Service TrainingCommercial VehiclesSelf-Study Programme Technology 505The Crafter 2012es, 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 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 nf o r m spec atio h re n in witthi sd o cu m enht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yiThe Crafter 2012 from Volkswagen Commercial Vehicles is a well known feature in its vehicle segment.  It has set new benchmarks with its ingenious vehicle concept and wide range of models. The new 2.0 l 4-cylinder common rail engines are set to capture a leading position in terms of economy and reliability. Innovative technologies such as BlueMotion Technology and the start/stop system with energy recovery (recuperation) help to boost efficiency even more. The Crafter 2012 in the new brand design communicates high value and performance at first glance. It offers outstanding ergonomic features in a comfortable interior. The Crafter 2012 combines extraordinary functions with high utility value for an extremely wide range of applications. Every detail supports the driver in tackling the demands of his or her everyday job.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 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 nf o r m spec atio h re n in witthi sd o cu m enIts particular strengths are economy, comfort, driving properties as well as the wide range of variants.agen lksw Vo byAG.Prote cted byThe self-study programme presents the design and function of new developments! The content will not be updated. Current testing, setting and repair instructions can be found in the provided service literature.2ht rig py Co t.c o p yri gh t. C op yis505_001Important noteAt a glanceIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5es Power units . . . . . . . . . . . .y V . o.lk.sw . a. . . . . . . . . . . . . . .o. .n. ot.g. . . . . . . . . . . . . . . . . . 8b ed ris o h t au ss. Volkswagen AG gen AG dua ran teeor 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 pStart/stop system in the Crafter 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enRadio and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29r fo ngun leht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yi3IntroductionThe Crafter 2012 in brand designThe newly designed front end of the new Crafter 2012 displays a powerful and self-assured appearance.  The overall appearance is more slender, giving it an additionally dynamic appeal.  The VW badges and letterings are adapted to the brand design. Note the following features of the Crafter 2012: • Wider radiator grille • Continuous, one-piece trim in body colour • New Volkswagen badges and letteringsurposes, 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 ng4ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yis505_067BodyFeatures of body technologyThe new design of the Crafter 2012 means that changes to the body were necessary.The front end of the Crafter 2012The front end of the new Crafter 2012 has been adapted to the brand design.BodyThe radiator grille has been made wider and is now delimited by the headlights.  There is a continuous trim fitted in the lower area.  The lock carrier has been adapted to the modified attachments.un 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 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 ss505_076r te o iva r rp fo g ndo c um ens505_077agen lksw Vo byAG.Attachment of the trimht rig py Co t.Prote cted by c o py rig ht . C op yi5BodyOverview of galvanized componentsCommercial vehicles are subject to elevated corrosion protection requirements during their tough everyday operation on construction sites and in haulage applications. The body structure of the Crafter 2012 has been further improved, in order to assist in achieving a long service life of the body. In particular, this includes galvanising additional surfaces of the body and the add-ons. The following graphics clarify which components in the new Crafter 2012 are galvanised in the open and closed designs.Range of galvanised components in the closed design of the Crafter 2012s no panel van or window van, for example. lksw is used in the Crafter 2012 The closed design of the Crafter 2012 o tg yVAG. Volkswagen AG d agen oees, in part or in w l purpos hole ercia , is n m ot compe rm itte dun lessb ed ris o th auua ran teeor acility 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 ndo c um enNot galvanised Electrolytically galvanised on one side Electrolytically galvanised on both sides Galvanised6ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig h t . Co py is505_074Range of galvanised components in the open design of the Crafter 2012es n w The open designs have a single or double cab and are used as theVbody ot g van, for olks for the Crafter 2012 platform y ua b d ran e example. is te ores, 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 oth au sseo 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 hisdo c um enNot galvanised Electrolytically galvanised on one side Electrolytically galvanised on both sides GalvanisedThe illustrations of the galvanised components do not provide any information about the steel qualities used, but only about the galvanisation methods applied. For more information about the body of the Crafter 2012, please refer to Self-Study Programme 369 “The Crafter 2006”.ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yis505_0757Power unitsThe engine range of the Crafter 2012The 2.0 l TDI engines of the Crafter 2012 are comparable with the 2.0 l engines in the Amarok and the  Transporter T5. Following market launch, the Crafter 2012 will be available with four different engines: 2.0 l 80 kW TDI engine with turbocharger 2.0 l 100 kW TDI engine with turbocharger 2.0 l 105 kW TDI engine with biturbo unit 2.0 l 120 kW TDI engine with biturbo unit AG. Volkswagen AG d agen ow olks yV b ed For a certain period,othe ris Crafter 2012 h t conjunction with sShiftmatic gearbox. au swill continue toes n ot g ua ran be offered with tee the or ac2.5 l 100 kW TDI engine inility 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 witCommon features of the 2.0 l TDI enginesThe engines of the Crafter 2012 have the following features in common: Common rail injection system with solenoid valves Exhaust gas circulation through the cylinder head Controlled EGR cooling Piston with cooled ring groove Plastic suction pipe Diesel particulate filter (EU5) Subframe for holding optional ancillary unitsDesign Cubic capacity Bore Stroke Valves per cylinder Compression ratio Engine management Injection system Diesel particulate filter change-over valveagen lksw Vo byAG.ht rig py Co t.4-cylinder diesel engine 1968 cm3 81 mm 4 95.5 mm 16.0 : 1thi sd o cu m enEDC 17CP 20 Common rail EU4 EU5What is EEV? EEV (Enhanced Environmentally Friendly Vehicle) is currently the strictest European exhaust standard for buses and trucks. These particularly environmentally friendly vehicles have emissions values that are well below those of the Euro 5 standard which came into force on October 2008 for all new buses and trucks.Prote cted by c o py rig h t . Co py ino: yes: yesEmissions standardEU4, EU5, EURO5, EEVFor more information about the technology of the 2.0 l diesel engines, refer to Self-Study Programmes 455 “2.0 l TDI engines in the T5 2010” and 463 “The Amarok 2011”.82.0 l TDI engines with turbochargerTechnical features • • Exhaust turbocharger with variable turbine geometry (VTG exhaust tubocharger) At market launch of the Crafter 2012, available in two power levels with 80 kW and 100 kW2.0 l 80pe rm itte dTechnical data[Nm] cial purposes, in part or in who le, is mer not comun leAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo th u r a80 a TDI engine kW 2.0 l c s ss505_069kW TDI engineTechnical dataCKTB 80 kW at 3500 rpm 300 Nm at 1500 to 2250 rpm VTG exhaust turbocharger Engine code Max. power Max. torqueility ab y li an pt ceEngine code Max. power Max. torque TurbochargingCKTC 100 kW at 3500 rpm 340 Nm at 1576 to 2250 rpm VTG exhaust turbochargerTurbochargingrrectness of i t to the co nform spec at i h re o n wit in t hisPower and torque curve[kW]Power and torque curve[kW] [Nm] 340 90 80 310or ate v i pr100 90 80 70 60 50 40 30 20 10 0do c um enr fo ng310 280 250 220 190 160 130 10060 50 40 30 20 10 070 40 1000 2000 3000 4000 [rpm]s505_02540 1000 2000 3000 4000 [rpm]s505_026agen lksw Vo by70ht rig py Co t.280 250 220 190 160 130 100 70AG.Prote cted by c o py rig ht . C op yi9Power units2.0 l TDI engines with bi-turbochargerTechnical features • • Bi-turbocharger with increased air flow volume At market launch of the Crafter 2012, available in two power levels with 105 kW and 120 kWs505_0682.0 l 105 kW TDI engineTechnical dataEngine code Max. power Max. torque Turbocharging CKUC 105 kW at 3500 rpm 340 Nm at 15752.0 l 120 kW TDI engineTechnical dataEngine code Max. power CKUB 120 kW at 3600 rpmes, in part or in w l purpos hole ercia , is n m ot comPower and torque curve[Nm]pe rm itte dun leagen AG AG. Volksw Max. torque 400 Nm at 1800 rpm does agen ksw not l o V g ua to 2250 rpmed by ran tee ris Turbocharging Bi-turbocharger o h Bi-turbocharger t or u ac a s sility ab y li an pt cePower and torque curve[Nm] [kW] 110 100 90 80 70 60 50 40 30 20 10 0rrectness of i t to the co nform spec a t i h re o n in wit thi s[kW]340 310 280 250 220 190 160 130 100 70 40 1000400 370 340 310 280 250 220 190 160120 110 100 90 80 70 60 50 40 30 20r te o iva r rp fo g ndo c um ens505_027200030004000[rpm]10AG.1001000200030004000 [rpm]s505_028agen lksw Vo by130ht rig py Co t.Prote cted by c o py rig ht . C op yiEngine technology of the 2.0 l TDI engines in the Crafter 2012The design features and systems described below: - Engine-mounted PTO - Engine cooling system - Exhaust gas recirculation system - Fuel system are found on all four power variants of the 2.0 l TDI engine, and therefore apply both to engines with VTG exhaust turbocharger and to engines with bi-turbocharger.Engine-mounted PTOThe ancillary unit carrier can be retrofitted, and in turn allows additional ancillary units to be fitted to all engine power levels. It is no longer necessary for this to be prepared at the factory.  The ancillary units requested by the customer are installed by the service partner or a body manufacturer. n AG. Volkswagen AG do age es n ksw l ot g o The ancillary unit carrier isudesigned for various yV b ara d e nte ris o ancillary units. e th ora cility ab y li an pt ces505_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 leau ssrrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um ens505_083A spacer is mounted behind the large pulley of the ancillary unit drive.r fo ngRefer to the workshop manual regarding setting the timings in vehicles with an engine-mounted PTO.ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi11Power unitsThe engine cooling systempe rm itte des, in part or in w l purpos hole ercia , is n m ot comThe engine cooling system shown here is a simplified standard model of the cooling system of the Crafter 2012. The precise structure of the cooling system depends on the engine used as well as the equipment and thus the application of the Crafter 2012.rrectness of i t to the co nform spec a t i h re o n in wit thi sun 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 s123r te o iva r rp fo g n6 4 5ht rig py Co t.71 2 3 4 5 6 7 8 9Expansion tank Pump for exhaust gas recirculation cooler V400 Thermostat 1 Exhaust gas recirculation cooling bypass valve 2 N387 Exhaust gas recirculation cooling bypass valve N387 Coolant temperature sender G62 EGR cooler Radiator Radiator outlet coolant temperature sender G8310 Coolant pump12AG.89 13101112 1411 Thermostat 2 12 Oil cooler 13 Coolant circulation pump V50 14 Heating heat exchangers505_035ility ab y li an pt cedo c um enagen lksw Vo byProte cted by c o py rig h t . Co py iNon-return valves and throttles in the cooling circuiturposes, 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 leNon-return valves and throttles are used in the vent pipes within the cooling circuit. These purely mechanical components are permanently integrated Choke G. Volkswagen AG d in the hoses of the cooling system.  lkswagen A oes not o gu yV ara The cooling system can no longer d b be bled If these e nte is r o eo components are missing or have been installed th u ra a c s s incorrectly. Non-return valvesility ab y li an pt ces505_064rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enNon-return valvesChokesThe non-return valves are intended to ensure that when the system is filled, the air escaping from the individual ventilation circuits cannot get into the other ventilation circuits.  The direction of flow must always be towards the expansion tank. If the valves are installed the wrong way round, it will not be possible to fill the system properly.r fo ngProte cted by c o py rig ht . C op yiThe chokes are used for reducing the coolant flow through the expansion tank. This means the necessary flow rate is reliably guaranteed in the main cooling circuit.  Without chokes, the flow rate through the expansion tank would be too great, which could result in foaming of the coolant.ht rig py Co t.agen lksw Vo byAG.13Power unitsExhaust gas recirculationgen AG. Volkswagen AG dBody1 2 3 4 5 6 7 8 9Intake airurposes, 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 lea oes ksw not Vol gu y b ara d All 2.0 l TDI engines of the rCrafter 2012 have exhaust gas recirculation. nte  ise o eo h t u ra A new feature is control a of the cooling of the recirculated exhaust gas by means c s sof a modified bypass structure.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 enThrottle flapExhaust gas recirculation valve N18 N345 change-over valve for cooler  of the exhaust gas recirculation Radiator EGR coolerExhaust gas recirculation cooling bypass valve N387 Exhaust gas recirculation cooling bypass valve 2 N387 Pump for exhaust gas recirculation cooler V40010 Radiator outlet coolant temperature sender G83 11 Coolant temperature sender G62 12 Engine control unit J623ht rig py Co t.13 ExhaustThe exhaust gas recirculation cooler The exhaust gas recirculation cooler of the 2.0 l TDI engine in the new Crafter 2012 does not have a builtin bypass which is opened and closed using a separate switching element. The bypass function which continues to be required for cooling the recirculated exhaust gas is now achieved using the two exhaust gas recirculation cooling bypass valves N386 and N387.s505_029This design measure simplifies the system structure of the exhaust gas recirculation.14agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yir fo ngs505_030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 ss505_031N387The exhaust gas recirculation cooling bypass valve  N386 The exhaust gas recirculation cooling bypass valve N386 is mounted on the right of the radiator. It is a pneumatic 2/2-way valve with the two switching positions “open” and “closed”. It is controlled by the exhaust gas recirculation cooler change-over valve N345. It is open in the rest position. In this switching status, it allows coolant to flow from the radiator to the EGR cooler.rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enility ab y li an pt ceV400N386s505_032ht rig py Co t.Prote cted by c o py rig ht . C op yir fo ngs505_033The exhaust gas recirculation cooling bypass  valve 2 N387 The exhaust gas recirculation cooling bypass valve 2 N387 is the counterpart to the valve N386. It is located above the radiator. It is closed in the rest position. In this switching status, it allows coolant to flow in from the cylinder head to the EGR cooler. Valve N387 is always controlled by the exhaust gas recirculation cooler change-over valve N345 so that it adopts the opposite switching status from that of the N386. If N386 is open, N387 must be closed. If N386 is closed, N387 must be open. This method achieves the bypass function for the