Service TrainingCommercial VehiclesSelf-study Programme 369The Crafter 2006es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um enht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiThe Crafter● ● ● ●Professional Multi-functional Comfortable Safees, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngn AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssThe LT2, which has enjoyed great success for a number of years, is to be succeeded by the new light transporter named the Crafter. As an entirely new development from Volkswagen and DaimlerChrysler, the vehicle concept will be implemented for both DaimlerChrysler and for Volkswagen Commercial Vehicles. Above all, brand-specific adaptations can be found in the design. Besides its technical features and multi-functionality, the Crafter is characterised by its modern exterior and interior design. The results achieved in the field of active and passive safety deserve particular emphasis.ht rig py Co t.thi sd o cu m enility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witS369_002Separate self-study programmes are available on the following topics:● ● ●SSP 370 SSP 371 SSP 372The Crafter - Electrical System The 2.5l TDI Engines in the Crafter TheShiftmatic Gearbox 0B81The self-study programme shows the design and function of new developments. The contents will not be updated.For current testing, adjustment and repair instructions, refer to the relevant service literature.2agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yiNEWImportant NoteContentses, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sIn brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4rrectness of i t to the co nf o r m spec atio h re n in witBody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22ht rig py Co t.Prote cted by c o py rig ht . C op yiility ab y li an pt cethi sd o cu m enTransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26AG.Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58agen lksw Vo by3In briefpe rm itte dThe history of the light transporteres, in part or in w l purpos hole ercia , is n m ot comVolkswagen's first light transporter – the LT1 – was developed entirely in-house within the Group. It was presented to the specialist world for the first time in 1975.rrectness of i t to the co nform spec a t i h re o n in wit thi s1975un leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt ceWhat is called the one-box-design of the first Volkswagen light transporter is striking. The driver is seated above the front axle, the engine is installed between the driver and front passenger, and the rear axle is used to drive the vehicle. The LT1 was built with two wheelbases and two roof heights. Vehicle variants included the minibus with up to 14 seats, the pure panel van and a dropside vehicle or a chassis. The dropside vehicle and chassis were available with both a single cab and a double cab. Both petrol and diesel engines were installed.r te o iva r rp fo g ndo c um enThe second generation of light transporter – the LT2 – was jointly developed by Mercedes-Benz (Sprinter) and Volkswagen, and was launched in 1996. Both manufacturers' vehicles are almost identical in design terms. In comparison with the predecessor model, they were characterised by a sloping front with a conventional bonnet. The LT2 was manufactured with three wheelbases and two roof heights. Once again, both petrol and diesel engines were installed. The diesel engines which were fitted were generally turbo diesel engines.4AG.Prote cted byS369_046ht rig py Co t.agen lksw Vo byc o p yri gh t. C op yi1996S369_0472006es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d S369_048 e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisThe third generation of the light transporter is also a joint development between DaimlerChrysler and Volkswagen. From 2006 onwards, Volkswagen's new light transporter will be launched under the name Crafter. Both manufacturers' vehicles are almost identical in design terms. Adaptations have primarily been carried out on the Crafter's front end. This has enabled a differentiation in the vehicle's appearance which corresponds to Volkswagen Commercial Vehicles' current design style. The Crafter will be manufactured with three wheelbases, 4 vehicle lengths, 6 platform lengths and three different heights. The weight classes are sub-divided into three basic weight classes and an extended weight class.Vehicle variants will include the crew bus with up to 9 seats, the panel van and a dropside vehicle or the chassis. The dropside vehicle and chassis will be built with both a single cab and a double cab. The vehicle will be fitted with a Volkswagen turbo diesel engine with common rail fuel injection in 4 power outputs ranging from 65 kW to 120 kW.do c um enht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi5In briefTechnical highlights in the CrafterThe Crafter has been developed to meet users' highest standards of quality and functionality. It is also characterised by its modern and striking design. As a panel van, it is able to cope with all of the tasks of an enclosed load transporter. This variant will, in turn, form the vast part of the production range.wage As a crew bus, it meets the broad demands of passenger transportation. olksurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leyV db ise r tho au s sn AG. Volkswagen AG do es n ot g ua ran tee or acility ab y li an pt ceExtended model range in comparison with the predecessor modelHigh level of active occupant protection with driver and front passenger airbag, side and curtain airbags in the front and 3-point seat belts on all seatsExtensive heating and climate control equipment variants, supplementary heating systemsExtensive storage compartment and securing option systemLarge payload and load compartment, particularly favourable loading conditions in 4.6 t vehicles with super-single tyres (5.0 t variant with lower load rating) Sliding door dimensions for particularly easy loading6agen lksw Vo byAG.Prote cted byComfortable radio/navigation and CD equipment optionsht rig py Co t.S369_011Diverse convenience component equipment such as, e.g. hill start assist, Park Distance Control, tyre pressure monitor, digital tachograph, light and rain sensor, heated windscreenrrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enc o p yri gh t. C op yir fo ngS369_038es, in part or in w l purpos hole ercia , is n m ot compe rm itte dThe and a double cab. The manufacturing range also includes a chassis variant, onto which optional bodies can be mounted according to the customer's wishes.ility ab y li an pt ceun leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o e osingle h t also be built as a dropside vehicle, with both a Crafter will u ra a c s srrectness of i t to the co nform spec a t i h re o n in wit thi sEngine range – turbo diesel engines with common rail fuel injection technology – with practical output levelsDiesel particulate filter as standardr te o iva r rp fo g nPassive occupant protection thanks to crashoptimised body and running geardo c um enJoystick gearshift in the dash panel6-speed manual gearbox for all engines, Shiftmatic gearbox (optional) for 80 kW and 100 kWLoad-dependent, 3rd generation electronic stabilisation programme, Bosch ESP 8.1, fitted as standardht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiDouble cab now with rear doors on both sides for the 2nd row of seats, double cab now also with short wheelbase of 3250 mmS369_039S369_012New 16" running gear, independent wheel suspension with glass fibrereinforced plastic leaf springs at the front, rigid rear axle with steel leaf springs7In briefTechnical dataCrafter – crew bus, panel vanAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt ceurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun lerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enS369_023r fo ngS369_024agen lksw Vo byProte cted byCrew bus and panel van dimensionsGross vehicle weight Roof load Trailed load Length Width Height1) Front overhang length Rear overhang length3000 - 5000 kg Max. 300 kg Max. 3500 kg 5244 - 7340 mm 1993 mm 2415 - 3045 mm 1000 mm 990 - 2015 mmHeight of load sill1) Load compartment volume Load compartment length Load compartment width Load compartment height Wheelbase Track width at front Track width at rear1) Unladen 2) The crew bus and panel van values apply to unspecified items. The Crafter is also available in the chassis version with single cab/double cab.8ht rig py Co t.AG.c o p yri gh t. C op yiS369_025665 - 765 mm 7.5 - 17 m3 2600 - 4700 mm Max. 1780 mm 1650 - 2140 mm 3250 - 4325 mm 1708 - 1732 mm 1521 - 1738 mmes, in part or in w l purpos hole ercia , is n m ot comCrafter – dropside vehicle with single/double cab, chassis with single/double cabpe rm itte dTechnical dataun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sS369_026r te o iva r rp fo g ndo c um enDimensions for dropside vehicle with single/double cab, chassis with single cab2)Chassis with single cab or double cab Dropside vehicle with single cab Dropside vehicle with double cabLength Width Height Rear overhang length Interior load length Interior load width Height of load sill1)5304 - 6846 mm 1993 mm 2340 - 2425 mm 1050 - 1517 mm -5328 - 6928 mm1074 - 1599 mm 2840 - 4300 mmht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iS369_1255558 - 7038 mm 2090 - 2190 mm 2340 - 2425 mm 1304 - 1709 mm 2120 - 3600 mm 2030 - 2130 mm 960 - 1070 mm9In briefThe Crafter model rangeWeight (t) Wheelbase (mm) Crew bus flat roof Crew bus high roof Panel van flat roof Panel van high roof3,0325036653,53250366543254325Les, in part or in w l purpos hole ercia , is n m ot compe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi s4,6*/5,0366543254325Lr te o iva r rp fo g ndo c um en* 4.6 t variant for use with super-single tyres10ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiPanel van super-high roofChassis with single cabChassis with double cabDropside vehicle with single cabDropside vehicle with double caburposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enr fo nght rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yi11BodyBody-in-whiteLike the predecessor model, the Crafter is also designed as a panel van and crew bus with a unitised, all-steel body as an integral construction. The body forms a common support system together with the vehicle frame. The Crafter's body has been optimised in terms of the following focal points:● ● ● ●The figure shows the crew bus/panel van body-in-white.Strength and stiffness Crash behaviour Comfort WeightA stable body shell makes an important contribution towards stability and therefore also a vehicle's driving safety. The Crafter's body shell stiffness has therefore been increased. Important measures for achieving this include:● ●es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nStrength and stiffnessn AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t his● ●●Computer-based optimisation of the body-in-white Continuous B-, C- and D-pillars with enclosed profile Increased rear portal stiffness Welding the lower side wall section to the side wall at the top and the sub-structure at the bottom Additional roof frames and roof members form a system which is extremely resistant to bending.ht rig py Co t.do c um enDepending on stress levels, steels of different stiffnesses are used for the body components.12agen lksw Vo byAG.Besides the geometrical design of the vehicle components, high priority was also given to the choice of relevant materials/material grades during these optimisations.Prote cted byc o p yri gh t . C op yiDue to design reasons, certain of the dropside vehicle body shell versions' body components are designed differently, whilst others have been . Volkswagen AG gen AG doare adapted. In addition,lk bake-hardening steels*** es n not used in the dropside swa ot g o V y ua b vehicles. d ran e sun leri ho ut a sstee or acility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot compe rm itte drrectness of i t to the co nform spec a t i h re o n in wit thi sSoft deep-drawing steels High-strength ZE steels* High-strength IF steels** High-strength, cold-rolled steels Bake-hardening steels*** Othersht rig py Co t.r te o iva r rp fo g ndo c um en*ZE … Symbol for electrolytically galvanised** IF … Symbol for Interstitial Free IF steels have no interstitially (on intermediate lattice spaces) dissolved alloying constituents and can therefore be easily formed. High-strength IF steels are based on a basic IF material. The higher strength is achieved via corresponding alloying. *** Bake-hardening steels: These are counted as higher- and highstrength steels. The bake-hardening effect leads to an increase in strength at paint stoving temperatures (150 - 200 °C).S369_009agen lksw Vo byAG.Prote cted by c o py rig h t . Co py i13BodyThe joining techniquesLaser soldering and laser weldingLaser soldering and welding enable a number of the additional parts required for the spot welding process, such as e.g. gusset plates, to be omitted.The main advantages are:●● ●urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p● ● ●Access to the weld seam on both sides is necessary Higher process speed Lower thermal entrainment and therefore less weld warping and stress entrainment Omission of weld seam finishing Considerably tidier seams Continuous weld seamsun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a not c s sility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enr fo ngS369_095Laser welding Laser soldering14ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiBondingIn modern bodies, bonded seams are increasingly being employed to joint parts which lie on each other. Depending on the purpose for which they are used, the bonding processes are sub-divided into:es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngG. Volkswagen AG d n Abonding If an adhesive is applied between two parts which ● Strength oes wage s k not l o gu yV are to be joined, an almost homogeneous material b ara d nte se transition is created. Under the shearing forces which thori In this case, sheet metal parts are firmly e o bonded u ra a c arise, relative movements between the two parts are together using adhesive. ss therefore unable to occur within the bond. The torsional stiffness which is achieved in this manner ● Support bonding makes a major contribution towards overall body stiffness. In this case, adhesive is applied between sheet metal parts so that the two parts are supported on each other via the bond which arises. This contributes towards both stiffness and noise reduction thanks to the avoidance of resonances.