Volkswagen-Self-study Programme 560 - Caddy

Service Training
Commercial
Vehicles
Self-study programme 560
The Caddy 2016

Worldwide, about 1.5 million Caddy vehicles of the previous generations have been sold over an 11 year period.
We intend to continue this success story with the new Caddy 2016. This is because the award winning urban
delivery van has been perfected and sharpened up in all areas. The same goes for its privately used brother. With
a total of 4 equipment variants, the compact van will appeal to a wide range of customers. And not forgetting the
leisure automobile, the Caddy Beach. It goes without saying that the new generation is once again available with
4-wheel drive (4MOTION).
Volkswagen Commercial Vehicles is responding to individual requirements with a diverse range of engines and
powertrains. In total, there are 4 TDI engines, 3 TSI engines and one TGI engine, optionally available with 5 or
6-speed manual gearboxes, 6 or 7-speed dual clutch gearbox. In addition, the four-wheel drive can be combined
with 2 engines and gearboxes.
S560_002
Self-Study Programme presents the Current testing, setting and repair instructions
design and function of new can be found in the service literature provided.
developments! Important
The content will not be updated. Note
2
At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Radio, telephone and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3
Introduction
The product features of the Caddy 2016

The overview lists new and striking product characteristics of the Caddy 2016. Deviations are possible depending
on the country.
• Roof rails
• 360° parking system
• Heated windscreen
• Multicollision brake
• Petrol engines of the

EA211 series
• Diesel engines of the

EA288 series
S560_004
• Front Assist with

Automatic Emergency Braking
S560_005
• 4MOTION with dual clutch gearbox and
generation V 4WD coupling
• Cruise control system (CCS) including speed limiter
• New range of colours
4
The recognition features of the Caddy 2016
Newly designed headlights

and front bumper
Dash panel with numerous

storage possibilities
Striking side profile line with cut-in, rectangular

turn signal repeater
Tailgate with larger number plate

panel and continuous rear window
Newly designed tail

light clusters
Moulded headliner and roll-up

tonneau cover
S560_006
5
Introduction
Technical data
Caddy panel van
View and dimensions taking the example
of a panel van with front-wheel drive and
short wheelbase
S560_007
879 2682 847
4408
1823
166
577
1536 1534
1793
2065
S560_061 S560_062
Weights (examples)*
Caddy panel van Caddy Comfortline
Short wheelbase Long wheelbase (Maxi)
7-seater
Unladen weight including driver* 1398 - 1603 kg 1537 - 1818 kg
Gross vehicle weight rating* 2045 - 2160 kg 2345 kg
Braked trailer load on 12% / 8% incline 1100 - 1500 kg /
1300 - 1500 kg / 1500 kg
1400 - 1500 kg
Payload/load capacity 557 - 647 kg 527 - 808 kg
Roof load 100 kg for all Caddy versions
* Depending on engine and equipment
6
Caddy window van, Trendline, Comfortline, Comfortline Edition, Beach
View and dimensions taking the example
of a Caddy Comfortline with front-wheel
drive and long wheelbase (Maxi)
S560_008
879 3006 993
4878
1868
158
581
1537 1544
1793
2065
S560_063 S560_064
Loading volume taking example

Additional dimensions of a Caddy Maxi Comfortline
Turning circle, short wheelbase 11.1 m With upright 3rd seat row to top 530 l
edge of backrest
Turning circle, long wheelbase 12.2 m
(Maxi) Behind 2nd seat row in passenger 1350 l
compartment with cover
Fuel tank volume front/4-wheel
55 l / 60 l
drive With double-folded 2nd seat row 3700 l
in the passenger compartment
Vehicle length with tow hitch 4506 mm
4976 mm (Maxi) Without seats in the passenger
3880 l
compartment
7
Body
The body
To a large extent, the body has been taken from the previous model. The front and rear ends are new – they have
been adapted to the current family face at Volkswagen and are the same for the can and commercial vehicles.
New features on the body:
• Engine lid
• Wing
• Radiator grille with Volkswagen badge
• Front bumper
• Rear bumper
• Tailgate
• Exterior mirror (car variant) S560_112
Tailgate with metal panel
The newly designed tailgate has a continuous

window. The panel van also has the option of a
tailgate with a complete metal panel.
S560_154
Front end
Assembly mount
Condenser
Water radiator for charge air cooling circuit
Cooler for power steering
Foam insert
S560_111
Impact beam
8
Bumper cover
The newly designed bumper cover is stabilised by 2 support inserts fitted at the sides. The support inserts
additionally serve as carriers for the fog lights. In bumpers in the painted version, the support inserts are
exclusively connected to the bumper cover using clip connections.
The illustration shows the painted version
1 10
1 3
1
1
9
2
6
5 7
7 8
S560_107
6
8
Legend
1 Trim strip 6 Air intake grille with opening for fog light
2 Radiator grille centre 7 Trim for fog light
3 Cap for towing eye 8 Fog light
4 Bumper cover 9 Radiator grille
5 Spoiler 10 Lettering
Bumper cover and radiator grille form one structural Bonded connection
unit in the non-painted, grained version. The support
inserts are connected to the bumper cover using clips
and 4 additional bonded connections. The bonded
connections provide spot connections for the
thermoplastic materials of the bumper cover and the
support insert. The air intake grilles with the openings
for the fog lights are covered by the support inserts.
To be able to remove the air intake grilles, it is first
necessary to remove the relevant support insert.
S560_155
9
Body
The body structure

To improve body stability in an accident, corresponding reinforcements have additionally been integrated into the
body structure.
Reinforcements for side-on collision

Web plate on sill panel
Insert for reinforcement

of the B-pillar
Web plate,
checker plate
Cover plate
floor
(on both sides) Sill panel reinforcement
(sill panel doubler)
Web plate of the sill panel