exhaust gas recirculation cooler.V400N387N386s505_034N386 and N387 must never be swapped over during repair work. Therefore, N387 has a grey housing and N386 has a black one.agen lksw Vo byAG.15Power unitsMode of function of the exhaust gas recirculation coolingThe cooling of the recirculated gases is controlled according to the coolant temperature which is measured by the engine control unit via the radiator outlet coolant temperature sender G83. Further influencing parameters are the outside temperature and the “Ignition on” and “Engine running” information.1 s505_063 2 3 4 5 6 7 8n 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 ssEngine control unit J623 Radiator outlet coolant temperature sender G83 Radiator Thermostat 1 Coolant pump/water pump Exhaust gas recirculation cooling bypass valve N387 Exhaust gas recirculation cooling bypass valve 2 N387 N345 change-over valve for cooler  of the exhaust gas recirculation Pump for exhaust gas recirculation cooler V400910 Thermostat 2 11 Coolant temperature sender G62 12 EGR coolerility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot compe rm itte dun leControl intervention is performed by the two exhaust gas recirculation cooling bypass valves N386 and N387.  In a control cycle, it is possible to differentiate between the following three control statuses.rrectness of i t to the co nform spec a t i h re o n in wit thi sControl status 1Condition: - Coolant temperature is 60 °C - Outdoor temperature is 17 °C - Ignition is “on” After the ignition has been switched on, the exhaust gas recirculation cooling bypass valve 2 N387 is opened by the engine control unit, and valve N386 is closed. The exhaust gas recirculation cooling is switched to “Warm supply”.agen lksw Vo byAG.Prote cted byr te o iva r rp fo g n16s505_058do c um enht rig py Co t.c o p yri gh t . C op yiControl status 2Condition: - Coolant temperature is 60 °C - Outdoor temperature is 17 °C - Engine running After the engine starts, the exhaust gas recirculation cooling remains set to “Warm supply” until the AG. Volkswagen AG d agen oe coolant temperature reaches 60 °C. w s no s k l o t gu yV b ara d The electric pump for exhaust gas recirculation cooler e nte s i r eo ho V400 is activated and is operating continuously. t ra au c ss The switching status of both valves remains unchanged.s505_059ility ab y li an pt cees, in part or in w l purpos hole ercia , is n m ot compe rm itte dun lerrectness of i t to the co nform spec a t i h re o n in wit thi sControl status 3Condition: - Coolant temperature is 60 °C - Outdoor temperature is 17 °C - Engine runningagen lksw Vo byr te o iva r rp fo s505_060 g ndo c um enIf the coolant temperature rises above 60 °C, valve N387 is closed and valve N386 is opened. The pump for exhaust gas recirculation cooler V400 now supplies the coolant from the radiator. The system is now in “Cold supply”.AG.Prote cted byht rig py Co t.c o p yri gh t . C op yi17Power unitsPractical notes on troubleshootingDiagnostic capability of the pneumatic switch elements  Exhaust gas recirculation cooling bypass valve N386 and N387 It is possible to check the function of valves N386 and N387 by electronic diagnosis, even if these are not electrically activated but are actuated by the vacuum system. By evaluating the temperature sensor G83 and G62, it is possible to draw conclusions about the function of the corresponding mechanical components.ComponentN386  Exhaust gas recirculation cooling  change-over valve P30D500 Exhaust gas recirculation cooling  bypass valve 2 malfunctionN387  Exhaust gas recirculation cooling  change-over valve P30D600 Exhaust gas recirculation cooling  bypass valve 2 malfunctionFault codeFault descriptionpe rm itte dun leDepending on the EGR cooler temperature, the engine control unit demands a changeover of the bypass valves to the low temperature circuit. As a result, the temperatures . Volkswagen AG n AGat e g does coolant temperature a the radiator outlet w not olks gu yV sender must change accordingly.  b ara d e nte ris If the expected temperature is not reached o eo h ut r athen the within the desired time window a c ss fault is set.ility ab y li an pt ceDepending on the EGR cooler temperature, the engine control unit demands a changeover of the bypass valves to the high temperature circuit. As a result, the temperatures at the radiator outlet coolant temperature sender must change accordingly.  If the expected temperature deviates from the measured temperature then the fault is set. Defective vacuum hoses to the valves. Valve sticking in the low temperature circuit (N387);  Actuator test: Use the exhaust gas recirculation cooler change-over valve in order to check the valve switching by a finger test. Rule out the possibility that valve 1 (N386) and valve 2 (N387) are swapped over, by checking the part numbers and colour coding.es, in part or in w l purpos hole ercia , is n m ot comNotes on troubleshooting--Defective vacuum hoses to the valves. Valve sticking in the low temperature circuit (N386);  Actuator test: Use the exhaust gas recirculation cooler change-over valve in order to check the valve switching by a finger test. Rule out the possibility that valve 1 (N386) and valve 2 (N387) are swapped over, by checking the part numbers and colour coding.rrectness of i t to the co nform spec a t i h re o n in wit thi s-r te o iva r rp fo g ndo c um en18ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yiThe fuel system of the Crafter 2012A Bosch common rail injection system is installed in the Crafter 2012. Depending on the operating status, the injection pressure is 230 to 1800 bar. Solenoid valve injectors are used for the fuel injection.  