Installation manual Volkswagen Caddy Maxi WAV-Conversion Petrol Version 1.5 Version 1.5 Volkswagen Caddy Maxi What is new in version 1.5 4.1 Dismounting the interior Page 12 Added the new motor for the lock. 5.2 Sawing out the floor Page 23 New picture for the primer. 6.1 Bonding the lowered floor Page 26 Replaced aluminium plate with a rubber plate. Page 28 Added a remark about the Caddy Maxi five seater. Page 28,29,30 New construction of bench remount. 6.2 Exhaust system Page 45 M10 bolt changed to M8 bolt. 6.6 Remounting the interior Page 52 Foam removal from 30 mm to 50 mm Page 54 New location 4 point switch 6.7 Mounting the rear and rear bumper Page 56 - 70 Changed the mounting for the bumperpart for the new (2010) Volkswagen locks. Page 76 Added a remark on the replacement of the parking sensors. 6.8 Ramp Page 78 - 86 Added the new Composite ramp. 6.9 4-Point belt fixation Page 93 Added comment about the 7/16 nut plate. 7.1 5 seated maxi set Page 88 - 93 New. 7.2 Mounting the stainless steel (INOX) protection plates Page 94 New.
7.3 Connecting the moved parking sensors Page 95, 96 7.4 Taxi Hinges Page 97 New. 7.5 Installation of the hydraulic kneeling system Page 98 - 111 New. 9. Contact Page 115, 116 Updated.
2 Version 1.5 Volkswagen Caddy Maxi General guidelines
Read the instructions carefully, before starting to convert the vehicle.
General guidelines:
• Never throw the dismounted parts away, unless mentioned otherwise. • Keep all the parts stored together. • Be sure that you have enough working space in- and outside the vehi- cle. • Before you start, you need to disconnect the connections to the bat- tery. • The vehicle must not move during the conversion, to assure a good geometry of it. • Never remove the steel bumper before the lowered floor is fixated in the vehicle. IMPORTANT: When the car is brand new, direct from the factory, the electrical system of the car needs to be reset. The VW dealer can do this. IMPORTANT: Holes (max. 20 mm) may be drilled in the hatched parts of the drawing below. Always use a metallic spacer!
3 Version 1.5 Volkswagen Caddy Maxi
You need an extra pair of hands.
Part can be thrown away. No need for it anymore.
No open fire or smoking.
Wear protection for eyes and ears.
4 Version 1.5 1. Table of contents Volkswagen Caddy Maxi 1. Table of contents 5 2. Tools list 6 2.1 Common tools 6 2.2 Electrical/compressed air tools 7 2.3 Special tools 7 3. Survey of the conversion kit 8 4. Dismounting 9 4.1 Dismounting the interior 9 4.2 Dismounting the exterior 13 5. Preparations 18 5.1 Protection of the vehicle 18 5.2 Sawing out the floor 19 6. Installing the conversion kit 24 6.1 Bonding the lowered floor 24 6.2 Fuel tank 33 6.3 Exhaust system 42 6.4 Fuel tank protection plate 47 6.5 Electrical installation for 4-point belt fixation 48 6.6 Remounting the interior 52 6.7 Mounting the rear and rearbumper 56 6.8 6.8 Ramp 78 6.9 4-Point belt fixation 87 7. Options 88 7.1 Caddy Maxi five-seated 88 7.2 Mounting the stainless steel (INOX) protection plates 94 7.3 Connecting the moved parking sensors 95 7.4 Taxi Hinges 97 7.5 Installation of the hydraulic kneeling system 98 8. Torque specifications 112 9. Notes 113 10. Contact 115 10.1 Contact persons 116 10.2 Other email addresses 116 11. Recommendation form 117
5 Version 1.5 Volkswagen Caddy Maxi 2. Tools list 2.1 Common tools • 4 columns bridge 1 1.
• 2 axl-stands 2
• Sealant gun 3
• Calibrated torque spanner 4 2.
• Pop riveter 5
5. 4. 3.
6 Version 1.5 Volkswagen Caddy Maxi 2.2 Electrical/compressed air tools • Abrasive machine (electrical/compressed air) 7 7.
• Circular saw (electrical) for metal (for example: Milwaukee MCS 65) 8
• Saw (compressed air) 9
• Impact nut setter (compressed air) 10 8.
• Pop riveter (compressed air) 11
• Drilling machine (electrical/compressed air) 12
12. 11. 10. 9.
2.3 Special tools • Bit for inner twelve-side screws M8 for Volkswagen, on general sale 13&14. (Gedore 6569330 code: 885*8) 13
• Bit for inner twelve-side screws M10 for Volkswagen, on general sale (Gedore 6569410 code: 885*10) 14 13&14. • Floor mould (on sale at Bierman, part number N200014001) 15
• Bumper mould (on sale at Bierman, part number N200014002) 16
16. 15.
