Volkswagen The Caddy 2021

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Volkswagen Commercial Vehicles – Converter guidelines – August 2024 edition The Caddy – Page 1 of 163

Converter guidelines

August 2024 edition

Converter guidelines

The Caddy (from model year 2021)

Main Page

Table of Contents2
General Information6
Introduction6
Concept of These Guidelines6
Means of Representation7
Vehicle Safety8
Operational Safety9
Note on Copyright9
General Notes10
Product and Vehicle Information for Converters10
Contact in Germany10
International Contact10
Electronic Repair and Workshop Information from Volkswagen AG (Erwin*)11
Genuine Parts Online Ordering Portal11
Online Owner's Manual11
Homologation12
European Type Approval and EC Certificate of Conformity13
Worldwide Harmonised Light Vehicles Test Procedure (WLTP)13
Manufacturer's Declaration14
Converter Guidelines, Consulting14
Letter of Non-Objection14
Application for the Letter of Non-Objection16
Legal Entitlements16
Warranty and Product Liability of the Converter17
Ensuring Traceability18
Trademarks18
Positions on Rear of the Vehicle18
Appearance of Overall Vehicle18
Non-Volkswagen Trademarks18
Recommendation for Vehicle Storage18
Compliance with Environmental Rules and Regulations20
Recommendations for Inspection, Maintenance and Repair21
Accident Prevention21
Quality System22
Planning Bodies23
Selecting the Base Vehicle23
Vehicle Modifications24
Vehicle Acceptance25
Optional Equipment26
Technical Data for Planning27
Base Vehicle27
Vehicle Dimensions27
Basic Data of Caddy Cargo28
Basic Data of Caddy30
Ramp Angle and Breakover Angle33
Vehicle Centre of Gravity34
Bodies with a High Centre of Gravity34
Determining the Centre of Gravity35
Steerability - Minimum Front Axle Load35
Running Gear36
Permitted Weights and Unladen Weights36
One-Sided Weight Distribution37
Turning Circle37
Authorised Tyre Sizes37
Modifications to Axles38
Modifications to the Steering System38
Brake System and Brake Control System ESC38
General Information38
Vehicle Stability and ESC39
Influence of Vehicle Conversions on the Function of ESC* Brake Regulation System40
Routing Additional Lines Along the Brake Hoses/Brake Lines41
Modification of Springs, Suspension Mounting, Dampers41
Rear Axle Running Gear for Heavy Installations (Retrofit Kit, PR Number UC5)41
Wheel Alignment Settings42
Body-In-White43
Roof Loads/Vehicle Roof43
Dynamic Roof Loads43
Modifications to the Body-In-White43
Screw Connections44
Welding Work45
Welded Connections45
Selection of Welding Process46
Spot Welding46
Shielding Gas Hole Spot Welding47
Tacking48
Welding Is Not Allowed48
Corrosion Protection after Welding48
Corrosion Protection Measures48
Planning Measures49
Component Design Measures50
Coating Measures50
Work on the Vehicle50
Interior51
Modifications in the Area of Airbags51
Modifications in the Area of Seats51
Belt Anchors52
Forced Ventilation52
Acoustic Insulation52
Electrics/Electronics53
Lighting53
Vehicle Lighting Devices53
Mounting Special Lights54
Additional Load Compartment Light54
Vehicle Electrical System55
Electrical Wiring / Fuses55
Additional Circuits56
Retrofitting Electrical Devices57
Electromagnetic Compatibility58
Mobile Communication Systems59
CAN Bus59
Current and Signal Take-Off of Vehicle Electrical System Potentials61
Electrical Interface for Special Vehicles62
General Notes on the Interfaces62
DC/AC Converter (PR No. 9Z3, 9Z6)64
Customer-Specific Functional Control Unit (CFCU)66
Vehicle Battery69
Installation of Additional Battery69
Intelligent External Charging Control73
Parameterised* Reactions on Reaching Certain Second Battery Charge Levels with Second Battery Monitoring74