There is no electric heating of the fuel filter in the fuel preheating. The fuel preheating is achieved by the warm fuel from the return flow.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 sility ab y li an pt ces505_044rrectness of i t to the co nf o r m spec atio h re n in witKeyG6 G81 G247 N30 N31 N32 N33 N276 N290Fuel system pressurisation pump Fuel temperature sender Fuel pressure sender Injector, cylinder 1 Injector, cylinder 2 Injector, cylinder 3 Injector, cylinder 4 Fuel pressure regulating valveProte cted by c o py rig h t . Co py i1 2 3 4 5High-pressure fuel pump Choke Fuel filter Fuel tankHigh-pressure accumulator (fuel rail)thi sd o cu m enFuel metering valveht rig py Co t.agen lksw Vo byAG.19Power unitsSystem overview for 2.0 l TDI engines  with VTG turbochargerF36 F71Clutch pedal switch Clutch pedal switch for  stop/start systemG28 Engine speed sender G31 Charge air pressure sender  G42 Intake air temperature sender G39 Lambda probe G40 Hall sender G62 Coolant temperature sender G69 Throttle valve potentiometer G70 Air mass meter G71 Intake manifold pressure sender G79 Accelerator position sender  G185 Accelerator position sender 2un leG81 Fuel temperature sender G83 Coolant temperature sender on the radiator outletAG. 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 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 prrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um enG212 Exhaust gas recirculation potentiometer G235 Exhaust gas temperature sender 1 G247 Fuel pressure senderJ623 Engine control unitG266 Oil level and oil temperature sender G450 Exhaust gas pressure sensor 1G495 Exhaust gas temperature sender 3positionerG648 Exhaust gas temperature sender 420ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiG581 Position sender for charge pressure r fo ngK29 Glow period warning lampJ17 G6 J17Fuel pump relay Fuel system pressurisation pumpK83 Exhaust emissions warning lamp K231  Diesel particulate filter warning lampJ338 Throttle valve module V157 Intake manifold flap motorJ179 Automatic glow period control unit Q10-Q13 Glow plugs 1 - 4 J179J285 Control unit in dash panel insertun leAG. Volkswagen AG d N18 Exhaust gas recirculation valve agen oes ksw not l o V g y ua db ran ise tee r o h or ut ac a ssN30- N33 Injectors, cylinders 1 - 4ility 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 pN75 Charge pressure control solenoid valveN79 Heater element for crankcase breather (cold country only)N276 Fuel pressure regulating valve N290 Fuel metering valve N345 Exhaust gas recirculation cooler change-over valveht rig py Co t.rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um ens505_052agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yir fo ngV50 Coolant circulation pumpV400 Coolant circulation pumpZ19Lambda probe heater21Power unitsSystem overview for 2.0 l TDI engines  with bi-turbochargerF36 F71Clutch pedal switch Clutch pedal switch for  stop/start systemG28 Engine speed sender G31 Charge air pressure sender  G42 Intake air temperature sender G39 Lambda probe G40 Hall sender G62 Coolant temperature sender G69 Throttle valve potentiometer G70 Air mass meter G71AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is Intake manifold pressure sender r o eo h ut ra a c s surposes, 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 leG79 Accelerator position sender  G185 Accelerator position sender 2 G81 Fuel temperature senderility 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 enG83 Coolant temperature sender on the radiator outletG212 Exhaust gas recirculation potentiometer G235 Exhaust gas temperature sender 1 G247 Fuel pressure senderJ623 Engine control unitG266 Oil level and oil temperature sender G447 Charge pressure sender 2r fo ngG450 Exhaust gas pressure sensor 1G584 Regulating flap potentiometerG648 Exhaust gas temperature sender 422AG.G495 Exhaust gas temperature sender 3ht rig py Co t.agen lksw Vo byProte cted by c o py rig h t . Co py iK29 Glow period warning lampJ17 G6 J17Fuel pump relay  Fuel system pressurisation pumpK83 Exhaust emissions warning lamp K231  Diesel particulate filter warning lampJ338 Throttle valve module  V157 Intake manifold flap motores, in part or in w l purpos hole ercia , is n m ot comJ285  Control unit in dash panel insertpe rm itte dun len AG. Volkswagen AG do es n J179 Automatic glow period control unit  wage s k l oQ10-Q13 o t gu Glow plugs 1 - 4 yV b ara ed n s i tee r J179 ho or ut ac a ss N18 Exhaust gas recirculation valveility ab y li an pt ceN30- N33 Injectors, cylinders 1 - 4rrectness of i t to the co nform spec a t i h re o n in wit thi sN75 Charge pressure control solenoid valveN79 Heater element for crankcase breather (cold country only)N220 Exhaust flap valver te o iva r rp fo g nN276 Fuel pressure regulating valvedo c um enN290 Fuel metering valveagen lksw Vo byAG.Prote cted byN345 Exhaust gas recirculation cooler change-over valveV50 