7 Version 1.5 Volkswagen Caddy Maxi 3. Survey of the conversion kit
In the picture below you see the most important parts of the conversion kit.
8 Version 1.5 Volkswagen Caddy Maxi 4. Dismounting 4.1 Dismounting the interior
Remove the rear shelf and the rubber of the rear, keep the rubber.
Remove the second back seat by pulling the cords. The upper one to fold the back rest and the lower one to remove the back seat out of the vehicle.
9 Version 1.5 Volkswagen Caddy Maxi
Remove the cover of the door latch.
Remove the door latch and attachement eyes (keep these parts + bolts).
Remove the other attachement eyes.
Unscrew the bolts of the second back seat (keep these bolts).
10 Version 1.5 Volkswagen Caddy Maxi
Dismount the rear points of support for the back seat (keep these parts).
Unscrew the bolts of the seat belts of the second back seat (keep the bolts). Remove the covers from the wheel arches, disconnect the connector plugs (left side).
11 Version 1.5 Volkswagen Caddy Maxi
Remove the covers from the front belts (both sides).
Remove the covers from the door sills, unscrew the bolts of the front seat belts (both sides).
Remove the lock, electric motor, cord and protection cap of the rear hatch (keep these parts).
Remove the cover of the rear hatch.
Fold the floor covering over the front seats to protect the interior.
12 Version 1.5 Volkswagen Caddy Maxi 4.2 Dismounting the exterior
Remove the spare wheel.
Removing the rear bumper: 1. Unscrew the screws in the wheel arches. 1. 2. Unscrew the screws were the plastic part is fixated on the metal part. 3. Remove the plastic part, but let the metal part be mounted on the vehicle.
3.
2.
Remove the connecting piece (keep this part).
13 Version 1.5 Volkswagen Caddy Maxi
Unscrew the mounting bracket at the rear, only keep the rubber.
Remove the mounting bracket at the middle, keep this part and the rubber.
Remove the bracket, only keep the nuts.
Carefully remove the exhaust.
Remove the heat shield, two parts. Keep the middle part.
14 Version 1.5 Volkswagen Caddy Maxi
Remove the iron wire out of the filler opening.
Saw through the filler pipe and the white pipes, at the places indicated in the pictures.
15 Version 1.5 Volkswagen Caddy Maxi IMPORTANT: Make sure that the fuel tank is empty before removing!!
Place a support underneath the fuel tank and unscrew the bolts of the braces at the side of the float element.
Disconnect the connector plug from the float element and both fuel pipes.
Carefully remove the fuel tank. The fuel tank braces can remain in place.
16 Version 1.5 Volkswagen Caddy Maxi
Remove the bolts of the anti-roll bar, and keep those.
Unscrew the bolts of both shock absorbers, and keep those. Bend them downwards!!
17 Version 1.5 Volkswagen Caddy Maxi 5. Preparations
5.1 Protection of the vehicle
Protect the doors and the windows.
18 Version 1.5 Volkswagen Caddy Maxi 5.2 Sawing out the floor
IMPORTANT: During the sawing you must al- ways wear protection glasses and protection for your ears!! IMPORTANT: Make sure that the vehicle is dry when sawing out the floor!! IMPORTANT: Be sure that all hydraulic pipes and electrical pipes are bent downwards, before sawing out the floor!!
Place the mould into the vehicle and fixate the mould on the vehicle.
Mark the lines (outer sides of the mould). Remove the mould from the vehicle.
19 Version 1.5 Volkswagen Caddy Maxi
First saw through the lines in the longitudinal directi- on of the vehicle using the circular saw (minimal saw depth 50 mm and maximum saw depth 65 mm). The other parts need to be sawn out with the air saw.
20 Version 1.5 Volkswagen Caddy Maxi
Saw away the edge on the front.
Saw on both sides a line of 35 mm to the outside of the vehicle.
Use a hammer to punch the lower part to the inner side of the vehicle and the upper part downwards.
21 Version 1.5 Volkswagen Caddy Maxi Unscrew the front bolt of the left leaf spring and reverse him.
!!WRONG!! !!RIGHT!!
Remount the bolts of both shock absorbers.
22 Version 1.5 Volkswagen Caddy Maxi
Dismount the rubber bump stop and metal plate (both sides).
Remount the rubber bump stop and metal plate (both sides) with the spacer and new bolt (included in the kit). Place the lowered floor carefully in the vehicle, check if it fits perfectly. The floor has to make contact with the floor of the vehicle. IMPORTANT: Always treat the sawing edges against corrosion!!
To treat the sawing edges against corrosion, use the primer that is included in the kit.
IMPORTANT: You always have to treat the sa- wing edges to prevent corrosion!! Your company is liable for the warranty!!
23 Version 1.5 Volkswagen Caddy Maxi 6. Installing the conversion kit
6.1 Bonding the lowered floor
IMPORTANT: Make sure that the vehicle is dry before preparing the vehicle.
IMPORTANT: Make sure that the parts which will be glued are prepared with Cleaner I and Prep M.