●Support bonding after top coat application In panel vans – without windows – a supporting adhesive is applied as a stiffening measure between the outer and inner skin following top coat application.ht rig py Co t.ility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witthi sd o cu m enStrength adhesive Supporting adhesive Supporting adhesive after top coat application S369_096agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi15BodyCrash-safe body designG. Volkswagesuch n AG das e.g. load volume, nA One important development goal was to retain the essential features of a transporter, age oes ksw not l o V for the front and rear passengers. gu y whilst simultaneously developing a stable passenger compartment ar dbe ris tho u a ssan tee or acility ab y li an pt ceurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leCo-ordinated force induction paths and energyabsorbing deformation zones were created, particularly for frontal impacts.Force induction via the longitudinal membersS369_098rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enThe drive train is an additional force induction path.Force induction via the drive train16ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiForce induction paths have also been provided for side impacts.r fo ngForce induction via the cross membersS369_100S369_099Front deformation zonesAt the front, the two longitudinal members are joined together via a bolted steel cross member. In the event of a frontal crash, this cross member primarily absorbs the force of the impact. The force is then guided into the longitudinal members and leads to deformation in the front area of one or both longitudinal members depending on the severity of the crash. The front area of the longitudinal members deforms even if the impact force is low. The rear area of the longitudinal members remains undamaged. In the event of repairs, the exposed, front ends of the members also enable the separation of a defined area and replacement with a pre-manufactured repair section.Deformation area at the front of the longitudinal member Bolted cross memberS369_101 Repair section Longitudinal memberThe detachable front axleThe front axle is designed as a so-called "detachable" front axle. If a specific force level is attained in the event of a frontal crash, the subframe's central threaded connection, which is linked to the front axle, is disconnected and additional deformation zones in the frame longitudinal member are "released".es, in part or in w l purpos hole ercia , is n m ot compe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sVehicle frame longitudinal memberCentral threaded connectionr te o iva r rp fo g nS369_102do c um enSubframeagen lksw Vo byht rig py Co t.AG.Prote cted by c o py rig h t . Co py i17BodyThe seatsThe first row of seats is comprised of the driver's seat as an individual seat and a front passenger seat, which is available as either an individual seat or a double seat bench.The seats are fitted with 3-point seat belts with ball bearing-type seat belt tensioners (centre seat without belt tension limiter).S369_049The double seat bench may have a folding storage compartment in the centre seat's backrest.es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witS369_050It also offers additional stowage space beneath the folding seat cushions.thi sd o cu m enS369_05118ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiDouble seat benches are fitted in the 1st and 2nd row of seats in the crew bus passenger compartment. The third row of seats is comprised of a triple seat bench. All seats are fitted with integral 3-point seat belts (without seat belt tensioners). The left-hand seat in the 1st and 2nd row can be optionally fitted with the Isofix system.urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt ceS369_052rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enIsofix mountingr fo ngThe second row of seats in the double cab is a quadruple seat bench. The entire seat cushion can be folded up, and the stowage space beneath it can be used to accommodate various utensils. All seats are fitted with 3-point seat belts (without seat belt tensioners); these are integral in the case of the centre seats.ht rig py Co t.Prote cted by c o py rig h t . Co py iagen lksw Vo byAG.S369_07819Occupant protectionOccupant protectionAG do agen The Crafter is equipped with an extensive occupant es n ksw l ot g o V ua by protection system. d ran seAG. Volkswagenurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pIn of lateral impact, the Crafter's occupants are exposed to a lower risk of injury, thanks to their raised seating position, than passenger car occupants. In comparison with the predecessor, this has been further improved via the specific development of a stable floor structure in the Crafter.un leri ho ut a ss event thetee or acility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enCurtain airbag for the driverBased on a stable passenger compartment which is able to withstand high loads, the available airbag and restraint systems additionally enhance occupant safety.Side airbag for the driverThe airbag systemht rig py Co t.The Crafter is equipped with a driver airbag as standard. The following are optionally available:● ●●Front passenger airbag Side airbag (in the seat) for the driver and front passenger – for the front passenger only if an individual seat is fitted Curtain airbag for the driver and front passenger – for the front passenger only if an individual seat is fitted20agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yir fo ngpe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o e o is h t The Crafter u ra a c s sThe seat belt systemequipped with 3-point seat belts as standard.ility ab y li an pt ceSeat belt system in the front seatsThe driver and front passenger seats are fitted with seat belts with pyrotechnical belt tensioners. In conjunction with airbags, the seat belts are combined with belt tension limiters.rrectness of i t to the co nform spec a t i h re o n in wit thi sDriver airbages, in part or in w l purpos hole ercia , is n m ot comFront passenger airbagr te o iva r rp fo g ndo c um enSeat belt system in the passenger compartmentThe seats in the passenger compartment are fitted with integral seat belts.S369_087ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiS369_137S369_13821EnginesEngine/gearbox combinationsEnginesMechanical 6-speed manual gearbox 0B7 330 NmMechanical 6-speed manual gearbox 0B7 350 NmShiftmatic gearbox 0B812.5l/65 kW R5 TDI engine (BJJ)es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nsswa olks yV b ed ris ho t au2.5l/80 kW R5 TDI engine (BJK) . Volkswagen AG gen AG does not gu ara nte eo ra cility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t his2.5l/100 kW R5 TDI engine (BJL)2.5l/120 kW R5 TDI engine (BJM)ht rig py Co t.do c um en22agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iThe 2.5l TDI engines with common rail fuel injection technologyA new generation of 5-cylinder diesel engines has been developed for the Crafter. This new engine generation's basic geometrical dimensions are based on the 2.5l 5-cylinder TDI engine with distributor-type injection pump, which proved its worth in the LT2.es, in part or in w l purpos hole ercia , is n m ot compe rm itte dun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g nS369_134do c um enThe engine is available in four output stages, from 65 kW