Coolant circulation pumpV400 Coolant circulation pumpZ19s505_053ht rig py Co t.c o p yri gh t . C op yiLambda probe heater23Start/stop system in the Crafter 2012The start/stop system with recuperation and energy managementility ab y li an pt ceAn effective measure to reduce consumption and, with it, CO2 emissions, is to switch off the internal combustion engine automatically when the vehicle is stationary; the engine is restarted automatically only when required. The start/stop system in the Crafter 2012 has been expanded for all four power variants of the 2.0 l TDI engine.rrectness of i t to the co nform spec at i h re o n wit in t hisThe start/stop system in the Crafter 2012 comprises the following functions: - Start/stop function - Energy management - Recuperation function The start/stop function is activated automatically when the ignition is switched on.Deactivation by the driver:ht rig py Co t.Prote cted by c o py rig ht . C op yies, 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 e nte is r o eo th u ra a c s sdo c um ens505_036Activation by the driver:If the start/stop function has been switched off, the function can be activated by the driver by once again pressing the engine start/stop button in the control unit for middle of dash panel J819. The display of system messages distinguishes between the Lowline and Highline equipment of the instrument cluster (control unit for dash panel insert).Display of the start/stop function in Lowline equipment (top) and Highline equipment (bottom) of the instrument cluster24agen lksw Vo byAG.When the start/stop function is active, it can be switched off manually by pressing the engine start/ stop button in the control unit for middle of dash panel J819.s505_054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 leBattery regulation control unit J840AG. 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 sThe battery regulation control unit is located in the substructure of the seat on the driver side.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 ens505_037The battery regulation control unit under the driver seatr fo ngIt is clipped into a holder on the base of the seat substructure. It forms the interface to the vehicle electrical system, and coordinates the energy management. J840 has the following tasks: - Assessment of electrical power requirement in the vehicle electrical system - Processing of the alternator load signal and controlling the alternator via LIN data bus - Evaluating the battery status information from the battery monitor control unit J367 - Requesting the engine start due to elevated electrical power consumption when the start/stop function is activeht rig py Co t.Energy managementIf a manual engine start is necessary in stop mode due to the energy management of the vehicle electrical system then a prompt for manual engine start is displayed for the driver on the multifunction display of the instrument cluster (Highline only). In addition, a gong sounds as an acoustic signal as well.s505_073In vehicles with a Lowline instrument cluster, a start request by the energy management is indicated by the battery symbol flashing on the instrument cluster after the start/stop symbol has gone out. Here too, there is also a gong sound.A detailed list of the necessary operating conditions for the start/stop function and information on operating the start/stop function can be found in the owner's manual of the Crafter 2012 as well as in Self-Study Programme 426 “The start/stop system 2009”.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi25Start/stop system in the Crafter 2012Battery monitor control unit J367The battery monitor control unit is connected to the battery instead of the battery earth strap. It is mounted on the negative battery terminal and is connected to the battery regulation control unit together with the alternator via LIN bus. The battery monitor control unit has a built-in resistor (shunt) located between the negative battery terminal and the earth cable, and therefore registers the entire battery current. The control unit supplies the following information: s505_038 - Instantaneous charge status of the vehicle . Volkswagen AG G A n e doe electrical system battery The battery monitor control unit on the negative terminal of wag s no olks t gu yV the vehicle electrical system battery. b a - Instantaneous battery voltage ran ed tee ris o h t or - Instantaneous battery current u ac sa s - Instantaneous battery temperatureility 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 witVoltage stabiliser J532The voltage stabiliser26ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yiThe voltage stabiliser is a DC/DC voltage converter. DC/DC (DC = Direct Current) means converting direct current into direct current. It is located under the cover of the fuse box on the left-hand side of the body. The high current consumption of the starter means there is a voltage dip in the vehicle electrical system voltage every time the engine starts. In order to avoid cut-outs of the infotainment components, the roof electronics and the digital tachograph when the engine is restarted, the electrical power supply to the engine is stabilised by J532 during the engine restart.thi sd o cu m ens505_050An AGM battery is used as the starter battery in the Crafter 2012 with BlueMotion Technology.  (AGM = absorbent glass mat) Optionally, a wet battery is fitted as a second battery.  Please bear the following aspects in mind when recharging or jump-starting:  As far as the negative terminal is concerned, the charging cable is not allowed to be connected directly to the negative terminal of the battery. Make the connection exclusively to the body earth. This ensures that the battery monitor control unit is not bypassed.AG. 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 ceAdvanced features of the start/stop functionDriver detectiones, 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 ngFor safety reasons, it is essential for the presence of the driver to be detected without ambiguity in order to achieve an automatic engine stop as part of the start/stop function, and for the engine to be restarted. An engine stop is only performed if the driver has his or her seat belt fastened, and the vehicle doors are closed.The following behaviour applies in stop mode:s505_039If the driver unfastens his or her seat belt or if the tailgate or one of the doors is opened then the engine control unit deactivates the start/stop function. The engine can be started manually all the same.thi sd o cu m enrrectness of i t to the co nf o r m spec atio h re n in witDeactivated start/stop function in the Highline displayIf the time period of 30 seconds is exceeded, the engine control unit switches the start/stop function off. The engine can now only be started manually. If the driver is unambiguously detected as being present again within 30 seconds then the engine control unit activates the start/stop function again, which means the engine can once again be started automatically.ht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yi27Start/stop system in the Crafter 2012Recuperationpe rm itte dRecuperation is a technical process of energy recovery. An interplay between various vehicle systems achieves a reduction in fuel consumption by means of recuperation. The following functions are required for this: - Alternator control - Registering the battery status - Registering the energy requirement in the vehicle electrical system - Registering the current engine operationrrectness of i t to the co nform spec a t i h re o n in wit thi sThis is how it worksThe battery regulation control unit J840 specifies a nominal voltage for the alternator when the engine is running, via the LIN interface. This nominal voltage depends, amongst other things, on the energy requirement in the vehicle electrical system, the status of the battery (temperature, charge status) and the requirements of the engine control unit.do c um enr te o iva r rp fo g nes, in part or in w l purpos hole ercia , is n m ot comun 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 ceThe engine control unit J623 calculates a recommendation for a voltage increase or reduction of the alternator, and sends this recommendation to the battery regulation control unit via the CAN data bus. This then specifies a corresponding nominal voltage for the alternator.AG.Reduction in the alternator voltage:  A voltage reduction leads to a reduction in the power output of the alternator, and therefore a lower fuel consumption.s505_024Increase in the alternator voltage:  A voltage increase results in an increase in the power output of the alternator, and is preferably requested in operating phases with low specific fuel consumption. The lowest fuel consumption is achieved during deceleration or braking, by means of the overrun  cut-off.s505_02328ht rig py Co t.agen lksw Vo byProte cted by c o py rig ht . C op yiCharge voltageCharge voltageRadio and navigationagen ksw The range of equipment Vol y bAG. Volkswagen AG d oes not gu ara nte eo navigation units are available for the ra cth radios and At present, the following auurposes, 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 pd ise or-RCD 2001 radio RCD 3002 radio RCD 4002 radio RNS 4010 navigation unit RNS 5010 navigation unitun lessCrafter 2012:The Crafter 2012 is designed for the new generation of radio and navigation units, therefore the MOST data bus has been discontinued.  Connecting an external CD changer or an external telephone control unit via MOST data bus is not necessary, because of the new unit functions.r fo ngRCD 2001 radioagen lksw Vo byility 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 en• • • •1-DIN radio AM/FM single tuner Single CD player MP3/WMA-capables505_045RCD 3002 radio• • • • • 5-inch colour display AM/FM single tuner Single CD player MP3/WMA-capable Internal Bluetooth telephonys505_046ht rig py Co t.AG.Prote cted by c o py rig h t . Co py i29Radio and navigationRCD 4002 radio• • • • • • 5-inch colour display AM/FM single tuner CD player 6 CD changer MP3/WMA-capable Internal Bluetooth telephonyAG. 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 ss505_047ility 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 ngNavigation unit  RNS 4010• • • • • • 5-inch colour display AM/FM double tuner 6 DVD changer MP3/WMA-capable Internal Bluetooth telephony Arrow navigationrrectness of i t to the co nf o r m spec atio h re n in witthi sd o cu m ens505_04830AG.