IMPORTANT: Be sure that the saw cuts are treated with the primer before bonding the lowered floor into the vehicle.
24 Version 1.5 Volkswagen Caddy Maxi Preperation of the vehicle, lowered floor and tie plates: • Prepare the parts of the lowered floor with sandpaper (P60). • Clean the parts with Cleaner I. Vehicle, lowered floor and tie plates. • Wait 5 minutes. • Treat the parts with Prep M (Only metal parts). Vehicle and tie plates. • Wait 5 minutes.
Tie plates
25 Version 1.5 Volkswagen Caddy Maxi
Now replace the original door latch on the lowered floor, using the plate with two bolts (included in the kit) and the one plate for underneath the door latch (included in the kit).
IMPORTANT: To glue the different parts you need to use the triangular nozzle (included in the kit).
IMPORTANT: Keep 1 cm distance between the sawing edges and the glue.
IMPORTANT: Put the glue on the vehicle in such a way that the triangle stands up and according the described pattern.
Apply the glue onto the vehicle in closed shapes.
26 Version 1.5 Volkswagen Caddy Maxi
Apply the glue in the front in three circles round the stud holes.
Now carefully lower the floor in the vehicle and press it down- wards. Use a screwdriver to centre the lowered floor to the stud holes.
27 Version 1.5 Volkswagen Caddy Maxi
IMPORTANT: When you are converting a Caddy Maxi with five seats instead of seven seats you have to go to page 88.
IMPORTANT: Put grease on the bolts, to isolate them from the glue.
The original Volkswagen bolts are used to fasten the lowered floor into the vehicle.
Remount the seat belts of the second back seat by using the original bolts, both sides.
28 Version 1.5 Volkswagen Caddy Maxi
Place the four bolts of the second back seat in the holes to fasten the lowered floor. The ones with the large bolt heads needs to go in front and the others (with the smaller bolt heads) in the back.
Back front
29 Version 1.5 Volkswagen Caddy Maxi
Place the two rings (included in the kit) on top of each other, to raise the rear points of support for the backseat.
Place the rear points of support for the backseat in the front of the lowered floor.
IMPORTANT: Now you can remove the steel bumper (keep the dismounted parts).
30 Version 1.5 Volkswagen Caddy Maxi
Apply the glue in three stripes on the tie plates and place them at each side of the vehi- cle. Fasten the tie plates by using the original nuts of the rear bumper.
31 Version 1.5 Volkswagen Caddy Maxi
Mount the anti-roll bar, using the original bolts, onto the bottom of the lowered floor using the two M12 nuts (included in the kit).
IMPORTANT: Tighten the bolts of the anti-roll bar with 108 Nm.
IMPORTANT: After bonding the lowered floor into the vehicle you must wait 48 hours before using the car. This way, you will get the maximum strength of the glue!!
Finally you need to fill up the open places with glue, the sides of the tie plates and underneath the car.
32 Version 1.5 Volkswagen Caddy Maxi 6.2 Fuel tank
Goes to the carbon canister.
Goes to the float element.
Goes to the fuel filter.
33 Version 1.5 Volkswagen Caddy Maxi
Place a support underneath the car and place the original fuel tank on it.
Connect the connector plug to the float element.
Remount the fuel pipes. The white one goes to the carbon canister and the black one goes to the fuel filter.
34 Version 1.5 Volkswagen Caddy Maxi
Now replace the original braces, fasten them on the side of the float element (use the original bolts).
Mount the other side of the braces to the brackets underneath the lowered floor. Use two M8 jam nuts and washers, included in the kit.
35 Version 1.5 Volkswagen Caddy Maxi
Use a file to smoothen the edges of the earlier sawn filler pipe, both sides.
36 Version 1.5 Volkswagen Caddy Maxi
After you smoothen the sawing edges you need to remove the edge on top off the original filler pipe, do this by using a file (as indicated in the pic- tures). Do this at both sides of the earlier sawn filler pipe
Attach the new filler pipe to the original fuel tank and filler pipe by using two hose clamps, 35-50 mm 12 mm (included in the kit).
37 Version 1.5 Volkswagen Caddy Maxi
Place the protection rubber (included in the kit) round the steel plate of the rubber axle bumper, to protect the filler pipe.
38 Version 1.5 Volkswagen Caddy Maxi
Place the tube shells in the white hoses (sawn through earlier, as well on the side of the filler pipe as on the side of the fuel tank), included in the kit.
Place the fuel hose (Ø 8 mm long 800 mm) on the original white hose , thinnest section through, using two earclamps (15,5, included in the kit). Place the fuel hose (Ø 11 mm long 800 mm) on the original white hose, middle section through, using two earclamps (17,5, included in the kit).
39 Version 1.5 Volkswagen Caddy Maxi
Place the clamp with rubber on the filler pipe to fasten it, use a screw and washer (included in the kit).