to 120 kW. All engine variants are designed around a standardised, basic engine.Equipped with a catalytically coated diesel particulate filter, all engine variants meet the EURO4/ EU4 emissions standard. Engines which meet the EURO3/EU3 emissions standard are not fitted with a diesel particulate filter.Detailed information on this engine generation is available in self-study programme 371 "The 2.5l TDI Engines in the Crafter".agen lksw Vo byAG.A multitude of engine components have been reengineered to meet the increased output, acoustics, emissions, consumption and extended service interval requirements. Switching the engine to common rail fuel injection technology is a particularly important factor in this regard.Prote cted byDepending on the output level, these have been adapted in terms of both mechanical system and engine management.ht rig py Co t.c o p yri gh t . C op yi23EnginesTechnical dataurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pTechnical features●● ● ● ● ● ● ● ●Common rail fuel injection system with piezo injectors Catalytically coated diesel particulate filter Electric intake manifold flap Electric exhaust gas recirculation valve Variable exhaust gas recirculation cooler Adjustable turbocharger Vertical oil filter module Cyclonic oil separator Oil level sender for extended service intervalun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enS369_019r fo ngDisplacement Bore Stroke Valves per cylinder Compression ratio Maximum output 65 kW at 3500 rpm 220 Nm at 2000 rpm 80 kW at 3500 rpm 280 Nm at 2000 rpmMaximum torqueEngine management Fuel Exhaust gas treatmentExhaust gas recirculation with exhaust gas cooling; catalytically coated diesel particulate filter EU4/EURO4 EU4/EURO4/ EURO3/EU3 (without diesel particulate filter and exhaust gas cooling) EU4/EURO4 EU4/EURO4 EURO3 (without diesel particulate filter)Emissions standard24AG.Type5-cylinder in-line engine 2461 cm3 81.0 95.5 2 16.8 : 1 100 kW at 3500 rpm 300 Nm at 2000 rpm EDC 16 C Diesel, at least 51 CN 120 kW at 3500 rpm 350 Nm at 2000 rpmagen lksw Vo byEngine codeBJJBJKht rig py Co t.Prote cted by c o py rig ht . C op yiBJLBJMTorque and output graphsThe 2.5l 65 kW TDI engine (BJJ)The 2.5l 80 kW TDI engine (BJK)Output (kW)S369_034 Engine speed (rpm) Engine speed (rpm)S369_035The 2.5l 100 kW TDI engine (BJL)es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sThe 2.5l 120 kW TDI engine (BJM)Output (kW)Engine speed (rpm)agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iS369_036S369_037Engine speed (rpm)Output (kW)ht rig py Co t.Torque (Nm)Torque (Nm)Output (kW)ility ab y li an pt ceTorque (Nm)Torque (Nm)rrectness of i t to the co nf o r m spec atio h re n in witthi sd o cu m en25TransmissionThe 6-speed manual gearbox 0B7The manual gearbox is vailable in two versions● ●Manual gearbox 0B7 – 330 Nm0B7 – for maximum torque of 330 Nm and 0B7 – for maximum torque of 350 NmRear gearbox housingThe two gearbox versions have a modular structure and are primarily fitted with the same components. The main components are:●● ●urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p●Diecast aluminium clutch housing housing Intermediate plate in the 0B7 – 350 Nm Internal gearbox components with the internal shift unit External gearshift mechanismun leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s gearbox andility ab y li an pt ceFront gearbox housing (with clutch housing)S369_021External gearshift mechanismrrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enIntermediate housing26ht rig py Co t.agen lksw Vo byAG.Prote cted byIn the 350 Nm version of 6-speed manual gearbox 0B7, an intermediate housing with an integrated, additional mounting for the shafts is installed between the front and rear gearbox housing due to the higher, maximum torque of 350 Nm which has to be transmitted.c o p yri gh t. C op yiManual gearbox 0B7 -350 Nmr fo ngS369_132Internal structure3 shafts are installed in the manual gearbox:● ● ●Drive shaft Output shaft Counter shaftFor the sake of simplification and better clarity, the selector forks driven by the central selector shaft are not shown.The output shaft is axially mounted in the drive shaft. Shifting is carried out via the central selector shaft, which takes up the external gearshift mechanism's movements and transfers these to the relevant sliding sleeves via a shift unit (module with selector forks).Drive shaft Central selector shaft Output shaft Sliding sleevees, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisS369_067Dual-mass flywheelCounter shaftClutchdo c um enThe figure shows manual gearbox 0B7 – 330 Nm (without intermediate plate).agen lksw Vo byProte cted byht rig py Co t.AG.c o p yri gh t. C op yi27TransmissionThe gear change mechanismThe gears are changed using a joystick gearshift. The gear lever is ergonomically located in the dash panel's centre console.S369_066es, in part or in w l purpos hole ercia , is n m ot comVia the gear knob on the selector lever, the selector movement for gate selection and the shift movement for gear engagement are forwarded to the selector housing, split and transmitted to the external gearshift mechanism on the gearbox via a gear change cable and a gate change cable.pe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sSelector leverility ab y li an pt ceGear change cablePull ringrrectness of i t to the co nform spec a t i h re o n in wit thi sr te o iva r rp fo g ndo c um enGate change cableReverse gear lock28ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iS369_004The power take-offsThe manual gearbox can be optionally equipped with power take-offs for driving additional, external devices:● ● ●Switch for gearbox neutral settingHydraulic pump, e.g. for crane/tipper External generators Compressors (high-pressure cleaner)Link for power take-off with flangeThe power is taken-off at the side of the gearbox from the counter shaft. The power take-off is engaged and disengaged via a switch in the dash panel; the shift cylinder is actuated and the power take-off is engaged.Shift cylinder for power take-offS369_129The power take-off is available in different wagen AG Volks G.two A does agen w s k not l variants: o g yV● ●es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nPower flange and Power take-off without flangeb ed ris o h t take-off with au ssua ran teeor acility ab y li an pt ceVersion without flangeBoth variants can be optionally equipped with or without a shift lock (gearbox lock).Link for power take-off without flangerrectness of i t to the co nform spec at i h re o n wit in t hisPower take-off output:The maximum, continuous output is 28 kW at 2780 rpm (engine speed) in the 330 Nm version ● 28 kW at 2713 rpm (engine speed) in the 350 Nm version●The maximum torque is ● 140 Nm at 1200 rpm (engine speed)ht rig py Co t.do c um enS369_130The gearbox is equipped as standard without gears/gear drive for the power takeoff – a power take-off cannot therefore be retrofitted.