• • • • • • • • • •6.5-inch colour display AM/FM double tuner Internal hard disk 6 DVD changer SD card reader MP3/WMA-capable Internal Bluetooth telephony Video input Music database Map navigationht rig py Co t.Navigation unit  RNS 5010agen lksw Vo byProte cted by c o py rig h t . Co py is505_049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 sUnit connectionss505_040The two navigation units RNS 4010 and RNS 5010 have an AM/FM double tuner. Only one AM/FM aerial is installed in the Crafter 2012 for the radio reception. This means no aerial diversity or phase diversity is possible. As a result, the two aerial inputs AM/FM1 and FM2 are connected via an aerial splitter. On the rear of the unit, there is also a connection for an external Bluetooth aerial. The possibility of a MOST databus connection on the unit is not used for the Crafter 2012.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 witUnit connections, taking the example of the RNS 5010: 1 2 3 AM/FM, FM2 video GPS 4 5 Bluetoothht rig py Co t.Prote cted by c o py rig h t . Co py iMOST databusThe aerial splitterThe Crafter 2012 has an aerial splitter for connecting radio and navigation units with a double tuner. It is located behind the radio installation frame and makes it possible to connect the two aerial inputs AM/ FM1 and FM2.s505_055 The aerial splitter behind the radio installation frames505_041By means of the aerial splitter, the unit can search in the background for alternative reception frequencies of the same station.Bluetooth aerialThe Bluetooth aerial is installed in all radio and navigation units with internal telephone function outside the unit. It is attached to the centre dash panel (right air nozzle) by means of an adhesive pad on the rear of the air nozzle.s505_042 The Bluetooth aerial on the heating duct to the right air nozzleagen lksw Vo byAG.31Radio and navigationTelephone preparationThe mobile phone preparation is available in various versions: - for vehicles without radio - for vehicles with radio preparation - for vehicles with RCD 2001 radio - for vehicles with RCD 3002 or RCD 4002 radio - for vehicles with RNS 4010 or RNS 5010 radio/navigation systemaThe mobile phone preparation for vehicles for vehicles without radio or with radio preparation (Fig. a) consists of a cradle on the dash panel. It has a Bluetooth hands-free device, a built-in amplifier and an external microphone for the hands-free device.wa The amplifier is connected to the standard olks yV b ed loudspeakers at the front.  ris ho t There is no separate control sunit au for the telephone, the s necessary electronics are installed in the cradle.  Operation is by means of the cradle.  This hands-free device is also suitable for audio streaming.. Volkswagen AG gen AG does not gu ara nte eo ra cility 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 n12s505_065rrectness of i t to the co nform spec at i h re o n wit in t his3do c um en32AG.2 3agen lksw Vo by1Prote cted byStart call End callVolume louder (+) / quieter (-)ht rig py Co t.c o p yri gh t . C op yis505_079un 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 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 pbThe mobile phone preparation for vehicles with radio  RCD 2001 (Fig. b) consists of the cradle on the dashboard which has a Bluetooth hands-free device as well as an external microphone for the hands-free device. There is no separate control unit for the telephone, the necessary electronics are installed in the cradle. In this variant, voice reproduction is amplified by means of the radio. This hands-free device is also suitable for audio streaming.rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um ens505_066r fo ng1243 s505_078 1 2 3 4 Start call Quick dial Breakdown call End callThe mobile phone preparation for the radios RCD 3002 and RCD 4002 as well as for radio/navigation systems RNS 4010 and RNS 5010 is completely built into the radio.  Only the microphone for the hands-free device is fitted outside the radio in these units.  There is no separate control unit for the telephone. This mobile phone preparation has a Bluetooth hands-free device. For communication between the mobile phone and the radio/radio/navigation system, these units have a Bluetooth aerial connected on the rear of the unit.  This hands-free device is not suitable for audio streaming.ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yi33n 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 nf o r m spec atio h re n in witthi sd o cu m enht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t . C op yies, 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 ngAG. 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 sdo c um enht rig py Co t.agen lksw Vo byAG.Prote cted by c o py rig ht . C op yir te o iva r rp fo g nes, in part or in w l purpos hole ercia , is n m ot compe rm itte dun le505 505es, 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 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 nf o r m spec atio h re n in witthi sd o cu m en© VOLKSWAGEN AG, Wolfsburg All rights reserved. Subject to technical modifications. 000.2812.62.20 Technical status 09/2011 Volkswagen AG After Sales Qualifizierung Service Training VSQ-1 Brieffach 1995 D-38436 Wolfsburg❀ This paper was manufactured using pulp bleached without the use of chlorine.ht rig py Co t.agen lksw Vo byAG.Prote cted byc o p yri gh t. C op yi