The last hose you need to place (Ø 16 mm long 800 mm), comes on the thickest original white hose, fasten it with two hose clamps, 12-22 mm (included in the kit).
40 Version 1.5 Volkswagen Caddy Maxi
Use the cable ties to keep the hoses together.
Important: The new fuel tank is full when the fuel gauge stands between 3/4 and 1/1, as indicated in the picture!! Cause of this problem is that the original fuel tank is remounted under the vehicle under a different angle than the original one!!
41 Version 1.5 Volkswagen Caddy Maxi 6.3 Exhaust system
Replace the middle part of the original heat shield.
Drill two holes (5 mm) at the rear end of the heat shield in the mounting bracket (of the fuel tank) under the lowered floor.
Mount the rear end of the heat shield with two blind rivets, included in the kit.
42 Version 1.5 Volkswagen Caddy Maxi
Parts you need to use for mounting the exhaust system.
43 Version 1.5 Volkswagen Caddy Maxi Place the original mounting bracket back on the place were it used to be, use the original bolt.
IMPORTANT: Before you mount the new exhaust system you have to fit it underneath the vehicle. Now you can see where you need to saw through the original exhaust pipe, the part which is still on the vehi- cle. The new exhaust system fits on the brackets (included in the kit), no adaptation needed.
Slide the exhaust silencer over the original exhaust and place it on the mounting bracket.
Make use of a exhaust clamp (included in the kit) to fasten the silencer to the original pipe.
44 Version 1.5 Volkswagen Caddy Maxi
Place the other mounting bracket (with original rubber) in front of the right leaf spring, use a M8 bolt and nut (included in the kit).
Slide the curved part of the exhaust over the silencer part and fasten it with a exhaust clamp (included in the kit).
45 Version 1.5 Volkswagen Caddy Maxi
Place the three toothed lock washers (included in the kit) on the axles.
46 Version 1.5 Volkswagen Caddy Maxi 6.4 Fuel tank protection plate
Mount the fuel tank protection plate using the original four nuts.
47 Version 1.5 Volkswagen Caddy Maxi 6.5 Electrical installation for 4-point belt fixation
Place the brown wire in front of the lowered floor. Make sure that the connector plug is going to the wheel arch.
Place the other cable on top of the wheel arch, connect the con- nector plug of the brown wire with the connector plug of the purple wire.
48 Version 1.5 Volkswagen Caddy Maxi
Place the ground switch abo- ve the left tail light, fasten the switch with a screw (included in the kit).
Loosen the left door stopper of the rear hatch.
Push the door stopper in and fasten it.
49 Version 1.5 Volkswagen Caddy Maxi
The green wire needs to go to the fuse box that is located inside the vehicle under the steering wheel. Attach this wire to the original cable tree.
Place the splitter on ID 23, as indicated in the picture. There should be no fuse present on ID23. IMPORTANT: Before you place the fuse on ID23 you should check if there is already a fuse present, if present this fuse must be equal or less then 10 A. Also you should check if the power is constantly 12V.
50 Version 1.5 Volkswagen Caddy Maxi
51 Version 1.5 Volkswagen Caddy Maxi 6.6 Remounting the interior
320 mm
Remove the floor covering out of the vehicle and cut of the front part as indicated in the picture.
50 mm
Remove the foam as indicated in the picture and place the floor covering back into the vehicle.
52 Version 1.5 Volkswagen Caddy Maxi
Remount the protection covers from the rear points of support for the back seat.
Fasten the front seat belt with the original bolt, replace the cover from the door sill (both sides). Replace the cover from the front seat belt (both sides).
53 Version 1.5 Volkswagen Caddy Maxi
Remove the edge indicated in the pictures from both caps (wheel arches).
Remount the covers from the wheel arches (both sides), connect the connector plugs on the left side.
If a hydraulic lowering system is going to be mounted, leave the right wheel arch cover off.
Make a hole Cut (22mm x 45 mm) in the left cover for the switch of the 4-point belt fixation (the exact location doesn’t matter).
54 Version 1.5 Volkswagen Caddy Maxi
Remount the rubber of the rear door. Begin with the original rubber at the top so you can fill up the room at the bottom with the rubber that is included in the kit.
55 Version 1.5 Volkswagen Caddy Maxi 6.7 Mounting the rear and rearbumper
Important: When you need to replace the parking sensors, make sure that you place the electrical line (of these two sensors) before mounting the new bumperpart!! See chapter 7.2
Dismounting the original gas springs: Remove the safety pins, at the bottom and top. Dismount the gas spring.
Replace the both original ball studs that are mounted on the car body (left and right). Tighten these ball studs with 33-35 Nm. Mount the new gas springs: Place the gas springs on the ball joints. Mount the safety pins.
56 Version 1.5 Volkswagen Caddy Maxi Now we need the earlier dismounted original lock and electric motor.
Preparations of the original Volkswagen lock.
Drill a hole (5,0 mm) at the indicated position.