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yi29TransmissionThe Shiftmatic gearbox 0B81The Shiftmatic gearbox is an automated manual gearbox. Like the manual gearbox, it is operated using the joystick selector lever. The gears can be engaged in two different operating modes:●es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n● Shifting the gears with automatic clutch actuation is carried out via electronic actuation by the gearbox Gear selection carried out depending on the control unit. lkswagen Vo AG.is AG d agen oes ksw main influencing variables: not l following Hydraulically operating components are actuated; o gu yV b ara d e nte these convert the gearbox control unit's signals into is r o eo th u ra ● Engine speed the relevant, mechanical gear change movement. s a c s ● Vehicle speed ● Selector lever position The clutch is controlled at the same time. A clutch ● Operating mode pedal is not required and is therefore omitted.Both in "automatic mode" and also in "manual mode"ility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um enHydraulic pump Hydraulic control unit with shift cylindersPressure accumulatorDetailed information on this gearbox can be found in self-study programme 372 "The Shiftmatic Gearbox 0B81".30ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiS369_017Technical features● ●Operating concept Operation is carried out via the selector lever located in the instrument panel; this offers 3 stable and 3 touch-shift positions.●●●Based on the 6-speed manual gearbox 0B7 Automatic mode (A) or manual shifting via touchshifting (+/–) The gearshift mode, the engaged gear and any operator error are displayed in the instrument cluster Changing gearshift modes during vehicle operation remains possible Designed for up to 330 NmPower take-offs are not possible in combination with the Shiftmatic gearbox.S369_065AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o Advantages of tthe Shiftmatic gearbox Safety e o functions h u ra a c s sility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n● ● ●● ● ●Added safety due to relieving strain on the driver Increased comfort thanks to smooth gear changes The vehicle is always operated in the optimal engine speed range (fuel consumption optimised in comparison with an automatic gearbox) Equipped with hill start assist as standard Less wear versus manual gearboxes Mature technology●●●●The Shiftmatic gearbox offers additional advantages in comparison with a fully-automatic gearbox:● ●●Payload advantage thanks to lower weight Less expensive●Engine can only be started in selector lever position N (gearbox neutral position) When the vehicle is stationary, a gear can only be engaged with the pedal depressed Operator errors such as starting with a gear engaged are not carried out, Engagement of reverse gear during forwards travel or gear changes counter to permissible engine speeds are not possible Warning buzzer signal when the driver's door is open, the engine is running and the pedal is not actuated; after a further three seconds, the gearbox is automatically set to neutral If the handbrake is not applied and the foot brake is not actuated, an acoustic warning is soundedrrectness of i t to the co nform spec at i h re o n wit in t hisdo c um enht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiThese functions prevent unintentional vehicle movement after starting the engine!31Running gearThe running gearIn comparison with the predecessor model, the Crafter is equipped with 16" running gear with a larger track. The running gear has been further developed from the predecessor model, the LT2.The front axleThe front axle is a spring strut with independent wheel suspension. The design familiar from the predecessor model has therefore been optimised. Technical●● ●urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p● ●●Acoustic decoupling of the front axle from the vehicle body Crash-optimised Suspension with GFP transverse leaf springs, enabling lower weight and increased stabilisation capacity Standard anti-roll bar Slightly understeering to neutral handling behaviour Assembly mountings in the form of two engine mountings and one gearbox mountingun leAG. Volkswagen AG d agen oes ksw not l o gu yV b features ara d e nte is r o eo h ut ra a c s sility ab y li an pt ceAnti-roll barrrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enCoupling rodThe subframe is the front axle module's supporting element. It is comprised of a weightsaving sheet steel construction with 3 cross members, which are designed as a multi-shelled, welded construction.r fo ngIts primary functions are:●●●●32AG.Absorbing the wheel control forces via the wishbones Supporting the weight of the engine and the engine's torque in the engine mounting brackets The steering box is mounted, and the gearbox cross member is secured, to the subframe Dissipation of energy in the event of a crash via specific detachment of the subframe's central threaded connection with the bodyGFP = Glass Fibre-reinforced Plasticht rig py Co t.agen lksw Vo byProte cted by c o py rig h t . Co py iEngine mountingEngine mountingThe transverse leaf springsThe transverse leaf springs are manufactured from glass fibre-reinforced plastic (GFP). This has enabled the weight of the transverse leaf springs to be significantly reduced in G comparison with a steel version and has essentially A . Volkswagen AG d agen oes w s k not increased the stabilisation capacity. Volssy db ise r tho aupe rm itte dun leAdvantages of GFP springs:● ● ● ●gu ara nte eo ra ces, in part or in w l purpos hole ercia , is n m ot comSubframeLow weight plus high strength at the same time Very high corrosion resistance Impact- and shock-resistant Long service liferrectness of i t to the co nform spec a t i h re o n in wit thi sility ab y li an pt ceGearbox mountingThe leaf spring suspension conceptThe suspension concept has been optimised in comparison with the predecessor model.do c um enSuspension strut mountinght rig py Co t.Prote cted by c o py rig h t . Co py ir te o iva r rp fo g nSuspension strutPreviously, the leaf springs were guided via all 4 mountings. In the case of the new solution in the Crafter, the leaf springs are now guided primarily via the two centrally located mountings. This contributes towards decoupling the suspension and axle guidance characteristics.S369_013Wheel bearing Transverse leaf spring Wishboneagen lksw Vo byAG.S369_09333Running gearThe rear axlen AG. Volkswagen AG do es n wage s k l ot g o The rear axle has been further devloped from the yV ua b ran ed s i tee r the LT2. It is a rigid rear axle, predecessor model, o h t or u ac a which is guided on longitudinal leaf springs. ssility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nCorresponding design adaptations have taken place in the Crafter due to the extended payload variants. The most important technical data are:●rrectness of i t to the co nform spec at i h re o n wit in t hisThe suspension concept has been optimised. The panel van and crew bus are fitted with larger bonded rubber bushes at the front, in order to improve acoustic decoupling. The front spring eye and the spring inclination have been co-ordinated to achieve understeering rear axle kinematics with reduced roll steer. This contributes extensively towards improved handling behaviour, e.g. when changing lanes. The shock absorbers are located further outwards, thereby enabling considerably better roll damping. The Crafter with a payload of 5.0 t is equipped with an anti-roll bar (diameter 28 mm) as standard. The 3.5 t payload version can be optionally equipped with an anti-roll bar (diameter 17 mm). Heavy-duty versions are additionally available: 21 mm diameter for the 3.5 t version 34 mm diameter for the 5.0 t