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Installation manual new tailgate part
WAV-Conversion
Version 1.0
Conversion set tailgate V1.0
Volkswagen Caddy
To place the new bumper part you need a original Hatch cover from Volkswagen. You can re-use the bolts
from the “old“ Bierman bumper part.
Cover hatch Antracite VW 2K08676055PL
Push rivet Antracite VW 7H086729971N
Cover hatch grey
Push rivet grey
VW 2K08676053Z4
VW 7H08672993U6
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Conversion set tailgate V1.0
Volkswagen Caddy
1. Upgrade tailgate-part
Remove all the bolts and remove the bumper part from the rear hatch.
Keep these bolts and washers.
Peal of the middle bumper from the fiber bumper part.
The bumper caps can remain in place.
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Conversion set tailgate V1.0
Volkswagen Caddy
1.1 Mechanical lock
Remove both lock brackets, the middle bracket, the lower bracket and the emergency cable.
Remove a lock from it’s
bracket and place it on the
new subframe.
Continue at page 5
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Conversion set tailgate V1.0
Volkswagen Caddy
1.2 Electric lock
Remove both lock brackets, the middle bracket, the lower bracket and
the emergency cable.
Replace on of the electric
motors back in it’s original
position in the rear hatch.
Remove a lock from it’s
bracket and place it on the
new subframe.
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Conversion set tailgate V1.0
Volkswagen Caddy
Remove the bolts and keep the catch and rubber spacer.
To secure the back plate under the lowered floor, put some
glue in one of the holes. drill the holes to Ø23mm and
place the caps in the holes.
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Conversion set tailgate V1.0
Volkswagen Caddy
Place the drill mould on the rear hatch as indicated in the picture.
Draw the 4 hole positions on the rear hatch and remove the mould.
Drill two holes in the rear hatch Ø 18 mm.
Drill two holes in the rear hatch Ø 30 mm.
Important: Treat all the holes against corrosion!
Place the two rubber grommets in the holes Ø 30.
Make sure they are seated properly on the hatch.
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Conversion set tailgate V1.0
Volkswagen Caddy
Place the second drill mould on the rear hatch as indicated in
the picture. Draw the 2 hole positions on the rear hatch and
remove the mould.
Drill the holes Ø 8 on the indicated locations
Important: Treat all the holes against corrosion!
Put locktite on the threads M8x35 and
place the treads left and right in the indicated places on the bumper part.
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Conversion set tailgate V1.0
Volkswagen Caddy
Place the stop in the hole as indicated in the
picture. The rear hatch can be opened from the
inside through this hole.
Cut of the original connector plug, the one with three
white wires. Mark the three cables with 1, 2 and 3.
Extend the 3 wires with the included cables and
cable connectors.
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Conversion set tailgate V1.0
Volkswagen Caddy
The frame can now be mounted onto
the rear hatch. Spray some silicone
on the frame and the grommets and
push the frame through.
Bolt the lower part of the frame onto
the rear hatch using the two M8
bolts and washers included in the
kit and the plate on the original lock
location.
Place the extra plate as indicated.
Move it back as far as possible.
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Conversion set tailgate V1.0
Volkswagen Caddy
Bolt the top part of the frame onto
the rear hatch using two M6 bolts
and washers included in the kit.
Remove the lower part of the motor.
This part can be slid off the motor and can
be thrown away.
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Conversion set tailgate V1.0
Volkswagen Caddy
Bolt the Volkswagen lock onto the
subframe as indicated in the picture
with the original bolts.
Bolt the ball joint of the cable onto
the hole in the lever of the lock.
Mechanical Lock
Electric Lock
Hand tighten the subframe onto the frame
using four M6 bolts and attach the end of
the cable to the original motor. Check the
lock for proper operation.
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Conversion set tailgate V1.0
Volkswagen Caddy
Important: If the lock does not release when the handle is operated the cable must be shortened. To
do this, cut a small piece of the thread. Make sure it still locks it’s first lock position.