Place the original lock onto the bracket (as indicated in the left picture), using two bolts (included in the kit).
57 Version 1.5 Volkswagen Caddy Maxi
Mount the original electric motor onto the bracket as in- dicated in the picture above, using two bolts with washers (included in the kit).
Connect the electric motor with the lock by using the indi- cated axle (included in the kit).
58 Version 1.5 Volkswagen Caddy Maxi Preparations of the rear hatch.
Drill the indicated original holes of the rear hatch to 9 mm. Use a drillstop to prevent damage.
59 Version 1.5 Volkswagen Caddy Maxi
Attach the blind rivet nuts in the indicated holes.
60 Version 1.5 Volkswagen Caddy Maxi
Attach the bumperpart to the rear hatch using four bolts. Mark the other two holes, where you need to drill. Dismount the bumperpart.
Drill the two marked holes (9 mm) and attach a blind rivet nut in each hole (included in the kit).
61 Version 1.5 Volkswagen Caddy Maxi
Place the lock bracket on the location indi- cated in the picture. Mark the hole that is not original on the vehicle (both sides). Drill the marked hole (9 mm), both sides.
Mount both assembled brackets on the rear hatch using two bolts (included in the kit). To fasten the bolts you use the support plates (indicated in the left picture), these plates are placed in the inner side of the rear hatch.
62 Version 1.5 Volkswagen Caddy Maxi
The cable for the emergency release is pre-assembled on the lock that is delivered with the kit. The other end of the cable needs to be placed in the earlier drilled hole in the original lock, as indicated in the pictures. Fasten the cable with a split pin (included in the kit).
63 Version 1.5 Volkswagen Caddy Maxi
Drill a hole (5 mm) at the location that is indicated in the picture. Fasten the bracket with a bolt, two washers and a jam nut (included in the kit) in the drilled hole. Fasten the cable of the emergency release to the bracket.
64 Version 1.5 Volkswagen Caddy Maxi
Drill a hole at the place that is indicated in the picture, the exact location does not matter.
Place the rubber tule (included in the kit) in the hole.
Put the emergency release through the rub- ber tule and mount the red handle.
65 Version 1.5 Volkswagen Caddy Maxi
Mount the plate, that is indicated in the picture, on the rear hatch of the vehicle. Do this by using the original bolts from the lock and the original holes.
Fasten the plate with two bolts (included in the kit).
66 Version 1.5 Volkswagen Caddy Maxi
Drill the other two holes (5 mm) and fasten the plate with two blind rivets. On the blind rivet that is indicated in the left picture you also mount a clamp with rubber (included in the kit) to fasten the cable of the emergency release.
67 Version 1.5 Volkswagen Caddy Maxi
The electric cable indicated in the left picture is the splitter cable for the electric motors. Connect all three connector plugs
68 Version 1.5 Volkswagen Caddy Maxi
The electric cable indicated in the left picture is the splitter cable for the locks.
Cut of the original connector plug, the one with three white wires. Mark the three cables with 1, 2 and 3. In the left picture you see which cable is 1, 2, and 3.
Connect the blue wire with wire 1 (marked earlier), connect the white wire with wire 2 and connect the red wire with wire 3. Connect both connector plugs to the locks on each side.
Important: Before you fixate the bumper part on the rear hatch check if the locks (and the proximity/ parking sensors) are working correctly!!
69 Version 1.5 Volkswagen Caddy Maxi
Fixate the bumperpart on the rear hatch by using the bolts with washers that are included in the kit.
70 Version 1.5 Volkswagen Caddy Maxi
Remount the original cord, fasten the cord with two bolts (included in the kit).
Remount the original protection cover.
71 Version 1.5 Volkswagen Caddy Maxi
Remount the steel rear bumper and mark the places where you need to saw through the bumper (both sides), 40 mm from the support. Saw through the bumper.
72 Version 1.5 Volkswagen Caddy Maxi
Place the bumper mould on the bumper and mark the sawing lines (both sides, top and bottom).
Saw through the bumper according the sawing lines. !!Keep all three parts!!
73 Version 1.5 Volkswagen Caddy Maxi
Drill the outer hole up to 9 mm and attach a blind rivet nut in the hole (both sides).
Place a bolt, used as marker, in the blind rivet nut and mount the bumper part. Press it downwards so you can see where you need to drill the hole (6 mm), do this at both sides of the vehicle.
74 Version 1.5 Volkswagen Caddy Maxi
Remount the bumper part at each side of the vehicle. Using the original screws in the wheel arches and a M6 bolt with plastic spacer (included in the kit) in the earlier drilled hole. The plastic spacer comes between the plastic and the metal bum- per part.
75 Version 1.5 Volkswagen Caddy Maxi If there are parkingsensors present in the rear bumper, con- nect them now and test it for proper functioning.
Place the middle part of the bumper on the rear, using the same glue as you used for the lowered floor.