versionAG.Prote cted by●do c um enShock absorbers●●●Optimisation of the rear axle encompasses both weight and noise reduction measures.34ht rig py Co t.agen lksw Vo byc o p yri gh t . C op yiHandbrake cable●Depending on payload, 1- to 3-layer leaf springs are fitted: 1-layer – for the panel van and vehicles with 3.0 – 3.5 t – for the crew bus with 3.5 t – for vehicles with 4.6 and 5.0 t2-layer 3-layer●Coupling rodThe rear axle differential housing is manufactured from grey cast iron. The axle tubes are manufactured from sheet steel and are pressed into the differential housing.Anti-roll bar Differential housinges, in part or in w l purpos hole ercia , is n m ot compe rm itte dun len AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or Longitudinalau leaf spring ac ssility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sWheel bearingAxle tubeS369_014r te o iva r rp fo g ndo c um enht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi35Running gearThe handbrake systemAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r The handbrake system operates with dual-servo o Dual-servo brakes eo h ut ra a c s brakes, in which drum brakes are integrated into the sun leThe drum brakes are actuated via the handbrake lever and the brake cables. The front cable leads to the cable adjuster, from which the two brake cables then lead to the drum brakes. The handbrake actuation mechanism is secured to the driver's seat bracket. It is optionally available as a folding handbrake actuation mechanism. Function:urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d prear disc brakes.Different dual-servo brakes are fitted depending on payload:● ●For 3.0 t and 3.5 t = diameter 180 mm x 25 mm For 5.0 t and 4.6 t = diameter 172 mm x 42 mmThe expander, which is mounted between the brake shoes, pushes both brake shoes apart on application of the handbrake. The expander's floating mounting enables both drums to lock in the direction of travel regardless of the direction of drum rotation. This is why this is also referred to as the dual-servo principle. An adjustment pinion serves to adjust the brake shoes.ht rig py Co t.ility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enUpper positionLower resting positionLocking knob36AG.To release the handbrake, the handbrake cable has to be raised again and then pushed down with the locking knob pressed in.agen lksw Vo byProte cted by c o py rig h t . Co py iWhen the handbrake is actuated, the handbrake lever can be pressed back down to its lower resting position from the upper position without pressing the locking knob. This is necessary if a swivel seat (camper) is installed, for example.r fo ngFront brake cableurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt ceExpanderExpander lever appliedrrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enAdjustment pinionr fo ngDrum brakeRear left brake cableCable adjusterAG.Rear right brake cableS369_089The figure shows the a handbrake system for an axle load of 3.0 t/3.5 t.ht rig py Co t.agen lksw Vo byProte cted by c o py rig ht . C op yiBrake shoes Drum brake37Running gearThe steeringThe Crafter is fitted with a rack and pinion power-assisted steering system, which operates according to hydraulic n AG. Volkswagen AG do principles. It offers the level of comfort found in passenger cars. e wageThe steering columnpe rm itte des, in part or in w l purpos hole ercia , is n m ot comThe steering column is designed to significantly reduce the consequences of an accident. Universal joints and telescopic intermediate steering shafts are employed to achieve this. In addition to the simple version of the steering column without adjustment option, a version offering longitudinal and inclination adjustment is also available. In the adjustable steering column, an additional telescopic section is installed in the upper column tube. Steering wheel locking (previously with a mechanical steering lock) is carried out via an electric steering column locking mechanism which is actuated directly by the electromechanical ignition lock.r te o iva r rp fo g nun leolks yV db e ris tho u a sss no t gu ara nte eo ra cElectric steering column locking mechanismility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sTelescopic intermediate steering shaftht rig py Co t.do c um enMounting plate on the front bulkheadAG.Intermediate steering shaftThe figure shows an adjustable steering column. In the non-adjustable steering column, only the adjustment unit and the upper column tube are missing.Hydraulic power steering38agen lksw Vo byProte cted by c o py rig ht . C op yiUniversal jointS369_122To optimally adjust it as the driver wishes, the steering column can be optionally equipped with an inclination and longitudinal adjustment facility. Its inclination can be adjusted by 4° mm, whilst longitudinal adjustment of 40 mm is possible. The locking lever can be used to release or lock the clamping mechanism for inclination or longitudinal adjustment.urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leSteering column adjustmentAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sLocking lever for inclination and longitudinal adjustmentility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enUpper column tube Crash capsuleht rig py Co t.Roller Adjustment unit for longitudinal and inclination adjustment Bracket for attachment to body Upper column tube Steel wire Retaining plate S369_094Non-adjustable steering column This is equipped with 3 universal joints and a telescopic intermediate steering shaft is installed in the lower area between the two universal joints. The telescoping sections are pushed into each other from the steering box side.Adjustable steering column In this case, a second telescopic section is installed in the upper column tube. This is activated by the driver's falling into the airbag. Energy is constantly absorbed over the course of this telescopic section's travel, as a steel wire is unreeled from a roller on each side of the steering column. The roller is mounted on a "crash capsule", which is firmly anchored to the dash panel cross member, counter to which the upper column tube, including the retaining plate, moves downwards, thereby unreeling the wire.AG.Longitudinal and inclination adjustment unit locking leveragen lksw Vo byProte cted by c o py rig h t . Co py ir fo ng39Running gearThe brake systemThe Crafter's brake system is designed as a dualcircuit system with diagonal division. The technical features of the brake system are:● ●Brake servo●● ● ●es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n● ●10" tandem brake servo Anti-lock Brake System (ABS), Traction Control System (TCS) and Electronic Stabilisation Programme (ESP) as standard Brake pad wear indicator on the front and rear axle Active wheel speed sensors AG. Volkswagen AG d agen oes Hydraulic brake assist system w s k not l Vo gu y b ara Electronic brake pressure distribution instead d e nte ris o eo h load-dependent brake pressure of automatic, t u ra c sa s regulator Hill start assist (optional) Handbrake integrated into the rear disc brake as a drum brakeS369_044 ESP unitility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisESP systemA Bosch version 8.1 ESP system, the most recent generation, is fitted. This system takes the relevant vehicle load into consideration (evaluating its acceleration behaviour), determines the centre of gravity and responds accordingly in terms of its control characteristics.ESP unitdo c um enControl unit S369_040 Hydraulic unit40ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yiFront brakesThe Crafter's front axle is fitted with a 16" floating caliper disc brake system with ventilated brake discs. The dimensions are Ø 300 mm x 28 mm.AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt cees, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngrrectness of i t to the co nf o r m spec atio h re n in witS369_042thi sd o cu m enRear brakesTwo different brake system versions are installed on the rear axle.