Workshop Manual Crafter 2006

Service
Workshop Manual
Crafter 2006 ➤
5-cylinder diesel engine
CEB CEB CEC CEC
Engine ID BJJ BJK BJL BJM A B A B
Edition 03.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
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28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg K0059030120

Crafter 2006 ➤
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.2 Safety precautions during road tests in which testing and measuring equipment is used . . 4
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2.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.4 Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.2 Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Rules for cleanliness and instructions for working on injection system . . . . . . . . . . . . . . . . 7
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3.4 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.5 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.2 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.3 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 16
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Assembly overview - flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4 Renewing needle bearing in flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3 Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Engine power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Removing and installing poly V-belt for power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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Crafter 2006 ➤
5-cylinder diesel engine - Edition 03.2016
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Assembly overview - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3 Removing and installing camshaft ............................................ 65
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4.3 Removing and installing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.4 Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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2.1 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o 85
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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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3.1 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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1.2 Coolant hose schematic diagram, vehicles with auxiliary heater . . . . . . . . . . . . . . . . . . . . 90

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1.3 Coolant hose schematic diagram, vehicles with auxiliary heater and 2nd heat exchanger
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1.4 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.3 Removing and installing viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Assembly overview - turbocharger (engine codes BJJ, BJK, BJL, BJM) . . . . . . . . . . . . . . 106
1.2 Assembly overview - turbocharger (engine codes CEBA, CEBB, CECA, CECB) . . . . . . . . 108
1.3 Removing and installing turbocharger (engine codes BJJ, BJK, BJL, BJM) . . . . . . . . . . . . 110
1.4 Removing and installing turbocharger (engine codes CEBA, CEBB, CECA, CECB) . . . . 111
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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Crafter 2006 ➤
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.2 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.3 Filling fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.1 Check pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.2 Removing and installing injectors (piezo injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.3 Removing and installing fuel overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.1 Schematic diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 136
5.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.4 Removing and installing fuel nmetering
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6.1 Assembly overview
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6.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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7.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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8.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

h re
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spec
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
es, in part or in w
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1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Assembly overview - silencer (engine codes BJJ, BJK, BJL, BJM) . . . . . . . . . . . . . . . . . . 151
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1.2 Assembly overview - silencers and SCR catalytic converters (engine codes CEBA, CEBB,
CECA, CECB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
l purpos
1.3 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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2.1 Assembly overview - diesel particulate filter (engine codes CEBA, CEBB, CECA, CECB)
m
........................................................................ 154
at
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2.2 Assembly overview - diesel particulate filter (engine codes BJJ, BJK, BJL, BJM) . . . . . . . . 156
c
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2.3 Removing and installing diesel particulate filter (engine codes CEBA, CEBB, CECA,
his
ate
do
riv
CECB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
p
cum
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2.4 Removing and installing diesel particulate filter (engine codes BJJ, BJK, BJL, BJM) . . . . 161
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2.5 Removing and installing catalytic converter (engine codes BJJ, BJK, BJL, BJM) . . . . . . . . 165
Co
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3 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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168
3.1 AdBlue® technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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3.2 Assembly overview - tank for reducing agent (Crafter panel van and Crafter window van)
Prote AG.
........................................................................ 168
3.3 Assembly overview - tank for reducing agent (Crafter dropside and Crafter chassis) . . . . 171
3.4 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 172
3.5 Removing and installing reducing agent delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.6 Removing and installing filler line for reducing agent (panel van and window van) . . . . . . 175
3.7 Removing and installing filler neck for reducing agent (panel van and window van) . . . . . . 177
3.8 Removing and installing reducing agent tank (panel van and window van) . . . . . . . . . . . . 177
3.9 Removing and installing reducing agent tank (platform van and chassis) . . . . . . . . . . . . . . 179
3.10 Emptying reducing agent tank (panel van and window van) . . . . . . . . . . . . . . . . . . . . . . . . 180
3.11 Emptying reducing agent tank (platform van and chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.12 Removing and installing heater element (heater cup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Contents iii
Crafter 2006 ➤
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

4.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.1 Handling ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.2 Testing glow plug 1 Q10 to glow plug 5 Q14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.3 Testing glow plug 1 Q10 to glow plug a5
geQ14
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1.4 Removing and installing glow bplugy Vo 1 Q10 to glow plug 5 Q14 .gu. a. . . . . . . . . . . . . . . . . . . . 190
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1.5 Removing and installing hengine
oris speed sender G28 . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . 194
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iv Contents
Crafter 2006 ➤
00 – Technical data
1 Technical data
(VRL008953; Edition 03.2016)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data

Four-digit engine codes have been introduced since model year
2009. The first 3 digits denote the mechanical design of the en‐
gine and are stamped on the engine as before. The fourth digit
denotes the power output of the engine and depends on the en‐
gine control unit. The four-digit engine code can be found on the
top part of the toothed belt guard, the vehicle data sticker and on
the engine control unit.
The engine number (“engine code” and “serial number”) is located
on the left below the vacuum pump on the cylinder block.
In addition, there is a sticker on the upper part of the toothed belt
guard with “engine code” and “serial number”.
cardiagn.com
The engine code can also be found on the vehicle data sticker.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 4 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter. gen AG. Volkswagen AG
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Code BJJ au r
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Manufactured 03.06 ► 03.06 ► 03.06 ► 03.06 ►

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Emissions fulfil EURO 4, EU 4 EURO 4, EU 4, EURO 4, EU 4 EURO 4, EU 4, EU‐
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EURO 3, EU 3 RO 3
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Capacity l 2.5 2.5 2.5 2.5
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Output kW at 65/3500 80/3500 100/3500 120/3500
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Torque Nm at 220/1750 … 280/2000 … 300/1750 … 2750 350/2000 … 3000
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rpm 2500 2250
Bore Diamete 81.0 81.0 81.0 81.0 rrectness of i
r, mm
Stroke mm 95.5 95.5 95.5 95.5
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Compression ratio 16.8 16.8 16.8 16.8

Fuel accord‐ DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
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Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3

ion in
Turbocharging/super‐ yes yes yes yes

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Particulate filter yes yes1) yes yes1)

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Charge air cooling yes yes yes yes

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1) Not in EURO 3 or EU 3 engines
1. Technical data 1
Crafter 2006 ➤
Code CEBA CEBB CECA CECB

Manufactured 05.09 ► 05.09 ► 05.09 ► 05.09 ►
Emissions fulfil EURO 5 EURO 5 EURO 5 EURO 5
Capacity l 2.5 2.5 2.5 2.5
Output kW at rpm 65/3300 80/3300 100/3500 120/3500
Torque Nm at 250/1900 … 300/1900 … 330/2000 … 2800 360/2000 … 2800
rpm 2300 2300
Bore Diameter, 81.0 81.0 81.0 81.0
mm
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 16.8 16.8 16.8 16.8
Fuel according DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
to
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Turbocharging/super‐ yes . Volkswagen AG yes yes yes
charging wa gen AG do e
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Particulate filter edb yes yes guara yes yes
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Reduction catalytic th con‐
o yes yes e or yes yes
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Charge air cooling yes yes yes yes

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Exhaust gas recirculation yes yes yes yes

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AdBlue® technology yes yes yes yes
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2 Rep. gr.00 - Technical data

Crafter 2006 ➤
2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
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page 3 olks
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⇒ “2.2 Safety precautions duringrisroad
ed tests in which testing and nte
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⇒ “2.3 Safety precautions when working on cooling system”, page
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⇒ “2.5 Safety precautions when working on injection system”,
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⇒ “2.6 Safety precautions when working on the SCR system”,
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page 6
2.1 Safety precautions when working on
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fuel supply system
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Caution
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When doing any repair work, especially in the engine compart‐
atio
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ment, pay attention to the following due to the cramped condi‐

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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
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vated charcoal filter system, coolant and refrigerant, brake
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fluid and vacuum) and electrical wiring in their original po‐

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♦ To avoid damage to lines, ensure sufficient clearance to
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all moving or hot components.
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♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
When removing and installing fuel gauge sender - G- or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m3/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
2. Safety instructions 3
Crafter 2006 ➤
2.2 Safety precautions during road tests in

which testing and measuring equipment
is used
WARNING
Danger of accidents due to distraction because of inadequately

secured testing and measuring equipment!
Danger due to triggering of front passenger airbag in the even
of an accident!
• Operation of test and measuring instruments while driving
results in distraction
• Increased risk of injury due to inadequately secured test‐
ing and measuring devices!
♦ Always strap test and measuring instruments in place on
rear seat and have a 2nd person operate them.
cardiagn.com
cooling system
WARNING
Steam may escape when expansion tank is opened. Wear eye G. Volkswagen AG d
protection and protective clothing to avoid eye injuries and lkswagen A oes
not
scalding. Cover cap with cloth and open carefully. by
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♦ To avoid damage to lines, ensure sufficient clearance from
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Crafter 2006 ➤
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers - VAS 6340- or hose clip pliers - VAS
6362- are recommended for installation of spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ The arrow markings on the coolant pipes must align with the
arrow markings on the coolant hoses.
♦ Only demineralised / distilled water to standard VDE-0510
may be used for mixing. Tap water does not have the required
quality to ensure the coolant's function.
cardiagn.com
charge air system
Caution
When mechanical damage is found on the turbocharger, e.g.

a destroyed compressor impeller, it is not only sufficient to re‐
new the turbocharger. To prevent this from causing further
damage, perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects. agen
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If foreign objects are found in the charge air system, the charg‐
ed by
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be renewed, if necessary. s aut ra
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2.5 Safety precautions when working on in‐

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WARNING
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♦ Test and measuring instruments must always be secured

to the rear seat and operated by a second person from this
location.
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♦ If test and measuring instruments are operated from front

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passenger seat and the vehicle is involved in an accident,

there is a possibility that the person sitting in this seat may
receive serious injuries when the airbag is triggered.
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♦ Persons wearing a pacemaker should not lean over the engine

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high voltage pulses.

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♦ No fuel lines may be opened while the engine is running.

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2. Safety instructions
AG.
Crafter 2006 ➤
♦ Always switch off the ignition before connecting or discon‐

necting injection and glow plug system wiring or tester cables.
♦ Always switch off ignition before cleaning engine.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, otherwise the engine control unit
could be damaged.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all the checks and
repairs, read the event memory and clear it if necessary.
2.6 Safety precautions when working on the

SCR system
WARNING
♦ The reducing agent can irritate skin, eyes and respiratory

organs.
♦ After skin contact with this agent, wash immediately with
plenty of water.
cardiagn.com
♦ If necessary, call a doctor.
Caution
Protect separated connectors against wetting from reducing

agent by suitable means, e.g. plastic bag and cable ties. Elec‐
trical connections may be damaged due to the high penetration
ability along with subsequent crystallisation of the reducing
agent.
Caution
AG. Volkswagen AG d
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Immediately seal allisopenings
ed
b
and connections using suitable ara
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plugs to stop ingress
ut
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of dirt. The smallest particle of dirt cantee or
cause extensivess damage to the system.
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Make sure that no reducing agent gets onto the trim panels or
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parts of vehicle body.

spec
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If this occurs, wash out reducing agent using clear water and
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a lint-free cotton cloth.

If the reducing agent has already crystallised, use warm water
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and a sponge.
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Reducing agent that has not been removed will crystallise and
damage the surface after some time.
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For information on storage and disposal see ⇒ Service net →

Environment → Workshop disposal ! For country specific infor‐
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mation about storage and disposal, ask the importer.

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Rep. gr.00 - Technical data Prote AG.
Crafter 2006 ➤
AG. Volkswagen AG d
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3 Repair instructions by ara
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⇒ “3.1 Rules for cleanliness whenssworking
a on fuel supply system”, c
page 7
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⇒ “3.2 Rules for cleanliness when working on charge air system”,
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⇒ “3.3 Rules for cleanliness and instructions for working on in‐
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⇒ “3.4 General notes on the lubrication system”, page 9
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⇒ “3.5 Foreign objects in engine”, page 9
3.1 Rules for cleanliness when working on
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fuel supply system
s
When working on the fuel supply and injection system, pay careful
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attention to the following “6 rules” for cleanliness:
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♦ Thoroughly clean all connections and surrounding areas be‐
atio
fore disconnecting.
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♦ Place removed parts on a clean surface and cover. Use only
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♦ Carefully cover opened components or seal if repairs cannot
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be carried out immediately.

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tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 Rules for cleanliness when working on

charge air system
When working on the turbocharger, pay careful attention to the
following “5 rules” for cleanliness:
♦ Thoroughly clean all connections and surrounding areas be‐
fore disconnecting.
lint-free cloths.
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
essary.
3.3 Rules for cleanliness and instructions

for working on injection system
♦ Clean tools and workbench etc. before working on injection
system.
3. Repair instructions 7
Crafter 2006 ➤ agen
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♦ Thoroughly clean all connections and surrounding
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♦ When removing components, plug all open connections im‐
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mediately with suitable clean sealing caps.
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♦ Do not remove sealing caps from components until immedi‐
ot
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be kept in new, sealable packaging (plastic bags or wooden
hole
boxes; not in cartons). If available, use the original new part
spec
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packaging).
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use parts that have not been stored in their packing (e.g. in
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♦ Before installation, check injectors and their surroundings vis‐

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♦ If components are not being renewed, always mark the high-

pressure fuel lines on removal. High-pressure fuel lines must
always be re-installed in their original positions (i.e. on the
same cylinder).
♦ Following components and O-rings must be renewed each
time injectors are removed and installed: Copper washer and
O-ring of injector return.
♦ Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. O-rings must be moist when
installed (assembly oil or clean engine oil).
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Align the high-pressure fuel lines so they are free of tension.
First tighten all unions hand-tight before tightening to final tor‐
que.
♦ Never attempt to reshape high-pressure fuel lines.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the return lines onto the injectors by hand from above
so that they engage audibly on each injector (do not press in
the release pins when doing this). Then press down the re‐
lease pin after connecting the return line. Check that the return
lines are seated securely by pulling them by hand from above.
Also check that they seal properly (fuel pressure in return line
as far as pressure retention valve: between 8 and 10 bar).
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.

Crafter 2006 ➤
3.4 General notes on the lubrication system
Note
The oil level must not be above the max. mark - danger of damage
to catalytic converter!
Caution
Finding metal shavings or a large quantity of small metal AG.par‐

Volkswagen AG
agen does
ticles during engine repair could indicate thatVothe
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♦ Thoroughly clean oil channels. ss c
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♦ Renew oil spray jets.
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♦ Renew engine oil cooler.
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♦ Renew oil filter element.
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3.5 Foreign objects in engine
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Note
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If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
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thoroughly and renew the engine oil cooler in order to prevent
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subsequent damage.
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3. Repair instructions 9
Crafter 2006 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Installing engine”, page 14
⇒ “1.3 Securing engine on engine and gearbox support VAS 6095
”, page 16
1.1 Removing engine
Special tools and workshop

equipment required
♦ Vehicle diagnostic tester
♦ Engine and gearbox sup‐
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♦ Spring-type clip pliersise-d b ara
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VAS 5024A- ut
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♦ Supplement tools - 3448-
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♦ Torque wrench - V.A.G pt

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♦ Torque wrench - V.A.G wit

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10 Rep. gr.10 - Removing and installing engine

Crafter 2006 ➤
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1. Removing and installing engine 11

Crafter 2006 ➤
♦ Workshop hoist - VAS 6100-

♦ Drip tray for workshop hoist - VAS 6208-
Note
♦ The engine is removed forwards together with the gearbox.

♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
Caution

tions:
sitions.
cardiagn.com
♦ The fuel and the fuel lines in the fuel system can become wage
very hot (danger of scalding)! yV
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♦ The fuel system is also under pressure! Before opening ris nte
tho e
the system, place cloths around the connections.sThen
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– Before removing, read event memories of all control units
h re
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⇒ Vehicle diagnostic tester.
spec
es, in part or in w
Vehicles with automated manual gearbox:
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– Perform function “Relieving pressure, gearbox hydraulics” ⇒
Rep. gr. 34 .
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Continuation for all vehicles:
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– With the ignition switched off, disconnect battery earth strap

⇒ Rep. gr. 27 .
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– Remove air filter ⇒ page 149 .

m
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– Remove any noise insulation ⇒ General body repairs, exteri‐

o
n in
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or; Rep. gr. 50 ; Noise insulation .

thi
te
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– Remove bumper ⇒ Rep. gr. 63 .

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– Remove lock carrier ⇒ Rep. gr. 50 .

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– Drain coolant ⇒ page 93 . t. C rig
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– Remove radiator and charge air cooler.
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Prote AG.
– Remove silencer and exhaust tailpipe (if fitted):
Engine codes BJJ, BJK, BJL, BJM ⇒ page 151
Engine codes CEBA, CEBB, CECA, CECB ⇒ page 152
Engine codes BJJ, BJK, BJL, BJM:
– Release propshaft from gearbox flange ⇒ Rep. gr. 39 .

Crafter 2006 ➤
Engine codes CEBA, CEBB, CECA, CECB: n AG. Volkswagen AG do

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– Remove particulate filter ⇒ page 158 . byV
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– Remove propshaft ⇒ Rep. gr. 39 . utho tee
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Vehicles with manual gearbox: ss
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– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 .
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– Disconnect line to slave cylinder from gearbox ⇒ Rep. gr. 30 .
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– Pull engine wiring harness connector off engine control unit -
, is n
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J623- .
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– Disconnect gearbox/body connectors ⇒ Rep. gr. 34 .
rrectness of i
– Remove exhaust gas pressure sensor 1 - G450- with bracket
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⇒ Item 10 (page 157) , hoses remain connected.

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– Separate connectors between engine wiring harness and

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body and lay engine wiring harness on engine.
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– Loosen securing bolts for vane pump belt pulley.

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– Remove poly V-belt ⇒ page 19 .

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– Remove vane pump and lay it to one side.
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Vehicles with air conditioning system: t. C rig
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Caution
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To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or
bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Release air conditioner compressor from bracket ⇒ Rep. gr.
87 .
– Secure air conditioner compressor to body so that the refrig‐
erant lines/hoses are not under tension.
– Disconnect fuel supply and fuel return lines -arrows- by ac‐

tuating release buttons.
– Separate all connecting, coolant, vacuum and intake hoses
from engine.
– Disconnect battery positive cable from battery positive termi‐
nal and lay cable to side.
– Pull off/disconnect all other connectors as necessary from en‐
gine, and lay them to one side.
– Remove intake manifold flap motor - V157-
⇒ Item 15 (page 146) .
– Remove right bracket for air filter ⇒ Item 12 (page 149) .
– Remove bonnet ⇒ Rep. gr. 55 .

Crafter 2006 ➤
– Unscrew securing bolts for gearbox -2-.

– Attach supplement tool - 3448- to workshop crane - VAS
6100- .
– Attach supplement tool - 3448- to engine as shown.
WARNING
Stop bolt -arrow- must be tightened.
cardiagn.com
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– Unscrew securing bolt for right engine mounting -arrow-.ised b ua
ran
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– Unscrew securing bolt for left engine mounting -arrow-.
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mer
When lifted out, the engine must be carefully guided to prevent

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damage to the body and steering rack.

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– Raise engine and pull out forwards.

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Securing engine to assembly stand ⇒ page 16 .

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1.2 Installing engine
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Installation is carried out in the reverse order; note the following:

Crafter 2006 ➤
Caution

tions:
sitions.
– Insert new dowel sleeves in cylinder block for centring engine

and gearbox.
– Lightly grease input shaft splines with grease ⇒ Electronic
Parts Catalogue (ETKA) .
– Check clutch and clutch operating mechanism and install ⇒
Rep. gr. 30 .
cardiagn.com
– When installing engine and gearbox assembly, ensure suffi‐
cient clearance to body and steering rack.
– Align engine mountings free of tension by rocking engine.
– Install bonnet ⇒ Rep. gr. 55 .
– Install intake manifold flap motor - V157-
⇒ Item 15 (page 146) .
– Install vane pump ⇒ Rep. gr. 48 .
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– Install air conditioner kcompressor
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– Install propshaft ise
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Engine codess au CEBA, CEBB, CECA, CECB:
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– Install particulate filter ⇒ page 158 .
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– Install silencer and exhaust tailpipe:

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Engine codes BJJ, BJK, BJL, BJM ⇒ page 151

h re
hole
spec
Engine codes CEBA, CEBB, CECA, CECB ⇒ page 152

es, in part or in w
t to the co
Vehicles with manual gearbox:

– Install selector mechanism and adjust if necessary ⇒ Rep. gr.
rrectness of i
34 .
– Connect line to slave cylinder at gearbox and bleed clutch
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control mechanism ⇒ Rep. gr. 30 .

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ercia

m
– Install lock carrier ⇒ Rep. gr. 50 .

at
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– Install bumper ⇒ Rep. gr. 63 .

in t
or
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ate
– Install any noise insulation ⇒ General body repairs, exterior;

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Rep. gr. 50 ; Noise insulation .

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for
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– Install air filter ⇒ page 149 .
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– Fill with coolant ⇒ page 93 .
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5-cylinder diesel engine - Edition 03.2016 s
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– Perform function “Learn gearbox selector settings” ⇒ Rep. gr.
ility
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34 .
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es, in part or in w
– Carry out road test and then read event memory ⇒ Vehicle
t to the co
diagnostic tester.
Specified torques:
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Threaded connection Specified torque
l purpos
Bolts, nuts M6 9 Nm
M8 20 Nm
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M10 40 Nm
m
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M12 65 Nm
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Engine bracket to engine mounting M10 55 Nm
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Engine mounting to subframe M10 55 Nm

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♦ ⇒ “2.1 Assembly overview - diesel particulate filter (engine co‐
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des CEBA, CEBB, CECA, CECB)”, page 154
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♦ ⇒ “7.1 Assembly overview - air filter”, page 149

♦ ⇒ “6.1 Assembly overview - intake manifold”, page 146
Bolt gearbox to engine ⇒ Rep. gr. 34
1.3 Securing engine on engine and gearbox

support - VAS 6095-
Special tools and workshop equipment required
♦ Engine and gearbox support - VAS 6095-
Secure engine to engine and gearbox support - VAS 6095- to

carry out repairs.
– Disconnect gearbox.
– Secure engine to engine and gearbox support - VAS 6095- .
Dowel sleeves must be removed.

Crafter 2006 ➤
13 – Crankshaft group
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⇒ “1.1 Assembly au
overview - cylinder block (pulley end)”, ac
ss
page 17
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⇒ “1.2 Assembly overview - poly V-belt drive”, page 18
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⇒ “1.3 Removing and installing poly V-belt”, page 19
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⇒ “1.4 Removing and installing tensioner for poly V-belt”,
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page 20
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⇒ “1.5 Renewing crankshaft oil seal - belt pulley end”,
t to the co
page 21
1.1 Assembly overview - cylinder block (pulley end)
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1 - Oil filter bracket

❑ Locked in installation
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position by fitted pins.
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2 - Bolt
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❑ 20 Nm
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3 - Banjo bolt
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❑ 100 Nm
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4 - Seal t. Cop py
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❑ Renew after removing
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5 - Gasket
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6 - Cylinder block
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 23 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 41
crankshaft
⇒ page 39 .
7 - Bolt
❑ 9 Nm
8 - Bracket
9 - Bolt
❑ 20 Nm
10 - Plug
❑ 30 Nm
11 - Engine bracket
12 - Bolt
❑ 50 Nm +180°
13 - Oil sump
❑ Removing and installing ⇒ page 76
1. Cylinder block (pulley end) 17

Crafter 2006 ➤
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ Remove and install on flywheel side using Allen key, long reach - T10058- .
❑ With flywheel installed: turn flywheel so that recess aligns with bolts.
❑ 8 Nm + 90°
16 - Bolt
❑ 60 Nm
17 - Bracket
❑ Locked in installation position by fitted sleeves.
18 - Dowel sleeve n AG. Volkswagen AG do
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1 - Bolt
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❑ 10 Nm + 90°
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❑ 20 Nm
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3 - Bracket
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4 - Tensioning element
❑ Note installation posi‐
rrectne
tion: “TOP” marking “at
top”
s
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tensioner for poly V-belt
f in
⇒ page 20 .
form
mer
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5 - Bolt
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❑ 20 Nm
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6 - Poly V-belt
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❑ Mark direction of rota‐

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tion before removing.

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❑ Check for wear.
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⇒ page 19 .
7 - Bracket
8 - Bolt
❑ 40 Nm
9 - Idler pulley
10 - Bolt
❑ 55 Nm
11 - Idler pulley
❑ Only in vehicles with air
conditioning system or second alternator
12 - Bolt
❑ 55 Nm
18 Rep. gr.13 - Crankshaft group

Crafter 2006 ➤
13 - Washer
❑ Diamond coated.
14 - Belt pulley and vibration damper
❑ When installing note fixing arrangement.
❑ Modified belt pulley/vibration damper in vehicles with power take-off.
❑ Remove cowling to remove ⇒ Item 6 (page 102) .
15 - Bolt
❑ 20 Nm + 90°
16 - Bolt
❑ Use counterhold tool - T10025- to loosen and tighten.
❑ 160 Nm +180°
17 - Belt pulley
❑ For viscous fan ⇒ Item 20 (page 98) .
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19 - Bolt orise nte
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20 - Dust cap
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22 - Bolt
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❑ 20 Nm
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23 - Tensioning roller
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1.3 Removing and installing poly V-belt

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Removing
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Note
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Before removing the poly V-belt mark the direction of rotation.

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– Remove poly V-belt for power take-off (if fitted) ⇒ page 36 .
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Prote AG.

Crafter 2006 ➤
– Swivel bracket to relieve poly V-belt tension in direction of ar‐

row and remove poly V-belt from alternator belt pulley.
Installing
Note
♦ Check tensioning device for damage and renew it, if neces‐

sary, before installing the poly V-belt ⇒ page 20 .
♦ Before installing the poly V-belt, ensure that all sub-assem‐ G. Volkswagen AG d
blies (alternator, air conditioner compressor, vane pump) are wage
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proper seating of belt in pulleys. ss
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♦ Routing belt ⇒ page 20 un
pt
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After completing repairs always:
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– Start engine and check belt running.
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Belt drive without air conditioner compressor
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Belt drive with air conditioner or 2nd alternator.

