal switch Triggering of the turn signals by the onboard supply control unit E2 M5 or M7 M6 or M8 ...

Page 58: ...ontrol unit directs the information on the selected wiper setting via the LIN data bus to the wiper motor control unit J400 that regulates the wiping cycles In intermittent mode the wiper cycles are speed related Legend D Ignition start switch E Windscreen wiper switch F266 Bonnet contact switch J104 ABS with EDL control unit J400 Wiper motor control unit J519 Onboard supply control unit J527 Stee...

Page 59: ...e obstacle then needs to be removed by hand The anti block function covers the whole wiper path just up to the top position If the wiper blade has frozen onto the bottom edge of the windscreen this is also recognised as an obstacle and the wiper will attempt to free itself five times After the fifth attempt it will stop Alternating rest position To avoid long term deformation of the wiper blades t...

Page 60: ...der The Lowline version also comes as a simplified basic version without a coolant temperature gauge A red LED illuminates when the coolant is too hot Midline has the following extras compared with the Lowline version Outside temperature Multi function display or Warning texts instead of multi function display and outside temperature Highline has the following extras compared with the Midline vers...

Page 61: ... lights are integrated in the bumper They are equipped with H1 bulbs Rear lights The rear lights are split into three main areas The brake light is at the top The upper part of the centre area with the clear lens contains the reversing light The lower part of this area holds the turn signal light with a yellow coloured bulb A twin filament bulb is fitted in the bottom section of the light for the ...

Page 62: ...Manual heating and ventilation system Semi automatic Climatic air conditioning Both systems use an air conditioning unit with the same design that has been adapted for the respective requirements The controls are different however S328_065 S328_163 Vent for passenger compartment in centre console Left hand vent for passenger compartment footwell Right hand vent for passenger compartment footwell V...

Page 63: ...onditioning unit to automatically regulate the interior temperature The air distribution is set only mechanically with the right hand rotary knob The ECON button switches the air conditioning on and off In ECON mode the preheater in vehicles with diesel engines is also switched off The Climatic air conditioning unit has a combined fresh air recirculation flap S328_066 S328_067 Operating unit for m...

Page 64: ...ical contacts for the combustion air fan are mounted directly on the control unit Furthermore the auxiliary coolant heating has a second NTC temperature sensor in the heating unit This improves the monitoring and control of the coolant temperature The fuel is injected via a Venturi injector and mixed with the combustion air S328_114 Water outlet Temperature sensor Heat exchanger Exhaust gas outlet...

Page 65: ...is carried out via the dash panel display in the Auxiliary heating sub item customisation 3 Using the separate remote start control for the auxiliary coolant heating Switching on and off with the remote control from distance of up to 600 m The immediate heat button in the operating unit shows the status of the auxiliary coolant heating The feedback LED is yellow while it is active When a switch on...

Page 66: ...r diagnosis Transport mode reduction of the current requirement during transport and rest times Radio telephone and navigation Radio RCD 300 Technical features 2 or 4 loudspeaker channels each 20 Watt the fader function is available when there are 4 channels RDS FM AM Europa radio 2 tuner FM Diversity Integrated single CD drive Control for an external 6 CD changer Telephone control hands free GALA...

Page 67: ...s with RDS names Control unit for aerial selection external change over box Control for an external 6 CD changer Telephone control hands free GALA Traffic Information Memory TIM Self diagnosis incl loudspeaker diagnosis Display of navigation arrows and navigation information in dash panel insert Highline Diversity refers to the different aerial signals The Diversity systems are used in the radio a...

Page 68: ...lection from houses and mountains The reflection causes the signals to be delayed and leads to interference 2 tuner FM Diversity system The RCD 300 radio has an integrated 2 tuner FM Diversity system with two internal receivers that process the incoming aerial signals separately and combine them to make a single signal Control unit for aerial selection The J515 aerial selection control unit extern...

Page 69: ...NS MFD 2 radio navigation system Remote control for auxiliary coolant heater When the vehicle is equipped with a telephone preparation for telephone and auxiliary coolant heating with remote control the reception signals are split by a frequency divider If only one of the two components are installed the respective signal runs straight to the receiver and a divider is not needed Auxiliary coolant ...

Page 70: ... operating mode checks all control units installed in the vehicle for fault entries and automatically compiles a system test plan from the results In conjunction with ELSA information for example the circuit diagrams or repair guides this mode guides you directly to the cause of the fault In addition you also have the option of compi ling your own test plan The function and component selection rec...

Page 71: ...71 Notes ...

Page 72: ...G 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 ...

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