●Vehicles with a gross vehicle weight of 3.0 t and 3.5 t are equipped with a 16" floating caliper disc brake system with solid brake discs. The brake disc dimensions are Ø 298 mm x 16 mm. Vehicles with a gross vehicle weight of 4.6 t and 5.0 t are fitted with ventilated brake discs. The brake disc dimensions are Ø 303 mm x 28 mm.●ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iS369_04341Running gearWheels and tyresThe Crafter has steel wheels. It can be equipped with the following dimensions:OverviewStandard equipment:Super-single 4.6 t Twin tyres 5.0 tFront axle3.0 t3.5 tTyre size Wheel size Rear axle Tyre size205/75R16C235/65R16C205/75R16C 5.5Jx16 H2195/75R16C 5.5Jx16 H2es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nAG. Volkswagen AG d agen oe6.5Jx16 H2 s no ksw 5.5Jx16 H2 l o t gu yV b a ran ed tee ris ho t or u ac a ssility ab y li an pt ce205/75R16C 5.5Jx16 H2235/65R16C 6.5Jx16 H2285/65R16C 8.5Jx16 H2195/75R16C 5.5Jx16 H2Wheel sizerrectness of i t to the co nform spec at i h re o n wit in t hisOptional equipment:Front axle3.0 t3.5 tSuper-single 4.6 tTwin tyres 5.0 tTyre size235/65R16C 6.5Jx16 H2--205/75R16C 5.5Jx16 H2Wheel size Rear axle Tyre size-do c um enWheel size6.5Jx16 H2AG.agen lksw Vo byOptional aluminium wheels are also available in addition to the steel wheels.42ht rig py Co t.235/75R16C--205/75R16C 5.5Jx16 H2Prote cted by c o py rig ht . C op yiSuper-single tyreses, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sAs an alternative to twin tyres, the Crafter may also be optionally equipped with new super-single tyres. This is an absolutely new feature in the transporter segment. These tyres have a wider, balloon-like cross-section and are also accordingly reinforced. The super-single tyres are fitted on panel vans with a gross vehicle weight of 4.6 t (as 5.0 t version "with lower load rating"). At high payloads, these tyres' narrower design offers significant advantages in comparison with the wider twin tyres. The Crafter is fitted with tyres with the dimensions 285/65R16C.Prote cted by c o py rig ht . C op yiTyre load capacity and permissible vehicle speed The tyre load capacity and permissible vehicle speed are revealed by the lettering "128N" on the tyre's flank. This information means:●●128 (load index) – means that the tyre has a maximum, permissible load capacity of 1800 kg N (speed index) – means a maximum, permissible vehicle speed of 140 km/hthi sd o cu m enility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witS369_131Advantages:●●The innovative all-weather profile guarantees safety, better handling and vehicle stability, lower fuel consumption, high mileage, traction and comfort plus low maintenance costs. Thanks to the installation space, which is narrower than that of twin tyres, additional load width, e.g. for loading pallets – transversely between the wheel housings – is acquired. On the whole, installation space conditions are therefore improved, e.g. including for bodies and adaptations.ht rig py Co t.agen lksw Vo byAG.Load indexSpeed index43Electrical systemThe data bus systemsData bus networkingThe Crafter's control units are networked via the CAN data bus and the MOST data bus. Networking enables data to be exchanged between the individual control units. Instead of using conventional (discrete) cable connections, the data are transmitted via the data buses in digital form as an electrical signal or as a light signal. This enables data to be made available to several control units. The CAN data bus is sub-divided into three individual systems, the CAN drive train data bus, the CAN convenience data bus and the CAN diagnostic data bus. All three bus systems are connected to each other via the electronic ignition lock D9, and are therefore able swagen AG AG. Volk does agen w s k not l to exchange information. o g yVb ed ris o h t au ssua ran teeor acility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nrrectness of i t to the co nform spec at i h re o n wit in t hisDiagnostic interfaceMOST bus interface MOST bus Data busht rig py Co t.CAN drive train data bus CAN convenience data busdo c um enK wireagen lksw Vo by44AG.Prote cted byc o p yri gh t. C op yiSerial data cableD9Electronic ignition lockes, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngn AG. Volkswagen A E16 Heater/heat output switch G do es n wage s k l o o t gu control unit V J104 ABS by ara ed ntcontrol s i J234 Airbag unit r ee ho t or with display in dash panel insert u J285 Control unit ac a ssJ301 J345 J364 J386 J412 J446 J502 J503J514 J519 J527 J528 J604 J621 J623 J764 J819 J820 R R41 T16AG.Air conditioning system control unit Trailer detector control unit Auxiliary heater control unit Driver door control unit Mobile telephone operating electronics control unit Parking aid control unit Tyre pressure monitor control unit Control unit with display for radio and navigation Electronic manual gearbox control unit Onboard supply control unit Steering column electronics control unit Roof electronics control unit Auxiliary air heater control unit Tachograph control unit Engine control unit Electronic steering column lock control unit Control unit for middle of dash panel Control unit for programmable special functions Radio CD changer 16-pin connector (diagnostic connection)ility ab y li an pt cerrectness of i t to the co nf o r m spec atio h re n in witthi sd o cu m enFurther information can be found in self-study programme No. 370 "The Crafter – Electrical System".S369_075ht rig py Co t.agen lksw Vo byProte cted byc o p yri gh t . C op yi45Electrical systemInstallation locations of the electrical componentsOverview of installation locationsThe vehicle electrical system has a decentralised structure; the fuse and relay installation locations are therefore in different locations throughout the vehicle.Junction boxes 2 and 3 for bus systems, on the right A-pillarurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra a c s sility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enFuse holder (SA), on right-hand side of battery, visible only following removal46ht rig py Co t.Connector (T16, diagnostic connection), on the left A-pillaragen lksw Vo byAG.Prote cted by c o py rig ht . C op yir fo nges, in part or in w l purpos hole ercia , is n m ot compe rm itte dun leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sFuse holder D (SD), beneath the driver's seatr te o iva r rp fo g ndo c um enFuse holder B (SB), on the left A-pillarht rig py Co t.Fuse holder C (SC), on the left A-pillarJunction box 1 for bus systems, beneath the front left dash panelagen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiS369_14447Electrical systemRadio systemsRCD 2001Radio system RCD 