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Prote AG.
1.4 Removing and installing tensioner for

poly V-belt

Crafter 2006 ➤
♦ Torque wrench - V.A.G 1331-
Removing
– Remove poly V-belt from tensioning device ⇒ page 19 .
– Remove securing bolts -arrows-.
Installing
cardiagn.com
Installing poly V-belt and routing belt ⇒ page 19
Specified torques
♦ ⇒ “1.2 Assembly overview - poly V-belt drive”, page 18
AG. Volkswagen AG d
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1.5 Renewing crankshaft oil seal - belt pul‐
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♦ Oil seal extractor - 3203-
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♦ Assembly tool - T10117-

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Prote AG.

Crafter 2006 ➤
Removing
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– Remove toothed belt ⇒ page 57 . olks es n
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– Remove crankshaft sprocket. hor is tee
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– Unscrew inner part of oil seal
ss extractor - 3203- two turns
(approx. 3 mm) from outer part, and lock it with knurled screw.
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– Oil threaded head of oil seal extractor - 3203- .
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spec
until oil seal is pulled out.
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Installing
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Note
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The oil seal sealing lip must not be additionally oiled or greased.
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– Remove oil residue from crankshaft journal using clean cloth.
on
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– Place guide sleeve - T10117/1- onto crankshaft journal.
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– Slide oil seal over guide sleeve onto crankshaft journal.

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Prote AG.
– Press oil seal in to stop using thrust sleeve from assembly tool
- T10117- and centre bolt.
– Install crankshaft sprocket.
– Install and tension toothed belt ⇒ page 57 .
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt”, page 55

Crafter 2006 ➤
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - flywheel”, page 23
⇒ “2.2 Removing and installing sealing flange on gearbox side”,
page 25
⇒ “2.2.1 Pressing out sealing flange with sender wheel”,
page 25
⇒ “2.2.2 Pressing in sealing flange with sender wheel”, olkswage es n
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page 27 d byV ua
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⇒ “2.2.3 A - Fit seal with sender wheel on assembly tooluthT50010
o
or
”, page 28 ss
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⇒ “2.2.4 B - Fit assembly tool T50010 with sealing flange on
pt
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crankshaft flange”, page 29
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⇒ “2.2.5 C - Bolting assembly tool T50010 onto crankshaft flange”,
ility
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page 30
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⇒ “2.2.6 D - Pressing sender wheel onto crankshaft flange using
spec
assembly tool T50010 ”, page 31
t to the co
cardiagn.com
⇒ “2.2.7 E - Checking sender wheel installation position on crank‐
shaft”, page 31
rrectne
⇒ “2.2.8 F - Re-pressing sender wheel”, page 32
⇒ “2.3 Removing and installing flywheel”, page 33
ss o
⇒ “2.4 Renewing needle bearing in flywheel”, page 34
cial p
f inform
2.1 Assembly overview - flywheel
mer
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n
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Cop py
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Prote AG.
2. Cylinder block, gearbox end 23

Crafter 2006 ➤
1 - Seal
❑ Renew. ⇒ page 21 .
2 - O-ring
❑ Renew if damaged.
3 - Bolt
❑ 9 Nm
4 - Suction line
5 - Engine speed sender -
G28-
⇒ page 194 .
❑ 5 Nm
6 - Sealing flange with oil seal
❑ Renew complete with oil gen AG
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❑ Renew. ⇒ page u25 th .
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ss
7 - Bolt
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❑ 8 Nm
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8 - Flywheel
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❑ To loosen securing
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, is n
bolts, lock using coun‐

h re
hole
terhold tool - 3386-

spec
es, in part or in w
❑ Removing and installing t to the co

⇒ page 33
9 - Bolt
rrectness of i

l purpos
❑ 60 Nm + 90°
10 - Needle bearing
nf
ercia
❑ Pulling out and driving in

orm
⇒ page 34 .
m
atio
om
n in
11 - Cylinder block
or c
thi
e
❑ Removing and installing crankshaft ⇒ page 39 .

t
sd
iva
o
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❑ Dismantling and assembling pistons and conrods ⇒ page 41

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12 - Drive for oil pump

t.
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Cop py
❑ With 4 drive lugs. ht. rig
rig ht
py by
❑ Break open to pull off. co Vo
by lksw
cted agen
❑ Heat new drive piece to max. 200°C before fitting.
Prote AG.
13 - Gasket
14 - Oil pump
❑ When installing, note drive on crankshaft ⇒ Item 12 (page 24) .
❑ Renew complete only.
❑ Must seat on dowel sleeves.
❑ Removing and installing ⇒ page 80 .
15 - Bolt
❑ 9 Nm

Crafter 2006 ➤
2.2 Removing and installing sealing flange

on gearbox side
♦ Locating pin - T50009-
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ab
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t to the co
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inform
mer
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n
c
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t.
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Cop py
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pyri by
Vo
co lksw
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Prote AG.
♦ 24 mm tool insert - V.A.G 1332/11-

♦ Vernier gauge
♦ 3 off M6 x 35 mm bolts
2.2.1 Pressing out sealing flange with sender

wheel
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
♦ The procedure is identical whether the engine is installed or
removed.

Crafter 2006 ➤
– Remove gearbox ⇒ Rep. gr. 34 .

– Remove flywheel ⇒ page 33 .
– Remove sump ⇒ page 76 .
– Remove upper toothed belt guard.
– Turn crankshaft in direction of engine rotation to TDC for No.
1 cylinder.
Note
Turn crankshaft until mark on camshaft pulley aligns with mark on

rear toothed belt guard -arrows-.
AG. Volkswagen AG d
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– Unscrew sealing plug -arrow- from cylinder block. hoCrankshaft
ris
eo
TDC bore must be visible. aut ra
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nl
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ab
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert locking pin - T50009- into bore. This stops the crank‐
l purpos
shaft turning.
nform
ercia
Note
m
at
om
ion
c
♦ If crankshaft cannot be locked, turn it back and forth a few

in t
or
times.
his
ate
do
priv
♦ No torque must be transferred to locking pin - T50009- .

um
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove engine speed sender - G28- -arrow- using a com‐
mercially available ball-ended hex key socket.
– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using three M6 x 35 mm bolts.

Crafter 2006 ➤
s wage es n
– Screw three M6 x 35 mm bbolts y V into threaded holes -arrows-t gof
olk o
ua
sealing flange. ir se
d ran
tee
tho
or
– ss
au
Screw bolts alternately (max. 1 /2 turn (180°) for each bolt) into ac
sealing flange, and press sealing flange together with sender
ce
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nl
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wheel off crankshaft. du
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spec
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2.2.2 Pressing in sealing flange with sender
rrectness of i
wheel
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nf
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Note
orm
m
atio
m
♦ The sealing flange with a PTFE seal is equipped with a sealing

o
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or c
cardiagn.com
lip support ring. This support ring serves as a fitting sleeve and
thi
e
must not be removed prior to installation.

t
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♦ Sealing flange and sender wheel must not be separated or
o
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f
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turned after removal from packaging.

t.
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Cop py
♦ The sender wheel is held in its installation position on the as‐
t. rig
gh ht
yri by
sembly device - T50010- by a locating pin. cop Vo
by lksw
cted agen
Prote
♦ Sealing flange and oil seal form one unit and must only be
AG.
renewed together with the sender wheel.

♦ The assembly device - T50010- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
Assembly tool - T50010-

A - Clamping surface
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pins

Crafter 2006 ➤
2.2.3 A - Fit seal with sender wheel on as‐

sembly tool - T50010-
– Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.
AG. Volkswagen AG d
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– Clamp assembly device - T50010- in a vice on clamping sur‐
ole,
spec
face -A- of threaded spindle.
t to the co
– Press assembly housing -C- downwards until it lies on hexa‐
gon nut -B- -arrow-.
cardiagn.com
– Screw hexagon nut onto threaded spindle until inner part of
rrectne
assembly device and assembly housing are at same height.
ss o
cial p
f inform
mer
atio
om
n
c
i
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– Remove securing clip -arrow- from new sealing flange.

iv
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fo
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Caution
Co
Cop py
t. rig
gh ht
yri by
The sender wheel must not be taken out of the sealing flange op Vo
by c lksw
or twisted. cted agen
Prote AG.
– Locating hole -A- on sender wheel -C- must align with mark
(notch) -B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat
surface.

AG. Volkswagen AG d
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horis Crafter
nte 2006 ➤
eo
aut 5-cylinder diesel engine - Edition r03.2016
ac
ss
ce
le
un
pt
– Push sealing lip support ring -A- downwards in direction of ar‐
an
d
itte
row until it lies on flat surface.
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
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com
tion in
r
te o
thi
s
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fo
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ng
t.
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op
cardiagn.com
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Place sealing flange with front side on assembly tool - T50010-

so that locating pin -B- can be inserted in sender wheel hole
-A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T50010- whilst tightening three
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2.2.4 B - Fit assembly tool - T50010- with seal‐

ing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.

Crafter 2006 ➤
– Screw hexagon nut -B- to end of threaded spindle.

– Press threaded spindle of assembly tool - T50010- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing
agen on sump sideAG
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ab
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ot p
– Secure assembly tool - T50010- to crankshaft flange using
wit
, is n
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hexagon socket head bolts -A-.
hole
spec
es, in part or in w
t to the co
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
rrectness of i
prox. 5 full turns).
cardiagn.com
l purpos
nf
ercia
orm
m
atio
om
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or c
– To guide sealing flange, screw two M6x35 mm bolts -A- into

thi
te
sd
a
cylinder block.
iv
o
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rp
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f
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
2.2.5 C - Bolting assembly tool - T50010- onto

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin -D- into crankshaft bore. This ensures that the
sender wheel reaches its final installation position.
– Tighten both hexagon socket head bolts of assembly tool -
T50010- hand-tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.

Crafter 2006 ➤
2.2.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T50010-
– Tighten hexagon nut of assembly tool - T50010- using torque
wrench - V.A.G 1331- and flared ring spanner tool insert AF
24 - V.A.G 1332/11- .
Specified torque
Component Specified torque
Hexagon nut of assembly tool - 35 Nm
T50010-
Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and asealing
gen AG flange. n AG do
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2.2.7 E - Checking sender wheel installation ho
cardiagn.com
t or
au ac
positions on crankshaft
s
ce
e
nl
pt
du
an
– Screw hexagon nut -E- to end of threaded spindle.
itte
y li
erm
ab
– Remove the two bolts -A- from cylinder block.
ility
ot p
wit
, is n
– Remove assembly tool - T50010- .
h re
hole
– Remove sealing lip support ring.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– The sender wheel is in the correct installation position on the

m
at
crankshaft if a gap -a- of 0.5 ± 0.1 mm exists between crank‐

om
io
shaft flange -A- and sender wheel -B-.

n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Set vernier gauge on crankshaft flange.

– Measure the distance -a- between crankshaft flange and
sender wheel.
If dimension -a- is too small:
– Re-press sender wheel ⇒ page 32 .
If dimension -a- is achieved:
– Tighten the new securing bolts for the sealing flange using al‐
ternate and diagonal sequence.
– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt.
– Install sump ⇒ page 76 .
– Pull out locking pin - T50009- .
– Screw sealing plug into cylinder block.
– Install flywheel using new bolts.
cardiagn.com
– Install gearbox ⇒ Rep. gr. 34 .
– Install upper toothed belt guard.
Specified torques
♦ ⇒ “2.1 Assembly overview - flywheel”, page 23
♦ ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page
17
Engine speed sender - G28- 5 Nm
lkswage es n
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2.2.8 F - Re-pressing sender wheel ho
ir se
d ran
tee
ut or
a ac
– Secure assembly tool - T50010- to crankshaft
ss flange using
hexagon socket head bolts -A-.
ce
le
un
pt
an
d
itte
– Hand tighten both hexagon socket head bolts.

y li
erm
ab
– Push assembly tool - T50010- by hand to sealing flange.

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d Crafter 2006 ➤
agen oes 5-cylinder diesel engine - Edition 03.2016
olksw not
byV gu
ara
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ris nte
– Screw hexagon ho nut -E- onto threaded spindle by hand until e o it
ut
lies on assembly
ss a housing -C-. ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Tighten hexagon nut of assembly tool - T50010- using torque
l purpos
wrench - V.A.G 1331- and flared ring spanner tool insert AF

24 - V.A.G 1332/11- .
nf
ercia
o
Specified torque
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
T50010-
cardiagn.com
o
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o
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f
en
ng
– Check installation position of sender wheel on crankshaft

t.
yi Co
again ⇒ page 31 . Cop py
ht. rig
rig ht
If dimension -a- is too small again: py by
co Vo
by lksw
cted agen
– Tighten hexagon nut using assembly tool - T50010- as follows: Prote AG.

T50010-
– Check installation position of sender wheel on crankshaft
again ⇒ page 31 .
2.3 Removing and installing flywheel


. Volkswagen AG
Crafter 2006 ➤ wage
n AG does
olks not
5-cylinder diesel engine - Edition
d b 03.2016
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♦ Counterhold tool - 3386- au
t ra
c
ss
ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
• Clutch is removed.
nf
ercia
orm
To do this, lock flywheel using counter-hold tool - 3386- .
m
atio
om
n in
– Rotate flywheel so that the bolts align with the holes.
or c
thi
te
sd
– When removing bolts, make sure that screw heads do not jam
iva
o
r
on flywheel.
rp
cu
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o
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f
en
ng
– Unbolt flywheel.
t.
yi Co
Cop py
. rig
Installing
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - flywheel”, page 23
2.4 Renewing needle bearing in flywheel

♦ Internal puller - Kukko 21/2- and counterhold - Kukko 22/1-
♦ Punch - 3264-

Crafter 2006 ➤
Removing
– Remove needle bearing using internal puller - Kukko 21/2- and
counterstay - Kukko 22/1- -A-.
Installing
– Drive in needle bearing to stop using drift - 3264- .
cardiagn.com
AG. Volkswagen AG d
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un
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ab
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ot p
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spec
t to the co
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cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
3 Power take-off
⇒ “3.1 Engine power take-off”, page 36
⇒ “3.2 Removing and installing poly V-belt for power take-off”,
page 36
3.1 Engine power take-off

Engine code BJL only
Note
There are two power take-off variants!
1. variant: Power take-off -A- with additional air conditioner com‐

pressor
lkswage es n
o ot g
yV
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d b ua
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tho
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2. variant: Power take-off -A- with preparation for hydraulic pump

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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3.2 Removing and installing poly V-belt for

s
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rp
power take-off
um
fo
en
ng
t.
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op
Special tools and workshop equipment required C py
t. rig
gh ht
yri by
♦ Assembly tool - T50016- cop Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
Note
♦ Before using for the first time, deburr the running groove ends
-arrows- of the assembly tool - T50016- -1- for the poly V-belt
pulley.
♦ Deburring is necessary to avoid possible poly V-belt pulley
damage/destruction.
Caution
♦ There is a risk of injury because of the high tension when

removing and installing the poly V-belt.
♦ Once fitted, a poly V-belt must not be removed using the
assembly tool - T50016- , but must always be cut.
Removing
cardiagn.com
Note
Once fitted, a poly V-belt must always be cut in order to remove

it.
– Use, for example, a commercially available

n AG. Vcraft
olkswaknife for
gen AG re‐
moving the poly V-belt. lkswage does
not
Vo gu
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Installing ed nte
oris eo
th
au ra
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Note
nl
pt
du
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♦ The assistance of a second mechanic is required to install the

ab
ility
poly V-belt.
ot p
wit
, is n
♦ Before installing the poly V-belt, ensure that all sub-assem‐

h re
hole
blies (air conditioner compressor, hydraulic pump) have been

spec
installed securely.
es, in part or in w
t to the co
♦ When installing poly V-belt, check direction of belt rotation and

proper seating of belt in pulleys.
rrectness of i
l purpos
– Place assembly tool - T50016- on belt pulley.

– Secure assembly tool - T50016- with knurled screw -1-.
nform
ercia
– Place poly V-belt -2- first on belt pulley/vibration damper and

m
then in assembly tool - T50016- , as shown in illustration.

at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Power take-off 37
Crafter 2006 ➤
– Position an appropriate 17 mm ring spanner -1- on assembly

tool - T50016- .
Note
The assistance of a second mechanic is required to fit the poly V-

belt.
– Use 17 mm ring spanner -1- to turn belt pulley carefully in

. Volkswagen AG
-direction of arrow-. swa
gen AG does
olk not
yV gu
– To provide support, poly-V-belt -2- is pulled downwardsise
d b by 2nd ara
nte
mechanic and is simultaneously guided into beltthpulley
or running eo
grooves. ss au ra
c
ce
e
– Then remove assembly tool - T50016- .
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
Ensure the belt is properly seated in pulleys.
hole
spec
es, in part or in w
cardiagn.com
After completing repairs always:
t to the co
– Start engine and check belt running.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
4 Crankshaft
⇒ “4.1 Assembly overview - crankshaft”, page 39
⇒ “4.2 Crankshaft dimensions”, page 40
4.1 Assembly overview - crankshaft
Note
When carrying out repairs, secure engine to engine and gearbox

support - VAS 6095- .
1 - Drive for oil pump

❑ With 4 drive lugs.
❑ Break open to pull off.
❑ Heat new drive piece to
max. 200°C before fit‐
ting.
cardiagn.com
2 - Bearing shells 1, 2, 3, 5 and
6
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
AG. Volkswagen AG d
❑ Do not interchange agen oes
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used bearing shells d byV gu
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(mark). orise nte
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3 - Bearing cap ss a c
ce
le
❑ Bearing cap 1: belt pul‐

un
pt
an
ley end.
d
itte
y li
rm
ab
❑ Bearing cap 4 with re‐
pe
ility
cesses for thrust wash‐
ot
wit
ers.
, is n
h re
hole
❑ Bearing shell retaining

spec
lugs in cylinder block
es, in part or in w
and bearing caps must

t to the co
align.
4 - Bolt
rrectness of i

l purpos
❑ To measure radial clear‐

ance, tighten to 65 Nm
but not further.
nform
ercia
❑ 65 Nm + 90°
m
a
com
tio
5 - Crankshaft
n in
r
te o
thi
❑ Axial clearance when

s
iva
do
new: 0.07 … 0.23 mm; Wear limit: 0.25 mm.

r
rp
cum
fo
❑ Do not rotate crankshaft when checking radial clearance.

en
ng
t.
yi Co
❑ Measure radial clearance using Plastigage; new: 0.016…0.075 mm; wear limit: 0.16 mm. ht. Cop py
rig
❑ Crankshaft dimensions ⇒ page 40 . rig ht
py by
co Vo
by lksw
6 - Thrust washer
cted agen
Prote AG.
❑ For bearing cap 4.

❑ Note fixing arrangement.
4. Crankshaft 39
Crafter 2006 ➤
7 - Bearing shell 4
❑ For bearing cap without oil groove.
❑ For cylinder block with oil groove.
8 - Thrust washer
❑ For cylinder block, bearing 4.
9 - Cylinder block
❑ Dismantling and assembling pistons and conrods ⇒ page 41
n AG. Volkswagen A G do
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Volks ot g
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4.2 Crankshaft dimensions tho
or
s au ac
s
(Dimensions in mm)
ce
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un
pt
an
d
itte
Honing dimen‐ Crankshaft bearing Conrod
y li
rm
ab
sion journal diameter journal diameter
pe
ility
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wit
Basic dimension 58.00 -0.022 50.90 -0.022
, is n
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-0.042 -0.042
hole
spec
Stage I 57.75 -0.022 50.65 -0.022
es, in part or in w
-0.042 -0.042
t to the co
cardiagn.com
Stage II 57.50 -0.022 50.40 -0.022
-0.042 -0.042
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Stage III 57.25 -0.022 50.15 -0.022
-0.042 -0.042
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Crafter 2006 ➤
5 Pistons and conrods

⇒ “5.1 Assembly overview - pistons and conrods”, page 41
⇒ “5.2 Checking piston and cylinder bore”, page 42
⇒ “5.3 Measuring piston projection at TDC”, page 43
⇒ “5.4 Piston and cylinder dimensions”, page 44
5.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 42 .
❑ Checking ring-to-groove
cardiagn.com
clearance ⇒ page 42 .
2 - Piston
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Arrow on piston crown
points to belt pulley end. en AG. Volkswagen AG
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❑ Remove and install us‐

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5 - Conrod
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❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
5. Pistons and conrods 41

Crafter 2006 ➤
❑ Do not rotate crankshaft when checking radial clearance.
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 43 .
❑ Piston and cylinder dimensions ⇒ page 44 .
8 - Conrod bearing cap
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the caps
only fit in one position and only on the appropriate conrod.
9 - Oil spray jet
❑ For piston cooling.
10 - Bolt
❑ Insert with sealant ⇒ Electronic Parts Catalogue (ETKA) .
❑ 8 Nm
11 - Conrod bolt
cardiagn.com
❑ Oil threads and contact surface.
❑ Use old bolt for measuring radial clearance.
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Test procedure
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– Push piston ring squarely from above down to approx. 15 mm
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Piston ring New Wear limit
dimensions in mm
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1st compression ring 0.20 … 0.40 1.0
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2nd compression ring 0.20 … 0.40 1.0

Oil scraper ring 0.25 … 0.50 1.0
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Checking ring-to-groove clearance

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Crafter 2006 ➤
Test procedure
– Clean ring groove before checking.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
Checking cylinder bores

♦ Cylinder gauge 50…100 mm
Test procedure
– Take measurements at 3 positions in both transverse -A- and
longitudinal -B- directions, as illustrated.
cardiagn.com
Difference between actual and nominal diameter max. 0.08 mm.
Nominal dimension ⇒ page 44
Note
Cylinder bores must not be measured when cylinder block is

mounted on engine and gearbox supporto-lkVAS 6095- , as meas‐
urements may be incorrect. swagen AG. V swagen AG does
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♦ Measuring bridge - VW 382/7-

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5. Pistons and conrods 43

Crafter 2006 ➤
♦ End dimension plate - VW 385/17-
♦ Dial gauge
Test procedure
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Check piston projection at TDC when installing new pistons or oa
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Cylinder head gasket identification ⇒ page 48 .
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5.4 Piston and cylinder dimensions
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Honing dimen‐ Piston diameter Cylinder bore ∅

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Basic dimension mm 80.96 81.01
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Crafter 2006 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 45
⇒ “1.2 Removing and installing cylinder head”, page 48
⇒ “1.3 Removing and installing cylinder head cover”, page 51
⇒ “1.4 Checking compression”, page 52
1.1 Assembly overview - cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between bucket tappets and cams
must be oiled after installation.
♦ The plastic protectors fitted to protect the open valves must be
cardiagn.com
removed only immediately before the cylinder head is fitted.
♦ When cylinder head is renewed, the complete coolant must be
renewed.
AG. Volkswagen AG d
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AG.
1. Cylinder head
Crafter 2006 ➤
1 - Pressure regulating valve

❑ With oil separator.
2 - Bolt
❑ 9 Nm
3 - O-ring
4 - Bolt
❑ 20 Nm
5 - Cylinder head cover
❑ With seal.
⇒ page 51
6 - Cylinder head bolt
❑ Observe sequence n AG. Volkswagen AG do
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tightening ⇒ page 48 . d b ua
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7 - Glow plug 1 - Q10- to glow aut or
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plug 5 - Q14- ss
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❑ Observe handling of ce‐
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⇒ page 189 .
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⇒ page 190
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8 - Injector (piezo injectors)
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⇒ page 125
9 - Bolt
❑ 22 Nm rrectness of i
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10 - Dished washer
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❑ If they are to be re-installed, the injectors and retainers must always be re-fitted in the same cylinder.
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13 - Lifting eye
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❑ 20 Nm
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16 - Vacuum pump
17 - Plunger
18 - High-pressure accumulator
❑ ⇒ Item 13 (page 120)
19 - Bolt
❑ 30 Nm
20 - Bolt
❑ 9 Nm
46 Rep. gr.15 - Cylinder head, valve gear

Crafter 2006 ➤
21 - Cap
22 - Rear toothed belt guard
23 - Bracket
❑ For Hall sender - G40- .
24 - Bolt
❑ 20 Nm
25 - Cylinder head gasket
❑ Position: Part number faces cylinder head and must be readable beneath 4th cylinder glow plug
❑ After replacing, renew entire coolant.
❑ Note marking ⇒ page 48 .
26 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning ⇒ page 57 .
cardiagn.com
27 - Bolt
❑ Use counterhold - 3036- to loosen and tighten.
❑ 100 Nm
28 - Camshaft pulley
❑ To remove, use two arm puller - T40001- .
29 - Cylinder head
❑ Check for distortion ⇒ page 47 .
❑ After replacing, renew entire coolant.
30 - Oil filler neck AG. Volkswagen AG d
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❑ Renew gasket if damaged or leaking.

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33 - Hose
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❑ To intake hose ⇒ Item 1 (page 149)

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Crafter 2006 ➤
AG. Volkswagen AG d
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Reworking diesel cylinder heads is not permissible.
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Note notches/holes -arrow-.
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Note
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♦ Different thicknesses of cylinder head gasket are fitted de‐
pending on the piston projection. When renewing gasket,
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install new gasket with same identification.

♦ If parts of the crankshaft drive have been renewed, the new
nform
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cylinder head gasket must be determined again by measuring

the piston projection at TDC ⇒ page 43 .
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1.2 Removing and installing cylinder head
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♦ Sandpaper

Crafter 2006 ➤
Removing
Caution

tions:
sitions.
– Drain coolant ⇒ page 93 .