(optimised) S560_137
Reinforcements for front-end collision

Reinforced mounting bracket Reinforcement side member top
(in LHD vehicles installed on left and in RHD vehicles
installed on both sides)
Reinforcement side member
Web plate
Web plate
Impact beam
Deformation element
(optimised) S560_138
10
The interior
Depending on equipment, there are two different dash panels in the Caddy 2016. Both variants appear in a new
design and offer numerous storage possibilities with a wider range of options. The convenience dash panel is
visually upgraded by decorative inlays and trims in different structures, colours and surface composition.
Upper central storage compartment Open storage compartment Glove box,

lockable
Open storage compartment with 12 volt socket and S560_060

USB/Aux interface (depending on equipment)
Convenience dash panel

Upper centre storage Glove box,
compartment with flap lockable
Open storage compartment with 12 volt socket and

USB/Aux interface (depending on equipment) S560_059
11
Body
Occupant protection
In vehicles without head curtain airbags for the driver
and passenger compartments, the side airbag on the
Module
driver and front passenger sides is configured as a Side airbag on front passenger side
head/thorax airbag.
Head airbag
Front passenger's side
(Front passenger and passenger
compartment)
Front passenger airbag
Module
Front passenger airbag
Driver's airbag
Airbag control unit with

crash sensor for front
airbags
Module
Driver's airbag
12
Head airbag
Driver side
(Driver and passenger compartment)
Three-point seat belt with belt tensioner,

attached to the body
(driver and FP sides)
S560_152
Crash sensor
in C-pillar at bottom
Module
Side airbag on driver side for vehicles with head curtain airbags
(Driver and passenger compartment)
Three-point seat belt with belt tensioner,

attached to the body
Crash sensor, in B-pillar at bottom

Side airbag on driver side
13
Power units
The Caddy 2016 uses the most economical engines, and with the lowest emissions, that Volkswagen Commercial
Vehicles has ever offered.
TSI engines
The TSI engines (engine series EA211) from Volkswagen Commercial Vehicles combine low displacement,
turbocharging and direct injection to deliver a very even application of power. The maximum torque is available at
low engine speeds.
TGI engine
As the successor of the "Caddy EcoFuel" (with 2.0 l natural gas engine), the Caddy 2016 features a new 1.4 l TGI
engine. The turbocharged 4-cylinder inline engine has been further optimised for natural gas operation. Due to its
increased power and turbocharging, the engine delivers significantly improved acceleration and in-gear
acceleration values.
TDI engines
On the basis of a 2.0 l TDI engine (EA288 engine series) with common rail direct injection, customers can select
from 4 performance stages to meet their requirements. Each version will attract customers by extremely low
consumption and emissions values.
Emission standard EU6

All new engines in the Caddy 2016 meet the EU6 emission standard. As a result, exhaust post treatment to reduce
nitrous oxides is required for all diesel engines. An SCR system (Selective Catalytic Reduction system) is used for this
purpose.
TDI engines with emission standard EU5

Until further notice, the new "Caddy panel van" (except "Caddy panel van BlueMotion") and "Caddy Maxi panel
van" are also available with the corresponding EU5 TDI engines of the previous series (except 125 kW or 170 HP).
For more information about these engines, please refer to the Self-Study Programme no. 472
"The Caddy 2011".
14
The TSI engines
1.0 l 75 kW TSI engine 1.2 l 62 kW TSI engine 1.4 l 92 kW TSI engine

CHZG CYVC CZCB
5-speed
manual gearbox
0AF
6-speed
manual gearbox
02S
7-speed
dual clutch
gearbox
0CW
The TGI engine (natural gas)
1.4 l 81 kW TGI engine

CPWA
6-speed
manual gearbox
02S
15
Power units
The 1.0 l 75 kW TSI engine

The 1.0 l 75 kW TSI engine comes from the EA211
engine series.
Technical features
• Exhaust turbocharger module with electric boost

pressure actuator
• Camshaft drive via a toothed belt
• Cylinder head with integrated exhaust manifold
• Coolant regulator housing with integrated coolant
pump
• Oil vane pump with drive directly from the
crankshaft
S560_083
Technical data Torque and power diagram
200 100
Engine code CHZG
Cubic capacity 999 cm3

Design 3-cylinder inline engine 160 80
Valves per cylinder 4
Bore 74.5 mm
120 60
Stroke 76.4 mm
Compression ratio 10.5 : 1

Torque [Nm]
Power [kW]
Max. power 75 kW at 80 40
5000 rpm
Max. torque 175 Nm at

1500 – 3500 rpm
40 20
Engine management Bosch Motronic
Fuel Regular unleaded with

RON 95
0 0
Turbocharger Wastegate turbocharger 1000 2000 3000 4000 5000 6000
Emissions standard EU6 Engine speed [rpm]
S560_133
16
The 1.2 l 62 kW TSI engine also belongs to
the EA211 engine series.
Technical features

pressure actuator
• Coolant regulator housing with integrated coolant
pump
• Duo-centric oil pump with drive directly from the
crankshaft
• Variable intake valve timing
S560_108
200 100
Engine code CYVC

Design 4-cylinder inline engine 160 80
Bore 71 mm
120 60
Stroke 75.6 mm
Torque [Nm]
Power [kW]
Max. power 62 kW at 80 40
4300 – 5300 rpm

1400 – 3500 rpm 40 20

RON 93 0 0
1000 2000 3000 4000 5000 6000
Turbocharger Wastegate turbocharger
Engine speed [rpm]
Emissions standard EU6
S560_082
17
Power units

The 1.4 l 92 kW TSI engine also belongs to
the EA211 engine series.
Technical features

pressure actuator
• Externally geared oil pump
• Variable intake valve timing
S560_010

300 100
Engine code CZCB

Design 4-cylinder inline engine
250 80
Bore 74.5 mm
Stroke 80 mm 200 60
Torque [Nm]
Power [kW]
Max. power 92 kW at
5000 – 6000 rpm
150 40
1500 – 3500 rpm

100 20
RON 95
Emissions standard EU6 50 0

1000 2000 3000 4000 5000 6000
Engine speed [rpm]

S560_084
18
The 1.4 l 81 kW TGI engine
(natural gas)
This engine was launched in the 2014 model year for
the Golf and Golf Variant. It differs from the 1.4 l
90 kW TSI engine only in that its components are
adapted for natural gas drive.
Technical features
• One engine control unit for natural gas and petrol

mode
• Electronic gas pressure regulator with a
mechanical and electronic pressure reduction
stage
• Gas rail with temperature and pressure sensor S560_012
Engine code CPWA