2001 is equipped with an audio CD drive and a CD changer connection. The radio unit has a single FM and AM tuner and a TP/TA traffic radio function.S369_029RCD 4001es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nRadio but is additionally equipped with a MOST data bus interface via which a CD changer and a mobile telephone can be connected.AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u ra system RCD 4001 is based on RCD 2001, a c s sility ab y li an pt cerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um enS369_03048ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiRNS 4001Radio/navigation system RNS 4001 is based on the RCD 4001, but its functions are extended by a navigation system with arrow depictions.S369_031n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ssility ab y li an pt ceurposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun lerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enRNS 5001Radio/navigation system RNS 5001 is based on the RNS 4001, but offers map depiction instead of arrow-based navigation and has a DVD drive instead of a CD drive.r fo ngS369_032ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yi49Heating and air conditioningClimate controles, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ngAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s sility ab y li an pt ceThe Crafter can be fitted with a heating and ventilation system as basic equipment or the "Climatic" semi-automatic air conditioning system.rrectness of i t to the co nf o r m spec atio h re n in witOptional extension of the "Climatic" system to control the climate in the rear passenger compartment is also possible.Heater/air conditioner unitthi sd o cu m enDepending on the system which is fitted, the following equipment components may be installed:● ●●●●PTC pre-heater for faster heating Fuel-driven pre-heater, 5 kW and 10 kW, with timer switch and radio remote control Heat exchanger for the rear load/passenger compartment Extended air conditioning system with 2nd evaporator in the rear Residual heat functionRadiatorEngineFront heat exchanger50AG.Hotht rig py Co t.agen lksw Vo byProte cted by c o py rig h t . Co py iColdThe figure shows the standard equipment with heating and ventilation system and optional pre-heaters.S369_082urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d pun leAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s sLoad/passenger compartment heat exchanger (with blower); the auxiliary hot air heater may also be installed at this pointility ab y li an pt cerrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enr fo ngagen lksw Vo byAdditional water heater/auxiliary heater fueldrivenAG.Prote cted byht rig py Co t.c o p yri gh t. C op yi51Heating and air conditioningThe heater and air conditioner unitHeating and ventilationThe Crafter is fitted with a heating and ventilation system as basic equipment. Technical features●●●●●es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n4-stage blower, fresh air/recirculated air circuit, dust and pollen filter (in the engine compartment intake housing) Heater/air conditioner unit Immediate heating response thanks to airside temperature regulation (previously on coolant-side) Evaporator tract Electric pre-heater in front (PTC = Positive Temperature Coefficient) for fast heating directly after starting (as standard in the crew bus, special equipment in all other models) Hot air supply to the windscreen wiper parking position via a separate duct to prevent the wiper blades from freezing on Hot/cool air duct to the load/passenger compartment for even air distribution up to the AG. Volkswagen agen compartment,AG does 1st row of seats in the passenger Primary flap ksw not l o gu yV b a without restricting s the ran ed footwell (as standard in the tee ri ho equipment for panel van without t or crew bus, special u ac a s s partition wall and double cab)ility ab y li an pt ceWide-range nozzlerrectness of i t to the co nform spec at i h re o n wit in t hisdo c um en52ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py iFront heat exchangerAir conditioning systemThe Crafter can also be fitted with the "Climatic" semiautomatic air conditioning system. G. Volkswagenpe rm itte dun leA AG do agen es n ksw ot g Vol y ua b d ran e The rheating/ventilation system and the semiis tee o h t or u automatic "Climatic" air conditioning system use the ac a sssame heater/air conditioner unit.es, in part or in w l purpos hole ercia , is n m ot comSecondary flap Defrost"Climatic" controls the climate in the driver's and front passenger's area. The "Climatic" system can be optionally extended by a 2nd evaporator (in the roof lining) to control the climate in the rear passenger compartment.ility ab y li an pt cerrectness of i t to the co nform spec a t i h re o n in wit thi sAir distributor flap kinematicsr te o iva r rp fo g ndo c um enOperating moduleagen lksw Vo byTemperature mixing flap kinematicsLateral air ventFootwell flapFootwellS369_083 PTCFloor air duct outletht rig py Co t.AG.Prote cted by c o py rig h t . Co py i53Heating and air conditioningFront air distributiones, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g nThe heating and air conditioning system distributes the heated air into both the driver's/front passenger's area and the rear load/passenger compartment. A pleasant climate is thereby guaranteed, at least for the first row of seats in the passenger compartment.ility ab y li an pt ceAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s srrectness of i t to the co nform spec at i h re o n wit in t his●In the dash panel area, the air is guided to the driver and front passenger area via corresponding nozzles and louvres.●Via the floor air duct, the air is routed on the left and right beneath the driver's and front passenger's seats and to the rear into the load/ passenger compartment.Heater and air conditioner unitLeft windscreen ventRight wind screen ventdo c um enRight side ventDriver's footwell ventCentre footwell ventTo seat box beneath driver's seatLoad/passenger compartment vents54AG.Left side ventht rig py Co t.agen lksw Vo byProte cted byc o p yri gh t. C op yiBlower motorFront passenger's footwell ventS369_092To seat box beneath front passenger's seatManual heatingThe heating and ventilation system ensures pleasant heating in the driver's/front passenger's area. The floor air duct, which transports the heated air backwards from the heater unit, serves to heat the load/passenger compartment.Operating/display unit – heating and ventilation – front (basic variant) Fresh air/ recirculated air button Rotary switch for air distributionNote holderAG. Volkswagen AG d The temperature for the driver/front passenger area agen oes ksw not l o V rotary gu y can be adjusted manually using the left-hand b ara d nte ise r o eo switch. h tpe rm itte dFour different blower stages can be set:es, in part or in w l purpos hole ercia , is n m ot comun leau ssra cility ab y li an pt ceS369_118Rotary temperature switchBlower stage thumb wheelIf the heating and ventilation system is equipped with an auxiliary heat exchanger for the load/passenger compartment, the temperature can be adjusted manually using the right rotary switch.r te o iva r rp fo g nOperating/display unit – heating and ventilation - rear with auxiliary heat exchanger for load/passeng