76 Version 1.5 Volkswagen Caddy Maxi
First: Place the bumper caps on the side bumper parts, using the same glue as you used for the lowered floor. Look if the rear hatch is closing good. Second: Place the bumper caps on the middle bumper part, using the same glue as you used for the lowered floor. Look if the rear hatch is closing correctly.
77 Version 1.5 Volkswagen Caddy Maxi 6.8 6.8 Ramp
Remove the spring and the hinges from the assembly, as indicated in the picture below (both sides).
78 Version 1.5 Volkswagen Caddy Maxi
Before you glue the mounting plates onto the lowe- red floor you have to make sure that thepart with the magnet is mounted as far as possible from the hole (both sides). You can adjust the position of this part by loosening the bolts and to shuffle the part to the correct position, indicated in the picture above.
79 Version 1.5 Volkswagen Caddy Maxi IMPORTANT: Make sure that the parts which will be glued are prepared with Cleaner I and Prep M.
Clean the indicated parts with Cleaner I.
80 Version 1.5 Volkswagen Caddy Maxi
Treat the indicated part with Prep M.
81 Version 1.5 Volkswagen Caddy Maxi IMPORTANT: Make sure that you use the same glue as you have done for bonding the lowered floor into the vehicle.
IMPORTANT: After bonding the mounting plates onto the sides of the lowered floor you must wait 48 hours be- fore using the ramp. This way, you will get the maximum strength of the glue!!
Apply the glue onto the mounting plate and place him on the lowered floor as indicated in the picture above.
82 Version 1.5 Volkswagen Caddy Maxi
When the mounting plates are fastened you can remount the hinges and the spring, as indicated in the pictures above (both sides).
83 Version 1.5 Volkswagen Caddy Maxi
The double folding ramp is for the basic-version.
The single ramp is for the comfort- and the air-version.
Mount the ramp onto the hinges, which are already installed, by using two bolts (both sides).
84 Version 1.5 Volkswagen Caddy Maxi
Now the ramp is installed you can adjust the position (in the vehicle) of it. Just loosen the indicated bolts on the mounting plates (both sides) and position the part with the magnet in the position you prefer. When the ramp is in the correct position you have to fasten the bolts again (both sides).
85 Version 1.5 Volkswagen Caddy Maxi
Basic- and Comfort-version
Mount the protection covers by using double sided tape on the inner top side and two screws at the bottom.
86 Version 1.5 Volkswagen Caddy Maxi 6.9 4-Point belt fixation
Electrical front retractors (front track): • Place the retractors as indicated in the picture. • Connect the connector plugs.
Rear retractors (rear rail): • Place the retractors as indicated in the picture. • Place the seatbelt extension in the vehi- cle.
IMPORTANT: When you are converting a Caddy Maxi with five seats instead of seven seats you have to go to page 88.
87 Version 1.5 Volkswagen Caddy Maxi 7. Options 7.1 Caddy Maxi five-seated
The five seated Maxi set (N681915001), contains:
Mounting hardware for the lowered floor and the 3-point belt.
3-point belt.
88 Version 1.5 Volkswagen Caddy Maxi Fastening the lowered floor:
For fastening the lowered floor into the vehicle you need the parts indicated in the picture below.
IMPORTANT: Put grease on the bolts, to isolate them from the glue.
Fasten the lowered floor with four bolts on the places indica- ted in the picture above. Finish the bolts by clicking the grey cap on top of the bolt, indicated in the left picture.
89 Version 1.5 Volkswagen Caddy Maxi
IMPORTANT: Put grease on the bolts, to isolate them from the glue.
The original Volkswagen bolts are used to fasten the lowered floor into the vehicle.
Place the two rings (included in the kit) on top of each other, to raise the rear points of support for the backseat.
Place the rear points of support for the backseat in the front of the lowered floor.
90 Version 1.5 Volkswagen Caddy Maxi
Place the two protection plates in the holes on each side of the lowered floor, indicated in the pictures above.
91 Version 1.5 Volkswagen Caddy Maxi Mounting the 3-point belt:
The following parts are required for mounting the 3-point belt.
3-point belt: First drill a hole (Ø 11) trough and through in the indicated location. Drill the hole in the lowered floor to Ø 16 and place the spacer (Ø 16x2 lg 18) Use the 7/16 bolt, the two washers and a 7/16 nut plate to place the bracket.
CHECK 98Nm
70 mm 55 mm
92 Version 1.5 Volkswagen Caddy Maxi
Mount the top point of the belt with the bolt CHECK and place the protection cap. Use the original VW hole in the pillar. 37Nm
If there is no thread in the original hole, a 7/16 nut plate is included in the set, that can be lowered into the D-style. Use the blind rivet to secure it’s position.
Go further with the conversion on page 31 of this installation manual.
93 Version 1.5 Volkswagen Caddy Maxi 7.2 Mounting the stainless steel (INOX) protection plates
Glue the protection plates on both sides of the lowered floor (as indicated in the pictures), use the same glue as you used for the lowered floor. The mounting of these plates is the same for all vehicles.