200 80
Bore 74.5 mm
Stroke 80.0 mm
Compression ratio 10.5 : 1 160 60
Torque [Nm]
Power [kW]
Max. power 81 kW at
4800 – 6000 rpm
120 40
1500 – 3500 rpm
Fuel Natural gas H
Natural gas L with reduced 80 20
range
Regular unleaded RON 95
Emissions standard EU6 40 0
1000 2000 3000 4000 5000 6000
Engine speed [rpm]

S560_076
19
Power units
Running on natural gas

In the Caddy 2016, a new natural gas engine is being launched with the 1.4 l TGI engine of the EA211 engine
series. It differs from the purely petrol-operated variant in that its components have been adapted for running on
natural gas. The adaptations have been made because natural gas not only burns more cleanly than petrol but
also has a higher knock resistance. For example, the octane number of natural gas H is up to RON 130. This
permits an earlier ignition time without engine knock during combustion. The efficiency increases, and so does the
combustion pressure and combustion temperature in the combustion chamber.
Furthermore, natural gas is very dry and does not have lubricating properties such as petrol.
Tailpipe
in front of the rear axle
High-pressure
Natural gas line
Fuel line
Petrol
Gas pressure regulator with sensor for tank

pressure G400
Hydraulic valve for gas mode N372
Low-pressure
Natural gas line
Decoupling element Underbody Silencer

Catalytic
20
Refuelling natural gas
The gas filler pipe is located on the left side of the
vehicle behind the tank flap next to the petrol filler
pipe. The Caddy 2016 has 4 or 5 natural gas tanks
(Caddy Maxi), which are arranged in 2 racks on the
floor of the vehicle. Between these is located the
petrol tank with a capacity of about 13 litres. The
natural gas fill quantity in the Caddy is about 26 kg
and in the Caddy Maxi about 37 kg.
S560_104
Natural gas gauge G411
The dash panel insert contains the natural gas gauge

G411 in the left round instrument, with the warning
light for natural gas mode K192. This lights yellow
when both fuel types have been consumed down to
the reserve level. The warning light illuminates green
Natural gas fuel tank
if the vehicle is in natural gas mode. The green warn-
(rear rack) ing light goes out when the natural gas supply has
been used up. The engine switches over to petrol
mode.
Filler pipe
Natural gas
Filler pipe
Petrol
Plastic cover
Petrol fuel tank
S560_103
Natural gas fuel tank
(front rack)
Warning light for Natural gas gauge
S560_100 natural gas mode G411
K192
For more information about natural gas technology, please refer to the Self-Study Programme no. 528
"Running on natural gas in the Golf/Golf Variant TGI BlueMotion".
21
Power units
The TDI engines
2.0 l 55 kW 2.0 l 75 kW 2.0 l 90 kW 2.0 l 110 kW

TDI engine TDI engine TDI engine TDI engine
CUUF CUUD CUUE CUUB
5-speed
manual gearbox
0A4
6-speed
manual gearbox
02Q-A
6-speed
manual gearbox
02Q-F
6-speed
dual clutch
gearbox
02E-A
6-speed
dual clutch
gearbox
02E-F
22
The 2.0 l 55 kW TDI engine
A new 2.0 l TDI engine is used in the Caddy 2016.
The engine is in the EA288 engine series.
Technical features
• Exhaust purification module with SCR system

• High and low-pressure exhaust gas recirculation
• Thermal management with coolant pump with on/
off function
• Suction pipe module with water-cooled charge air
cooler
• Bosch common rail injection system
S560_011

300 100
Engine code CUUF

250 80
Bore 81 mm 200 60
Stroke 95.5 mm
Torque [Nm]
Power [kW]

150 40
Max. power 55 kW at
2400 – 4500 rpm

1200 – 2300 rpm 100 20
Engine management Bosch EDC 17
Fuel Diesel acc. to DIN EN 590 50 0

Turbocharger VTG turbocharger 1000 2000 3000 4000 5000 6000
Exhaust gas recirculation Yes Engine speed [rpm]
Emissions standard EU6 with SCR system S560_078
23
Power units

This engine also belongs to the EA288 engine series.
The power and torque are controlled by the engine
management system.
Technical features

off function
cooler
S560_011
Engine code CUUD
Cubic capacity 1968 cm3 300 100


250 80
Bore 81 mm
Stroke 95.5 mm
Torque [Nm]
Power [kW]

Max. power 75 kW at
2900 – 4000 rpm
Max. torque 250 Nm at 150 40

1300 – 2800 rpm
Turbocharger VTG turbocharger
Exhaust gas recirculation Yes 50 0

Emissions standard EU6 with SCR system 1000 2000 3000 4000 5000 6000
Engine speed [rpm]
S560_079
24
The power and torque are controlled by the engine
management system.
Technical features

off function
cooler
S560_011
Engine code CUUE
Cubic capacity 1968 cm3 300 100


250 80
Bore 81 mm
Stroke 95.5 mm
Torque [Nm]
Power [kW]
Max. power 90 kW at
2900 – 4500 rpm
Max. torque 300 Nm at 150 40

1500 – 2800 rpm
Exhaust gas recirculation Yes 50 0
Emissions standard EU6 with SCR system 1000 2000 3000 4000 5000 6000
Engine speed [rpm]
S560_080
25
Power units

At the moment, it is the most powerful diesel engine in
the Caddy 2016.
Technical features

off function
cooler
S560_011
Engine code CUUB

350 120
Valves per cylinder 4 300 100
Bore 81 mm
Stroke 95.5 mm
250 80
Torque [Nm]
Power [kW]
Max. power 110 kW at

3500 – 4000 rpm
200 60
1750 – 3000 rpm

150 40
Fuel Diesel acc. to DIN EN 590

100 20
Exhaust gas recirculation Yes
Emissions standard EU6 with SCR system
50 0
1000 2000 3000 4000 5000 6000
Engine speed [rpm]

