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General body repairs, exterior

For Caddy / Caddy KA / Caddy Maxi

Original Volkswagen repair manual


31,26 €7% VAT incl.

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Language: English

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14.245 KB

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Detailed technical data

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This repair manual contains: Lock carrier to 2011, Wings on vehicles manufactured up to 2011, Bulkhead, Bonnet, Tank flap, Central locking, Sliding door, Repair instructions, Radiator grille and front trim, Decorative film, Exterior mirror and Lettering and emblem. Show more
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Repair manual Caddy / Caddy KA / Caddy Maxi General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Lock carrier to 2011
    1
  • 1.1 Assembly overview – lock carrier
    1
  • 1.2 Removing and installing lock carrier
    2
  • 1.3 Moving to and back from service position
    4
  • 2 Lock carrier from 2011
    8
  • 2.1 Assembly overview – lock carrier
    8
  • 2.2 Removing and installing lock carrier
    9
  • 2.3 Moving to and back from service position
    11
  • 3 Wings on vehicles manufactured up to 2011
    18
  • 3.1 Assembly overview - wing
    18
  • 3.2 Assembly overview – additional wing cover
    19
  • 3.3 Removing and installing wing
    19
  • 3.4 Removing and installing wing bracket
    23
  • 3.5 Removing and installing wing securing bracket
    24
  • 4 Wings on vehicles manufactured as of 2011
    26
  • 4.1 Assembly overview - wing
    26
  • 4.2 Removing and installing wing
    27
  • 4.3 Removing and installing wing bracket
    30
  • 5 Bulkhead
    31
  • 5.1 Assembly overview - plenum chamber bulkhead
    31
  • 5.2 Assembly overview - plenum chamber bulkhead
    32
  • 5.3 Assembly overview - plenum chamber cover
    34
  • 5.4 Removing and installing plenum chamber cover
    34
  • Bonnet, rear lid
    37
  • 1 Bonnet
    37
  • 1.1 Assembly overview - bonnet
    37
  • 1.2 Assembly overview - bonnet lock and release components
    39
  • 1.3 Removing and installing bonnet
    39
  • 1.4 Adjusting bonnet
    41
  • 1.5 Removing and installing bonnet lock on vehicles up to 2010
    44
  • 1.6 Removing and installing bonnet lock on vehicles as of 2011
    45
  • 1.7 Removing and installing bonnet release lever
    46
  • 1.8 Removing and installing striker pin on vehicles as of 2011
    46
  • 1.9 Removing and installing hinge
    47
  • 1.10 Detaching Bowden cable
    48
  • 1.11 Removing and installing insulation
    48
  • 1.12 Removing and installing gas strut
    50
  • 1.13 Releasing gas from gas strut
    52
  • 2 Rear lid
    53
  • 2.1 Assembly overview - rear lid
    53
  • 2.2 Assembly overview – locking and release components
    55
  • 2.4 Removing and installing rear lid
    58
  • 2.5 Adjusting rear lid
    60
  • 2.6 Removing and installing bonnet lock
    66
  • 2.7 Removing and installing hinges
    68
  • 2.8 Removing and installing striker pin
    70
  • 2.9 Removing and installing latch carrier
    71
  • 2.10 Removing and installing lock cylinder carrier
    75
  • 2.11 Removing and installing exterior handle without lock cylinder, vehicles as of 2011
    75
  • 2.12 Dismantling exterior handle without lock cylinder
    82
  • 2.13 Removing and installing light strip
    87
  • 2.14 Attachment of registration plate
    88
  • 2.15 Removing and installing rear lid seal
    89
  • 2.16 Removing and installing gas strut
    90
  • 2.17 Releasing gas from gas strut
    92
  • 3 Tank flap
    93
  • 3.1 Assembly overview - fuel tank flap
    93
  • 3.2 Assembly overview – tank flap locking unit
    94
  • 3.3 Removing and installing fuel tank flap
    94
  • 3.4 Removing and installing tank flap locking unit
    96
  • Front doors, door components, central locking
    98
  • 1 Rear door
    98
  • 1.1 Assembly overview – door hinge
    98
  • 1.2 Assembly overview – door hinges on postal and parcel delivery vehicles
    100
  • 1.3 Removing and installing inner door seal
    102
  • 1.4 Removing and installing outer door seal
    103
  • 1.5 Removing and installing door hinge
