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Installation Manual Volkswagen Caddy Maxi WAV-Conversion Petrol

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Installation Manual Volkswagen Caddy Maxi WAV-Conversion Petrol 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.
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