S560_081
26
The exhaust flap control unit J883
The task of the control unit is to generate a slight back The exhaust gas recirculation valve controls the
pressure after the diesel particulate filter, using an amount of returned exhaust gases depending on the
exhaust flap operated by an electric motor. The characteristic map. This back pressure is measured by
resulting positive pressure of 30 – 40 mbar above the pressure sensor 1 for exhaust gas G450.
exhaust gas pressure produces a positive flow
gradient (purge rate) in the exhaust gas recirculation
cooler and the exhaust gas recirculation valve
arranged after it.
Oxidising catalytic converter Exhaust flap control unit J883
Diesel particulate filter
Flex tube
Trap catalytic converter

S560_136
Trap catalytic converter
The combined diesel particulate filter with SCR The carbon monoxide (CO) resulting from soot
catalytic converter is followed by a trap catalytic regeneration is oxidised by the coating containing
converter which carries out two tasks: precious metals, to produce carbon dioxide (CO2).
As its 2nd task, the trap catalytic converter ensures
that no ammonia (NH3) leaves the exhaust system
under any circumstances. NH3 is oxidised into
nitrogen (N2) and water (H2O).
27
Power units
The exhaust post-treatment with SCR system

In order to achieve the EU6 emissions limits, a Selective Catalytic Reduction system (SCR system) is used in the
Caddy 2016. This means only the nitrogen oxides specifically are reduced amongst the exhaust gas constituents.
The nitrogen oxides (NOx) are converted in the reduction catalytic converter into nitrogen (N2) and water (H2O).
To do this, a reducing agent is continuously injected into the exhaust gas stream.
Overview
Injector for reducing agent N474 Engine control unit J623
Exhaust purification
module
Filler neck for reducing agent
Heated metering line to the injector for

reducing agent N474
Reducing agent tank with pump module Trap catalytic converter
28
Filling the tank for reducing agent
In addition to the fuel tank with a capacity of about
55 litres (front-wheel drive), there is also a reducing
agent tank with a capacity of about 9 litres in the
engine compartment. This capacity achieves a range
of about 6000 km.
The tank for reducing agent is replenished via a filler
connection in the engine compartment at the front left
out of replenishment containers, and is closed by a
blue tank cap.
Filler neck for reducing agent

S560_024
Diesel fuel tank
Exhaust flap control unit J883
Control unit for reducing agent heating J891
S560_015
For more information about exhaust post-treatment, please refer to the Self-Study Programme no. 446
"The 2.5 l TDI EURO V engines with SCR system in the Crafter - design and function".
29
Power transmission
The 4WD coupling generation V

In the Caddy 2016, 4-wheel drive is offered in all
vehicle variants with the following engines:
• 2.0 l 90 kW TDI engine

• 2.0 l 110 kW TDI engine
The 4WD coupling is integrated into the rear final

drive. The 4WD coupling between the front and rear
final drives controls the drive torque to the rear axle.
S560_054
It directs the required torque to the rear axle
depending on the pressure in the multi-plate clutch.
Structure and function
The Haldex coupling of generation V is characterised

primarily by a new pressure control. The hydraulic
pressure required for the 4WD coupling is generated
by a pump with centrifugal force controller. This
technology has allowed the weight to be reduced
compared to generation IV of the 4WD coupling
(Haldex) by 1.7 kg.
The control logic in the various driving situations has

been taken from generation IV of the 4WD coupling
(Haldex), see Self-Study Programme no. 414
"4MOTION with 4WD coupling generation IV".
Left drive shaft
Crown wheel with hypoid

gearing
Rear end cover
30
Oil fill
Haldex oil drain plug Haldex oil filler plug
The oil is changed every 3 years in the Caddy, without

any limitation in terms of mileage. Please use the
correct oil filler and drain plug! For more information,
refer to the electronic service information system
(ElsaPro).
S560_094
Final drive oil filler plug Final drive oil drain plug
(concealed)
Rear final drive breather Control unit for 4WD Clutch cage with clutch pack
coupling J492 (Haldex coupling)
Flange for holding the propshaft
Pump for
Haldex coupling V181
Double oil seal
S560_086
Right drive shaft Drive pinion
31
Running gear
Overview of the running gear and driver assist systems

The overview shows important running gear equipment of the Caddy 2016 that is fitted as standard and
optionally. It can be equipped with standard running gear, sports running gear or reinforced suspension.
Running gear
The design of the running gear and brake system is
based on the technology of the previous model:
• Suspension strut front axle according to the
McPherson principle with double wishbones and
anti-roll bar
• Rigid rear axle on leaf springs with load-
dependent dampers and anti-roll bar as well as
4WD coupling generation V (Haldex) depending
on engine and model
• Electromechanical power steering
• Brake system of the modular transverse matrix
• ABS/ESC Continental MK 100
The ESP unit is fitted on the right longitudinal member

in the engine compartment. It comprises the control
unit for ABS J104 and the hydraulic unit.
Behind the Volkswagen badge: Brake system of the

Control unit for distance control J428 modular transverse matrix
32
Driver assistance systems
• Cruise control system (CCS)
• Speed limiter
• Adaptive cruise control (ACC)
• Front scan system (Front Assist) with
automatic emergency braking (AEB)
• Multicollision brake
• Main beam assistant (FLA)
• Parking distance control
• Optical 360° parking system (OPS)
• Park Assist system 2.0 (Park Assist)
• Rear view camera
• Tyre pressure monitor (TPM+)
• Fatigue detection (MKE)
S560_052
Control unit for ABS J104
The yaw rate sender G202, the lateral acceleration

Rear axle with 4WD coupling sender G200 and the longitudinal acceleration
(Haldex V) sender G251 are integrated in the ABS control unit
J104. In addition to the familiar functions from the
previous model, the ABS control unit additionally
provides assistance systems such as the tyre pressure
monitoring display RKA+ and the multicollision brake.
33
Running gear
Adaptive cruise control ACC

Adaptive cruise control ACC is a speed control system with intelligent control of the vehicle speed. The system
accelerates and decelerates comfortably.
Function
If there is no vehicle in front, ACC operates like a cruise control system. If the radar sensor detects a vehicle driving
in front in the same lane, ACC decelerates the vehicle if necessary and keeps it at the preselected following
distance. In combination with a dual clutch gearbox (DSG), the vehicle can be decelerated automatically to a
standstill and stopped.
In vehicles with a manual gearbox, the vehicle is automatically accelerated or braked to the desired speed. The
system switches off automatically at speeds less than 20 km/h.
Control unit for distance control J428
S560_055
Control unit for distance control J428