    104
  • 1.7 Greasing new door hinges
    108
  • 1.8 Removing and installing front door
    108
  • 1.9 Removing and installing front doors on postal and courier service vehicles
    110
  • 1.10 Adjusting door
    111
  • 1.11 Adjusting striker pin
    114
  • 2 Door components
    115
  • 2.1 Assembly overview - subframe
    115
  • 2.2 Assembly overview - door handle and door lock
    116
  • 2.3 Removing and installing subframe
    117
  • 2.4 Removing and installing lock cylinder housing
    122
  • 2.5 Removing and installing door handle
    124
  • 2.6 Removing and installing door lock
    126
  • 2.7 Installing mounting bracket
    127
  • 3 Central locking
    128
  • 3.1 Overview of fitting locations – central locking
    128
  • 3.2 Assembly overview - ignition key to 2010
    130
  • 3.3 Assembly overview - ignition key from 2010
    131
  • 3.4 Assembly overview – ignition key with light
    132
  • 3.5 Removing and installing ignition key battery to 2010
    132
  • 3.6 Removing and installing ignition key battery from 2010
    133
  • 3.7 Removing and installing battery for ignition key with light
    134
  • Rear doors, door components
    136
  • 1 Sliding door
    136
  • 1.1 Assembly overview - sliding door roller guides
    136
  • 1.2 Assembly overview – door arrester
    137
  • 1.3 Assembly overview – guide rail cover
    137
  • 1.4 Assembly overview – middle guide rail
    140
  • 1.5 Removing and installing sliding door
    140
  • 1.6 Adjusting sliding door
    143
  • 1.7 Removing and installing hinge
    150
  • 1.8 Removing and installing door arrester
    150
  • 1.9 Removing and installing upper stop
    151
  • 1.10 Removing and installing guide rail cover
    152
  • 1.11 Removing and installing middle guide rail
    154
  • 1.12 Removing and installing inner door seal
    157
  • 1.13 Removing and installing top door seal on Caddy, short version
    158
  • 1.14 Removing and installing top door seal on Caddy Maxi
    158
  • 1.15 Removing and installing bottom door seal on Caddy, short version
    159
  • 1.16 Removing and installing bottom door seal on Caddy Maxi
    159
  • 2 Components of sliding door
    160
  • 2.1 Assembly overview – sliding door locking and release components
    160
  • 2.2 Assembly overview – remote release mechanism
    162
  • 2.3 Assembly overview – mounting bracket
    162
  • 2.4 Assembly overview - interior operating mechanism
    164
  • 2.5 Removing and installing striker pin
    164
  • 2.6 Removing and installing door lock
    165
  • 2.7 Removing and installing exterior door handle
    166
  • 2.8 Removing and installing remote release mechanism
    167
  • 2.9 Removing and installing mounting bracket
    169
  • 2.10 Removing and installing interior door handle
    170
  • 3 Wing door
    173
  • 3.1 Assembly overview – right wing door
    173
  • 3.2 Assembly overview - rear left wing door
    174
  • 3.3 Assembly overview – wing door hinges
    175
  • 3.4 Removing and installing wing door
    175
  • 3.5 Removing and installing rear wing door hinges
    177
  • 3.6 Adjusting wing door
    179
  • 3.7 Removing and installing wing door seal
    184
  • 3.8 Removing and installing inner seal of wing door
    185
  • 4 Components of rear wing door
    186
  • 4.1 Assembly overview – locking and release components of rear wing door
    186
  • 4.2 Assembly overview - release lever
    188
  • 4.3 Assembly overview – remote release motor carrier
    189
  • 4.4 Assembly overview – exterior door handle
    190
  • 4.5 Removing and installing upper and lower striker pins
    190
  • 4.6 Removing and installing upper lock
    191
  • 4.7 Removing and installing lower lock
    192
  • 4.8 Removing and installing release lever
    193
  • 4.9 Removing and installing motor carrier part for remote release
    194
  • 4.10 Removing and installing interior door handle
    196
  • 4.11 Removing and installing exterior door handle
    196
  • 4.12 Removing and installing light strip
    198
  • 4.13 Removing and installing lock cylinder
    199
  • Bumpers
    200
  • 1 Front bumper cover to 2011
    200
  • 1.1 Assembly overview – front bumper cover, standard equipment version
    200