– Remove intake manifold flap motor - V157- and exhaust gas
recirculation valve - N18- ⇒ page 146 .
cardiagn.com
– Remove exhaust gas recirculation cooler (if fitted) from cylin‐
der head ⇒ Item 12 (page 188) .
G. Volkswagen
– Remove turbocharger ⇒agItem
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– Remove dip stick
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Always read rules for cleanliness and instructions for working

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Follow these instructions before starting work and while work‐

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– Clamp off all necessary fuel lines/hoses.

– Remove bracket ⇒ Item 15 (page 121) from high-pressure
rrectness of i
accumulator.
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– Separate all connection, coolant, vacuum and intake hoses

from cylinder head.
nform
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– Pull off/disconnect all electrical connections as necessary

from cylinder head and lay them to one side.
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– Remove vacuum pump ⇒ Item 16 (page 46) with plunger

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⇒ Item 17 (page 46) .

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– Remove toothed belt ⇒ page 57 .

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– Remove cylinder head cover.

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– Unbolt coolant pipe from cylinder head. t. C rig
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– Remove camshaft pulley ⇒ page 59 .
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– Remove rear toothed belt guard.
1. Cylinder head 49
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– Maintain sequence when
tho loosening cylinder head bolts. or
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– Remove cylinder head.
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Note
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The cylinder head must be guided carefully to prevent damage.
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Installing
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Note
ss
♦ There must be no oil or coolant in the cylinder head bolt pock‐
o
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ets in the cylinder head.
nform
mer
♦ Do not remove new cylinder head gasket from its packing until
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immediately before installing.

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♦ Handle new gasket with extreme care. Damage will cause
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♦ Renew cylinder head bolts.
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– Place clean cloths in cylinders so that no dirt or emery cloth gh ht
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– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure that surfaces are not scored or scratched
(if abrasive paper is used, grade must not be less than 100).
– Carefully remove metal particles, emery residue and cloths.
– If crankshaft is turned in the meantime, position piston of No.
1 cylinder at TDC and turn crankshaft back slightly.
– Fit new cylinder head gasket.
Note
♦ Note identification on cylinder head gasket ⇒ page 48 .

♦ Position: Part number faces cylinder head and must be read‐
able beneath 4th cylinder glow plug.
– Fit cylinder head.

– Insert new cylinder head bolts and tighten hand-tight.

Crafter 2006 ➤
– Tighten cylinder head bolts as follows in the sequence shown:

Stage Tighten
1 – Tighten to 35 Nm using torque wrench.
2 – Tighten to 60 Nm using torque wrench.
3 – Turn 90° further (1/4 turn) using a rigid wrench.
4 – Turn 90° further (1/4 turn) using a rigid wrench.
Note
♦ After repair work it is not necessary to retighten the cylinder

head bolts.
♦ When camshaft is turned, crankshaft must not be at TDC.
Danger of damage to valves and piston crowns.
– Install toothed belt and adjust the valve timing ⇒ page 57 .

cardiagn.com
Specified torques
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♦ ⇒ “1.1 Assembly overview
Vol
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♦ ⇒ “6.1 Assembly
or overview - intake manifold”, page 146 tee
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♦ ⇒ “1.1 Assembly overview - turbocharger (engine codes BJJ,

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BJK, BJL, BJM)”, page 106

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♦ ⇒ “1.2 Assembly overview - turbocharger (engine codes CE‐

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BA, CEBB, CECA, CECB)”, page 108

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1.3 Removing and installing cylinder head

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Removing Prote AG.

– Remove intake manifold flap motor - V157- and exhaust gas
recirculation valve - N18- ⇒ page 146 .
– Remove fuel accumulator ⇒ Item 1 (page 120) (fuel hoses
remain connected).
– Pull hose off pressure control valve.
– Remove bracket ⇒ Item 7 (page 146) .
1. Cylinder head 51
Crafter 2006 ➤
– Remove oil filler neck ⇒ Item 30 (page 47) .

– Remove cylinder head cover.
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 45
♦ ⇒ “6.1 Assembly overview - intake manifold”, page 146
♦ ⇒ “1.2 Assembly overview - fuel system”, page 119
1.4 Checking compression

equipment required
♦ U/J extension and socket,
10 mm - 3220-
cardiagn.com
♦ Torque wrench -
V.A.G 1331-
♦ Adapter - V.A.G 1381/12-
♦ Compression tester -
V.A.G 1763-
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Prote AG.
Rep. gr.15 - Cylinder head, valve gear
Crafter 2006 ➤
Test procedure
Caution
G. Volkswage
♦ Observe instructions
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ceramic
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⇒ page 189
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Test prerequisites
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• Engine oil temperature must be at least 30°C.
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• The battery voltage must be at least 11.5 V.
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• If the vehicle is equipped with an air conditioner, it must be
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Test sequence:
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– Pull connectors off at injectors.
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– Pull off connector for high-pressure pump and central con‐
cardiagn.com
nector for ceramic glow plugs.
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– Remove ceramic glow plugs ⇒ page 190 .

m
– Pull fuse 6 ( fuel system pressurisation pump - G6- ) out of fuse at

om
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holder “C” on left A-pillar ⇒ Current flow diagrams, Electrical
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fault finding and Fitting locations.

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1. Cylinder head 53
Crafter 2006 ➤
– Screw in adapter - V.A.G 1381/12- into first cylinder in place

of ceramic glow plugs and connect compression tester - V.A.G
1763- .
Note
♦ Using the compression tester ⇒ Operating instructions .

♦ Avoid allowing the high-pressure pump to run dry under all
circumstances.
– Operate starter until tester shows no further pressure in‐

crease.
– Test all cylinders in succession; avoid letting the high-pressure
pump run dry due to excessively long starter actuation.
Compression pressures:
New: 25 ... 31 bar.
Wear limit: 21 bar agen
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Maximum permissible difference between all cylinders: 5 bar yV gu
cardiagn.com
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After the test has been completed: ut
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– Install ceramic glow plugs ⇒ page 190 .
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– Connect connector for high-pressure pump and central con‐
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nector for ceramic glow plugs.
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– Install fuse for fuel pump.
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Note
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♦ The high-pressure pump must first be filled with fuel before the
engine is started ⇒ page 122 .
rrectness of i
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circumstances.
– Check fuel system for leaks ⇒ page 122 .
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Note
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Faults will have been stored in the memory because connectors

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clear it, if necessary ⇒ Vehicle diagnostic tester.

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– Carry out a road test. Observe applicable safety precautions
rig ht
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during road test ⇒ page 5 .
co lksw
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Crafter 2006 ➤
2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt”, page 55
⇒ “2.2 Removing and installing toothed belt”, page 57
2.1 Assembly overviewG. V-otoothed

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❑ Mark direction of rota‐
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❑ Removing, installing
spec
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⇒ page 57 .
3 - Bolt
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❑ 20 Nm
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4 - Bolt
❑ Use counterhold - 3036-
to loosen and tighten.
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❑ 100 Nm
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5 - Camshaft pulley tion in

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❑ To remove, use two arm

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puller - T40001- .
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⇒ page 57 .
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6 - Idler pulley
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7 - Nut
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❑ Threads and contact
surfaces must be oiled
❑ Use counterhold tool -
3036- to loosen and
tighten.
❑ 45 Nm
8 - Toothed belt pulley
❑ For high-pressure pump
9 - Bolt
❑ 20 Nm
10 - Bolt
❑ 9 Nm
11 - Bracket
❑ For Hall sender - G40- .
12 - Cap
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ 9 Nm
2. Toothed belt drive 55

Crafter 2006 ➤
16 - Hall sender - G40-

❑ To remove:
Remove toothed belt ⇒ page 57 .
Remove rear toothed belt guard ⇒ Item 13 (page 55)
17 - Idler pulley
18 - Bolt
❑ 10 Nm + 90°
19 - Crankshaft pulley
20 - Toothed belt guard lower part
21 - Bolt
❑ 9 Nm
22 - Bolt
❑ 20 Nm
23 - O-ring
cardiagn.com
24 - Coolant pump
❑ Check for ease of movement.
❑ If damaged or leaking, renew complete.
25 - Tensioning roller
26 - Bolt AG. Volkswagen AG d
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27 - Bolt aut
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28 - Toothed belt guard

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Prote AG.

Crafter 2006 ➤
5-cylinder
wagen Adiesel
G. Volksengine -
wagen AG Edition
doe 03.2016
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Vol t gu
by ara
2.2 Removing and installing toothed belt ed
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nl
pt
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equipment required
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♦ Two-arm puller - T40001-
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♦ Torque wrench -
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V.A.G 1332-
hole
spec
♦ Counterhold tool - T10025-
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t to the co
♦ Torque wrench -
V.A.G 1331-
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♦ Setting bar - 2065 A- l purpos
♦ Counterhold tool - 3036-
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Prote AG.


Crafter 2006 ➤
♦ Locating pin - T50009-
Removing
– Remove viscous fan ⇒ page 104 .
– Remove cowling ⇒ Item 6 (page 102) .
– Remove belt pulley for viscous fan.
cardiagn.com
– Remove guide roller ⇒ Item 9 (page 18) from bracket.
– Remove upper toothed belt guard.
– Remove cylinder head cover ⇒ page 51 .
– Locate counter-hold tool - T10025- and loosen centre bolt of
crankshaft vibration damper/toothed belt sprocket.
– Loosen 4 securing bolts for crankshaft vibration damper/tooth‐
ed belt sprocket.
olkswagen AG
en AG. V
– Turn crankshaft in direction of engine rotation to TDC for oNo.
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ag does
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Note
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Turn crankshaft until mark on camshaft pulley aligns with mark on

rear toothed belt guard -arrows-.
rrectness of i
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ate
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priv
cum
for
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t.
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Cop py
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by c lksw
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Prote AG.

Crafter 2006 ➤
– Unscrew sealing plug from cylinder block -arrow-. Crankshaft

TDC bore must be visible.
– Insert locking pin - T50009- into bore. This stops the crank‐
shaft turning.
Note
♦ If crankshaft cannot be locked, turn it back and forth a few

times.
cardiagn.com
♦ No torque must be transferred to locking pin - T50009- .
– Unscrew 4 securing bolts for crankshaft vibration damper/

toothed belt sprocket.
– Unscrew centre bolt for vibration damper.
– Remove vibration damper.
– Remove toothed belt guard ⇒ page 55 .
– Mark direction of rotation of toothed belt.
– Release tension at toothed belt tensioning roller using open
ring spanner, 32 mm - 3355- . gen AG
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d a oes
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– Remove toothed belt. Vol gu
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Installing tho eo
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• Crankshaft locked in position with locking pin - T50009- .

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– Remove bearing cap and oil seal for camshaft ⇒ page 63 .

ility
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– Re-install bearing cap.

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hole
spec
– Lock camshaft using adjustment bar - 2065 A- .

es, in part or in w
t to the co
– Align adjustment bar - 2065 A- as follows: Turn locked cam‐

shaft until one end of adjustment bar contacts cylinder head.
Measure gap at other end of adjustment bar with a feeler
rrectness of i
gauge. Slide a feeler gauge, of half of gap, between adjust‐

ment bar and cylinder head. Now turn camshaft until end of
l purpos
adjustment bar contacts feeler gauge. Now slide a second

feeler gauge, of same dimension as other feeler gauge, be‐
nform
ercia
tween adjustment bar and cylinder head.

m
– Loosen securing bolt for camshaft pulley 1/2 turn; use coun‐
at
om
ion
terhold - 3036- for this.

c
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or
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ate
do
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cum
for
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Cop py
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by c lksw
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Prote AG.

olkswagen AG
en AG. V
Crafter 2006 ➤ ksw
ag does
not
Vol
5-cylinder diesel engine - Edition 03.2016 ed by gu
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– Pull camshaft pulley off with two arm puller
ss - T40001-
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pt
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ab
ility
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hole
spec
es, in part or in w
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– Turn camshaft pulley until mark on camshaft pulley aligns with

mark on rear toothed belt guard -arrows-.
nf
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install tensioning roller -1- so that tensioning roller tab -2- lies
over pin on toothed belt lower guard.
– Fit toothed belt. Note direction of rotation with used belts.
– Tighten securing bolt finger-tight.

Crafter 2006 ➤
– To tension toothed belt, turn belt tensioner clockwise (direction

of arrow) using open ring spanner, 32 mm - 3355- until right
edge of indicator -A- aligns with right edge of indicator -B-.
Note
♦ Right edge of indicator -A- must not pass beyond right edge
of indicator -B- otherwise there is a danger of damaging the
belt tensioner.
♦ If it has been turned too far, relieve tension on belt tensioner
completely and retension again. The eccentric must not simply
be turned back by the amount it has been turned too far.
– Tighten securing bolt for tensioning roller.

– Tighten camshaft wheel securing bolt using counterhold -
3036- .
– Remove adjustment bar - 2065 A- and locking pin - T50009- .
– Install toothed belt guard ⇒ page 55 .
– Position vibration damper with new washer and new centre
cardiagn.com
bolt.
– Insert counterhold - T10025- into vibration damper.

– Tighten new central bolt.
– Tighten 4 new securing boltsgefor vibration
n AG. Volkswagdamper/crankshaft
en AG
does
pulley. Volkswa not
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– Turn crankshaftotwo
ris rotations in engine direction of rotation
e ran
tee
until crankshaft
au is set to TDC No. 1 cylinder again.
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– Check belt tensioner indicator position again. If the right edges

spec
of indicators -A- and -B- do not align, the tensioning procedure

es, in part or in w
t to the co
must be repeated.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Insert locking pin - T50009- into bore.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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un
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Mark on camshaft pulley must be located in shaded area

itte
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-arrows-.
ab
ility
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– Remove locking pin - T50009- .
wit
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t to the co
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rrectness o
cial p
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mer
– Screw sealing plug into cylinder block -arrow-.

atio
m
– Install bearing cap and oil seal for camshaft ⇒ page 63 .

o
n
c
i
or
n thi
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– Installing poly V-belt ⇒ page 19 .

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sd
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– Installing viscous fan ⇒ page 104 .

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Specified torques
Co
Cop py
ht. rig
♦ ⇒ “2.1 Assembly overview - toothed belt”, page 55 rig ht
py by
co Vo
by lksw
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 45 cted agen
Prote AG.

♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 102

Crafter 2006 ➤
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 63
⇒ “3.2 Measuring axial play of camshaft”, page 64
⇒ “3.3 Removing and installing camshaft”, page 65
⇒ “3.4 Removing and installing valve stem seals”, page 66
3.1 Assembly overview - valve gear
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
1 - Bearing cap
❑ Bearing cap 1: camshaft
cardiagn.com
sprocket end
❑ When installing, seal
parting surface of bear‐
ing caps 1 and 4 with AG. Volkswagen AG d
silicone adhesive seal‐ lksw
agen oes
not
ant ⇒ Electronic d by VParts
o gu
ara
Catalogue o(ETKA)
ris
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th eo
❑ Installation
s au position ra
c
⇒ page 64 .
s
ce
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nl
pt
❑ Installation sequence
du
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itte
⇒ page 65 .
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ility
2 - Nut
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❑ 20 Nm
h re
hole
spec
3 - Camshaft
es, in part or in w
❑ Checking radial clear‐

t to the co
ance with Plastigage;

wear limit: 0.11 mm.
rrectness of i
❑ Runout: max. 0.01 mm.

❑ Checking axial clear‐
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ance ⇒ page 64 .
nf
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⇒ page 65 .
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4 - Bucket tappet
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❑ Do not interchange.
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❑ With hydraulic valve

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clearance compensa‐
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❑ Set down with contact C py
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surface facing upwards.
gh ht
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Vo
co
❑ Oil contact surface.
by lksw
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Prote AG.
❑ Before installing, check
camshaft axial clearance ⇒ page 64 .
5 - Cotters
6 - Valve spring plate
7 - Valve spring
❑ Cylinder head removed: Remove and install using valve spring compressor - 2037- .
3. Valve gear 63
Crafter 2006 ➤
❑ Cylinder head installed ⇒ page 66 .
8 - Valve stem seal AG. Volkswagen AG d
agen oes
❑ Renew. ⇒ page 66 . olksw not
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9 - Repair valve guide horis nte
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❑ Repair guide with collar. ss a ra
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❑ Checking ⇒ page 70 .
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10 - Seal
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❑ To remove and install remove bearing cap 4 ⇒ Item 1 (page 63) .
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11 - Cylinder head hole
spec
es, in part or in w
❑ See note ⇒ page 63 .
t to the co
❑ Reworking valve seats ⇒ page 69 .
12 - Valves
rrectness of i
❑ Valve dimensions ⇒ page 72
l purpos
13 - Seal
❑ To remove and install, remove bearing cap 1 ⇒ Item 1 (page 63) and toothed belt ⇒ page 57 .
nform
ercia
cardiagn.com
14 - Valve guide
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Installation position of camshaft bearing caps
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Note that bearing caps are not symmetrical. Before installing rig ht
py by
camshaft, fit bearing caps and determine installation positions. co Vo
by lksw
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3.2 Measuring axial play of camshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge

Crafter 2006 ➤
Check with bucket tappets removed and first and last bearing
caps fitted.
Wear limit: max. 0.15 mm
3.3 Removing and installing camshaft

cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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Removing
un
pt
an
d
itte
– Remove toothed belt and camshaft pulley ⇒ page 57 .

y li
rm
ab
pe
ility
– Remove vacuum pump ⇒ Item 16 (page 46) with plunger

ot
wit
⇒ Item 17 (page 46) .

, is n
h re
hole
– First remove bearing caps 1 and 3. Then loosen bearing caps

spec
2 and 4 alternately and diagonally.

es, in part or in w
t to the co
Installing
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Valve gear 65
Crafter 2006 ➤
Note
♦ When camshaft is installed, No. 1 cylinder cams must point

upwards.
♦ When installing bearing caps, note that caps are not symmet‐
rical; before installing bearing cap, set in place and determine
fitting position.
♦ Seal parting surface of bearing caps 1 and 4 with silicone ad‐
hesive sealant ⇒ Electronic Parts Catalogue (ETKA) .
– Oil cam contact surfaces of camshaft.

– Initially tighten bearing caps 2 and 4 alternately and diagonal‐
ly, then tighten them to specified torque.
– Install bearing caps 1 and 3.
– Install toothed belt ⇒ page 57 . lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Note auth or
ac
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ss
ce
le
When new bucket tappets have been installed the engine must
un
pt
an
d
not be started for about 30 minutes. The hydraulic compensation

itte
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elements must settle (otherwise valves will strike pistons).
erm
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ility
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Specified torques
h re
ole,
spec
♦ ⇒ “3.1 Assembly overview - valve gear”, page 63
t to the co
rrectne
3.4 Removing and installing valve stem seals
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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ara
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aut
h
ra Crafter 2006 ➤
s c
s 5-cylinder diesel engine - Edition 03.2016
ce
e
nl
pt
du
an
itte
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erm
equipment required
ab
ility
ot p
♦ Valve assembly device -
wit
, is n
2036-
h re
hole
spec
♦ Puller - 3047 A-
es, in part or in w
t to the co
♦ Fitting tool - 10 - 204-
♦ Valve lever - VW 541/1 A-
rrectness of i
♦ Thrust piece for VW 541 / 1
l purpos
A and 2037 - VW 541/5-
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mercia
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c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
cardiagn.com
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– Remove camshaft ⇒ page 65 .
– Remove bucket tappets (do not interchange) and store with
cam contact surface upwards.
– Set piston of relevant cylinder to top dead centre (TDC).
– Insert valve assembly device - 2036- and adjust mounting to
height of studs.
– Remove valve springs using valve lever - VW 541/1 A- and
press tool for VW 541 / 1 A and 2037 - VW 541/5- .
Note
The valves are supported by the piston crown.
3. Valve gear 67
Crafter 2006 ➤
– Pull off valve stem seals using puller - 3047 A- .

Installing
lkswage es n
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a ac
ss
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un
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d
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ab
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ility
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– To prevent damage to new valve stem seals, place plastic
, is n
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sleeve -A- on valve stem.
hole
spec
– Lightly lubricate sealing lip of valve stem seal -B-.
es, in part or in w
t to the co
– Slip valve stem oil seal over plastic sleeve.
– Carefully press valve stem seal onto valve guide using press
rrectness of i
tool fitting tool - 10 - 204- .
l purpos
cardiagn.com
– Remove plastic sleeve.
Specified torques
nform
ercia
♦ ⇒ “3.1 Assembly overview - valve gear”, page 63

m
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com
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te o
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
4 Inlet and exhaust valves

⇒ “4.1 Reworking valve seats”, page 69
AG. Volkswagen AG d
agen oes
⇒ “4.2 Checking valve guides”, page 70 Volksw not
gu
d by ara
e
⇒ “4.3 Removing and installing valve guides”, page horis70 nte
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aut ra
⇒ “4.4 Valve dimensions”, page 72 ss c
ce
e
nl
pt
4.1 Reworking valve seats
du
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♦ Depth gauge , is n
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♦ Valve seat refacing tool
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ When repairing engines with leaking valves, it is not sufficient
to rework or renew valve seats and valves. There is also a
l purpos
requirement to check the valve guides for wear. This is par‐
cardiagn.com
ticularly important on high mileage engines.
nf
ercia
o
♦ Valve seats are only to be reworked to the extent required to
rm
m
yield a proper surface appearance. Before beginning to rework
atio
m
valve seats, calculate the maximum permissible reworking di‐

o
n in
c
mensions. If the reworking dimension is exceeded, the hy‐

or
thi
e
draulic valve clearance compensation can no longer be

t
sd
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guaranteed and the cylinder head must be renewed.
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The max. permissible reworking dimension is calculated as fol‐ Cop py
lows:
t. rig
gh ht
pyri by
Vo
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by c
– Insert valve and press firmly against seat.
lksw
cted agen
Prote AG.
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve 35.8 mm
Exhaust valve 36.1 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
Measured distance -a- 36.5 mm
- Minimum dimension 35.8 mm
= Max. permissible reworking dimension 0.7 mm
4. Inlet and exhaust valves 69

Crafter 2006 ➤
Reworking inlet and exhaust valve seats

Dimension Inlet valve seat Exhaust valve seat
Diameter a mm 37.20 2)
33.202)
Diameter b mm 34.80 30.40
c mm 2.70 2.05
45° Valve seat angle
15° Correction angle
2) Max. external dimension of refacing cutter
4.2 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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♦ Dial gauge s au ra
c
s
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Test procedure
nl
pt
du
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itte
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– Insert new valve in guide. Valve stem end must be flush with
erm
ab
guide. On account of differing stem diameters, only use inlet
ility
ot p
valve in inlet guide and exhaust valve in exhaust guide.
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– Determine rock.
hole
Rock: max. 1.3 mm. spec

es, in part or in w
t to the co
rrectness of i
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nf
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or
4.3 Removing and installing valve guides

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Cop py
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co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
♦ Drift - 10 - 206-
♦ Reamer, 8 mm - 10 - 215-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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cardiagn.com
or eo
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aut ra
ss c
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pt
du
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ility
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♦ Cooling lubricant
h re
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Removing
spec
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– Clean and check cylinder head. Cylinder heads in which the

valve seats can no longer be reworked or cylinder heads which
have already been machined to the minimum dimension are
unsuitable for having their valve guides replaced.
rrectness of i
– Press out worn valve guides with drift - 10 - 206- , from cam‐
l purpos
shaft side (repair-version valve guides with shoulder from

combustion chamber side).
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Installing
m
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– Moisten new guides with oil and then press them from cam‐
on
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Prote AG.
– Ream valve guide with reamer, 8 mm - 10 - 215- . Use plenty

of cutting fluid.
– Reworking valve seats ⇒ page 69 .
4. Inlet and exhaust valves 71

Crafter 2006 ➤
4.4 Valve dimensions

Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

Diameter a mm 36.00 31.50
Diameter b mm 7.97 7.95
c mm 96.85 96.85
α ∠° 45 45
cardiagn.com
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Rep. gr.15 - Cylinder head, valve gear cted agen
Prote AG.
Crafter 2006 ➤
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 73
⇒ “1.2 Removing and installing oil sump”, page 76
⇒ “1.3 Removing and installing oil pump”, page 80
⇒ “1.4 Measure oil consumption”, page 83
⇒ “1.5 Engine oil”, page 83
1.1 Assembly overview - sump/oil pump
Note
♦ If large quantities of swarf or metal particles (caused, for ex‐

ample, by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when performing repairs, clean the
cardiagn.com
oil passages thoroughly and renew the engine oil cooler in or‐
der to prevent subsequent damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! AG. Volkswagen AG d
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1. Sump, oil pump 73

Crafter 2006 ➤
1 - Oil filter element

2 - Cap
❑ Remove and install with
oil filter tool - 3417- .
❑ 25 Nm
❑ Locked in installation
position by fitted pins.
4 - Bolt
❑ 20 Nm
5 - Banjo bolt
❑ 100 Nm
6 - Seal
7 - Gasket
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8 - Bolt
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10 - Bolt
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❑ 9 Nm
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11 - O-ring
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12 - Oil spray jet spec

❑ For piston cooling.

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13 - Bolt
❑ Insert with sealing paste
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⇒ Electronic Parts Catalogue (ETKA) .

❑ 8 Nm
ss o
14 - Oil pressure switch - F1-

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❑ 0.7 bar switch: brown.

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❑ If seal is leaking, nip open and renew.