94 Version 1.5 Volkswagen Caddy Maxi 7.3 Connecting the moved parking sensors
3 of the 4 parking sensors cables need to be lengthened. Cut the wires of the two middle parking sensors. Manouvre the wire of the set through the D-style of the car into the rear hatch. Below is an example of how the wires can be connected.
Use the provided cable connectors to connect the wires.
95 Version 1.5 Volkswagen Caddy Maxi
Lead the wire through here.
96 Version 1.5 Volkswagen Caddy Maxi 7.4 Taxi Hinges In order to use the taxi hinges, all the steps are the same as the installation of the ramp.
Place the flanged bearing (2) as indicated into the hole. Use the bolt (1) to tighten the ramp onto the hinge and use the nut (3) to secure it.
97 Version 1.5 Volkswagen Caddy Maxi 7.5 Installation of the hydraulic kneeling system
98 Version 1.5 Volkswagen Caddy Maxi Parts of the lowering system Item Title Qty Art.nr. 1 Hydraulic fluid 1 2 Electric set 1 N150011011 3 Small Material 1 N150013024 4 Fuel parts packet Maxi 1 N150013029 5 Bump stop spacer 10 mm 1 N150013031 6 Fuel pipe set 1 N300005001 7 Cylinder brackets Maxi 1 N100005003 8 Pump bracket Maxi 1 N100005004 9 Axle brackets Maxi 1 N100005007 10 Pump with pressure guard 1 HE1-AP-SETA 11 Pull cylinder 2 N726605001 12 hydraulic tubing set 1 901315002
2.
7. 10. 7.
1. 12.
6. 11. 11.
9. 9. 3. 5.
8. 4.
Warning: The hydraulic cylinders in combination with the pump have a maximum force of 7000 N per cylinder. Make sure the pump is disconnected when working on ! the hydraulic system.
99 Version 1.5 Volkswagen Caddy Maxi Removal of parts For easier access it is advised to remove both rear wheels and both outer wheel arch covers. Remove the interior wheel arch cover on the right hand side. Remove both the bump stops and any material (grease, kit etcetera) that prevents the brackets to be mounted snug onto the beams of the vehicle. If the car has already been converted with the Bierman kit; remove the preformed fuel hose and any other fuel hoses around the bump stop. Mounting the lowering system Bolt each special lowering cylinder on the cylinder brack- ets with the included M10 x 55 Bolts (1), M10 lock wash- ers (3) and M10 washers (5) . The cylinders are identical and can therefore be mounted left or right.
Mount the longest hoses on the left cylinder and the shortest hoses on the right cylinder. The top (A) will later on be fitted on the right side of the pump, the pipes with the pressure switch.
B A B A
100 Version 1.5 Volkswagen Caddy Maxi The brackets with the cylinders can now be mounted under the vehicle. The brackets should fit flat on the beams of the vehicle. To mount the rear of the bracket onto the vehicle, put the plate with the M10 thread (9) into the beam and mount the bracket with the thread (8), nut (6) and washer (3). Place the spacer between the bracket and the original bump stop and mount with the bolt M10 x 45 from the N150013031 set.
9 8
3
6
Bolt the beam between the two brackets, using the M8 x 25 bolts (2) and the M8 spring washers (4). Ad- ditional M8 washers (10) should be used to fill the space between the brackets and the beam. Make sure the beam is slightly under tension, as retainer for both brackets.
2 12 The hydraulic pipes should be 11 screwed into place on the beam with 4 of the tube clamps (11) and the included self tapping screws (12). 4 Do not screw the tube clamps in the lowered floor!
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The axle brackets can me mounted on the rear axle as indicated in the drawing. Place one rivet (4) between the axle bracket and the shock absorber bracket.
Do not place the hooks on the brackets yet! Wait until the lowering system is fully in place ! and the vehicle is standing on its’s wheels.
There should be one rivet nut in the original body of the vehicle behind the right wheel arch cover.
The two other holes should be drilled to Ø 9 in order to place the included rivet nuts.
The pump bracket can now be mounted with the three M6x16 bolts and the M6 spring washers.
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Drill two holes (ø 24mm) in the steel wheel arch for the throughput of the hydraulic hoses. You can use the included rubber grommet or seal the hole with the kit you use to attach the composite lowered floor in the car.
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Route the cable through the car as depicted in the drawing. The side with the attached eye should go on the battery.
Attach this cable to the battery ONLY if the connections of the battery are disconnected!
1
2 The connector for the 10 mm² cable is 3 preassembled onto the pump relays. Connect it to the cable in similar to the one that is 4 already attached to the cable.
5 6 Connect the wires onto the six locations of the pump and the relays as indicated in the picture. Do not connect the wires onto the pump bracket just yet.
105 Version 1.5 Volkswagen Caddy Maxi The purple wire should be mounted in the same manner as the wire from the 4 point fixation.