The control unit for distance control J428 is fitted behind the Volkswagen badge so as to detect the traffic situation
in front of the vehicle. The control unit is connected to the Extended CAN in the Caddy 2016. A radar sensor is
integrated in the control unit.
34
Operation
The radar sensor continuously measures the distance and speed of the vehicle driving in front. Using the ACC
controls on the multifunction steering wheel, the system can be activated and deactivated, and the required speed
and following distance can be set. The dash panel insert displays all relevant information about the system such as
the required speed and warning messages.
Resume ACC control Switching ACC on/off/

cancelling
Decelerating during Accelerating during ACC

ACC control control
Activating ACC Change between ACC and

speed limiter
Set the distance level

S560_057
For more information about the driver assist systems, refer to Self-Study Programme no. 516
"The Golf 2013 driver assist systems".
Speed limiter
The speed limiter has the task of limiting the vehicle's speed to a preset maximum speed, even if the driver presses
the accelerator pedal to demand a higher speed. The function is implemented by precise interventions in the
engine management system. Automatic brake interventions are not carried out by the speed limiter.
Operation
The speed limiter can be operated using the left steering column lever or the buttons on the multifunction steering
wheel, depending on the equipment.
It is possible to temporarily overrule the preset limit

speed using kickdown. There is a visual warning for
the period during which the limit value is exceeded,
as well as a one-time audible warning each time the
vehicle is driven faster than the limit value.
S560_093
Change between cruise control

system and speed limiter
For detailed information about operating the speed limiter, refer to the owner's manual of the vehicle.
35
Running gear
The high beam assistant (FLA)

The high-beam assistant permits the high beams to be
switched on and off automatically depending on the
traffic situation. The "eye" of the system is an RGB
camera with a resolution of about 0.5 megapixels
that is accommodated in the mirror base.
The main beam assist is integrated in the data bus
network via the powertrain CAN bus for the dash
panel insert.
S560_097
Front camera for driver

assist systems R242
Control unit for main

beam assist J844
S560_098
For more information about the main beam assist, please refer to the Self-Study Programme no. 498
"The Golf convertible 2012".
36
The Park Assist system 2.0
The Park Assist system assists the driver when entering and exiting parking spaces, and during manoeuvring. It
carries out the steering movements automatically. The driver only needs to engage the corresponding gear, press
the accelerator and the brake. The driver can terminate the function of the Park Assist system at any time, and take
over control. 6 sensors are mounted on the front of the vehicle and 6 on the rear for the Park Assist system. This
also enables the 360° OPS function.
The functions of the Park Assist system are:
• The park pilot, also referred to as parking distance control (PDC). This is also available without Park Assist
system and must also be activated in vehicles with Park Assist system, e.g. when parking forwards.
• The park steering function for the active parking process.
• Perpendicular parking
• Parking on bends
• Parallel parking
- with two or all wheels on pavements
- between other obstacles (trees, bushes or motorcycles)
• Driving out of a parallel parking space
• ESP intervention when parking if the speed is too fast or there is a risk of collision to reduce damage
S560_085
For more information about 360° OPS, please refer to Self-Study Programme no. 517 "The Golf 2013
electric". For more information about the Park Assist system 2.0 with all components, refer to the Self-
Study Programme no. 494 "The Park Assist system 2.0".
37
Running gear
The tyre pressure monitoring display (RKA+)

Task
The tyre pressure monitoring display (TPM+) uses the
wheel speed sensors G44 – G47 to compare the
rolling circumference and vibration behaviour of the
individual wheels.
The vibration behaviour and the rolling circumference
of the wheels change when the tyre pressure changes.
A change in the tyre pressure at one or more wheels

is indicated on the tyre pressure monitoring display in
the multifunction display on the dash panel insert. No
additional sensors are required in the tyres. The
change in the tyre pressure is detected by a
calculation model in the ABS control unit J104. S560_116
Function
The tyre pressure monitor display system is part of the Changes to the rolling circumference and the
software in the ABS control unit J104. vibration behaviour of a wheel are displayed on the
Event memory entries for the tyre pressure monitoring dash panel insert by the tyre pressure monitoring
display are stored in the ABS control unit. display warning lamp K220 lighting up.
The tyre monitor display must have its teach-in The rolling circumference and the vibration behaviour
process repeated after the following work: can change due to:
• Change of tyre pressure • Insufficient tyre pressure

• Changing one or more wheels • Damage to the tyre
• Interchanging wheels, e.g. from front to rear • One-sided loading of vehicle
• Influence of snow chains
After the teach-in process, the system learns the • Changing a wheel
characteristic parameters of the new pressure and • Increased load on one axle, e.g. when towing a
tyre conditions at various speed intervals and stores trailer
them. • Operation with temporary spare wheel
38
The multicollision brake
About 22 % of all accidents involving personal injury are multicollisions. Multicollisions are collisions in which the
first impact is followed by further collisions, e.g. with side barriers or oncoming traffic.
Function
The multicollision brake triggers automatic brake To trigger the multicollision brake, the airbag control
intervention when a first collision is detected. This unit sends a corresponding message to the ABS
automatic braking should prevent follow-on collisions, control unit. Exclusively the sensors of the airbag
or at least reduce the impact energy of a follow-on control unit are used for activating the multicollision
collision. The multicollision brake decelerates the brake.
vehicle at maximum 6 m/s2, at the same time as
activating the emergency brake light and the hazard The multicollision brake can be overridden by the
warning lights. driver at any time. If the driver accelerates or presses
The ESP lamp in the instrument cluster informs the the brake pedal for an even higher deceleration, the
driver about the brake intervention. In all cases, the system is overridden.
multicollision brake performs braking down to a
vehicle speed of 10 km/h. In this way, the vehicle
can remain under the driver's control even after a
collision, depending on the accident situation.
S560_135
39
Running gear
The Driver Alert System (DAS)