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❑ 25 Nm
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15 - Adapter
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16 - Spring
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17 - Oil pressure retention valve
18 - Bolt
❑ 9 Nm
19 - Bolt
❑ 20 Nm
20 - Suction line
❑ Clean strainer if soiled.
74 Rep. gr.17 - Lubrication

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AG. Volkswagen AG d
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21 - Seal tho eo
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22 - Bolt
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❑ 8 Nm + 90°
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23 - Oil level and oil temperature sender - G266-
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24 - Bolt
spec
es, in part or in w
❑ Remove and install on flywheel side using Allen key, long reach - T10058- .
t to the co
❑ With flywheel installed: turn flywheel so that recess aligns with bolts.
❑ 8 Nm + 90°
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25 - Bolt
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❑ 9 Nm
26 - Oil sump
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27 - Oil pressure relief valve

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❑ Opening pressure: 5.3…6.3 bar.
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❑ 45 Nm
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28 - Seal
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❑ Renew. ⇒ page 21 . C py
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29 - Crankshaft pulley
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30 - Bolt
❑ 9 Nm
31 - Oil drain plug
❑ Renew plug with attached seal.
❑ 30 Nm
32 - O-ring
33 - Bolt
❑ 20 Nm
34 - Toothed belt guard lower part
35 - Oil pump
❑ When installing, note drive on crankshaft ⇒ Item 1 (page 39) .
❑ Renew complete only.
❑ Must seat on dowel sleeves.
36 - Gasket
37 - Cylinder block
38 - Oil dipstick
❑ The oil level must not be above the max. mark!
❑ Markings ⇒ page 84 .
39 - Gasket

Crafter 2006 ➤
40 - Cap
41 - Bolt
❑ 9 Nm
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43 - Banjo bolt ss a c
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❑ 32 Nm
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44 - Plug
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❑ 25 Nm
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45 - Seal
h re
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spec
46 - Oil supply line
t to the co
❑ To turbocharger:
Engine codes BJJ, BJK, BJL, BJM ⇒ Item 10 (page 107)
rrectne
Engine codes CEBA, CEBB, CECA, CECB ⇒ Item 10 (page 109)
ss
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o
❑ To install, tighten both banjo bolts hand-tight and then tighten.
cial p
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47 - Engine oil cooler
mer
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❑ Ensure clearance to adjacent components.

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❑ Checking for leaks ⇒ page 85 .
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48 - O-ring
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1.2 Removing and installing oil sump
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♦ Support bracket - 10 - 222 A- with adapter - 10 - 222 A /9-
♦ Allen key, long reach - T10058-

Crafter 2006 ➤
♦ Allen key, long reach - T10347-

AG. Volkswagen AG d
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♦ For example: “Hazet 958/6” adapter set
♦ Commercially available “T30” Torx bit (200 long)
rrectness of i
♦ Eye protection
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♦ Flat scraper
♦ Hand drill with plastic brush attachment
nform
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♦ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)

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The long adapters from each of two adapter sets are required as
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adapters - 10 - 222 A /9- .

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Removing pyri by
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– Remove air filter ⇒ page 149 . Prote AG.

– Drain engine oil.
Note
Observe environmental regulations for disposal.

– Remove silencer and exhaust tailpipe (if fitted) ⇒ page 151 .
– Release propshaft from gearbox flange ⇒ Rep. gr. 39 .

Crafter 2006 ➤
Engine codes CEBA, CEBB, CECA, CECB:

– Release propshaft ⇒ Rep. gr. 39 and secure to body with, for
example, commercially available cable tie.
– Unbolt clamps ⇒ Item 13 (page 155) and
⇒ Item 13 (page 155) from particulate filter.
– Remove intake particulate filter nuts -arrows-.
– Pull 3-pin connector off oil level and oil temperature sender -
G266- .
– Unclip cowling ⇒ Item 6 (page 102) .
– Remove washer fluid reservoir ⇒ Rep. gr. 92 .
– Remove air pipe ⇒ Item 6 (page 114) .
– Unscrew coolant pipes ⇒ Item 15 (page 98) . Coolant hoses
remain connected.
– Unbolt coolant pipe from right longitudinal member.
– Set up support bracket - 10 - 222 A- with adapters - 10 - 222
cardiagn.com
A /9- and support engine in installation position.
Note
The long adapters from each of two adapter sets are required as
adapters - 10 - 222 A /9- .
AG. Volkswagen AG d
– Unscrew securing bolt for right engine mounting -arrow-. agen oes
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– Unscrew securing bolt for left engine mounting -arrow-.

rrectness of i
– Raise engine using support bracket - 10 - 222 A- .

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Prote AG.

Crafter 2006 ➤
– Loosen securing bolt -1- for toothed belt guard bracket -2-.
– Remove securing bolts for sump to gearbox.
– Unscrew sump bolts.
Note
To loosen bolts on flywheel side, turn flywheel so that recess

aligns with bolts. Unscrew bolts using Allen key, long reach 5 mm
- T10058- , socket Torx T30 - T10347- or commercially available
“T30”Torx bit (length: 200 mm).
– Remove sump, it may be necessary to release sump by tap‐

ping lightly with a rubber head hammer.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump with a rotating brush, e.g.

an electric hand drill with a plastic brush attachment (wear eye
protection).
– Clean sealing surfaces. They must be free of oil and grease.
cardiagn.com
Installing
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ The sealant bead must not be thicker, otherwise excess seal‐
ing compound will enter the oil sump and may block the oil
suction line strainer. wage
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– Cut off tube nozzle at forward marking (diameter
tho of nozzle ap‐ eo
prox. 3 mm). au ra
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– Apply silicone sealing compound, as shown, to clean sealing

pt
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surface on sump. Sealant bead must be:

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♦ 2…3 mm thick.
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♦ Run bead along inner side of bolt holes -arrows-.

h re
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79
AG.
1. Sump, oil pump
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Crafter 2006 ➤ kswagen AG n AG d
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– Press coolant
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t
-3- towards radiator and insert sump. or ac
ss
– Pull toothed belt guard bracket -2- slightly away from cylinder
ce
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block and position sump on cylinder block.
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– Tighten bolts slightly.
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Note
spec
t to the co
♦ When installing sump with engine out of the vehicle, ensure
that sump is flush with cylinder block at flywheel end.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
rrectne
ling oil sump. Only then fill with engine oil.
ss
– Tighten sump bolts.
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– Tighten sump/gearbox bolts.
form
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Engine codes CEBA, CEBB, CECA, CECB:
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– Renew gasket ⇒ Item 12 (page 155) .
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– Renew clamps ⇒ Item 13 (page 155) and

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⇒ Item 13 (page 155) .

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Specified torques . Cop py
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♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 73 py by
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♦ Bolts between sump and gearbox; ⇒ Rep. gr. 34
1.3 Removing and installing oil pump

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ss
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nl
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equipment required
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♦ Torque wrench - V.A.G
spec
1331-
es, in part or in w
t to the co
1332-
rrectness of i
♦ Silicone sealant ⇒ Elec‐
tronic Parts Catalogue (ET‐
l purpos
KA)
♦ Flat scraper
nform
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♦ Hand drill with plastic brush

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Cop py
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Removing
– Pull oil dipstick out.
– Remove crankshaft toothed belt pulley ⇒ page 57 .
– Drain off engine oil.
– Remove sump ⇒ page 76 .

Crafter 2006 ➤
– Unscrew suction line bolts -arrows- and remove suction line.
– Loosen bolts -1- for oil pump -2-.

– Remove oil pump -2-, loosening with light blows of a rubber-
headed hammer if necessary.
– Remove gasket -3- from oil pump -2-. Remove sealant resi‐
dues from cylinder block -1- with scraper, if necessary.
cardiagn.com
Clean sealing surfaces. They must be free of oil and
olks
wgrease.
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Installing db ran
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Installation is carried out in the reversess aorder; note the following: ac
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Renew gaskets and seals.

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– Install using assembly tool - T10053- .

spec
t to the co
– Fit oil pump gasket.

– Locate oil pump, tighten bolts ⇒ Item 33 (page 75) finger-tight
and then tighten to specified torque.
rrectne
– Remove press sleeve - T10053- .

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Crafter 2006 ➤
– Locate suction line, tighten bolts ⇒ page 73 -arrows- finger-

tight and then tighten to specified torque.
Note
Do not forget the suction line O-ring.
– Install sump ⇒ page 76 .

– Install crankshaft toothed-belt pulley ⇒ page 57 .
– Install toothed belt ⇒ page 57 .
– Install poly V-belt ⇒ page 19 .
– Fill engine oil.
– Perform road test.
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 73
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♦ ⇒ “1.2 Assembly overview o-lkpoly
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♦ Bolts between sumprisand
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1.4 Measure oil consumption s
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Procedure
h re
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spec
– Pull handbrake on.

es, in part or in w
t to the co
– Manual gearbox: gear stick in neutral.

– Connect ⇒ Vehicle diagnostic tester.
rrectness of i
– Switch ignition on.

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– Carry out program “oil consumption measurement” using

nf
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1.5 Engine oil

orm
m
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Engine oil specifications:

o
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⇒ Maintenance ; Booklet 10.2

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Crafter 2006 ➤
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil! AG. Volkswagen n AG do
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b - Oil level within hatched olks
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c - Area min. mark
s a up to hatched zone: top-up engine oil!!
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Cop py
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Prote AG.

Crafter 2006 ➤
2 Engine oil cooler

⇒ “2.1 Checking engine oil cooler for leaks”, page 85
AG. Volkswagen AG d
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Special tools and workshop ss a c
equipment required
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♦ Refractometer - T10007-
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♦ Hose clamps up to 25 mm - pe
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3094-
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♦ Cooling system tester -
hole
spec
V.A.G 1274-
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t to the co
♦ Adapter for cooling system
tester - V.A.G 1274/8-
rrectness of i
♦ Spring-type clip pliers -
VAS 5024 A-
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♦ Drip tray - VAS 6208-
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Prote AG.
2. Engine oil cooler 85

Crafter 2006 ➤

Not illustrated.
♦ Expansion tank
♦ Plug
♦ Cap
♦ Coolant hose
Prerequisites:
• Engine cold
Test procedure
– Clamp engine oil cooler supply and return lines using hose
clamps, up to 25 mm - VAS 3094- .
– Loosen hose clips using spring-type clip pliers - VAS 5024- .
cardiagn.com
Note
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Collect escaping coolant with drip tray -edVAS 6208- .
by ua
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– Pull coolant hoses off enginesoil
s cooler.
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– Slide filler cap -5- onto rear connection of engine oil cooler
an
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– Secure sealing plug -2- to breather connection of expansion

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– Secure coolant hose -3- to engine oil cooler and expansion spec
es, in part or in w
tank. t to the co
– Fill expansion tank up to max. marking.

– Attach cooling system tester - V.A.G 1274- with cooling sys‐
rrectness of i
tem tester adapter - V.A.G 1274/8- to expansion tank.

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– Use hand pump on tester to create a pressure of about 1.6 bar.

– Watch pressure drop on pressure gauge. A pressure drop
nform
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within 10 minutes is not permitted.

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If pressure drops:
ion
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– Renew engine oil cooler ⇒ Item 47 (page 76) .

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Installation is carried out in the reverse order. When installing,

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note the following:

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– Check coolant level, replenish coolant if necessary C py
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⇒ page 93 .
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Crafter 2006 ➤
3 Oil filter, oil pressure switch

⇒ “3.1 Checking oil pressure and oil pressure switch”,
page 87
3.1 Checking oil pressure and oil pressure switch

equipment required agen
AG. Volkswagen AG d
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♦ Oil pressure tester - V.A.G ed by
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♦ Voltage tester - V.A.G 1527
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♦ Auxiliary measuring set -
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V.A.G 1594C-
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Prote AG.
Test prerequisites
• Engine oil level OK.
• Engine oil temperature at least 80°C
Note
Functional check and repair of the optical and acoustic oil pres‐
sure gauge: current flow diagrams ⇒ Vehicle diagnostic tester.
3. Oil filter, oil pressure switch 87

AG. Volkswagen AG d
agen oes
olksw not
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Crafter 2006 ➤ ise d b ara
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r
5-cylinder dieselut engine - Edition 03.2016
ho eo
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s
Test sequence:
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pt
du
an
itte
– Remove oil pressure switch - F1- and screw it into oil pressure
y li
erm
ab
tester - V.A.G 1342- .
ility
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wit
– Screw oil pressure tester - V.A.G 1342- into cylinder block in‐
, is n
h re
stead of oil pressure switch.
hole
spec
– Connect brown wire of tester to earth (-).
es, in part or in w
t to the co
– Connect voltage tester - V.A.G 1527 B- with test cables from
adapter set - V.A.G 1594C- to battery positive (+) and oil pres‐
sure switch. LED must not light up.
rrectness of i
– Start engine and increase engine speed. At 0.55...0.85 bar,
l purpos
the LED must light up, otherwise oil pressure switch must be
renewed.
nf
ercia
o
– Increase engine speed further. At 2,000 rpm and an oil tem‐
rm
m
perature of 80°C, the oil pressure should be at least 2.0 bar.
atio
om
n in
c
At higher engine speed, oil pressure must not exceed 7.0 bar.
or
thi
te
sd
a
– Renew oil excess pressure valve ( ⇒ Item 27 (page 75) ) or oil

iv
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pressure retention valve ( ⇒ Item 17 (page 74) ) if necessary.
o
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f
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ng
t.
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cardiagn.com
Co
Cop py
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by c lksw
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Prote AG.

Crafter 2006 ➤
19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram”, page 89
⇒ “1.2 Coolant hose schematic diagram, vehicles with auxiliary
heater”, page 90
⇒ “1.3 Coolant hose schematic diagram, vehicles with auxiliary
AG. Volkswagen AG d
heater and 2nd heat exchanger”, page 91 ksw
agen oes
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⇒ “1.4 Checking cooling system for leaks”, page 91 edb ran
ris tee
tho
⇒ “1.5 Draining and filling coolant”, page 93 au
or
ac
ss
ce
1.1 Coolant hose schematic diagram
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un
pt
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ab
ility
1 - Expansion tank
ot p
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2 - Vacuum valve
h re
ole,
spec
cardiagn.com
3 - Heat exchanger for heater
unit
t to the co
4 - Continued coolant circula‐
tion pump - V51-
rrectne
5 - Exhaust gas recirculation
cooler
ss o
❑ Not for engine code BJK
cial p
f in
with EU 3 or EURO 3
form
mer
6 - Cylinder block
atio
om
n
c
7 - Cylinder head
i
or
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8 - Coolant pump
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9 - Radiator
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t.
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10 - Engine oil cooler C py
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Prote AG.
1. Cooling system, coolant 89

Crafter 2006 ➤
1.2 Coolant hose schematic diagram, vehicles with auxiliary heater
1 - Expansion tank
unit
tion pump - V51-
4 - Vacuum valve
cooler AG. Volkswagen AG d
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❑ Not for engine code BJK Vo lksw
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(engines complianted bywith ara
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EU 3/EURO t3hostand‐
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ard). s au ra
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❑ Assembly overview
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un
pt
⇒ page 187 .
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6 - Cylinder head
ab
ility
ot p
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wit
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⇒ page 45 .
h re
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spec
⇒ page 48 .
t to the co
7 - Cylinder block
8 - Coolant pump rrectne
⇒ page 97 .
ss o

cial p
f i
⇒ page 99 .
nform
mer
9 - Radiator
atio
om
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c
i
or
⇒ page 102 .
thi
te
sd
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i
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pr
cum
⇒ page 103 .
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t.
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10 - Engine oil cooler t. Cop py
rig
❑ Checking for leaks
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⇒ page 85 .
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by c lksw
cted agen
Prote AG.
90 Rep. gr.19 - Cooling

Crafter 2006 ➤
AG. Volkswagen AG d 5-cylinder diesel engine - Edition 03.2016
agen oes
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byV gu
1.3 Coolant hose schematic diagram, vehicles with auxiliary heater and 2nd
d ara
ise nte
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heat exchanger ss aut ra
c
ce
le
un
pt
an
d
1 - Expansion tank itte
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rm
ab
pe
ility
ot
unit
wit
, is n
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hole
spec
tion pump - V51-
es, in part or in w
t to the co
4 - Vacuum valve
rrectness of i
cooler
❑ Not for engine code BJK
l purpos
(engines compliant with

EU 3/EURO 3 stand‐
nform
ercia
ard).
m
a
com
ti
⇒ page 187 .
on in
r
te o
thi
6 - Cylinder head
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s
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⇒ page 45 .
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❑ Removing and installing Cop py
⇒ page 48 . ht. rig
rig ht
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7 - Cylinder block
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Prote AG.
8 - Coolant pump
⇒ page 97 .
⇒ page 99 .
9 - Radiator
⇒ page 102 .
⇒ page 103 .
10 - Engine oil cooler
❑ Checking for leaks
⇒ page 85 .
1.4 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-

Crafter 2006 ➤
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-
cardiagn.com
AG. Volkswagen AG d
agen oes
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Test prerequisite aut
h
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• Engine at operating temperature.
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itte
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WARNING
ab
ility
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wit
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Steam may escape when expansion tank is opened. Wear eye
h re
protection and protective clothing to avoid eye injuries and
hole
spec
scalding. Cover cap with cloth and open carefully.
es, in part or in w
– Open cap for coolant expansion tank. t to the co

rrectness of i
– Attach cooling system tester - V.A.G 1274- with cooling sys‐
tem tester adapter - V.A.G 1274/8- to expansion tank.
l purpos
– Use hand pump on tester to create a pressure of about 1.0 bar.

nform
ercia
If pressure drops:
m
at
om
– Find leaks and rectify.

ion
c
in t
or
his
ate
do
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cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter for
cooling system tester - V.A.G 1274/9- on cap -1-.
– Build up pressure using hand pump of cooling system tester.
• The pressure relief valve should open at a pressure of 1.4…
1.6 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
1.5 Draining and filling coolant

equipment required
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist
cardiagn.com
- VAS 6208-
. Volkswagen AG
♦ Hose clip pliers w-aVAS
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6340- Volks not
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♦ Coolingho system charge unit
r eo
ut
-sVAS
s a 6096- ra
c
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nl
pt
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an

itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
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cted agen
Prote AG.

Crafter 2006 ➤
Draining
Note
♦ Collect drained coolant in a clean container for re-use or dis‐

posal.
♦ Observe waste disposal regulations.
WARNING
Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
– Open cap for coolant expansion tank.

– Remove any noise insulation ⇒ General body repairs, exteri‐ AG. Volkswagen AG d
or; Rep. gr. 50 ; Noise insulation . agen oes
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– Detach coolant hoses -arrows- from coolant pipes.
cardiagn.com
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Filling ss a c
ce
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nl
pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
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Note orised
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♦ Only distilled water may be used for mixing with coolant addi‐ ss c
ce
e
tives. The use of distilled water ensures optimum protection
nl
pt
du
against corrosion.
an
itte
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erm
ab
♦ The amount of water used in the coolant mixture has a great
ility
ot p
influence on its effectiveness. Since water quality differs from
wit
, is n
country to country and even region to region, it is necessary
h re
to set a standard for the quality of water to be used. Distilled
hole
spec
water fulfils all requirements. For this reason, we recommend
es, in part or in w
using distilled water when mixing coolant for topping up or re‐
t to the co
placing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
rrectness of i
tronic Parts Catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
l purpos
age could lead to loss of coolant and subsequent severe

damage to the engine.
nform
ercia
♦ The correct coolant solution ratio helps prevent damage due

m
to freezing and corrosion as well as scaling. Moreover, the
at
om
io
boiling temperature is raised. Therefore, the cooling system
n
c
cardiagn.com
in t
must be filled all year round with coolant additive.
or
his
ate
do
riv
♦ Because of its higher boiling point, the coolant improves en‐

p
cum
gine reliability under heavy loads, particularly in countries with
for
en
g
tropical climates.
n
t.
yi Co
Cop py
♦ The refractometer - T10007A- must be used to determine the ht. rig
rig ht
current anti-freeze value.
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co Vo
by lksw
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♦ Frost protection must be guaranteed down to -25°C as a min‐
Prote AG.
imum and, in countries with arctic conditions, down to approx.

-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, only be increased to a maximum of -48°C. Otherwise,
the cooling effect of the coolant will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read the frost protection value from the respective scale for
the coolant additive being used.
♦ The temperature read off the refractometer - T10007A- equa‐
tes to the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Do not reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixture ratios:

Frost protection Coolant additive Coolant ad‐ Distilled wa‐
to portion ditive 3) ter3)
-25°C 40% 3.6 l 5.4 l
-36°C 50% 4.5 l 4.5 l
3) The quantity of coolant can vary depending upon vehicle equipment.
– Re-attach coolant hoses and secure with clips.

Crafter 2006 ➤
– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio.
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
expansion tank -1-.
– Mount cooling system charge unit - VAS 6096- on adapter -
V.A.G 1274/8- .
– Feed vent hose -2- into a small container -3-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 … 10 bar.
cardiagn.com
– Open valve -B-; turn lever in direction of flow to do this.
• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move into green area.
– In addition, open valve -A- briefly by turning lever in direction
of flow until expansion tank hose of cooling system charge unit
- VAS 6096- fills with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• In cooling system, vacuum continues to be generated by suc‐
tion jet pump; needle of gauge must remain in green area.
– Close valve -B-. AG. Volkswagen AG d
agen oes
lksw not
• The needle on the gauge should stop in the green zone. by V The
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ara
vacuum level in the cooling system is then sufficient
ris for sub‐
ed
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sequent filling. aut
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• If the needle does not reach the green zone, repeat the proc‐
ce
le
un
pt
ess.
an
d
itte
y li
• If vacuum drops, cooling system must be checked for leaks.

erm
ab
ility
ot p
– Pull off compressed air hose.

wit
is n
h re
– Open valve -A-.

ole,
spec
• Vacuum in cooling system causes coolant to be extracted from

t to the co
coolant expansion tank of cooling system charge unit -

VAS 6096- and the cooling system to be filled.
– Then install cooling system charge unit - VAS 6096- again on
rrectne
coolant expansion tank.

s
– If present, install noise insulation ⇒ General body repairs, ex‐

s o
terior; Rep. gr. 66 ; Noise insulation; Removing and installing

cial p
f in
noise insulation .
form
mer
atio
om
n
c
i
or
n thi
te
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o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
96
Prote AG.
Rep. gr.19 - Cooling
Crafter 2006 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 97
⇒ “2.2 Removing and installing coolant pump”, page 99
⇒ “2.3 Removing and installing thermostat”, page 100
2.1 Assembly overview - coolant pump, thermostat
1 - Cylinder block
2 - Thermostat
❑ Checking: heat thermo‐
stat in water.
❑ Opening begins at ap‐
prox. 87°C.
❑ Ends at approx. 102°C.
❑ Opening lift at least 8
cardiagn.com
AG. Volkswagen AG d
agen oes
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❑ Removing and installing orise nte
⇒ page 100 aut
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3 - O-ring
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nl
pt
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itte
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erm
ab
4 - Connection
ility
ot p
❑ On cylinder head.
wit
, is n
h re
5 - Bracket
hole
spec
❑ For exhaust gas recircu‐
es, in part or in w
t to the co
lation cooler.
6 - Nut
rrectness of i
❑ 20 Nm
l purpos
7 - Connection
⇒ page 100
nform
mercia
8 - Breather valve
at
om
io
❑ 2 Nm
n
c
in t
or
his
e
9 - Bolt
at
do
priv
❑ 9 Nm
um
for
en
ng
t.
yi
10 - Coolant hose
Co
Cop py
t.
❑ To exhaust gas recircu‐
rig
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yri by
lation cooler. op Vo
by c lksw
cted agen
❑ Not for engine code BJK with EU 3 or EURO 3 Prote AG.
11 - Retaining clip
12 - Coolant temperature sender - G62-
13 - Bolt
❑ 40 Nm
14 - Connection
❑ On cylinder block.
2. Coolant pump, regulation of cooling system 97

Crafter 2006 ➤
15 - Coolant pipe
❑ Remove air pipe ⇒ Item 6 (page 114) to remove.
16 - Bolt
❑ 20 Nm
17 - Bracket
❑ ⇒ Item 7 (page 18)
18 - Mounting
19 - Flange shaft
20 - Belt pulley
21 - Bolt
❑ 40 Nm
22 - Bolt
❑ 40 Nm
23 - Viscous fan
cardiagn.com
24 - From heat exchanger
26 - Coolant pump
❑ Check for ease of movement.
❑ If damaged or leaking renew complete only.
❑ ⇒ Item 13 (page 55)
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
2.2 Removing and installing coolant pump

equipment required
♦ Refractometer - T10007 A-
♦ Drip tray - V.A.G 1306- or
drip tray - VAS 6208-
VAS 5024 A-
♦ Cooling system charge unit
- VAS 6096-
♦ Torque wrench -
V.A.G 1331-
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
Removing
inform
mer

atio
om

c
i
or
n thi
te
– Remove camshaft pulley ⇒ page 59 .

sd
iva
o
pr
cum
r
– Remove rear toothed belt guard ⇒ Item 13 (page 55) .

fo
en
ng
t.
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– Remove securing bolts for coolant pump -arrows- and care‐ Cop py
. rig
fully remove coolant pump.
ht ht
rig by
copy Vo
Installing
by lksw
cted agen
Prote AG.
– Moisten new O-ring with coolant.

Crafter 2006 ➤
– Insert coolant pump into cylinder block, and tighten securing

bolts -arrows-.
– Install rear toothed belt guard ⇒ Item 13 (page 55) .
– Install toothed belt ⇒ page 57 .
Specified torques
2.3 Removing and installing thermostat

♦ Torque wrench - V.A.G 1331- agen
AG. Volkswagen AG d
oes
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
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h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Remove air filter with air duct ⇒ page 149 .
l purpos

⇒ Rep. gr. 27 .
nf
ercia

orm

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atio
om
n in

or c
thi
te
– Unclamp coolant hose -1- from union.

sd
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– Remove wiring harness bracket -2-.

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f
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ng
t.
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– Unscrew bolts -arrows- for union and pull union out together t. Cop py
with thermostat.
rig
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pyri by
Vo
co
Installing
by lksw
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Prote AG.
Note
Renew O-ring.
– Clean sealing surface.

– Insert thermostat with new O-ring into cylinder block.
– Ensure that thermostat installation position is correct -1-.
– It must engage in inner mounting -arrow- of union.

Crafter 2006 ➤
– Illustration shows thermostat in removed condition.