  • 1.2 Assembly overview – front bumper cover painted in vehicle colour
    202
  • 1.3 Assembly overview – add-on parts, standard equipment version
    203
  • 1.4 Assembly overview – add-on parts painted in vehicle colour
    204
  • 1.5 Assembly overview - substructure components
    205
  • 1.6 Assembly overview - front bumper carrier
    206
  • 1.7 Removing and installing front bumper cover, standard equipment version
    206
  • 1.8 Removing and installing front bumper cover painted in vehicle colour
    208
  • 1.9 Repairing front bumper cover
    209
  • 2 Front bumper cover from 2011
    210
  • 2.1 Assembly overview - front bumper cover
    210
  • 2.2 Assembly overview - front bumper cover, add-on parts
    212
  • 2.3 Assembly overview - front bumper cover, add-on parts, »Cross Caddy«
    213
  • 2.4 Assembly overview - front bumper cover, substructure components
    214
  • 2.5 Assembly overview - front bumper carrier
    215
  • 2.6 Assembly overview - parking aid and brackets in front bumper cover
    216
  • 2.7 Removing and installing front bumper cover
    216
  • 2.8 Repairing front bumper cover
    220
  • 2.9 Installing brackets for parking aid system
    220
  • 3 Bumper, rear
    225
  • 3.1 Assembly overview - rear bumper cover
    225
  • 3.2 Assembly overview - rear bumper cover for towing bracket
    227
  • 3.3 Assembly overview - rear bumper cover, add-on parts
    228
  • 3.4 Assembly overview - rear bumper cover, add-on parts, »Cross Caddy«
    229
  • 3.5 Assembly overview - parking aid, brackets in rear bumper cover
    230
  • 3.6 Assembly overview - bumper carrier with rear bumper cover
    232
  • 3.7 Removing and installing rear bumper cover
    232
  • 3.8 Removing and installing rear bumper cover for towing bracket
    235
  • 3.9 Removing and installing bumper carrier with rear bumper cover
    237
  • 3.10 Repairing rear bumper cover
    238
  • 3.11 Installing brackets for parking aid system
    239
  • Glazing
    244
  • 1 Repair instructions
    244
  • 1.1 Minimum curing period
    244
  • 1.2 Window repair
    245
  • 1.3 Installation instructions for bonded windows
    245
  • 1.4 Preparing old undamaged windows for fitting
    246
  • 1.5 Preparing new windows for installing
    247
  • 1.6 Preparing body flange for glazing
    248
  • 1.7 Touching up paint damage
    249
  • 1.8 Cleaning in the event of dirt caused by adhesive sealant
    249
  • 2 Windscreen
    251
  • 2.1 Assembly overview - windscreen
    251
  • 2.2 Dimensions for adhesive bead and glass/paint primer on windscreen
    252
  • 2.3 Removing and installing windscreen
    252
  • 3 Rear windscreen
    257
  • 3.1 Assembly overview - rear window
    257
  • 3.2 Dimensions for adhesive bead and glass/paint primer on rear window
    258
  • 3.3 Removing and installing rear window
    258
  • 4 Rear wing door window
    261
  • 4.1 Assembly overview – rear wing door window
    261
  • 4.2 Dimensions for adhesive bead and glass/paint primer on rear wing door window
    262
  • 4.3 Removing and installing rear wing door window
    263
  • 5 Side window
    265
  • 5.1 Assembly overview – side window in sliding door
    265
  • 5.2 Assembly overview - sliding window in sliding door
    267
  • 5.3 Assembly overview – side window
    268
  • 5.4 Assembly overview – side window
    269
  • 5.5 Assembly overview - sliding window in side panel
    270
  • 5.6 Assembly overview - movable section of sliding window
    271
  • 5.7 Dimensions for adhesive bead and glass/paint primer on side window
    273
  • 5.8 Removing and installing side window in sliding door
    275
  • 5.9 Removing and installing sliding window in sliding door
    277
  • 5.11 Removing and installing side window
    284
  • 5.12 Removing and installing sliding window in side panel
    286
  • 5.13 Removing and installing movable section of sliding window
    288
  • 6 Front door window
    290
  • 6.1 Assembly overview - front door window
    290
  • 6.2 Assembly overview – window channel
    292
  • 6.3 Removing and installing door window
    292
  • 6.4 Removing and installing window regulator motor
    295
  • 6.5 Removing and installing window channel
    296
  • 7 Windows having threaded connections
    299