Between and 5 and 25 % of all accidents are caused by fatigue. Driving when fatigued is a cause of more severe
accidents than other accident causes.
The driver alert system (DAS) is a convenience function that supports the driver and has a preventative effect by
detecting the driver's fatigue level.
Function
Fatigue is detected by evaluating the steering In addition to the steering behaviour, data regarding
behaviour. If the system detects that the driver is at the driving situation (vehicle speed, accelerator pedal
risk of falling asleep, there is an acoustic warning as operation, use of turn indicators, time of day, duration
well as a text prompt to take a break displayed on the of driving, etc.) and the driver's activity operating the
multifunction display of the dash panel insert. settings and comfort elements (air conditioning
system, use of telephone, etc.) are recorded and sent
via the CAN data bus to the diagnostic interface for
the data bus where the data is evaluated. The
software is integrated in the gateway.
Operation and display

Operation
Activation and deactivation is via the dash panel Fatigue

detected.
insert. The function is available from a speed of
65 km/h onwards. Following activation, the system
requires about 15 minutes to collect sufficient data on Please take a
break.
which to draw a conclusion about the driver's fatigue
as driving continues.
S560_134
Display
If driver fatigue is detected, a message is displayed in the dash panel insert and a gong sounds for 5 seconds. The
message and gong are repeated if the driver does not take a break within the next 15 minutes. After this repetition
there is no further warning.
40
The area monitoring system (Front Assist)
If the risk of a collision is detected, the brake system is At a speed of more than 30 km/h, the automatic
pre-filled. The hydraulic brake assist system is deceleration is up to 6 m/s2.
reduced to a lower triggering threshold and the driver If the driver does not respond to the brake jolt either,
is given a visual and audible warning. In addition, an Front Assist brakes automatically in order to avoid a
automatic brake jolt alerts the driver to the danger. collision in the most favourable case, or at least
If the driver responds with insufficiently powerful reduce the severity of the accident.
braking, the vehicle automatically generates the
brake pressure required by the situation.
S560_143
1. Advance warning 3. Automatic partial braking
• Reduction in stopping distance 1: • Reduction in stopping distance 3 (5 – 210 km/h):
- Prefill of the brake, hydraulic - Automatic deceleration,
brake assist system threshold changeover if the driver does not respond (up to 6 m/s2).
• Reduction in stopping distance 2: • Reduction in stopping distance 3 (less than or
- Visual and audible warning equal to 30 km/h):
- Automatic deceleration,
2. Main warning if the driver does not respond (up to 8 m/s2).
• Reduction in stopping distance 1:
- Hydraulic brake assist system 4. Target braking
Threshold changeover highest level • Reduction in stopping distance 3:
• Reduction in stopping distance 2: - Boosting of the driver's braking
- Brake jolt to avoid a collision or
reduce the consequences of an accident.
For more information about Front Assist, refer to the Self-Study Programmes no. 470
"The Touareg 2011 – electric/electronic systems" and no. 488 "The Passat 2011".
41
Running gear
Automatic emergency braking (AEB)

Automatic emergency braking is an expansion to the automatically triggers full braking to a standstill, in
Front Assist system, and uses the radar sensor to order to reduce the accident severity. The system
monitor the area in front of the vehicle. The system provides support by applying maximum braking
operates in the speed range below 30 km/h. If the effort if the driver does not press the pedal firmly
driver does not respond when there is a risk of a rear- enough. Like all of these systems, automatic
end collision with a vehicle driving or parked in front, emergency braking cannot release the driver from
the brake system is brought to an increased level of his/her responsibility for driving the vehicle, and thus
braking readiness, in the same way as with Front cannot be guaranteed to prevent an accident from
Assist. If required, automatic emergency braking occurring.
S560_142
1. No driver warning 3. Target braking
• Reduction in stopping distance 1: • Reduction in stopping distance 3:
- Prefill of the brake, hydraulic - Boosting of the driver's braking
brake assist system threshold changeover to avoid a collision or
reduce the consequences of an accident.
2. Automatic partial braking
• Reduction in stopping distance 3
(less than or equal to 30 km/h):
- Automatic deceleration,
if the driver does not respond (up to 8 m/s2).
The proximity alarm

The proximity alarm gives the driver a visual
notification if the distance from the vehicle in front is
critical (less than 0.9 s). The proximity alarm function
uses the radar sensor behind the Volkswagen badge
to measure the distance to the vehicle driving in front.
If the system detects that there is a safety risk, the
driver is warned by a corresponding display.
The proximity alarm is active in the speed range from
70 – 210 km/h.
S560_144
42
Heating and air conditioning
The heated windscreen Z2

The heated windscreen helps with de-icing the windscreen and only functions when the engine is running.
Heating wires
Earth connections
Connection of right heating panel Connection of left heating panel S560_091
Switching on/off
Windscreen heating switch E180 is located in the control unit of the air conditioning system or the Climatronic or is
located in the switch module in the centre console, depending on which variant is fitted. A CAN message is sent to
the onboard supply control unit to switch the heated windscreen on and off. This then controls the relay of the
heated windscreen. Intervention by the energy management is possible. The windscreen heating remains switched
on for about 4 minutes. It can be switched off early by pressing the switch again.
The windscreen heating is switched off when the engine is stopped.
Windscreen heating switch E180 Windscreen heating switch E180

in the switch module on the centre console in the air conditioning control unit
S560_153 S560_092
43
Heating and air conditioning
Air conditioning
In addition to the manual heating and ventilation system, the Caddy 2016 is also available with an air conditioning
system. 2 versions of the air conditioning system are used:
• Air conditioning system

• Fully automatic 2-zone Climatronic
Controls
Heating and ventilation system
The heating and ventilation system operates manually using Bowden cables. The temperature flap and air flaps
are adjusted mechanically. The fresh air blower has 5 stages.
4 5 6
S560_028
1 2 3
Air conditioning system
The climate control system operates manually/electrically. The temperature flap and air flaps are adjusted using
control motors.
All settings are made manually and adjusted manually if required. Like in the heating and ventilation system, the
fresh air blower has 4 stages.
7 5 6 4
S560_029
1 8 2 9 3
44
2-zone Climatronic
In this climate control system, different temperatures can be set on the driver and front passenger sides, depending
on requirements. The blower stages and flap position are controlled fully automatically, as is the control of the air
blowing out of the nozzles and the interior temperature.
8 3 4 9
S560_030
10 5 11 12 2 13 14 15 7 16
Key to the figures
1 Temperature 11 Defrost, defined blower setting and air distribution