– Install and tighten connecting piece.
– Install air filter with air duct ⇒ page 149 .
– With ignition switched off, disconnect battery earth strap ⇒
Rep. gr. 27 .
Specified torques agen
AG. Volkswagen AG d
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ed byV overview - coolant pump, thermostat”,
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ara
page h97 oris nte
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♦ ⇒ s“7.1 Assembly overview - air filter”, page 149
s c
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
cardiagn.com
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
3 Radiator/radiator fan
⇒ “3.1 Assembly overview - radiator/radiator fan”, page 102
⇒ “3.2 Removing and installing radiator”, page 103
⇒ “3.3 Removing and installing viscous fan”, page 104
3.1 Assembly overview - radiator/radiator fan

AG. Volkswagen AG d
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1 - Radiator ed by gu
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❑ Removing ut
h o and installing eo
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⇒ page
ss a 103 . c
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❑ After replacing, renew

nl
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entire coolant.
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itte
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2 - Coolant hose
ility
ot p
❑ To coolant circulation
wit
, is n
pump - V50- .
h re
hole
spec
3 - O-ring
es, in part or in w
t to the co
cardiagn.com
4 - Lower coolant hose
rrectness of i
❑ To thermostat connec‐
tion.
l purpos
5 - Air duct
nf
ercia
6 - Cowling
orm
m
❑ Remove viscous fan

atio
m
⇒ page 104 and charge

o
n in
c
air cooler
or
thi
e
⇒ Item 3 (page 114) to

t
sd
iva
remove.
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o
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f
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ng
7 - Bolt
t.
yi Co
op
❑ 10 Nm
C py
t. rig
gh ht
yri by
8 - Cap
op Vo
by c lksw
cted agen
Prote AG.
9 - Expansion tank
❑ Checking cooling sys‐
tem for leaks
⇒ page 91 .
10 - Coolant hose
❑ To coolant pipe
11 - Coolant shortage indicator sender - G32-
12 - Coolant hose
❑ To cylinder head
13 - Bracket
14 - Continued coolant circulation pump - V51-
❑ To remove, remove air filter ⇒ page 149
15 - From radiator
16 - To heat exchanger for heater unit.
17 - Charge air cooler
❑ Assembly overview ⇒ page 114 .

AG. Volkswagen AG d
agen oes
o lksw not
byV gu
aa
rised
Crafter r2006
nte ➤
o eo
aut
h
5-cylinder diesel engine - Edition 03.2016 ra
ss c
ce
e
18 - Bolt
nl
pt
du
an
itte
❑ 8 Nm
y li
erm
ab
ility
19 - Upper coolant hose
ot p
wit
, is n
❑ To connection on cylinder head.
h re
hole
spec
es, in part or in w
t to the co
3.2 Removing and installing radiator
rrectness of i
equipment required
♦ Refractometer - T10007 A- l purpos
nf
ercia
o
♦ Drip tray - V.A.G 1306- or
rm
m
drip tray for workshop hoist
atio
m
- VAS 6208-
o
n in
or c
thi
te
sd
iva
VAS 5024A-
o
r
rp
cu
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m
f
♦ Cooling system charge unit
en
ng
t.
yi
- VAS 6096-
Co
cardiagn.com
Cop py
ht. rig
rig ht
py by
o Vo
tester - V.A.G 1274/8- by c lksw
cted agen
Prote AG.
3. Radiator/radiator fan 103

Crafter 2006 ➤

AG. Volkswagen AG d
Removing lksw
agen oes
not
Vo gu
y
– Drain coolant ⇒ page 93ris.ed b ara
nte
tho eo
– Remove viscous fans a⇒ page 104 .
u ra
c
s
ce
e
– Pull coolant hoses off radiator.

nl
pt
du
an
itte
– Remove cowling ⇒ Item 6 (page 102) .
y li
erm
ab
ility
– Remove radiator grille ⇒ Rep. gr. 66 .
ot p
wit
, is n
– Unbolt radiator from charge air cooler.
h re
hole
spec
– Remove radiator upwards.
es, in part or in w
t to the co
Installing
rrectness of i
– Bolt radiator to charge air cooler.
l purpos
– Install cowling ⇒ Item 6 (page 102) .

– Install viscous fan ⇒ page 104 .
nform
ercia
cardiagn.com
– Install radiator grille ⇒ Rep. gr. 66 .
m
at
om
ion
c
in t
or
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te
Specified torques
a
do
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cum
or
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 102

f
en
ng
t.
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Cop py
3.3 Removing and installing viscous fan
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.
♦ 2-hole pin wrench - 3212-
Removing

Crafter 2006 ➤
– Remove charge air cooler ⇒ Item 3 (page 114) .

– Block belt pulley with pin wrench - 3212- and loosen viscous
fan. wage
e
olks s no
yV t gu
Installing edb ara
ris nte
Installation ho
utis carried out in the reverse order; note the following:
eo
a ra
ss c
– Tighten securing bolt for viscous fan.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Specified torques
wit
, is n
h re
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
hole
spec
page 97
es, in part or in w
t to the co
rrectness of i
l purpos
cardiagn.com
nf
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orm
m
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n in
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Radiator/radiator fan 105

Crafter 2006 ➤
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger (engine codes BJJ,
⇒ “1.2 Assembly overview - turbocharger (engine codes CEBA,
CEBB, CECA, CECB)”, page 108
⇒ “1.3 Removing and installing turbocharger (engine codes BJJ,
⇒ “1.4 Removing and installing turbocharger (engine codes CE‐
1.1 Assembly overview - turbocharger (en‐

gine codes BJJ, BJK, BJL, BJM)
AG. Volkswagen AG d
agen oes
Note olksw not
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b ara
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d
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♦ All hose connections are secured by clips.
autho eo
ra
s s c
♦ Secure all hose connections with hose clips which conform to
ce
le
un
production standard.
pt
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d
itte
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♦ Charge air system must be free of leaks.
erm
ab
ility
ot p
♦ Renew self-locking nuts.
wit
is n
h re
♦ After installing the turbocharger, run the engine for about 1
ole,
spec
minute at idling speed and do not rev up immediately. This
ensures that the turbocharger is fully primed with oil
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
106 Rep. gr.21 - Turbocharging/supercharging

Crafter 2006 ➤
1 - To exhaust gas recircula‐

tion cooler.
❑ ⇒ Item 12 (page 188)
❑ For engine code BJK
with EU 3 or EURO 3 to
connecting pipe
⇒ Item 19 (page 188)
2 - Connecting pipe
3 - Exhaust manifold
4 - Gasket
5 - Nut
❑ 25 Nm
6 - Heat shield
7 - Washer
8 - Nut
cardiagn.com
❑ 20 Nm AG. Volkswagen AG d
agen oes
lksw not
9 - Bolt by Vo gu
ara
d
❑ 10 Nm rise nte
tho eo
au ra
10 - Oil supply line ss c
ce
le
❑ Before installing, fill tur‐

un
pt
an
d
bocharger with engine

itte
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oil through oil supply line
rm
ab
pe
ility
connection.
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❑ To install, tighten both
h re
banjo bolts hand-tight
hole
spec
and then tighten.
es, in part or in w
t to the co
11 - Seal
12 - Banjo bolt rrectness of i
l purpos
❑ 32 Nm
13 - Bolt
nform
ercia
❑ 11 Nm
m
14 - Oil return line

com
tion in
❑ To cylinder block.
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Installation sequence:
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fo
❑ Tighten oil return line hand-tight to turbocharger.

en
ng
t.
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op
❑ Tighten oil return line hand-tight to cylinder block. C py
t. rig
gh ht
❑ Tighten bolts. yri
p by
co Vo
by lksw
cted
15 - Bolt
agen
Prote AG.
❑ 20 Nm
16 - Intake hose
❑ From air filter ⇒ Item 1 (page 149) .
❑ Do not cant when installing.
17 - Air intake hose
❑ To charge air cooler ⇒ Item 3 (page 114) .
1. Turbocharger 107
Crafter 2006 ➤
18 - Bolt
❑ 10 Nm
AG. Volkswagen AG d
19 - Bracket wage
n oes
Volks not
gu
❑ For control lines ⇒ Item 2 (page 157) and ⇒ Item
ed 3 (page 157) .
by ara
nte
is
or eo
20 - Vacuum hose au
th ra
ss c
❑ From charge pressure control solenoid valve - N75-
ce
e
nl
pt
du
an
21 - Screw-type clip
itte
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erm
ab
❑ 5.5 Nm
ility
ot p
22 - Bolt
wit
, is n
h re
❑ 40 Nm
hole
spec
es, in part or in w
23 - Support
t to the co
❑ Between turbocharger and engine bracket.
24 - Nut
rrectness of i
l purpos
❑ 25 Nm
25 - Turbocharger
cardiagn.com
nf
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❑ Can only be renewed complete with vacuum unit.
rm
m
atio
om
n in
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26 - To particulate filter
thi
te
sd
iva
❑ ⇒ Item 26 (page 158)
o
r
rp
cu
o
m
❑ To catalytic converter in vehicles without particulate filter.
f
en
ng
t.
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op
27 - Rubber seal C py
ht. rig
rig ht
❑ Renew if damaged. py by
co Vo
by lksw
❑ Connect the rubber seal carefully, to prevent damage cted agen
Prote AG.
28 - Banjo bolt
❑ 19 Nm
29 - Exhaust gas temperature sender 1 - G235-
❑ Grease thread of sender using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
❑ 45 Nm
1.2 Assembly overview - turbocharger (en‐

gine codes CEBA, CEBB, CECA,
CECB)
Note

♦ Secure all hose connections with hose clips which conform to
production standard.
♦ Charge air system must be free of leaks.
♦ After installing turbocharger run engine for approx. 1 minute
at idling speed, do not rev engine. This guarantees oil supply
to turbocharger.

Crafter 2006 ➤
1 - To exhaust gas recircula‐

tion cooler.
❑ ⇒ Item 12 (page 188)
2 - Connecting pipe
3 - Exhaust manifold
4 - Gasket
5 - Nut
❑ 25 Nm
6 - Heat shield
7 - Washer
8 - Nut AG. Volkswagen AG d
agen oes
❑ Renew after removing Volksw not
gu
by ara
❑ 20 Nm rised
nte
ho eo
ut
9 - Bolt a ra
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ss c
❑ 10 Nm
ce
le
un
pt
an
d
itte
10 - Oil supply line
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rm
ab
❑ Before installing, fill tur‐
pe
ility
ot
bocharger with engine
wit
, is n
oil through oil supply line
h re
hole
connection.
spec
es, in part or in w
❑ To install, tighten both
t to the co
banjo bolts hand-tight
and then tighten.
rrectness of i
11 - Seal
l purpos
12 - Banjo bolt nform

ercia
❑ 32 Nm
m
13 - Bolt
a
com
tion in
❑ 11 Nm
r
te o
thi
s
14 - Oil return line

iva
do
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rp
❑ To cylinder block.
um
fo
en
ng
t.
yi
Installation sequence:
Co
Cop py
t. rig
gh
❑ Tighten oil return line hand-tight to turbocharger.
ht
pyri by
Vo
o
by c lksw
❑ Tighten oil return line hand-tight to cylinder block. Prote
cted AG.
agen
❑ Tighten bolts.
15 - Bolt
❑ 20 Nm
16 - Intake hose
❑ From air filter ⇒ Item 1 (page 149) .
❑ Do not cant when installing.
❑ To charge air cooler ⇒ Item 3 (page 114) .
❑ 5.5 Nm
1. Turbocharger 109
Crafter 2006 ➤
19 - Vacuum hose
20 - Bolt
❑ 40 Nm
21 - Support
❑ Between turbocharger and engine bracket.
22 - Nut
❑ 25 Nm
23 - Turbocharger
24 - To particulate filter
AG. Volkswagen AG d
❑ ⇒ Item 5 (page 155) agen oes
olksw not
byV gu
ara
25 - Banjo bolt rised
nte
ho eo
❑ 19 Nm s aut ra
c
s
26 - Exhaust gas temperature sender 1 - G235-
ce
le
un
pt
an
d
❑ Grease thread of sender using high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
itte
cardiagn.com
y li
rm
ab
❑ 45 Nm
pe
ility
ot
wit
27 - Rubber seal
, is n
h re
hole
spec
❑ Connect the rubber seal carefully, to prevent damage
es, in part or in w
t to the co
1.3 Removing and installing turbocharger
rrectness of i
(engine codes BJJ, BJK, BJL, BJM)
l purpos
Special tools and workshop equipment required nform

ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
Caution

for soiling.
for foreign objects.
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Removing
⇒ Rep. gr. 27 .
– Remove heater air duct.
cardiagn.com
AG. Volkswagen AG d
– Pull vacuum hose off turbocharger.olkswagen oes
not
V gu
by
– Remove the intake hose -4-.rised ara
nte
tho eo
– Loosen bolt ⇒ Item 6 (page
s a 157) from
u bracket -3-. ra
c
s
ce
e
– Release control lines -2- ⇒ Item 2 (page 157) and

nl
pt
du
⇒ Item 3 (page 157) if necessary and lay to one side.
an
itte
y li
erm
ab
– Remove air intake hose -5-.
ility
ot p
wit
– Remove support for particulate filter -7-.
, is n
h re
hole
– Remove support -6- from turbocharger. Only loosen securing

bolt on engine bracket. spec
es, in part or in w
t to the co
– Remove clamp -1-.
– Remove oil return line ⇒ Item 14 (page 107) at cylinder block.
rrectness of i
– Remove oil supply line ⇒ Item 10 (page 107) at turbocharger.

l purpos
– Unscrew turbocharger from exhaust manifold.

nf
ercia
Installing
orm
m
atio

om
n in
c

or
thi
te
sd
a
♦ Renew seals for oil supply line

iv
o
r
rp
cu
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f
♦ Renew oil return line gasket

en
ng
t.
yi Co
op
♦ Disconnect battery ⇒ Rep. gr. 27
C py
t. rig
gh ht
yri by
Specified torques
op Vo
by c lksw
cted agen
Prote AG.
♦ ⇒ “1.1 Assembly overview - turbocharger (engine codes BJJ,
1.4 Removing and installing turbocharger

(engine codes CEBA, CEBB, CECA,
CECB)
1. Turbocharger 111
Crafter 2006 ➤
cardiagn.com
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
erm
ab

ility
ot p

wit
is n

h re
ole,

spec
t to the co
for soiling.
rrectne
for foreign objects.

ss
ed air routing must be cleaned and the charge air cooler must
o
cial p
be renewed, if necessary.
inform
mer
atio
m
Removing
o
n
c
i
or
n thi
e

t
sd
va
⇒ Rep. gr. 27 .
i
o
pr
cum
r
fo

en
ng
t.
yi Co
op py
– Remove intake hose ⇒ Item 1 (page 149) . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Pull off vacuum hose and connector from turbocharger

-arrows-.
. Volkswagen AG
wa gen AG does
– Remove air intake hoseV-3-.
olks not
gu
y
db ara
– Remove support -2- ris from
e
turbocharger. Only loosen securing nte
ho eo
bolt on engine abracket.
ut ra
ss c
ce
le
un
pt
an
d
– Remove oil return line ⇒ Item 14 (page 109) at cylinder block.

itte
y li
rm
ab
pe
– Remove oil supply line ⇒ Item 46 (page 76) at oil filter bracket.
ility
ot
wit
, is n
– Unscrew turbocharger from exhaust manifold.
h re
hole
spec
Installing
es, in part or in w
t to the co
rrectness of i
♦ Renew seals for oil supply line
l purpos
♦ Renew oil return line gasket

♦ Disconnect battery ⇒ Rep. gr. 27
nform
ercia
cardiagn.com
Specified torques
m
a
com
tio
♦ ⇒ “1.2 Assembly overview - turbocharger (engine codes CE‐
n in
r
te o
thi
s
iva
do
r
rp
des CEBA, CEBB, CECA, CECB)”, page 154 cum

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Turbocharger 113
Crafter 2006 ➤
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 114
⇒ “2.2 Checking charge air system for leaks”, page 114
2.1 Assembly overview - charge air system
Note

♦ Secure all hose connections with hose clips
agen
Awhich
G. Volkconform
swagen AGto
d
production standard. Vol
ksw
oes
not
gu
d by ara
♦ Charge air system must be free ris of leaks.
e
Checking charge air nte
ho eo
system for leaks ⇒ page 114
au .
t ra
ss c
ce
le
un
pt
an
d
itte
1 - Bolt
y li
erm
ab
❑ 8 Nm
ility
ot p
cardiagn.com
wit
is n
2 - Radiator
h re
ole,
❑ ⇒ Item 1 (page 102)
spec
3 - Charge air cooler
t to the co
❑ Remove bumper cover
to remove ⇒ Rep. gr.
rrectne
63 . In vehicles with an
air conditioning system
unclip condenser and
ss
remove radiator fan
o
cial p
housing ⇒ Rep. gr. 87 . f inform

mer
4 - Air intake hose

atio
m
❑ From turbocharger
o
n
c
i
or
⇒ Item 25 (page 108) .

thi
te
sd
va
5 - Air intake hose

i
o
pr
cum
r
fo
❑ To intake manifold flap

en
ng
t.
yi
motor - V157-
Co
op py
⇒ Item 15 (page 146) .
t. C rig
gh ht
pyri by
Vo
6 - Air pipe
o
by c lksw
cted agen
Prote AG.
7 - O-ring
8 - Charge pressure sender -
G31- and intake air tempera‐
ture sender - G42-
9 - Bolt
❑ 2 Nm
10 - Bolt
❑ 7 Nm
12 - Air duct
2.2 Checking charge air system for leaks


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Crafter 2006 ➤
s
s 5-cylinder diesel engine - Edition 03.2016
ce
le
un
pt
an
d
itte
♦ Charge air system tester - V.A.G 1687-
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
♦ Adapter - V.A.G 1687/1-
atio
om
n
♦ Ultrasonic tester - V.A.G 1842-
c
i
or
n thi
te
sd
♦ Hose clamps up to 25 mm - 3094-
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
cardiagn.com
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Connect adapter - 1687/1- in intake hose -1- and secure with
clip.
– Pull hose off pressure control valve ⇒ Item 1 (page 46) .
– Clamp off hose with hose clamps, up to 25 mm - 3094- .
Prepare charge air system tester - V.A.G 1687- as follows:
2. Charge air system 115

Crafter 2006 ➤
– Unscrew pressure regulating valve -2- and close valves -3-

and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect charge air system tester - V.A.G 1687- toVoadapter -
cardiagn.com
. lkswagen AG
1687/1- as shown. swagen AG does
olk not
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edb ara
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tho eo
au ra
c
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
wage
e ks s no
Vol t
– Check the charge air systemed
by for leaks by hearing, touching,guar
a
with commercially available
s leak detector spray or using ultra‐ ntee
cardiagn.com
ri
ho
sonic tester - V.A.G
sa
u 1842- .
t or
ac
s
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
wit
, is n
instructions
h re
hole
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 114 . spec
es, in part or in w
t to the co
♦ Before removing the adapter, depressurise the test circuit by
pulling coupling off adapter - 1687/1- .
rrectness of i
l purpos
nf
ercia
orm
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atio
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n in
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thi
te
sd
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f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
2. Charge air system 117

Crafter 2006 ➤
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 118
⇒ “1.2 Assembly overview - fuel system”, page 119
⇒ “1.3 Filling fuel system”, page 122
⇒ “1.4 Checking fuel system for leaks”, page 122
1.1 Schematic overview - fuel system
Caution

cardiagn.com
1 - High-pressure pump
❑ High-pressure pump
generates fuel pressure AG. Volkswagen AG d
up to 1600 bar. agen oes
olksw not
yV gu
❑ With gear-type pre-sup‐ rised b ara
nte
ply pump. ut
ho eo
ra
a
❑ Gear-type pre-supply ss c
ce
e
pump generates fuel

nl
pt
du
pressure between 4 and

an
itte
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5 bar.
erm
ab
ility
❑ With fuel metering valve
ot p
- N290- . wit
, is n
h re
❑ Removing and instal‐
hole
spec
ling, renewing with fuel
es, in part or in w
overflow valve
t to the co
⇒ page 128 .
❑ Removing and instal‐
rrectness of i
ling, renewing with reg‐

ulating valve
l purpos
⇒ page 133 .
2 - Fuel temperature sender -
nform
ercia
G81-
m
at
3 - Fuel accumulator
om
ion
c
in t
r
4 - Fuel pressure regulating

o
his
te
valve - N276-
a
do
priv
cum
or
f
en
ng
t.
yi Co
6 - Fuel pressure sender - . Cop py
G247-
ht rig
rig ht
py by
co Vo
7 - Injectors (piezo injectors)
by lksw
cted agen
Prote AG.
❑ With injector, cylinder 1
- N30- to injector, cylin‐
der 5 - N83- .
118 Rep. gr.23 - Mixture preparation - injection

Crafter 2006 ➤
AG. Volkswagen AG d 5-cylinder diesel engine - Edition 03.2016
agen oes
o lksw not
8 - Fuel return by Vlines (from injectors) gu
ara
ed
ris nte
❑ utFuel
ho return lines must not be dismantled; they e omay
ra
only be renewed together with pressure retention
ss a valve ⇒ Item 9 (page 119) as one unit. c
ce
le
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
un
pt
check fuel return lines for leaks.
an
d
itte
y li
erm
ab
9 - Pressure retention valve
ility
ot p
❑ The function of the pressure retention valve is to maintain a residual pressure of approx. 10 bar in the
wit
is n
fuel return lines ⇒ Item 8 (page 119) at all times.
h re
ole,
spec
❑ This residual pressure is required for the control function of the piezo injectors
❑ The pressure retention valve may only be renewed together with the fuel return lines.
t to the co
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
10 - Fuel system pressurisation pump - G6-
rrectne
❑ In fuel tank
s
❑ Pressurisation pressure approx. 1 bar.
s o
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11 - Fuel filter
form
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❑ Assembly overview - fuel filter
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1.2 Assembly overview - fuel system

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1. Injection system 119

Crafter 2006 ➤
❑ Do not interchange fuel
hoses.
2 - Bolt
❑ 20 Nm
3 - Copper washer
4 - Injectors (piezo injectors)
❑ With injector, cylinder 1
- N30- to injector, cylin‐
der 5 - N83- .
❑ Following components
and O-rings must be re‐
newed each time injec‐
tors are removed and
installed: Copper wash‐
er ⇒ Item 3 (page 120)
and O-ring of injector re‐
turn
⇒ Item 5 (page 120) .
cardiagn.com
❑ If they are to be re-in‐
stalled, the injectors,
high-pressure lines and
retainers must always
be re-fitted in their origi‐
nal positions (i.e. on the
same cylinder).
⇒ page 125
5 - O-ring
❑ Renew. ⇒ page 125 . AG. Volkswagen AG d
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7 - Retainer aut ra
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❑ If they are to be re-installed, the injectors and retainers must always be re-fitted in the same cylinder.
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8 - Dished washer
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9 - Bolt
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❑ 22 Nm
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10 - Fuel return lines (from injectors)

spec
❑ Fuel return lines must not be dismantled; they may only be renewed together with pressure retention
t to the co
valve ⇒ Item 17 (page 121) as one unit.

❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
check fuel return lines for leaks.
rrectne
11 - High-pressure line
ss
❑ Tighten using socket - T40055- .

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❑ 23 Nm
nform
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12 - Fuel pressure sender - G247-

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❑ 110 Nm
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14 - High-pressure fuel line
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Crafter 2006 ➤
15 - Bracket
16 - Retainer
❑ For return (leakage) lines (fuel return lines)
17 - Pressure retention valve
❑ The pressure retention valve always maintains a residual pressure of approx. 10 bar in the fuel return
lines.
❑ This residual pressure is required for the function of the piezo injectors.
❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
❑ Pressure retention valve must be re-installed in its original position to prevent fuel return lines from com‐
ing into contact with exhaust gas recirculation connecting pipes.
❑ Check ⇒ page 124 .
18 - Fuel line
19 - Fuel return line
❑ To fuel tank.
20 - Retainer
❑ For fuel lines
cardiagn.com
21 - Fuel supply line lkswage es n
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❑ From fuel filter. ir se
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22 - High-pressure pump ss
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❑ High-pressure pump generates fuel pressure up to 1600 bar.
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❑ With gear-type pre-supply pump.

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❑ Gear-type pre-supply pump generates fuel pressure between 4 and 5 bar.
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❑ Removing and installing, renewing with fuel overflow valve ⇒ page 128 .
hole
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❑ Removing and installing, renewing with fuel metering valve - N290- ⇒ page 133 .
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23 - Seal
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24 - Banjo bolt
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❑ 25 Nm
25 - Fuel return line
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26 - Fuel supply line

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27 - Retaining clip
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28 - Fuel temperature sender - G81-

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30 - Housing
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❑ For fuel temperature sender - G81- .
AG.
31 - O-ring
32 - Fuel pressure regulating valve - N276-

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5-cylinder diesel engine - Editionth03.2016
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1.3 Filling fuel system
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Caution
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After installation, the high-pressure pump must first be filled
h re
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with fuel before the engine is started (the pump must NOT be
spec
allowed to run while still empty). es, in part or in w
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Note
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♦ When installing the high-pressure pump, it is essential to en‐
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♦ Only remove the plugs immediately before fitting the fuel lines.
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♦ There must be sufficient fuel in the tank.
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Proceed as follows to fill high-pressure pump with fuel: t. C rig
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– Connect vehicle diagnostic tester .
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– Switch ignition on.
– On ⇒ Vehicle diagnostic tester, under “Functions”, select
“Bleed fuel system”.
– The fuel pump starts up.
– Follow instructions of ⇒ Vehicle diagnostic tester.
– After system has been bled, start engine.
– After filling fuel system, leave engine running at moderate
speed for a few minutes and then switch off again.
– Clear event memory entry using ⇒ Vehicle diagnostic tester.
– Then, road-test the vehicle over a distance of at least 20 km.
Accelerate with full throttle at least once. Then, inspect the
high-pressure system again for leaks ⇒ page 122 .
Note
If there is any air left in the fuel system, the engine may switch to
backup mode ('emergency running' mode) during the road test.
Switch off the engine and erase the fault memory. Then continue
the road test.
– Read the event memory again ⇒ Vehicle diagnostic tester.
1.4 Checking fuel system for leaks

– Allow engine to run for several minutes at average revs.
– Switch off ignition.
– Check the entire fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.