Retrofitting of Alternators76
Driver Assist Systems76
General Overview78
Electromechanical Steering78
Electronic Stability Control (ESC)79
Tyre Pressure Monitoring System (TPMS)80
Front Camera for Driver Assist Systems82
Rain/Light Sensor83
Parking Aids83
Lane Departure Warning "Lane Assist85
Front Assist / ACC85
Earth Points87
Engine Peripherals/Drive Train88
Engine / Drive Train Components88
Drive Shafts88
Fuel System88
CNG* Fuel System90
Exhaust System91
Hybrid Powertrain Exhaust System (PHEV)94
SCR System (EU6)95
Installation Position of the Adblue® Tank in the Vehicle95
Filling the Adblue® Tank96
Engine Power Take-Off Systems98
Compatibility with Base Vehicle99
Retrofitting Air Conditioning System101
Retrofit Load Compartment Cooling System101
Specifications of Genuine Refrigerant Compressor102
Maximum Cooling Output102
Weight of the Refrigerant Compressor102
Pulley Diameter of the Refrigerant Compressor103
Specification of the Poly V-Belt103
Connection Dimensions of Genuine Refrigerant Compressor103
Add-Ons/Units104
Roof Carriers104
Rear Luggage Carrier/Rear Ladders105
Towing Brackets105
Maximum Trailer Weights105
Retrofitting a Trailer Towing Bracket105
Clearance According to UN-R 55105
Raising the Vehicle108
Modifications to Closed Bodies109
Body-In-White/Body109
Side Wall Cut-Outs109
Subsequent Installation of Windows110
Roof Cut-Outs111
Modifications to the Roof of the Caddy Cargo / Caddy113
Modifying the Partition Wall/Forced Ventilation114
Partition Connection Points116
Interior117
Safety Features117
Ecall Emergency System118
Seat Retrofitting / Seating with Standard Seats118
Add-Ons119
Accessories119
Implementations of Special Bodies120
Motor Vehicles for the Transport of Persons with Disabilities (KMP)120
Base Vehicle Equipment120
Selection of Steering Rack for Conversions for People with Disabilities121
Notes on Conversion Solutions for the Wheelchair Transporter121
Notes on Installing Manual Operating Devices for the Foot Brake123
Deactivating the Airbag/Belt Tensioner System123
Refrigerated Vehicles125
Shelf Installation/Workshop Vehicles126
Shelf and Workshop Installations126
Emergency Vehicles128
Preparation for Taxis and Private Hire Cars129
Preparation for Taxis and Private Hire Cars Ex Works129
Interior Lighting Control129
Pin Assignment on CFCU* (Input and Output Assignment / Pins on CFCU*)129
Function Description131
Programming According to Customer Requirements133
Leisure Vehicles134
Vehicles for Local and Public Authorities135
Vehicles for Couriers and Logistics136
Plug-In Hybrid Electric Vehicle (PHEV)137
High-Voltage System137
Power and Control Electronics for Electric Drive138
Modifications to the Underbody Area of the High-Voltage Battery and the Drive138
12-V Vehicle Electrical System142
Technical Data143
Build Dimension Drawings143
Diagrams (Foil Templates)144
Current Flow Diagrams145
CAD Models146
Calculations147
Determining the Centre of Gravity147
Determining the Centre of Gravity in X-Direction147
Determining the Centre of Gravity in Z-Direction149
Weighing Equipment152
Weights (Masses)153
Notes on Homologation of Modifications and Conversions154
Availability with Complete Certificate of Conformity Ex Works - Light Duty WLTP154
Technical Specifications155
Permissible Aerodynamic Changes and Min./Max. Weights Apply to the Following Variants155
Permissible Aerodynamic Changes and Max. Dimensions156
Listings157
List of Changes157

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Volkswagen The Caddy 2021 Specifications

General

Brand	Volkswagen
Model	The Caddy 2021
Category	Automobile
Language	English

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