2 Blower speed towards the windows
3 Air distribution 12 Air conditioning system and blower switched off
4 Air recirculation mode 13 Automatic control of the blower, temperature and air
distribution depending on the sunshine intensity,
5 Rear window heating outside and inside temperatures
6 Immediate heat button of the auxiliary heater 14 Synchronisation of the climate zones to the driver's
7 Air conditioning system operation value
8 Seat heating left 15 Temperature right
9 Seat heating right 16 Temperature setting to "LO", maximum blower
10 Temperature left output, air distribution to the nozzles
Depending on the engine load or the load on the electrical system, the power of the air conditioning
system/Climatronic can be reduced or switched off.
45
Electrical system
The networking concept

The overview shows all control units that can be
connected to the bus systems. Some of the control
units shown here are optional or vehicle-specific
equipment. a
Legend
Powertrain CAN bus

Convenience CAN bus
CAN bus extended
LIN bus
Infotainment CAN bus
Dash panel insert CAN bus
CAN bus line
LIN bus line
Immobiliser participant
Component protection participant
a CAN bus diagnosis
b FBAS (colour image muting signal)
46
b
S560_053
C Three-phase generator J428 Control unit for distance control

E313 Selector lever J446 Control unit for park distance control
G85 Steering angle sender J453 Control unit for multifunction steering wheel, in
G397 Sensor for rain and light detection steering wheel
G578 Anti-theft alarm sensor J492 Four-wheel drive control unit
H12 Alarm horn J500 Power steering control unit
J104 ABS control unit J519 Vehicle electrical system control unit
J234 Airbag control unit J527 Steering column electronics control unit
J255 Climatronic control unit J533 Data bus diagnostic interface
J285 Control unit in dash panel insert J608 Control unit for special vehicles
J301 Air conditioning control unit J623 Engine control unit
J345 Trailer detection control unit J743 Mechatronic unit for dual clutch gearbox
J362 Immobilizer control unit J791 Park Assist control unit
J364 Auxiliary heater control unit J794 Control unit 1 for information electronics
J367 Battery monitor control unit J844 Control unit for main beam assist
J386 Driver side door control unit R Radio
J387 Front passenger side door control unit R189 Reversing camera
J400 Wiper motor control unit
47
Electrical system
The dash panel insert

A new generation of dash panel inserts is fitted in the Caddy 2016. These contain the immobiliser control unit
J362. In addition to the displayed variants, there is also a variant without multifunction display (MFD) available.
With MFD
This variant has a black/white segment display with a
maximum of 240 display segments.
A loudspeaker for outputting warning signals is
integrated. The time can be set or the trip recorder
reset using adjustment buttons.
S560_034
With MFD Plus

This variant has a black/white TFT display as MFD,
with a dot matrix of 110 x166 pixels.
Compared to the instrument cluster with MFD, it has
an advanced display possibility as a precondition for
fitting various equipment items such as driver assist
systems.
S560_035
Vehicles with natural gas engine

In this variant, there are displays and warning lights
for natural gas and petrol operation. In this case, the
coolant temperature gauge is replaced by the natural
gas tank gauge.
Natural gas Fuel gauge G1

gauge G411
Warning light for natural Warning light for fuel
gas mode K192 reserve K105
S560_056
48
The multifunction steering wheel
Depending on the equipment variant of the vehicle, the optionally available multifunction steering wheel is availa-
ble in three variants for the market launch of the Caddy 2016. If no multifunction steering wheel is fitted in the
vehicle, the available functions are operated using buttons on the left and right steering column levers.
Depending on the equipment an engine, the buttons and switches for operating the cruise control system (CCS) and
the speed limiter may be fitted in the turn indicator and main beam levers.
Variant 1
This variant has the controls for the MFD, audio and
telephone. The left-hand steering wheel spoke carries
the control buttons for controlling the audio output,
while the right-hand spoke carries the buttons for
controlling the MFD in the dash panel insert and the
S560_037
telephone. If this multifunction steering wheel is fitted,
the corresponding buttons are not fitted on the
steering column lever for the MFD operation.
Variant 2
This variant has the controls for MFD, audio,
telephone, cruise control or speed limiter. The left-
hand steering wheel spoke carries the control buttons
for controlling the cruise control system, while the
right-hand spoke carries the buttons for controlling S560_038
the MFD in the dash panel insert and the telephone.
Audio output is controlled using the buttons recessed
downwards on both steering wheel spokes.
Variant 3
In this variant, the controls for MFD, audio, telephone,
cruise control system or speed limiter and ACC are
included. The left-hand steering column spoke carries
the operating buttons for controlling the cruise control
and ACC. Changing over between the two driver assist S560_039
systems is performed using the MODE button. The
right-hand steering wheel spoke carries the operating
buttons for controlling the MFD in the dash panel
insert and the telephone. Audio output is controlled
using the buttons recessed downwards on both
steering wheel spokes.
49
Electrical system
The headlights
The exterior design and internal structure of the Caddy 2016 headlight unit has been adapted to the current
design language at Volkswagen Commercial Vehicles. The headlight units have a clear glass structure and are
fitted in the H4, H7 and bi-xenon headlight variants depending on equipment.
Headlight module H4 Daytime running/ Dipped beam/

Turn signal side lights main beam
H, 21 W W, 21/5 W H4, 60/55 W
This headlight module has an H4 bulb for the dipped
and main beams.
As standard, the headlights are equipped with a
daytime running light.
S560_016
Headlight module H7 Main beam Side lights Dipped beam

H7, 55 W W, 5 W H7, 55 W
This headlight module has one H7 bulb each for the

dipped beam and main beam headlights.
As standard, the headlights are equipped with a
daytime running light.
S560_017
Turn signal Daytime running
H, 21 W lights H, 21 W
Headlight module bi-xenon Dipped beam/