Crafter 2006 ➤
– Then carry out a road test with at least one full-throttle accel‐
eration.
– Then, check high-pressure system again for leaks.
cardiagn.com
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Crafter 2006 ➤
2 Injectors/high-pressure accumulator
(rail)
⇒ “2.1 Check pressure retention valve in fuel return line”,
page 124
⇒ “2.2 Removing and installing injectors (piezo injectors)”,
page 125
⇒ “2.3 Removing and installing fuel overflow valve”, page 128
2.1 Check pressure retention valve in fuel

return line
Special tools and workshop equipment required agen
AG. Volkswagen AG d
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♦ Fuel return system tester - VAS 6330- d by ara
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The pressure retention valve maintains a residualaupressure
th
of ap‐ ra
prox. 10 bar in the return lines. ss c
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This residual pressure is required for the control function of the
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piezo injectors.
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Caution
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– Cover the return line connection from cylinder no. 1 with a line-
s o
free rag.
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– Pull release pins -1- upwards -arrow- and pull return line con‐
mer
nection off injector.
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♦ Illustration shows injector of cylinder no. 5

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♦ Adhere strictly to the rules for cleanliness; no dirt must be al‐ t. C rig
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connection.
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– Install fuel return system tester - VAS 6330- between return

line connection on injector and return line.
– Close shut-off tap -arrow-.
– Start engine.
– Check pressure on pressure gauge.
♦ Specification: 8…14 bar
If the specification is not reached, replace the pressure retention
valve ⇒ Item 17 (page 121) .
– Remove fuel return system tester - VAS 6330- .
– Renewing O-ring on injector return ⇒ page 125 .

Crafter 2006 ➤
2.2 Removing and installing injectors (piezo injectors)

equipment required
♦ Socket, 14 mm - 3150-
1331-
♦ Ratchet - V.A.G 1331/1-
♦ Puller - T10055-
♦ Socket - T40055-
cardiagn.com
AG. Volkswagen AG d
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t.
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Cop py
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2. Injectors/high-pressure accumulator (rail) 125

Crafter 2006 ➤
♦ Tool set for FSI engines - T10133-

♦ Tool insert 17 mm - V.A.G 1331/6-
Removing
AG. Volkswagen AG d
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Always read rules hor
for cleanliness and instructions for working eo
ut
on fuel system
ss a ⇒ page 7 . ra
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When a new injector is installed, the adaptation value for the
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diagnostic tester.
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Used injectors, retainers and high-pressure lines may only be
es, in part or in w
re-installed on the same cylinder.
t to the co
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Caution
nform
ercia
Mark cylinder numbers on injectors. The adaptation value for

the injectors is stored in the engine control unit.
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Observe rules for cleanliness when working on the injection
n
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system.
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Plug open connections with suitable sealing caps immediately.

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– Pull connectors off at injectors to be removed. t. C rig
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– Pull release pins -1- upwards -arrow- to detach return line cted agen
Prote AG.
connections from injectors.
– Loosen union nut of high-pressure line -2- on injectors using
tool insert, AF 17 - V.A.G 1331/6- .
– Remove high-pressure accumulator ⇒ page 119 .
– Release securing bolt -1- and remove retainer -2-.

Crafter 2006 ➤
– Detach injector units using tool set for FSI engines - T10133-
or puller - T10055- and adapter - T10055/1- .
– After removal, lay injectors on a clean cloth.
Important instructions for installing injectors
• Following components and O-rings must be renewed ageach
en AG. V
olkswagen AG
does
time injectors are removed and installed: copper olksw
washer and not
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O-ring of injector return. ise
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• Used injectors, retainers and high-pressure
sa
ut lines may only be or
ac
re-installed on the same cylinder. s
ce
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un
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• Make sure that the injectors and the installation area are clean
an
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before installing.
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• The injectors must be completely undamaged.
wit
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• Lubricate all O-rings with engine oil or assembly oil before in‐
ole,
stalling.
spec
t to the co
If a used injector is being re-installed:
– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
rrectne
cardiagn.com
– Carefully clamp seized copper oil seals in a vice until copper
oil seal is just prevented from turning between jaws. Then
ss o
carefully pull and twist the injector out of the copper seal by
cial p
f i
hand.
nform
mer
– Clean sealing surface underneath copper seal.
atio
om
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– Fit new copper oil seal.
i
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– Be careful when fitting new O-ring for fuel return connection in

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order to avoid damaging O-ring.
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– To remove carbon deposits from the injector sealing surface,
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clean the injector seat in the cylinder head with a cloth soaked
C py
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in engine oil or rust solvent. Take care not to damage the
ht
pyri by
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sealing surface.
c by lksw
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Installing
– Fit injectors into cylinder head.
– Install retainer, and tighten securing bolt to 22 Nm.
– Remove high-pressure accumulator with high-pressure lines
⇒ page 119 .
– Tighten union nuts on high-pressure lines finger-tight initially.
– Ensure that high-pressure lines are not under tension.
– Tighten union nuts of high-pressure lines on injectors using
torque wrench - V.A.G 1331- and tool insert, AF 17 - V.A.G
1331/6- .
– Tighten union nuts of high-pressure lines on high-pressure
accumulator.
– Press return line connections carefully over O-ring and onto
injector (check O-ring for damage first). The catch should en‐
gage audibly. Then press release pin down carefully.
Caution
Route return lines such that they do not touch the connecting
pipes of the exhaust gas recirculation system.
– Connect connectors to injectors.

Crafter 2006 ➤
Note
♦ After at least one injector has been renewed, the “injector de‐
livery calibration” and “injector voltage calibration” values for
the new injector(s) must be written into the engine control unit
♦ Additionally, check that the injector delivery calibration values
and injector voltage calibration values have been entered cor‐
rectly for all the other injectors. Do not under any circumstan‐
ces attempt to re-enter these calibration values if the correct
values are already stored in the engine control unit.
Bleeding fuel system and checking for leaks

– Run engine at idling speed for several minutes and then switch
off.
– Check the complete fuel system and return line connections
for leaks.
cardiagn.com
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
Note
The return lines can only be renewed together with the pressure
retention valve as one unit.
– Then carry out a road test. In this, the engine must reach its
operating temperature and be accelerated at full-throttle at
least once. Then, check high-pressure system again for leaks
⇒ page 122 . agen
AG. Volkswagen AG d
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d by ua
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Note utho or
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ss
If there is any air left in the fuel system, the engine may switch to
ce
e
nl
pt
du
the backup mode ('emergency running' mode) during the road

an
itte
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test. Switch off the engine and erase event memory ⇒ Vehicle
erm
ab
diagnostic tester. Then continue the road test.

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Specified torques
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spec

es, in part or in w
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2.3 Removing and installing fuel overflow

valve
rrectness of i
l purpos

nform
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ion
c
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or
his
ate
do
priv
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for
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Crafter 2006 ➤
Removing AG. Volkswagen AG d

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Caution ris ed ara
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When doing any repair work, especially
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tions:
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the system, wrap cleaning cloths around the connection

and carefully loosen connection to release the pressure!
nf
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o
♦ Make sure that no escaping fuel runs onto radiator hoses
rm
m
atio
and belts, as these are not resistant to fuel!
om
n in
c
♦ Wear eye and hand protection when performing all as‐

or
thi
e
sembly work on the fuel system!

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Caution
co Vo
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Prote AG.
Extreme care and cleanliness are required when removing and

installing the fuel overflow valve.
♦ Use only lint-free cleaning cloths.
♦ A fuel overflow valve which has been removed must al‐
ways be renewed.
♦ Additionally renew fuel accumulator (new part number
with index “A”) ⇒ Electronic Parts Catalogue (ETKA) on
right in engine compartment.

Crafter 2006 ➤
– Carefully clean area around high-pressure pump -1- with

cleaning agents.
– Then blow all surfaces dry with compressed air.
– Place lint-free cloths below high-pressure pump to collect es‐
caping fuel.
olkswagen AG
en AG. V
– Completely remove guide tube -1- for oil dipstick olkswag does
not
⇒ Item 9 (page 74) . ed
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– Remove fuel supply pipe -2- and fuel returnaut pipe -3- from high-
h eo
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pressure pump -4-. ss c
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– Catch escaping fuel with a cleaning cloth.
an
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spec
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Note
s
Seal pipe openings -1- and -2- with a lint-free cleaning cloth.
s o
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– Using an appropriate 16 mm ring spanner e.g., release fuel
mer
overflow valve -3- approx. 2 revolutions.
atio
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– Then again clean area around fuel overflow valve.

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– Then unscrew fuel overflow valve.

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– Clean particles of dirt from threads in high-pressure pump.

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Installing C py
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Installation is carried out in the reverse order; note the following: co Vo
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– Renew fuel overflow valve.
AG.
– Coat fuel overflow valve threads and seal with fuel.

– Screw fuel overflow valve back in, and tighten it.
Note
♦ Renew oil seals.

circumstances.

Crafter 2006 ➤
– Fit fuel supply line -2- and fuel return line -3- with new seals
and install on high-pressure pump -4-.
– Install guide tube -1- for oil dipstick ⇒ Item 9 (page 74) .
– Additionally renew fuel accumulator -1- on intake manifold

⇒ Item 3 (page 146) .
– Pull off both pipes -2- at fuel accumulator to do this.
Note
n AG. Volkswagen AG
Note new part onumber
lksw
age with index “A” ⇒doElectronic
es n Parts Cata‐
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logue (ETKA)
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Caution
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Risk of irreparable damage to high-pressure pump if allowed

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to run dry.
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The high-pressure pump must first be filled with fuel before the
, is n
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engine is started ⇒ page 122 . Avoid allowing the high-pressure

hole
spec
pump to run dry under all circumstances.

es, in part or in w
t to the co

rrectness of i
Specified torques
l purpos

nform
mercia
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ion
c
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or
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ate
do
priv
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for
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t. rig
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co lksw
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Prote AG.

Crafter 2006 ➤
3 Vacuum system
⇒ “3.1 Schematic diagram - vacuum system”, page 132
3.1 Schematic diagram - vacuum system
1 - Brake servo
2 - Vacuum valve
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3 - Coolant circuit valve - N214- Volkswa not
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4 - Vacuum actuator ris
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6 - Filter
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7 - Charge pressure control
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solenoid valve - N75-
hole
spec
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cooler changeover valve -
N345-
❑ Only with EU 4 engines.
rrectness of i
9 - Vacuum reservoir
l purpos
10 - Non-return valve
nform
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AG. Volkswagen AG d
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thor eo Crafter 2006 ➤
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ss a 5-cylinder diesel
c engine - Edition 03.2016
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4 High-pressure pump
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pe
ility
⇒ “4.1 Removing and installing high-pressure pump”, page 133
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4.1 Removing and installing high-pressure
hole
spec
pump
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♦ Puller - 3032-
rrectness of i
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Prote AG.
Removing
Caution

tions:
sitions.
4. High-pressure pump 133

Crafter 2006 ➤
– Loosen central nut for high-pressure pump shaft using coun‐

ter-hold tool - 3036- .
– Use puller - 3032- to pull off belt sprocket for high-pressure
pump.
– Remove fuel supply line -1- and fuel return line -2- from high-
pressure pump -4-.
– Remove high-pressure fuel line -5-.
– Pull off connector -3-.
cardiagn.com
AG. Volkswagen AG d
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rrectness of i
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nform
mercia
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com
tion in
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Unscrew securing bolts -arrows-.

– Remove high-pressure pump.
Installing
Caution

to run dry.
engine is started ⇒ page 122 . It is essential not to allow the
high-pressure pump to run while still empty.
AG. Volkswagen AG d
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♦ Renew oil seals. th
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ss c
♦ The high-pressure pump cone and the bore of the high-pres‐
ce
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le
un
pt
sure pump pulley must be free from oil and grease.
an
d
itte
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rm
♦ Install toothed belt ⇒ page 57 .
ab
pe
ility
ot
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, is n
h re
hole
spec
es, in part or in w
circumstances.
t to the co
rrectness of i
Specified torques
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nform
mercia

a
com
tion in
Bolts of high-pressure pump to 20 Nm
r
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bracket
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Cop py
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by
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Prote AG.
4. High-pressure pump 135

Crafter 2006 ➤ agen
AG. Volkswagen AG d
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5-cylinder diesel engine - Edition 03.2016 by
Vol not
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5 Senders and sensors s a c
s
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un
pt
⇒ “5.1 Removing and installing fuel pressure regulating valve
an
d
itte
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N276 ”, page 136
erm
ab
ility
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⇒ “5.2 Checking fuel pressure regulating valve N276 ”,
wit
is n
page 138
h re
ole,
⇒ “5.3 Removing and installing fuel pressure sender G247 ”, page
spec
138
t to the co
⇒ “5.4 Removing and installing fuel metering valve N290 ”,
page 140
rrectne
⇒ “5.5 Removing and installing air mass meter G70 ”, page 145
5.1 Removing and installing fuel pressure
ss o
cial p
f
regulating valve - N276-
inform
mer
The fuel pressure regulating valve - N276- is located in the high-
atio
m
pressure accumulator. It maintains a constant pressure in the

o
n
c
i
high-pressure accumulator and high-pressure lines (high-pres‐
or
n thi
e
sure fuel circuit).

t
sd
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p
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If the pressure in the high-pressure fuel circuit is too high, the fuel
um
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pressure regulating valve - N276- opens to allow some of the fuel

t.
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to flow back from the high-pressure accumulator to the fuel tank Cop py
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via a return line. opyri
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If the pressure in the high-pressure fuel circuit is too low, the valve Prote
cted agen
closes and seals off the high-pressure section of the system from
AG.
the low-pressure section.
Caution

Removing
– Remove high-pressure accumulator ⇒ Item 13 (page 120) .
– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using, for example, commercial cold
cleaning solvent (no dirt must enter bore in high-pressure ac‐
cumulator).
Note
Clean carefully; cleaning solvent must not enter the electrical

connector.
– Dry off fuel pressure regulating valve - N276- .

Crafter 2006 ➤
– Loosen union nut -1- while holding hexagonal flats on fuel

pressure regulating valve - N276- -2-. Then unscrew and re‐
move by hand.
Note
Seal off high-pressure accumulator hole immediately with a suit‐

able plug to preventswdirt
agenfrom entering. AG does
AG. Volkswagen
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Installing orise nte
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Installation
ss is carried out in the reverse order; note the following:
c
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Note
rm
ab
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ility
ot
♦ The fuel pressure regulating valve - N276- has a deformable
wit
, is n
sealing lip and no separate seal; it can therefore be used only
h re
hole
once.
spec
es, in part or in w
♦ Check that sealing surfaces (deformable sealing lip) and
t to the co
threads on new fuel pressure regulating valve - N276- are not
cardiagn.com
damaged.
rrectness of i
♦ Also check sealing surface at high-pressure accumulator bore.
l purpos
♦ Thread on fuel pressure regulating valve - N276- must be free

of oil and grease. nform
ercia
♦ Coat new O-ring with assembly oil or engine oil before instal‐
ling.
m
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tion in
r
– Install fuel pressure regulating valve - N276- with new O-ring.

te o
thi
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iva
do
– Screw on union nut by hand.

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cum
fo
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– Align fuel pressure regulating valve - N276- so that connecting

n
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wire is free of tension after connector is attached.
ht. Cop py
rig
rig ht
Tighten union nut in 2 stages.
py by
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cted agen
1- Stage 1: 60 Nm (when tightening, counterhold on hexagonal
Prote AG.
flats on housing).
2- Then back off union nut 1/ 4 turn (90°); counterhold hexag‐
onal flats on housing.
3- Stage 2: 80 Nm (when tightening, counterhold on hexagonal
flats on housing).
– Install high-pressure accumulator ⇒ Item 13 (page 120) .
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Check fuel system for leaks.
– Read event memory ⇒ Vehicle diagnostic tester.
⇒ page 122 .
– Read event memory again ⇒ Vehicle diagnostic tester.
Specified torques
5. Senders and sensors 137

Crafter 2006 ➤
5.2 Checking fuel pressure regulating valve n AG. Volkswagen AG

wage does
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- N276- y V gu
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Special tools and workshop equipment required aut ra
c
ss
♦ Engine bung set - VAS 6122-
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Measuring instrument - V.A.G 1348/2B-
nform
mercia
a
com
ti
cardiagn.com
on in
r
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s
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
♦ Measuring container, fuel-resistant
WARNING
⇒ page 7
– Remove fuel return hose from high pressure accumulator

⇒ Item 13 (page 120) . To do this, release hose clip -arrow-.
– Seal open fuel return hose using a bung from engine bung set
- VAS 6122- .
– Connect auxiliary hose to return connection of high-pressure
accumulator ⇒ Item 13 (page 120) .
– Hold auxiliary hose in meter - V.A.G 1348/2B- or measuring
container to measure return flow rate.
– Start engine and run at idling speed for 30 seconds.
• Specified amount in 30 seconds: 90 ... 110 ml.
If the specification is not attained, the fuel pressure regulating
valve - N276- is defective.
5.3 Removing and installing fuel pressure

sender - G247-

Crafter 2006 ➤
The fuel pressure sender - G247- is located in the high-pressure

accumulator and continuously measures the current fuel pressure
in the high-pressure system. It transmits a corresponding voltage
signal to the engine control unit - J623- .
Should the sender fail, the engine control unit will control the fuel
pressure via a mapped open-loop backup function, allowing a
. Volkswagen AG
maximum of approx. 3000 rpm. swagen AG does
olk not
cardiagn.com
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Removing edb ara
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Caution ss c
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an
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove high-pressure accumulator ⇒ Item 13 (page 120) .
rrectness of i
– Before removal, clean area around thread for fuel pressure
sender - G247- , using e.g. a commercially available cold
l purpos
cleaning solvent. No dirt must enter hole in high-pressure ac‐

cumulator.
nform
mercia
at
om
Note
ion
c
in t
or
his
e
Clean carefully; cleaning solvent must not enter the electrical

at
do
riv
connector.
p
cum
for
en
ng
t.
yi
– Dry fuel pressure sender - G247- .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Unscrew fuel pressure sender - G247- -1-.
Note
Seal off high-pressure accumulator bore immediately with a suit‐

able plug to prevent dirt from entering.
Installing
Note
♦ The fuel pressure sender - G247- has a deformable sealing

lip, not a separate oil seal; it can therefore be used only once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure sender - G247- are not dam‐
AG. Volkswagen AG d
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no
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♦ Also check sealing surface at high-pressure
ris
ed accumulator bore. ara
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♦ The thread on the new fuel pressure
sa
u sender - G247- has a ra
c
lubricating coating and musts therefore be kept free of oil and
ce
le
grease.
un
pt
an
d
itte
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erm
ab
– Screw in fuel pressure sender - G247- by hand.
ility
ot p
wit
– Tighten fuel pressure sender - G247- . To tighten, use torque
is n
h re
wrench - V.A.G 1332- with socket.
ole,
spec
– Install high-pressure accumulator ⇒ Item 13 (page 120) .
t to the co
– After installation, run engine at moderate speed for several rrectne
minutes and then switch off.
– Check fuel system for leaks.
ss o
cial p

inform
mer
atio

om

c
i
or
⇒ page 122 .
thi
te
sd
iva
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p
cum
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fo
en
ng
Specified torques
t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
5.4 Removing and installing fuel metering

valve - N290-

Crafter 2006 ➤
Removing
Caution

tions:
cardiagn.com
sitions.
carefully loosen connection to release the pressure! . Volkswagen AG
gen AG does
swa
♦ Make sure that no escaping fuel runs onto radiator y Vhoses
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and belts, as these are not resistant to fuel! rised
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♦ Wear eye and hand protection when performing
s au any type ra
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of repair work on the fuel system! s ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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Caution
hole
spec
es, in part or in w
Extreme care and cleanliness are required when removing and

t to the co
installing the fuel metering valve - N290- .

♦ If a fuel metering valve - N290- is removed, it must always
rrectness of i
be renewed.
l purpos
♦ Use only lint-free cleaning cloths.

♦ Additionally renew fuel accumulator (new part number
nform
ercia
with index “A”) ⇒ Electronic Parts Catalogue (ETKA) on

right in engine compartment.
m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Carefully clean area around high-pressure pump -1- with

cleaning agents.
– Then blow all surfaces dry with compressed air.
– Place lint-free cloths below high-pressure pump to collect es‐
caping fuel.
– Completely remove guide tube -1- for oil dipstick

⇒ Item 9 (page 74) .
– Remove fuel supply pipe -2- and fuel return pipe -3- from high-
pressure pump -4-.
– Catch escaping fuel with a cleaning cloth.
cardiagn.com
Note
Seal pipe openings -1- and -2- with a lint-free cleaning cloth.
gen AG
. Volkswagen AG
d wa oes
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ab
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
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Prote AG.

agen
AG. Volkswagen AG d
oes
Crafter 2006 ➤
olksw 5-cylinder diesel engine
not - Edition 03.2016
V g
by ua
ed ran
ris tee
– Pull connector -2- off fuel metering valve
auth - N290- -1-.
o
or
ac
ss
– Loosen 3 securing bolts -3- for fuel metering valve - N290-
ce
le
un
approx. 2 turns.
pt
an
d
itte
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erm
ab
ility
ot p
Note
wit
is n
h re
ole,
3rd securing bolt is not shown in illustration, It is located beneath
spec
valve.
t to the co
– Again clean area around fuel metering valve - N290- .
– Completely unscrew 3 securing bolts for fuel metering valve -
rrectne
N290- .
ss o
cial p
f
Note
inform
mer
atio
Do not tilt the fuel metering valve - N290- when unscrewing it and
om
do not lever it out with a screwdriver.
n
c
i
or
n thi
te
sd
va
– Withdraw fuel metering valve - N290- steadily while rotating it

i
o
r
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p
cum
constantly.
r
fo
en
ng
t.
yi
– Clean particles of dirt from opening in high-pressure pump.
Co
Cop py
ht. rig
Installing
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
Note
♦ If a fuel metering valve - N290- is removed, it must always be

renewed.
♦ It must be possible to press the fuel metering valve - N290- in
until it no longer protrudes.
– Coat seals of new fuel metering valve - N290- with fuel.

– Rotate fuel metering valve - N290- as you re-install it.
– Hand-tighten securing bolts -3- of fuel metering valve - N290-

-1-.
– Tighten securing bolts -3- in two stages.
– Connect connector -2- to fuel metering valve - N290- -1-.
Note
♦ Always renew fuel line connection seals.

circumstances.

Crafter 2006 ➤
. Volkswagen AG
does gen AG
– Fit fuel supply line V-2-
olksand fuel return line -3- with
wa notnew seals
and install on high-pressure
ed by pump -4-. gu
ara
is nte
or
– Install guide
au tube -1- for oil dipstick ⇒ Item 9 (page 74) . r a
th eo
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Additionally renew fuel accumulator -1- on intake manifold
rrectness of i
⇒ Item 3 (page 146) .
l purpos
– Pull off both pipes -2- at fuel accumulator to do this.
nform
ercia
Note
m
a
com
tio
Note new part number with index “A” ⇒ Electronic Parts Cata‐
n in
cardiagn.com
r
logue (ETKA) for fuel accumulator.

te o
thi
s
iva
do
r
rp
cum
fo
en
Caution
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
to run dry.
cop Vo
by lksw
cted agen
Prote AG.
engine is started ⇒ page 122 . Avoid allowing the high-pressure
pump to run dry under all circumstances.
Note
Faults will have been stored in the memory because connectors

have been disconnected. Therefore, read the event memory and
clear it, if necessary.

⇒ page 122 .
Specified torques
Fuel metering valve - N290- Initially tighten to 3 Nm (then,
tighten to 7 Nm).

Crafter 2006 ➤
5.5 Removing and installing air mass meter

- G70- Volkswa n AG. gen AG
wage does
Removing Volks not
gu
by ara
ed
– Loosen clip -A- of intake hoseho-1-
ris and pull hose off air mass nte
eo
meter - G70- -2-. au
t ra
c
ss
– Detach connector -B- from air mass meter - G70- -2-.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove bolts -arrows-.
s
– Carefully pull air mass meter - G70- out of guide on air filter
s o
cial p
housing.
cardiagn.com
inform
mer
Installing
atio
m

o
n
c
i
or
n thi
e
To ensure the proper function of the air mass meter - G70- it is

t
sd
va
important to adhere to the following work sequences.

i
o
pr
cum
r
fo
en
ng
t.
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op
Note C py
t. rig
gh ht
pyri by
Vo
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♦ If the air filter element is very dirty or wet, particles of dirt or
c by lksw
cted agen
water may reach the air mass meter and falsify the measured
Prote AG.
air mass value. This would lead to loss of power, since a

smaller injection quantity is calculated.
♦ Always use genuine part for air filter element.
♦ Always renew seal if damaged (air leaks).
♦ Use a silicone-free lubricant to install the air hose and seal.
♦ Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
♦ Secure all hose connections with hose clips corresponding to
the series equipment ⇒ Electronic Parts Catalogue .
– Check for salt residue, dirt and leaves in air mass meter and
air hose (clean air side).
– Check intake channel for contamination as far as air filter el‐
ement. If contamination is found, remove salt residue, dirt and
leaves from top and bottom part of air filter housing (rinse out
or use vacuum cleaner if necessary).
Specified torques

Crafter 2006 ➤
6 Intake manifold
⇒ “6.1 Assembly overview - intake manifold”, page 146
⇒ “6.2 Removing and installing intake manifold”, page 146
6.1 Assembly overview - intake manifold
1 - Exhaust gas recirculation AG. Volkswagen AG d

valve - N18- with exhaust gas agen oes
olksw not
recirculation potentiometer - d byV gu
ara
G212- orise nte
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h
ut
❑ Renew. ss a ra
c
⇒ Item 5 (page 187) .
ce
le
un
pt
an
2 - Bolt
d
itte
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rm
ab
❑ 20 Nm
pe
ility
ot
wit
, is n
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❑ Do not interchange fuel
hole
spec
hoses.
es, in part or in w
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t to the co
4 - Seal
rrectness of i
5 - Intake manifold
l purpos

⇒ page 146 .
nform
ercia
6 - Gasket
m
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com
tion in
7 - Bracket
r
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thi
8 - Bolt
s
iva
do
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❑ 20 Nm
um
fo
en
ng
t.
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9 - Heat shield
Co
Cop py
ht. rig
10 - Support rig ht
py by
co Vo
by lksw
11 - Bolt
cted agen
Prote AG.
❑ 20 Nm
12 - Connecting pipe
❑ For exhaust gas recircu‐
lation.
13 - Bolt
❑ 9 Nm
14 - From charge air cooler
❑ ⇒ Item 3 (page 114)
15 - Intake manifold flap motor - V157-
❑ The intake manifold flap is closed for approx. 3 seconds when stopping engine and then opens again.
This reduces the stop jolt.
16 - Bolt
❑ 9 Nm
6.2 Removing and installing intake manifold


Crafter 2006 ➤
♦ Transport guard - T10404-

Removing
– Remove air intake hose ⇒ Item 5 (page 114) .
– Remove exhaust gas recirculation connecting pipe -1-.
cardiagn.com
– Remove support -2-.
– Pull connector off intake manifold flap motor - V157- and ex‐
haust gas recirculation valve - N18- .
– Remove intake manifold flap motor - V157- with exhaust gas
recirculation valve - N18- .
– Remove turbocharger ⇒ page 106 . n AG. Volkswagen AG do
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
thi
te
sd
iva
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cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Intake manifold 147

Crafter 2006 ➤
– Disconnect connector for Lambda probe - G39- -1-.