  • 7.1 Assembly overview - front side window
    299
  • 7.2 Assembly overview – vent wing
    299
  • 7.3 Removing and installing front side window
    300
  • 7.4 Removing and installing vent wing
    301
  • Exterior equipment
    303
  • 1 Radiator grille and front trim
    303
  • 1.1 Assembly overview - radiator grille
    303
  • 1.2 Removing and installing radiator grille up to 2011
    303
  • 1.3 Removing and installing radiator grille on vehicles from 2011
    305
  • 2 Mouldings, trims, extensions
    307
  • 2.1 Assembly overview - protective side mouldings
    307
  • 2.2 Assembly overview - protective side moulding, »Edition 30«
    308
  • 2.3 Assembly overview - tunnel cross-piece
    309
  • 2.4 Removing and installing protective side mouldings
    309
  • 2.5 Removing and installing sill panel moulding, »Edition 30«
    311
  • 2.6 Removing and installing decorative strip for light strip
    313
  • 3 Noise insulation
    316
  • 3.1 Assembly overview – noise insulation
    316
  • 4 Decorative film
    319
  • 4.1 Decorative film for rear wing door window
    319
  • 4.2 Decorative film for rear bumper, »Edition 30«
    320
  • 4.3 Decorative film on side member, »Cross Caddy«
    323
  • 5 Roof railing
    326
  • 5.1 Assembly overview - roof railing
    326
  • 5.2 Removing and installing roof railing
    326
  • 6 Exterior mirror
    332
  • 6.1 Assembly overview - exterior mirror
    332
  • 6.2 Assembly overview – insulation, sealing strip and fabric strip for exterior mirror
    333
  • 6.3 Removing and installing mirror housing
    333
  • 6.4 Removing and installing mirror glass
    335
  • 6.5 Removing and installing exterior mirror
    335
  • 7 Wheel housing liners
    338
  • 7.1 Assembly overview - front wheel housing liner
    338
  • 7.2 Assembly overview - rear wheel housing liner
    339
  • 7.3 Removing and installing front wheel housing liner
    339
  • 7.4 Removing and installing rear wheel housing liner
    341
  • 8 Lettering and emblem
    343
  • 8.1 Assembly overview – front emblem on radiator grille
    343
  • 8.2 Dimensions - lettering and badges
    344
  • 8.3 Removing and installing emblem in front bumper cover, vehicles up to 2011
    353
  • 8.4 Removing and installing emblem, vehicles as of 2011
    353
  • 9 Special add-on parts
    356
  • 9.1 Assembly overview - special add-on parts, »Cross Caddy«
    356
  • 9.2 Repair instructions
    358
  • 9.3 Removing and installing trim insert for side member extension
    361
  • 9.4 Removing and installing side member extension
    363
  • 9.5 Removing and installing wheel housing extension for wing
    366
  • 9.6 Removing and installing wheel housing extension for sliding door
    369
  • 9.7 Removing and installing wheel housing extension for side panel
    372
  • 9.8 Removing and installing front and rear door trim
    375
  • 9.9 Removing and installing front spoiler
    377
  • 9.10 Removing and installing rear spoiler
    380
  • 10 Towing bracket
    383
  • 10.1 Installation instructions for towing brackets
    383
  • 10.2 Assembly overview – towing bracket up to 2008
    383
  • 10.3 Assembly overview – towing brackets as of 2009
    385
  • 10.4 Removing and installing towing bracket on vehicles up to 2008
    387
  • 10.5 Removing and installing towing bracket on vehicles as of 2009
    390
  • 11 Spare wheel mounting
    393
  • 11.1 Assembly overview – spare wheel holder
    393
  • 12 Roof load flap
    396
  • 12.1 Assembly overview – roof load flap
    396
  • 12.2 Assembly overview - cross member
    398
  • 12.3 Removing and installing roof load flap
    398
  • 12.4 Removing and installing roof load flap lock cover
    399
  • 12.5 Removing and installing hinge
    400
  • 12.6 Removing and installing gas strut
    401
  • 12.7 Removing and installing seal
    404
  • 12.8 Removing and installing roof load flap stop buffer on cross member
    405
  • 12.9 Removing and installing cross member
    405
  • 12.10 Adjusting cross member
    406
  • 12.11 Removing and installing cross member attachments
    407
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)
Suitable car types 2K, 2C
Category Reparaturanleitung

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