Turn signal Daytime running/ main beam Xenon
H, 21 W side lights LED D8S, 25 W, 42 V
A D8S 25 W xenon bulb is used for the dipped and
main beams. The luminous flux is less than
2000 lumen. Headlight washer system and automatic
headlight range control are thus not required. The
headlight range is set using the headlight range
control (potentiometer) in the dashboard, like with
halogen headlights.
S560_018
50
The tail light clusters
The tail light cluster is configured as a multi-chamber light. All tail light cluster versions are also available tinted as
an option.
Vehicles with wing doors Vehicle with tailgate
Turn signal
P, 21 W
Rear fog light or

reversing light Rear fog light or
P, 21 W reversing light
P, 21 W
Turn signal
P, 21 W
Brake
Brake
Tail light
Tail light
P, 21 W
P, 21 W
S560_113
S560_019
Tail light Tail light

3x W, 5 W 3 x W, 5 W
Fog lights/cornering light

The fog lights are each equipped with one H11-55 W
bulb. As an option, fog lights with static cornering
light can be fitted.
If a static cornering light is fitted, the fog light on the

inside of the corner is switched on depending on the
speed, up to 40 km/h, and if the lighting system is
switched on and the steering wheel is turned or a turn
signal is activated. This provides better illumination of
S560_020
the edge of the road on the inside of the corner.
Fog lights/cornering light
H11, 55 W
51
Electrical system
The component protection

The Caddy 2016 has component protection for
various control units. This is intended to prevent an
unauthorised exchange of components. The control
unit in the dash panel insert J285 is the master for
component protection.
In addition to the stated control unit, the control unit S560_110
for distance control J428 and the control unit 1 for
information electronics J794 also participate in
component protection.
The participants in the component protection are

checked when terminal 15 is switched on. If the
comparison result is negative, the corresponding
component blocks its function partially or entirely and
stores this in the event memory. The component
protection function must then be enabled online with
the vehicle diagnostic tester.
For more information about component protection, refer to Self-Study Programme ho. 517
"The Golf 2013 electrics".
52
The reversing camera R189
The reversing camera R189 is used in the Caddy 2016, and improves visibility to the rear when reversing. It is
attached to the tailgate above the number plate, and supplies a real video image of the area behind the vehicle.
The reversing camera can be combined with the Composition Colour, Composition Media and Discover Media.
Reversing camera R189
S560_058
Radio display
Discover Media display example
When terminal 15 is on and reverse gear engaged,
the video signal from the camera is shown on the
screen.
The screen shows the real video image. The static help
lines that overlay the surrounding picture in the colour
display are applied by the screen and are used for
gauging distances better. The reversing camera R189
does not require calibration. S560_067
Static lines
53
Radio, telephone and navigation
The radios and navigation systems

A new generation of radios and navigation systems is
launching in the Caddy 2016 and T6 2016 for
Volkswagen Commercial Vehicles. They set new
standards in terms of operation and connection
possibilities for external devices. All devices can be
combined with a provision for mobile telephone.
The following devices are available:
• Composition Audio radio S560_140
• Composition Colour radio

• Composition Media radio
• Discover Media navigation system
The Car-Net
For the first time, Volkswagen Commercial Vehicles is
presenting mobile online services, also referred to as
Car-Net. This involves using online data for certain
applications, which are referred to as services. These
can be provided for various application areas.
The following services are currently available:
• Guide & Inform (improved navigation and

infotainment)
• App Connect (smartphone connections and apps)
• Media Control (infotainment expansions via app)
S560_141
For more information about the radios and navigation systems as well as Car-Net, refer to Self-Study
Programme no. 562 "Infotainment and Car-Net in T6 2016 and Caddy 2016".
54
Notes
55
560
© VOLKSWAGEN AG, Wolfsburg

All rights reserved. Subject to technical modifications.
000.2813.17.20 Technical status 07/2015
Volkswagen AG
Volkswagen Commercial Vehicles, After Sales
After Sales Technology NV-K/K
Brieffach 2940
D-30405 Hannover
❀ This paper was manufactured using pulp bleached without the use of chlorine.

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Service Training

Self-study programme 560

The Caddy 2016

Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Radio, telephone and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

The product features of the Caddy 2016

• 360° parking system

• Petrol engines of the

• Diesel engines of the

• Front Assist with

• Cruise control system (CCS) including speed limiter

• New range of colours

Newly designed headlights

Dash panel with numerous

Striking side profile line with cut-in, rectangular

Tailgate with larger number plate

Newly designed tail

Moulded headliner and roll-up

* Depending on engine and equipment

Loading volume taking example

New features on the body:

Tailgate with metal panel

The newly designed tailgate has a continuous

Water radiator for charge air cooling circuit

Cooler for power steering

The illustration shows the painted version

The body structure

Reinforcements for side-on collision

Insert for reinforcement

Web plate of the sill panel

Reinforcements for front-end collision

Reinforcement side member

Upper central storage compartment Open storage compartment Glove box,

Open storage compartment with 12 volt socket and S560_060

Convenience dash panel

Open storage compartment with 12 volt socket and

Front passenger airbag

Airbag control unit with

Three-point seat belt with belt tensioner,

Three-point seat belt with belt tensioner,

Crash sensor, in B-pillar at bottom

Side airbag on driver side

Emission standard EU6

TDI engines with emission standard EU5

1.0 l 75 kW TSI engine 1.2 l 62 kW TSI engine 1.4 l 92 kW TSI engine

The TGI engine (natural gas)

1.4 l 81 kW TGI engine

The 1.0 l 75 kW TSI engine

• Exhaust turbocharger module with electric boost

Technical data Torque and power diagram

Cubic capacity 999 cm3

Valves per cylinder 4

Compression ratio 10.5 : 1

Max. torque 175 Nm at

Fuel Regular unleaded with

• Exhaust turbocharger module with electric boost

Technical data Torque and power diagram

Cubic capacity 1197 cm3

Valves per cylinder 4

Compression ratio 10.5 : 1

Max. torque 160 Nm at

Fuel Regular unleaded with

The 1.4 l 92 kW TSI engine