– Pull line or connector -2- off bracket.
– Remove heat shield -4-.
– Unscrew intake manifold.
– Unscrew fuel accumulator -3- from intake manifold.
Installing
♦ Self-locking nuts must be renewed.
♦ Renew intake manifold gasket
♦ Installing turbocharger ⇒ page 106 .
♦ Install intake manifold flap motor - V157- and exhaust gas re‐
circulation valve - N18- ⇒ page 146
♦ Install connecting pipe ⇒ Item 19 (page 188)
♦ Install air hose ⇒ Item 5 (page 114)
♦ Install air filter ⇒ page 149
cardiagn.com
Specified torques
AG. Volkswagen AG d
♦ ⇒ “6.1 Assembly overview - intake manifold”, page 146 agen oes
olksw not
V gu
d by ara
♦ ⇒ “7.1 Assembly overview - air filter”, page 149 orise nte
h eo
ut ra
♦ ⇒ “1.2 Assembly overview - turbocharger (engine codesssCE‐
a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
7 Air filter
⇒ “7.1 Assembly overview - air filter”, page 149
7.1 Assembly overview - air filter
1 - Intake hose
❑ To turbocharger.
2 - Screw-type clip
❑ 3.5 Nm
3 - Bolt
❑ 1.6 Nm
4 - Air mass meter - G70-
5 - O-ring
6 - Bolt
cardiagn.com
❑ 1.6 Nm
7 - Intake manifold pressure
sender - G71- with altitude
sender - F96-
8 - O-ring
9 - Air filter upper part
10 - Bolt agen
AG. Volkswagen AG d
oes
lksw not
❑ 1.6 Nm d by
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11 - Filter elementutho eo
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12 - Bracket s
ce
e
nl
pt
❑ For air filter

du
an
itte
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erm
13 - Nut
ab
ility
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❑ 15 Nm
wit
, is n
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14 - Rubber bush
hole
spec
15 - Jump starting point

es, in part or in w
t to the co
16 - Air duct
❑ Secured to lock carrier.
rrectness of i
17 - Air filter lower part

l purpos
18 - Rubber bush
❑ Secured to lock carrier.
nf
ercia
orm
19 - Hose
m
atio
m
❑ To pressure control valve ⇒ Item 1 (page 46) .

o
n in
or c
thi
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sd
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
7. Air filter 149

Crafter 2006 ➤
8 Engine control unit

⇒ “8.1 Removing and installing engine control unit J623 ”,
page 150
8.1 Removing and installing engine control

unit - J623-
Note
If the engine control unit needs to be renewed, connect the ⇒ Ve‐

hicle diagnostic tester, and carry out function “Renew engine
control unit”.
Removing
– Release connectors on engine control unit - J623- and pull off.
– Release engine control unit - J623- -arrows- and pull out.
cardiagn.com
Installing
– Push engine control unit - J623- into mounting bracket and
lock.
– Fit connectors and lock in position.
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es, in part or in w
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Prote AG.

Crafter 2006 ➤
26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencer (engine codes BJJ, BJK, BJL,
BJM)”, page 151
⇒ “1.2 Assembly overview - silencers and SCR catalytic convert‐
ers (engine codes CEBA, CEBB, CECA, CECB)”, page 152
⇒ “1.3 Checking exhaust system for leaks”, page 153
1.1 Assembly overview - silencer (engine

codes BJJ, BJK, BJL, BJM)
WARNING
AG. Volkswagen AG d
agen oes
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Risk of burns. by Vol not
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Parts of the exhaust system thmay
or be hot. eo
u ra
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a
Allow exhaust system to cool
ss
before removing. c
ce
le
un
pt
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ility
1 - Clamp
ot
wit
, is n
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hole
❑ 35 Nm
spec
es, in part or in w
t to the co
2 - Spring nut
rrectness of i
3 - Retaining ring
l purpos
❑ Slide retaining ring and

spring nut
nform
ercia
⇒ Item 2 (page 151) on‐

to silencer up to stop.
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tion in
4 - Silencer
r
te o
thi
5 - Retaining ring
s
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t.
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6 - Exhaust tailpipe
Co
Cop py
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7 - Clamp
ht
pyri by
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co
❑ 23 Nm
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Prote AG.
8 - Dimension -a- = 50 mm
1. Exhaust pipes, silencers 151

Crafter 2006 ➤
1.2 Assembly overview - silencers and SCR catalytic converters (engine codes
CEBA, CEBB, CECA, CECB)
1 - Clamp
❑ 35 Nm
2 - Speed nut
3 - Retaining ring
❑ Push up to stop on si‐
lencer
4 - Injector for reducing agent -
N474-
⇒ page 172 .
5 - Gasket
cardiagn.com
6 - Clamp n AG. Volkswagen AG do
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❑ Renew after removing byV
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❑ 5 Nm ir se tee
tho
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7 - Nut ss
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e
❑ 10 Nm
nl
pt
du
an
itte
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8 - NOx sender - G295-
erm
ab
ility
❑ To remove, remove
ot p
wit
heat shield
, is n
h re
❑ With NOx sender con‐
hole
spec
trol unit - J583-
es, in part or in w
t to the co
❑ 50 Nm
9 - Heat shield
rrectness of i
10 - Speed nut
l purpos

11 - Retaining ring
nf
ercia
orm
m
atio
12 - Retaining clip
om
n in
c
❑ For NOx sender - G295- line

or
thi
te
sd
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13 - Silencer
o
r
rp
cu
o
❑ To remove, remove heat shield

f
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t.
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❑ Remove control unit for NOx sender - J583- t. Cop py
rig
gh ht
14 - Exhaust tailpipe yri
p by
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cted
15 - Dimension -a- = 50 mm
agen
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16 - Clamp
❑ 23 Nm
17 - Reduction catalytic converters
❑ To remove, remove heat shield
❑ Remove control unit for NOx sender - J583-
152 Rep. gr.26 - Exhaust system

Crafter 2006 ➤
1.3 Checking exhaust system for leaks

Procedure
– Start engine and run at idling speed.
– Seal end exhaust pipes with cloths or plugs, for example, for
the duration of the leakage
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n AG. Volktest.
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doe
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Vol t
– Check (by ed listening) points of connection between
by gu
ara exhaust
manifold
horis and cylinder head, between turbocharger nte
e and ex‐
haust
s au manifold, between particulate filter and turbocharger
t or
ac
etc.
s to make sure there are no leaks.
ce
le
un
pt
– Rectify any leaks that are found.
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
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mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
1. Exhaust pipes, silencers 153

Crafter 2006 ➤
2 Emission control
⇒ “2.1 Assembly overview - diesel particulate filter (engine codes
CEBA, CEBB, CECA, CECB)”, page 154
⇒ “2.2 Assembly overview - diesel particulate filter (engine codes
BJJ, BJK, BJL, BJM)”, page 156
⇒ “2.3 Removing and installing diesel particulate filter (engine co‐
⇒ “2.4 Removing and installing diesel particulate filter (engine co‐
⇒ “2.5 Removing and installing catalytic converter (engine codes
BJJ, BJK, BJL, BJM)”, page 165
2.1 Assembly overview - diesel particulate

filter (engine codes CEBA, CEBB, CE‐
CA, CECB)
Note n AG. Volkswagen AG do

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♦ After working on thehoexhaust
ris system, ensure that the system ntee
is not under tension
sa
u and that there is sufficient clearance to
t or
ac
the bodywork. If necessary, loosen clamps and align silencer
s ce
le
and front exhaust pipe so that sufficient clearance is main‐

un
pt
tained to the bodywork and the mountings are evenly loaded.

an
d
itte
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erm
ab

ility
ot p
wit
♦ The decoupling element of the diesel particulate filter must not

is n
h re
be bent more than 10°, otherwise it could be damaged.

ole,
spec
♦ After a new diesel particulate filter has been installed, connect

t to the co
the ⇒ Vehicle diagnostic tester, and carry out function “Renew

diesel particulate filter”.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
1 - Exhaust gas pressure sen‐

sor 1 - G450-
❑ After renewing, carry
out “Adapt G450 ex‐
haust gas pressure sen‐
sor 1” function using
⇒ Vehicle diagnostic
tester.
2 - Nut
❑ 6 Nm
3 - Bracket
4 - Exhaust gas temperature
sender 3 - G495-
❑ Grease thread of sender
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
❑ 45 Nm
5 - Particulate filter
cardiagn.com
❑ Do not bend the decou‐
pling element of the par‐
ticulate filter more than
10°, otherwise it could
be damaged
⇒ page 158 AG. Volkswagen
n AG do
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olks
6 - Exhaust gasy Vtemperature ot g
ua
sender 4 - rG648-
ise
d b ran
tee
ho
❑ Grease
au
t thread of sender or
ac
ssusing high-temperature
ce
le
paste ⇒ Electronic
un
pt
Parts Catalogue (ET‐

an
d
itte
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KA) .
rm
ab
pe
ility
❑ 45 Nm
ot
wit
, is n
7 - Nut
h re
hole
spec
❑ 23 Nm
es, in part or in w
t to the co
8 - Mounting
rrectness of i
9 - Control pipe
❑ 45 Nm
l purpos
10 - Retaining clip
nform
ercia
❑ For control line

m
11 - Bolt
com
tion in
❑ 9 Nm
r
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thi
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12 - Gasket
do
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fo
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Co
Cop py
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13 - Clamp
ht
pyri by
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❑ 7 Nm Prote
cted AG.
agen
14 - Lambda probe - G39-

❑ Grease only thread with high-temperature paste . The high-temperature paste ⇒ Electronic parts catalog
(ETKA) must not get into the slots on the probe body.
2. Emission control 155

Crafter 2006 ➤
❑ Remove and install using lambda probe open ring spanner set - 3337- .
❑ 52 Nm
15 - Nut
❑ 6 Nm
16 - Nut
❑ 4 Nm
2.2 Assembly overview - diesel particulate

filter (engine codes BJJ, BJK, BJL, BJM)
Note
♦ Catalytic converter only in EURO 3 or EU 3 engines AG. Volkswagen AG d

agen oes
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Particulate filter is shown in assembly overview. by V l not
♦ o gu
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♦ The installation of the particulate filter corresponds
ut
hor
to the proc‐ eo
ess for the catalytic converter. The only difference
s a is the ra
c
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s
absence of components ⇒ Item 1 (page 157) to
ce
le
un
⇒ Item 12 (page 157) .
pt
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itte
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♦ Removing and installing catalytic converter ⇒ page 165 .
rm
ab
pe
ility
♦ After working on the exhaust system, ensure that the system
ot
wit
, is n
is not under tension and that there is sufficient clearance to
h re
the bodywork. If necessary, loosen clamps and align silencer
hole
spec
and front exhaust pipe so that sufficient clearance is main‐
es, in part or in w
tained to the bodywork and the mountings are evenly loaded.
t to the co
rrectness of i
l purpos
WARNING
Risk of burns.
nform
ercia
Parts of the exhaust system may be hot.

m
a
com
tion in
Allow exhaust system to cool before removing.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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ht. rig
rig ht
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Crafter 2006 ➤
5-cylinder
AG. Volkswagediesel
nA engine - Edition 03.2016
n G do
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Volks ot g
1 - Temperature sender after ed
by ua
ran
particulate filter - G527- oris tee
th or
❑ 45 Nm au ac
ss
ce
le
2 - Control pipe
un
pt
an
d
itte
❑ 45 Nm
y li
erm
ab
ility
3 - Control pipe
ot p
wit
is n
❑ 45 Nm
h re
ole,
spec
4 - Lambda probe - G39- urposes, in part or in wh
❑ Grease only the threads
t to the co
with high-temperature
paste ; high-tempera‐
ture paste ⇒ Electronic
rrectne
Parts Catalogue (ETKA)
must not get into the
ss
slots of probe body.
o
cial p
f i
❑ Remove and install us‐
nform
ing lambda probe open
mer
ring spanner set -
atio
m
3337- .
o
n
c
i
or
n thi
❑ 52 Nm
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o
r
5 - Bracket
p
cum
r
fo
en
ng
6 - Bolt
t.
yi Co
Cop py
❑ 6 Nm ht. rig
rig ht
py by
o Vo
7 - Temperature sender before by c lksw
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particulate filter - G506- Prote AG.
❑ 45 Nm
8 - Bolt
❑ 6 Nm
9 - Hose
10 - Exhaust gas pressure sen‐
sor 1 - G450-
11 - Bolt
❑ 4 Nm
12 - Clip
13 - Gasket
14 - From turbocharger
❑ ⇒ Item 25 (page 108)
15 - Clamp
❑ 7 Nm
16 - Bolt
❑ 23 Nm
17 - Nut
❑ 53 Nm
18 - Support
❑ Between particulate filter and cylinder block.

Crafter 2006 ➤
19 - Support
❑ Between particulate filter and engine bracket
20 - Bolt
❑ 22 Nm
21 - Damper weight
22 - Bolt
❑ 9 Nm AG. Volkswagen AG d
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23 - Bolt d by
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❑ 23 Nm horis
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24 - Bracket ss c
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e
nl
❑ Between particulate filter and gearbox
pt
du
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itte
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25 - Bolt
erm
ab
ility
ot p
❑ 53 Nm
wit
, is n
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26 - Particulate filter
hole
spec
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es, in part or in w
t to the co
❑ Removing and installing catalytic converter ⇒ page 165 .
27 - To silencer
rrectness of i
❑ ⇒ Item 4 (page 151)
l purpos
2.3 Removing and installing diesel particu‐

nf
ercia
late filter (engine codes CEBA, CEBB,

rm
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atio
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CECA, CECB)
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or c
thi
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
Note
After a new diesel particulate filter has been installed, connect the
⇒ Vehicle diagnostic tester, and carry out function “Renew diesel
particulate filter”.
Removing
WARNING
Risk of burns. agen

AG. Volkswagen AG d
oes
olksw not
V
Parts of the exhaust systeme d by may be hot. gu
ara
nte
ris
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Allow exhaust system
aut
h to cool before removing. ra
ss c
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nl
pt
du
an
– With ignition switched off, disconnect earth strap from battery
itte
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⇒ Rep. gr. 27 .
erm
ab
ility
ot p
wit
, is n
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h re
– Disconnect connector for Lambda probe - G39- -1- on intake
hole
spec
manifold.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
– Disconnect connector for exhaust gas temperature sender 3 -

do
priv
G495- -arrow-.
um
for
en
ng
t.
– Remove silencer with reduction catalytic converters
yi Co
op py
⇒ page 152 . t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect connector for exhaust gas temperature sender 4 -

G648- -2-.
– Unscrew control lines -1- from particulate filter.

Crafter 2006 ➤
– Unscrew bracket for control lines -1-.

– Pull control line out of particulate filter and put down to side.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
– Unscrew mounting of particulate filter -1- from subframe
y li
erm
ab
-arrows-.
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
Do not bend the decoupling element of the particulate filter
t to the co
more than 10°, otherwise it could be damaged.
cardiagn.com
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Turn particulate filter as shown and remove .to

Vorear.
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Installing Volks not
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ed
Installation is carried out in theorisreverse order; note the following: nte
eo
th
au ra
c
ss
Caution
ce
le
un
pt
an
d
itte
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The decoupling element of the diesel particulate filter must not
rm
ab
pe
be bent more than 10°, otherwise it could be damaged.
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Make sure clamp and particulate filter are correctly seated.
rrectness of i
♦ After a new diesel particulate filter has been installed, connect
the ⇒ Vehicle diagnostic tester, and carry out function “Renew
l purpos
diesel particulate filter”.
nform
ercia
– Put new gasket onto particulate filter.

m
cardiagn.com
a
com
t
– Position particulate filter on turbocharger.
ion in
r
te o
– Position new clamp.
thi
s
iva
do
r
– Tighten clamp screw.

rp
cum
fo
en
g
– Install silencer with reduction catalytic converters

n
t.
yi Co
op
⇒ page 152 . C py
ht. rig
rig ht
by
– Bolt mounting of particulate filter onto subframe. copy Vo
by lksw
cted agen
Prote
– Bolt control lines onto particulate filter.
AG.
– Bolt bracket for control lines onto particulate filter.

– Push together connectors for exhaust gas temperature sender
4 - G648- , exhaust gas temperature sender 3 - G495- and
Lambda probe - G39- and re-secure cables with a cable tie.
– Install heater air duct.
– Connect earth strap onto battery ⇒ Rep. gr. 27 .
Specified torques
♦ ⇒ “1.2 Assembly overview - silencers and SCR catalytic con‐
verters (engine codes CEBA, CEBB, CECA, CECB)”,
page 152
2.4 Removing and installing diesel particu‐

late filter (engine codes BJJ, BJK, BJL,
BJM)

Crafter 2006 ➤
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Note rised
nte
ho eo
aut ra
After a new diesel particulate filter has been installed, connect the ss c
ce
e
⇒ Vehicle diagnostic tester, and carry out function “Ash mass

nl
pt
du
comparison”.
an
itte
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erm
ab
ility
ot p
wit
Caution
, is n
h re
hole
spec
The particulate filter compensator is sensitive to kinking. Dur‐

es, in part or in w
ing transport or removal and installation, ensure that no stress

t to the co
is transferred to bellows element area -arrow-.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
Compensator
Removing
WARNING
Risk of burns.

⇒ Rep. gr. 27 .
– Unplug connectors for Lambda probe - G39- and temperature
sender before particulate filter - G506- .
Cut through any cable ties.
– Unscrew control line bracket from turbocharger.
cardiagn.com
– Unscrew upper control line from particulate filter.
– Remove silencer and exhaust tailpipe ⇒ page 151 .
– Loosen clamp ⇒ Item 15 (page 157) .
– Unscrew lower control line from particulate filter and then de‐
tach control line from particulate filter.
– Unplug connector for temperature sender after particulate filter
- G527- .
Cut through any cable ties.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Unscrew supports -1- and -2- from particulate filter.
Note
If the particulate filter is re-used, the supports -1- and -2- must be
detached from the engine mounting or cylinder block to avoid
damaging the bellows element.
G. Volkswagen AG d
– Remove bracket ⇒ Item 24 (page 158) from diesel lparticulate
wage
nA oes
filter and gearbox, and remove diesel particulate V o ks down‐
filter
not
gu
by ara
wards. ris
ed nte
tho eo
Installing s au ra
c
s
ce
le

un
pt
an
d
itte
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Caution
pe
ility
ot
wit
, is n
It is essential to observe the specified installation sequence to
h re
hole
avoid damaging the particulate filter.
spec
es, in part or in w
t to the co
cardiagn.com
Note
rrectness of i
l purpos
After a new diesel particulate filter has been installed, connect the
⇒ Vehicle diagnostic tester, and carry out function “Ash mass
comparison”.
nform
mercia
a
– Loosen securing nut on engine bracket support.
com
tion in
r
– Loosen securing bolts on cylinder block support.

te o
thi
s
iva
do
– Fit new gasket to particulate filter.
r
rp
cum
fo
– Insert particulate filter.

en
ng
t.
yi Co
op py
– Bolt bracket ⇒ Item 24 (page 158) to gearbox.
. C rig
ht ht
rig by
py
– Locate particulate filter on turbocharger.
co Vo
by lksw
cted agen
Prote AG.
– Start diesel particulate filter securing bolts on bracket
⇒ Item 24 (page 158) .
– Fit new clip.

Crafter 2006 ➤
– Locate particulate filter securing bolts on supports -1- and

-2-.
– Tighten securing nut for engine bracket support.
– Tighten securing nut for cylinder block support.
– Tighten diesel particulate filter securing bolts at supports.
– Tighten diesel particulate filter securing bolts at bracket.
– Screw lower control line to diesel particulate filter.
– Install silencer and exhaust tailpipe ⇒ page 151 .
– Attach connector for temperature sender after particulate filter
- G527- and secure line again using cable tie.
– Screw upper control line to aparticulate
gen AG
. Volksfilter.
wagen AG
do w es n
olks o
– Attach connectorsefor d b Lambda probe - G39- and temperature
yV t gu
ara
sender before particulate
horis filter - G506- and secure lines again
nte
eo
using cable tie.
au
t ra
c
ss
– Bolt bracket for control lines to turbocharger.
ce
le
un
pt
cardiagn.com
an
d
itte
– Install heater air duct.
y li
rm
ab
pe
– Fit earth strap to battery ⇒ Rep. gr. 27 .
ility
ot
wit
, is n
Specified torques
h re
hole
spec
es, in part or in w

t to the co
2.5 Removing and installing catalytic con‐
rrectness of i
verter (engine codes BJJ, BJK, BJL,

l purpos
BJM)
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
Caution
The particulate filter bellows element is sensitive to kinking.

During transport or removal and installation, ensure that no
stress is transferred to bellows element area -arrow-.
Bellows element
Removing
WARNING
Risk of burns.

⇒ Rep. gr. 27 .
cardiagn.com
– Remove silencer and exhaust tailpipe ⇒ page 151 .
– Loosen clamp ⇒ Item 15 (page 157) .
– Unscrew supports -1- and -2- from catalytic converter.
Note
If the catalytic converter is re-used,swthe

agesupports -1-
n AG. Volksw and -2-
agen AG
doesmust
be detached from the engine bmounting
y Volk
or cylinder block to avoid
not
gu
damaging the bellows element.ris
ed ara
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– Remove bracket ⇒s Item 24 (page 158) from catalytic converter
s
ce
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and gearbox, and remove catalytic converter downwards.

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– Loosen securing nut on engine bracket support.

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– Fit new gasket to catalytic converter.

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– Insert catalytic converter.

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Crafter 2006 ➤
– Locate catalytic converter securing bolts on supports -1- and

-2-.
– Tighten securing nut for engine bracket support.
– Tighten securing nut for cylinder block support.
– Tighten catalytic converter securing bolts at supports.
– Tighten catalytic converter securing bolts at bracket.
– Install silencer and exhaust tailpipe ⇒ page 151 .
Specified torques
♦ ⇒ “1.1 Assembly overview - silencer (engine codes BJJ, BJK,
BJL, BJM)”, page
wag151
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Crafter 2006 ➤
3 SCR system (selective catalytic re‐

duction)
⇒ “3.1 AdBlue® technology”, page 168
⇒ “3.2 Assembly overview - tank for reducing agent (Crafter panel
van and Crafter window van)”, page 168
⇒ “3.3 Assembly overview - tank for reducing agent (Crafter drop‐
side and Crafter chassis)”, page 171
⇒ “3.4 Removing and installing injector for reducing agent N474
”, page 172
⇒ “3.5 Removing and installing reducing agent delivery line”, page
173
⇒ “3.6 Removing and installing filler line for reducing agent (panel
van and window van)”, page 175
⇒ “3.7 Removing and installing filler neck for reducing agent (pan‐
el van and window van)”, page 177
⇒ “3.8 Removing and installing
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van)”, page 180

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⇒ “3.11 Emptying reducing agent tank (platform van and chas‐

ility
ot p
sis)”, page 181

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⇒ “3.12 Removing and installing heater element (heater cup)”,

hole
page 183
spec
es, in part or in w
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3.1 AdBlue® technology

rrectness of i
Note
l purpos
♦ To keep the following description as short as possible the

“NOx reducing agent AUS 32” (AdBlue®) is just called a re‐
nform
ercia
ducing agent.
m
at
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♦ The design and function of AdBlue® technology is described

on
c
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in ⇒ Self-study programme No. 424 ; Selective Catalytic Re‐

or
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plenty of water.
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3.2 Assembly overview - tank for reducing agent (Crafter panel van and Crafter
window van)

Crafter 2006 ➤
1 - Bolt
❑ 5 Nm
2 - Delivery module
❑ With pump for reducing
agent - V437- .
❑ With heater for reducing
agent pump - Z103- .
❑ With pressure sender n AG. Volkswagen AG do
for reducing agent me‐ lkswage es n
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or
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nl
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for reducing agent
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⇒ page 177 .
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❑ Connector ⇒ page 170
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3 - Spacer ring
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4 - Delivery line
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❑ For reducing agent
cardiagn.com
agent line - Z104- .
rrectness of i
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⇒ page 173 .
5 - Cap
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10 - Evaluation unit for reducing agent level - G698-
❑ To remove, remove tank for reducing agent ⇒ page 177 .
❑ 3.5 Nm
12 - Connecting hose
13 - Securing strap
14 - Bolt
❑ 56 Nm
15 - Tank for reducing agent
❑ Routing wiring ⇒ page 170 .
16 - Securing strap
17 - Drain hose
❑ Emptying tank for reducing agent ⇒ page 180 .
3. SCR system (selective catalytic reduction) 169

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20 - Heat shield
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21 - Gasket
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22 - Rubber cup
t to the co
23 - Heater element (heater cup)
❑ With heater for reducing agent tank - Z102- .
rrectness of i
❑ With reducing agent level sender - G697- . l purpos
❑ With temperature sender for reducing agent - G685- .
nform
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24 - Locking ring
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i
❑ Remove and install using wrench - T50014- .
on
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❑ 80 Nm
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25 - Breather
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Routing wiring

Crafter 2006 ➤
3.3 Assembly overview - tank for reducing agent (Crafter dropside and Crafter
chassis)
1 - Cover
2 - Bolt
❑ 5 Nm
3 - Delivery module
❑ With pump for reducing
agent - V437- .
agent pump - Z103- .
❑ With pressure sender
for reducing agent me‐
tering system - G686- .
❑ With reversal valve for
reducing agent - N473- .
⇒ page 177 .
cardiagn.com
Note
With the platform van and chassis

the delivery module can be removed
and installed without having to re‐
move the reducing agent tank
⇒ Item 8 (page 171) .
4 - Seal
5 - Spacer ring
6 - Rubber cup
7 - Evaluation unit for reducing lkswage es n
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agent level - G698- byV ua
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8 - Tank for reducing agent auth or
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⇒ page 179 .
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11 - Cap
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12 - Control unit for reducing agent heater - J891-

13 - Gasket
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14 - Heater element (heater cup)

mer
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❑ With heater for reducing agent tank - Z102- .

om
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❑ With reducing agent level sender - G697- .