Remove the two relays from their socket and screw the socket under the wheel arch cover. Place the relays back in their sockets.
106 Version 1.5 Volkswagen Caddy Maxi The pump can now be mounted onto the pump bracket, using two M10 bolts with rivets.
Connect the yellow wire and the brown wires to the pump bracket as indicated in the picture.
Attach the hydraulic pipes as indicated below and fill the pump with the hydraulic fluid. The level should be just under the fill opening.
B A B A
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Test if the cylinders operate as expected!
90 mm Cut a hole (22mm x 45 mm) in de right wheel arch cover as indicated in the picture. Place the switch of the kneeling system in the hole.
Mount the preformed hose between the filler pipe and the fuel tank under the lowered floor, but above the steal beam. Make sure it is not situated above the point of attachment of the torsion bar on the rear axle. The other Course of the fuel hoses underneath the vehicle fuel hoses included in the lowering system package can follow the same path. Make sure to use the included brass tube shells to install in the original fuel lines.
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When the weight has been lifted from the suspension it takes some time to get back into it’s original position. Best is to make a quick ! drive before assembling the hooks onto the axle brackets.
To place the hooks: Rotate the cylinders just until the grabbers are pointing forward. The hooks should fit on the axle brackets as below. Mark the holes of the axle bracket on the hook and drill through the hook Ø 9mm. Each hook can now be assembled with the two M8 bolts, 4 rivets and 2 lock nuts.
Check all hydraulic connections (pump, cylinders and Tee fittings) for any leakage. Test if the system is working appropriately. If the system is not working as it should, check the fuses, the mass (door switch) and the battery connection.
109 Version 1.5 Volkswagen Caddy Maxi Electric scheme of the hydraulic lowering system
110 Version 1.5 Volkswagen Caddy Maxi Hydraulic scheme of the hydraulic lowering system
111 Version 1.5 Volkswagen Caddy Maxi 8. Torque specifications
IMPORTANT: always use a calibrated torque spanner.
Bolt type Class 8.8 Class 10.9 M6 * 1.00 8.5 Nm 12.5 Nm M7 * 1.00 14 Nm 20.5 Nm M8 * 1.00 22 Nm 32 Nm M8 * 1.25 20.5 Nm 30 Nm M10 * 1.00 45 Nm 67 Nm M10 * 1.25 43 Nm 64 Nm M10 * 1.50 41 Nm 60 Nm M12 * 1.25 77 Nm 112 Nm M12 * 1.50 74 Nm 108 Nm M12 * 1.75 71 Nm 104 Nm M14 * 1.50 121 Nm 175 Nm M14 * 2.00 113 Nm 165 Nm M16 * 1.50 180 Nm 270 Nm M16 * 2.00 170 Nm 250 Nm M18 * 1.50 270 Nm 390 Nm M18 * 2.50 245 Nm 350 Nm M20 * 1.50 380 Nm 540 Nm M20 * 2.50 350 Nm 490 Nm M22 * 1.50 510 Nm 720 Nm M22 * 2.50 470 Nm 670 Nm
112 Version 1.5 Volkswagen Caddy Maxi 9. Notes
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114 Version 1.5 Volkswagen Caddy Maxi 10. Contact
Bierman BV P.O. Box 99, 2150 AB Nieuw-Vennep Pesetaweg 16, 2153 PJ Nieuw-Vennep The Netherlands
Tel.: +31 252 210611 Fax: +31 252 232985 E mail: [email protected] E mail: [email protected] www.bierman.eu
115 Version 1.5 Volkswagen Caddy Maxi 10.1 Contact persons
Erik Henneken (NL-UK-D-F) email: [email protected] tel: +31 252 210611 • General Manager
Nicolette van Berkel (NL-UK-D) email: [email protected] tel: +31 252 629150 • Booking trainings, travel + hotel • Dealercontracts • Database of s/n’s, orders, customers, VIN’s • Order intake + invoicing Stefan Bostelaar (NL-UK) email: [email protected] tel: + 31 252 629172 • Technical advise/helpdesk • Training • Installation manual • Warranty
Anton Kerkvliet (NL-UK) email: [email protected] email: [email protected] tel: +31 252 629156 • Parts • Distribution
10.2 Other email addresses
Sales: [email protected] Manuals: [email protected]
116 Version 1.5 Volkswagen Caddy Maxi 11. Recommendation form Dear installer,
Bierman strives to excel in delivering the highest quality wheelchair conversion kits for vehicles. However this is an ongoing process. Therefore we are interested in your opinion! So if you have any com- ments, improvements or recommendations, please tell us. After all, with your input we are able to improve the conversion kit (and manual). This is not only in our favour, but also you and your company will benefit from this!
Please send an e-mail to [email protected], or send this feedback-form to fax nr. +31 252 - 232985.
Company:
Your name:
Date:
Vehicle:
Engine type:
Conversion:
Manual version:
YOUR REMARKS:
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