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Conversion set tailgate V1.0
Volkswagen Caddy
Close the hatch with the frame and subframe and indicate where the lock is situated on the lowered floor.
Drill a hole Ø 100mm in the indicated location and saw it out perpendicular
to the outer edge of the lowered floor
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Conversion set tailgate V1.0
Volkswagen Caddy
Place the composite cup in the hole created in the lowered floor and bond it
with the kit included in the set.
Glue the aluminium plate under the lowered floor and the cup and bolt it onto
the rail using the bolts included in the set.
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Conversion set tailgate V1.0
Volkswagen Caddy
Close the rear hatch and indicate in the cup
where the catch is exactly situated.
Drill the holes and place the catch in the
desired location. Check the rear hatch for
proper operation.
Check the fitting of the lock on the catch.
Front and back adjustment can be done with
the catch and left and right adjustment can be
done with the lock on the frame.
Important: Mark the exact location of the bolts
on the subframe.
Tie the cable with the included cable ties to the right
side of the frame.
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Conversion set tailgate V1.0
Volkswagen Caddy
Remove the cable from the lock motor in the rear hatch and remove the electric connector from the lock.
Remove the subframe with the lock to place the plastic bumper part.
If there are parking sensors present in the rear bumper, place
the wire trough the bumper part before placing,
Slide the plastic bumper part over the frame so the frame is level with the bumper-
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Conversion set tailgate V1.0
Volkswagen Caddy
Hand tighten the M6 nuts with ring and two
DIN9021 washers onto the studs of the plastic
part onto the rear hatch.
Close the rear hatch and align the bumper part with the lowered floor. Make sure the space between the
lowered floor and the bumper part are the same on the left and right. If everything is properly aligned, the
subframe with the lock can be placed again.
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Conversion set tailgate V1.0
Volkswagen Caddy
Connect the electric wire to the
lock and guide the cable through
the rear hatch.
Reconnect the cable to the lock motor.
Bolt the subframe onto the bumper part, using two M6x12 bolts
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Conversion set tailgate V1.0
Volkswagen Caddy
Bolt the subframe onto the frame using four M6x12 bolts
Tighten the M6 nuts with ring onto the studs of
the plastic part onto the rear hatch.
Important: Check the rear hatch for proper operation. Make sure the hatch and lock are closing well.
Glue the two rubber pieces on the rear hatch
using the same glue as used for bonding the
lowered floor.
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Conversion set tailgate V1.0
Volkswagen Caddy
Drill a hole (5 mm) at the location that is indicated in the picture (left or
right side of the car).
Fasten the bracket with a bolt, two washers and a jam nut (included in the
kit) in the drilled hole.
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Conversion set tailgate V1.0
Drill a hole at the place that is indicated in the
picture, the exact location does not matter.
Volkswagen Caddy
Place the rubber tule (included in the kit) in
the hole.
Put the emergency release through the rubber
tule and mount the black handle.
Cut the other end of the inner- and outer cable to the desired
length and tie it as indicated in the picture.
Check if the cable is operating properly.
Mechanical lock
Electric lock
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Conversion set tailgate V1.0
Place two M6 x 12 bolts with nylon
washers.
Volkswagen Caddy
Remount the original cover and cord, using the original bolts and pins.
Remount the original protection cover.
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Conversion set tailgate V1.0
Volkswagen Caddy
Place the two aluminium brackets on the
bumper part as indicated in the picture using four M6 bolts, four DIN9021 washers
and four spring washers.
Place the bumper over the aluminium bracket
and draw the hole location on the inside of
the bumper. (the holes from the bumper can
later be placed in the bumper mould). Drill
the holes Ø 5mm in the bumper.
Fix the bumper on the aluminium brackets using four push rivets.
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Conversion set tailgate V1.0
Volkswagen Caddy
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.
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