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AG.
Crafter 2006 ➤
Note
With the platform van and chassis

the heater element (heater cup) can
be removed and installed without
having to remove the reducing
agent tank ⇒ Item 8 (page 171) .
15 - Locking ring
❑ Remove and install using wrench - T50014- .
❑ 80 Nm
16 - Delivery line
❑ For reducing agent
❑ With heater for reducing agent line - Z104- .
17 - Clip
3.4 Removing and installing injector for re‐
cardiagn.com
ducing agent - N474-
Note
To keep the following description as short as possible the “NOx

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WARNING
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Crafter 2006 ➤
– Then press securing clips of delivery line -arrow- together and

pull off injector for reducing agent - N474- .
Caution
♦ Immediately seal all openings and connections using suit‐

able plugs to stop ingress of dirt. The smallest particle of
dirt can cause extensive damage to the system.
♦ Protect separated electrical connections against wetting
from reducing agent by suitable means, e.g. plastic bag
and cable ties. Electrical connections may be damaged
due to the high penetration ability along with subsequent
crystallisation of the reducing agent.
– Pull connector off injector for reducing agent - N474- .

– Remove clamp -2- and remove injector for reducing agent -
N474- .
Installing
cardiagn.com
– Connect injector for reducing agent - N474- with a new sealing
washer, observing lug on reduction catalytic converter (elec‐
trical connector faces upwards).
– Place new securing bolt over connection and push together
until it engages. This action locates the injector for reducing
agent - N474- .
– Start bolt and tighten it to specified torque.
– First connect electrical cable followed by delivery line. AG. Volkswagen AG d
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Crafter 2006 ➤
Caution
Protect separated electrical connections against wetting from

reducing agent by suitable means, e.g. plastic bag and cable
ties. Electrical connections may be damaged due to the high
penetration ability along with subsequent crystallisation of the
reducing agent.
Panel van and window van:

– Remove tank for reducing agent ⇒ page 177 .
Platform van and chassis:
AG. Volkswagen AG d
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– To pull off delivery line, first push delivery line onto delivery
module -2- as far as stop.
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pull delivery line off delivery module.
ss o
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Caution
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Immediately seal all openings and connections using suitable

o
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Crafter 2006 ➤
– Press securing clips of delivery line -arrow- together and pull

delivery line off injector for reducing agent - N474- .
– Carefully free delivery line from fittings and remove it.
Caution

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– Install tank for reducing agent ⇒ page 177 .
– Connect electrical connector of delivery line. rrectness
– Remove plug and connect delivery line onto delivery module.

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– Install cover ⇒ Item 1 (page 171) .

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Specified torques
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gh ht
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3.6 Removing and installing filler line for re‐
ducing agent (panel van and window
van)
Note


Crafter 2006 ➤
Removing
WARNING

organs.
plenty of water.
olkswagen AG
– Emptying tank for reducing agent ⇒ spage
wage 180 .
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aut ⇒ Rep. gr. 68 . ra
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– Remove door storage compartment.
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h re
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– Unfasten screw-type clip -3- and pull connecting hose -2- off
reducing agent tank.
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– Push securing clip -arrow B- together and pull off filler line. C py
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Installing
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AG.
– Remove plug and connect filler line to reducing agent tank and
to filler neck.
– Press filler line into its clips.
– Install door storage compartment.
– Install step insert (right-side) ⇒ Rep. gr. 68 .
– Install front right wheel housing liner ⇒ Rep. gr. 66 .
– Fill reducing agent tank ⇒ Maintenance ; Booklet 10.2 .

Crafter 2006 ➤
3.7 Removing and installing filler neck for

reducing agent (panel van and window
van)
Note

reducing agent AUS 32” (AdBlue ®) is just called a reducing agent.
AG. Volkswagen AG do
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– Emptying tank for reducing agent ⇒ page 180 .
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– Remove filler neck and coolant expansion tank from lock car‐
rier -arrows-.
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– Push securing clip -arrow A- together and pull off vent pipe.
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– Push securing clip -arrow B- together and pull off filler line.
Installing
– Fill tank for reducing agent ⇒ Maintenance ; Booklet 10.2 .
Specified torque
Securing bolts for filler neck 10 Nm
3.8 Removing and installing reducing agent

tank (panel van and window van)
Note


Crafter 2006 ➤
WARNING

organs.
plenty of water.
Removing
Caution

cardiagn.com
reducing agent.
– Remove connectors of delivery module -1- from their holder

and disconnect connectors.
– Unclip wiring harness and delivery aline
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– Place engine and gearbox jack - V.A.G 1383 A- under reduc‐

es, in part or in w
ing agent tank.

t to the co
– Unscrew securing bolts of tensioning straps -1-.

rrectness of i
– Lower reducing agent tank until vent pipe and delivery line can
be pulled off.
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Crafter 2006 ➤
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not engine - Edition 03.2016
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an
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Installing
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Make sure that all components are attached to reducing agent

m
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com
tion in
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– Carefully lift reducing agent tank using engine and gearbox
s
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jack - V.A.G 1383 A- until securing bolts of tensioning straps
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– Fill reducing agent tank ⇒ Maintenance ; Booklet 10.2 .

Specified torques
♦ ⇒ “3.2 Assembly overview - tank for reducing agent (Crafter
panel van and Crafter window van)”, page 168
3.9 Removing and installing reducing agent

tank (platform van and chassis)
Note

WARNING

organs.
plenty of water.
Removing
– Remove cover ⇒ Item 1 (page 171) .

Crafter 2006 ➤
Caution

plugs to stop ingress of dirt. Then Asmallest
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t to the co
– Separate electrical connector -4- of delivery line.
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– Pull connector -3- off delivery module -2-.
l purpos
– Remove tensioning straps ⇒ Item 9 (page 171) .
cardiagn.com
– Pull reducing agent tank of body a little.
nform
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– Pull connector off evaluation unit for reducing agent level -

m
G698- ⇒ Item 7 (page 171) .

a
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tion in
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r
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⇒ Item 12 (page 171) on tank for reducing agent.

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Installing
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Note
Make sure that all components are attached to reducing agent

tank and that no lines are squashed.
– Install tensioning straps ⇒ Item 9 (page 171) .

– Fill tank for reducing agent ⇒ Maintenance ; Booklet 10.2 .
Specified torques
dropside and Crafter chassis)”, page 171
3.10 Emptying reducing agent tank (panel

van and window van)
Note
♦ To keep the following description as short as possible the

“NOx reducing agent AUS 32” (AdBlue®) is just called a re‐
ducing agent.
♦ Reducing agent tank fill volume is about 25 litres.

Crafter 2006 ➤
WARNING

organs.
plenty of water.
Caution
Always ensure that no reducing agent contacts clothing or

bodywork.
If this occurs, wash out reducing
agen
agent
AG using
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a lint-free cotton cloth. Volksw es n
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If the reducing agent
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damage the surface after some time.
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Environment → Workshop disposal ! Request country specific
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– Open cap on reducing agent tank. t to the co

– Pull drain hose -1- off reducing agent tank.
rrectne
– Hold drain hose over a suitable drip tray.

– Push securing clip -arrow- together and pull off cap -2-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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op py
3.11 Emptying reducing agent tank (platform
t. C rig
gh ht
yri by
van and chassis)
cop Vo
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cted agen
Prote AG.
♦ Vacuum box - VAS 6557-
Note


Crafter 2006 ➤
WARNING

organs.
plenty of water.
Note
♦ Tank for reducing agent is emptied via filler neck.

♦ Reducing agent tank fill volume is about 28 litres.
Caution
Always ensure that no reducing agent contacts clothing or
cardiagn.com
bodywork.
If this occurs, wash out reducing agent using clear water and
a lint-free cotton cloth.
G. Volkswagen AG d
If the reducing agent has already crystallised, use warm water
lksw
agen
A
oes
not
and a sponge. by
Vo gu
ara
d
ise nte
Reducing agent that has not been removed uwill
tho crystallise
r
and eo
damage the surface after some time. ss
a ra
c
ce
le

un
pt
an
d
Environment → Workshop disposal ! Request country specific

itte
y li
information concerning storage and disposal from importer.
erm
ab
ility
ot p
wit
is n
h re
– Lift attachment of cap -1- slightly and turn it anticlockwise so
ole,
spec
that indentations -2- are exposed.
– Insert special wrench from toolkit -3- into indentations and un‐ t to the co
screw cap.
Prepare vacuum box - VAS 6557- as follows:
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
– Close shut-off taps -A-, -B- and -C-.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Crafter 2006 ➤
– Connect coupling -D- with connection to shut-off tap -A- and

pressurise compressed air hose with compressed air.
– Open shut-off tap -A-.
A vacuum is established in vacuum box - VAS 6557- .
– Close shut-off valve -A- as soon as the pressure gauge reg‐
isters a pressure of 0.8 bar.
AG. Volkswagen AG d
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– Disconnect coupling -D- from connection on shut-off tap -A-
ce
le
un
pt
and interrupt compressed air supply at compressed air hose.
an
d
itte
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hole
spec
es, in part or in w
t to the co
cardiagn.com
rrectness of i
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– Guide end of hose -E- into filler neck as far as base of reducing
nform
ercia
agent tank and open shut-off tap -B-.

m
a
com
tion in
Note
r
te o
thi
s
iva
do
The reducing agent is then drawn from the tank and into the vac‐
r
rp
cum
uum box - VAS 6557- by the vacuum. The capacity of the vacuum
fo
en
g
box - VAS 6557- is 11 litres. The extracted volume is sufficient for

n
t.
yi Co
op
removal of the reducing agent tank. If the reducing agent tank C py
ht. rig
holds a greater amount and the tank is to be emptied, then repeat rig ht
py by
the process. co Vo
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Prote AG.
– To empty vacuum box - VAS 6557- , hold connection on shut-

off tap -C- over suitable container and open shut-off taps -A-
and -C-.
Caution
Never reuse extracted reducing agent. For information on stor‐

age and disposal see ⇒ Service net → Environment → Work‐
shop disposal ! Request country specific information concern‐
ing storage and disposal from importer.
– Flush out vacuum box - VAS 6557- carefully using water when
work sequence is complete.
3.12 Removing and installing heater element

(heater cup)

Crafter 2006 ➤
♦ Special wrench - T50014-
♦ Torque wrench - V.A.G 1332/-
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AG. Volkswagen AG d
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Note s aut ra
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nl

pt
du
an
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reducing agent AUS 32” (AdBlue®) is just called a reducing agent. y li

erm
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ility
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wit
, is n
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WARNING
hole
spec
es, in part or in w

t to the co
organs.
rrectness of i
plenty of water.
l purpos

nf
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Removing
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
With the platform van and chassis the heater element (heater cup)
rp
cu
o
can be removed and installed without having to remove the re‐

f
en
ng
t.
yi
ducing agent tank ⇒ Item 8 (page 171) .
Co
Cop py
t. rig
gh ht
yri by
– Remove reducing agent tank:
op Vo
by c lksw
cted agen
Prote AG.
Panel van and window van ⇒ page 177
Platform van and chassis ⇒ page 179

Crafter 2006 ➤
Caution

reducing agent.

– Remove delivery module ⇒ Item 2 (page 169) .
– Unclip vent pipe from locking ring.
– Remove delivery module ⇒ Item 3 (page 171) .
cardiagn.com
– Place special wrench - T50014- onto locking ring as shown
and unscrew.
– Open cover of heater element using removal wedge - 3409- if
necessary.
– Carefully reach into cup of heater element and release it from
its locked position by turning anticlockwise.
– Remove heater element upwards out of reducing agent tank.
Installing
– Place gasket ⇒ Item 21 (page 170) into opening in tank for
reducing agent. n AG. Volkswagen AG age does
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– Place heater element into reducing
yV
ol agent tank and engage byot g
ua
db
turning clockwise. ris
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te
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s au ra
c
– Moisten sealing with water and carefully push websof cover
ce
le
into gasket. Marks -A- and -B- must align.

un
pt
an
d
itte
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– Put on locking ring and tighten until finger-tight.

rm
ab
pe
ility
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Caution
h re
hole
spec
Ensure sealing ring is not cross threaded on threads of tank for

es, in part or in w
reducing agent. This will cause leaks along with serious cor‐
t to the co
rosion damage.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
185
cted agen
Prote
3. SCR system (selective catalytic reduction)
AG.
Crafter 2006 ➤
– Place special wrench - T50014- onto locking ring as shown

and tighten.
Volkswagen AG
– Wash off any leaks of reducing agent with swater.
wage
n AG. does
k not
Vol gu
Panel van and window van: d by ara
e nte
ris
ho eo
– Install delivery module ⇒ Item a2 (page 169)
ut . ra
c
ss
– Push connector onto delivery module.
ce
le
un
pt
an
d
itte
– Clip in vent pipe from locking ring.
y li
rm
ab
pe
ility
ot
wit
, is n
– Install delivery module ⇒ Item 3 (page 171) .
h re
hole
spec
es, in part or in w
t to the co
– Install reducing agent tank:
Panel van and window van ⇒ page 177
rrectness of i
Platform van and chassis ⇒ page 179
l purpos
Specified torques
nform
ercia
cardiagn.com
panel van and Crafter window van)”, page 168
m
a
com
t
ion in
dropside and Crafter chassis)”, page 171
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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Vo
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Prote AG.

AG. Volkswagen AG d
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V
Craftert g2006
ua
ran ➤
e
oris 5-cylinder diesel engine - Edition 03.2016 tee
h
aut or
ac
ss
ce
le
4 Exhaust gas recirculation
un
pt
an
d
itte
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ab
⇒ “4.1 Assembly overview - exhaust gas recirculation”,
ility
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page 187
wit
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4.1 Assembly overview - exhaust gas recir‐
ole,
spec
culation
t to the co
Note
rrectne
♦ The exhaust gas recirculation system is activated by the en‐
s
gine control unit - J623- via the exhaust gas recirculation
s o
potentiometer - G212- .
cial p
f inform
mer
atio
m
♦ Vacuum hose schematic diagram ⇒ page 132 .

o
n
c
i
or
n thi
te
sd
iva
o
pr
c
1 - Bolt
um
r
fo
en
ng
❑ 9 Nm
cardiagn.com
t.
yi Co
Cop py
t.
2 - Intake manifold flap motor -
rig
gh ht
yri by
V157- op Vo
by c lksw
cted agen
❑ The intake manifold flap Prote AG.
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
3 - O-ring
4 - To intake manifold.
❑ ⇒ Item 5 (page 146)
valve - N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Remove connecting
pipe
⇒ Item 19 (page 188) to
remove.
❑ If renewed, adapt en‐
gine control unit to ex‐
haust gas recirculation
potentiometer - G212- ,
⇒ Vehicle diagnostic
tester
6 - Gasket
7 - Support
❑ Between exhaust gas
recirculation valve -
N18- and lifting eye.
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 20 Nm
4. Exhaust gas recirculation 187

AG. Volkswagen AG d
agen oes
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Craftero2006
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5-cylinder
aut diesel engine - Edition 03.2016 ra
c
ss
ce
10 - Bracket le
un
pt
an
d
itte
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11 - Bolt
erm
ab
ility
❑ 25 Nm
ot p
wit
is n
12 - Exhaust gas recirculation cooler
h re
ole,
spec
❑ Not for engine code BJK with EU 3 or EURO 3
❑ With bypass flap in EU 4 engines
t to the co
❑ When installing, hand-tighten all nuts and bolts for connecting pipes and bracket
⇒ Item 14 (page 188) . Next tighten connecting pipe bolts. Then tighten bracket
rrectne
⇒ Item 14 (page 188) .
ss o
❑ To exhaust manifold
cial p
f inform
14 - Bracket
mer
atio
m
15 - Vacuum hose
o
n
c
i
or
n
❑ To exhaust gas recirculation cooler changeover valve - N345-
thi
te
sd
va
16 - Vacuum actuator
i
o
pr
cum
r
fo
❑ For bypass flap.

en
ng
t.
yi Co
❑ Only with EU 4 engines.
cardiagn.com
Cop py
t. rig
gh
❑ Renew only together with exhaust gas recirculation cooler
ht
pyri by
Vo
o
by c lksw
17 - Coolant hose
cted agen
Prote AG.
❑ Coolant hose schematic diagram ⇒ page 89 .
18 - Bolt
❑ 9 Nm

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
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28 – Glow plug system
Vo gu
by ara
d
rise nte
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au ra
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1 Glow plug system
s
ce
le
un
pt
an
d
itte
⇒ “1.1 Handling ceramic glow plugs ”, page 189
y li
rm
ab
pe
ility
⇒ “1.2 Testing glow plug 1 Q10 to glow plug 5 Q14 ”, page 189
ot
wit
, is n
⇒ “1.3 Testing glow plug 1 Q10 to glow plug 5 Q14 (removed) ”,
h re
hole
page 190
spec
es, in part or in w
⇒ “1.4 Removing and installing glow plug 1 Q10 to glow plug 5
t to the co
Q14 ”, page 190
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
rrectness of i
194
l purpos
1.1 Handling ceramic glow plugs
nform
ercia
Caution
m
a
com
tio
♦ Due to their special material properties, ceramic glow
n in
cardiagn.com
r
te o
plugs are easily damaged and require extra care when
thi
s
iva
handling during removal/installation. Always observe the
do
r
rp
c
special instructions when removing and installing ceramic
um
fo
glow plugs.
en
ng
t.
yi Co
op
♦ Transport and store only in original packaging or packed
C py
t. rig
gh
separately in bubble wrap.
ht
pyri by
Vo
co lksw
by
cted
♦ Do not remove ceramic glow plugs from packaging until
agen
Prote AG.
immediately before installing.
♦ Ceramic glow plugs are sensitive to knocks and bending.
For this reason, ceramic glow plugs which have been
dropped (even from a height of only about 2 cm) must not
be installed, even if no damage is apparent (hair-line
cracks may not be visible).
♦ If there is any doubt as to the condition of the ceramic glow
plugs, they should be renewed without exception.
♦ Damaged ceramic glow plugs (e.g. heater pin of the glow
plug is damaged) will invariably cause engine damage.
♦ If the heater pin of the glow plug is damaged, the frag‐
ments must be removed from the combustion chamber
before starting the engine for the first time, otherwise this
will invariably cause mechanical damage (piston seizure).
♦ Mixed installation of ceramic glow plugs and metal glow
plugs on the same engine is not permissible.
1.2 Testing glow plug 1 - Q10- to glow plug

5 - Q14-
Note
The test for the glow plug system is described in ⇒ Vehicle diag‐
nostic tester.
1. Glow plug system 189

Crafter 2006 ➤
1.3 Testing glow plug 1 - Q10- to glow plug

5 - Q14- (removed)
♦ Hand-held multimeter - V.A.G 1526D-
♦ Auxiliary measuring set - V.A.G 1594C-

wage
e ks s no
Vol t gu
d by ara
e
cardiagn.com
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utho eo
ra
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Test procedure
rrectness of i
– Connect wire of hand-held multimeter - V.A.G 1526D- to glow

plug 1 - Q10- using auxiliary clips from auxiliary measuring set
l purpos
- V.A.G 1594C- .
nf
– Apply test probe of hand-held multimeter - V.A.G 1526D- to

ercia
glow plug 1 - Q10- “earth” and test resistance.

rm
m
atio
m
Glow plug is OK if resistance is up to 1 ohm.

o
n in
or c
thi
– Test glow plug 2 - Q11- , glow plug 3 - Q12- and glow plug 4
te
sd
iva
- Q13- etc. in succession.

o
r
rp
cu
o
m
f
If the specified value is not reached, the engine glow plugs - Q6-
en
ng
t.
yi
must be renewed.
Co
Cop py
t. rig
gh ht
1.4 Removing and installing glow plug 1 - Q10- to glow plug 5 - Q14-
pyri by
Vo
co lksw
by
cted agen
Prote AG.
190 Rep. gr.28 - Glow plug system

Crafter 2006 ➤

equipment required
♦ U/J extension and socket,
10 mm - 3220-
1331-
♦ Hand-held multimeter -
V.A.G 1526C-
♦ Auxiliary measuring set -
V.A.G 1594C-
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Prerequisites
• Ignition switched off
rrectne
Procedure
ss o
cial p
Note
inform
mer
atio
Do not tilt ceramic glow plugs when removing and installing. Any
om
components which form an obstacle must also be removed during

n
c
i
or
installation.
thi
te
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Remove lifting eyes -1- and -2- from cylinder head

⇒ Item 13 (page 46) .
– Remove guide tube -1- for oil dipstick ⇒ Item 9 (page 74) .
– Remove fuel supply pipe -2- and fuel return pipe -3- from high-
pressure pump -4-.
Note
Seal line openings of high-pressure pump with lint-free cloths.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Remove air intake hose -1- ⇒ Item 5 (page 114) .
Caution
♦ It is very important to observe all notes on removing the

ceramic glow plugs ⇒ page 189 .
– Then remove ceramic glow plugs using U/J extension and

socket, 10 mm - 3220- .
Note
If a ceramic glow plug is broken, remove all fragments from the

engine, otherwise these can cause damage to the engine.
Installing
– Before installing, completely remove any deposits from cylin‐
der head hole and thread of ceramic glow plugs.
cardiagn.com
Note
♦ Never oil or grease thread of cylinder head bore or of ceramic

glow plugs.
♦ If the defective ceramic glow plug is broken, remove all frag‐
ments from the engine, otherwise these can cause damage to
the engine.
AG. Volkswagen AG d
Caution agen oes
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ed
nte
♦ It is very important to observe all the instructionsthoon in‐
ris
eo
stalling the ceramic glow plugs ⇒ page 189 . s au ra
c
s
ce
e
♦ Always perform a resistance test at all ceramic glow plugs

nl
pt
du
after their installation and before starting the engine the

an
itte
y li
first time.
erm
ab
ility
ot p
wit
, is n
h re
♦ Specification: max. 1.0 Ω
hole
spec
– If the specification is exceeded, renew the defective ceramic

es, in part or in w
t to the co
glow plug.
– Screw ceramic glow plugs into cylinder head manually using
U/J extension and socket, 10 mm - 3220- .
rrectness of i
– Then tighten the ceramic glow plugs.

l purpos
nf
ercia
Note
orm
m
atio
m
♦ The fuel system must be filled with fuel before the engine is
o
n in
c
started for the first time ⇒ page 122 .

or
thi
te
sd
♦ Faults will have been stored in the memory because connec‐

iva
o
r
tors have been disconnected. Therefore, read the event mem‐

rp
cu
o
ory and clear it, if necessary.

f
en
ng
t.
yi Co
Cop py
ht. rig
Specified torques rig ht
py by
co Vo
by lksw
♦ ⇒ “7.1 Assembly overview - air filter”, page 149 Prote
cted AG.
agen

Crafter 2006 ➤

Ceramic glow plug 15 Nm
1.5 Removing and installing engine speed

sender - G28-
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1331- agen oes
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an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
cardiagn.com
t to the co
Removing
rrectne
– Remove air filter with air duct ⇒ page 149 .
ss
– Remove air pipe ⇒ Item 6 (page 114) .
o
cial p
f in
– Pull connector off engine speed sender - G28- .
form
mer
atio
– Remove securing bolt -arrow- and pull out engine speed send‐
om
er - G28- .
n
c
i
or
n thi
e
Installing
t
sd
iva
o
pr
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um
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fo
en
ng
t.
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Specified torque
Co
Cop py
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ht
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Component Specified torque Prote AG.
Engine speed sender - G28- 5 Nm

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg K0059030120

2.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.3 Removing and installing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.1 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.2 Coolant hose schematic diagram, vehicles with auxiliary heater . . . . . . . . . . . . . . . . . . . . 90

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

7.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1.3 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1.1 Engine number, engine data

Manufactured 03.06 ► 03.06 ► 03.06 ► 03.06 ►

Emissions fulfil EURO 4, EU 4 EURO 4, EU 4, EURO 4, EU 4 EURO 4, EU 4, EU‐

Capacity l 2.5 2.5 2.5 2.5

Torque Nm at 220/1750 … 280/2000 … 300/1750 … 2750 350/2000 … 3000

Compression ratio 16.8 16.8 16.8 16.8

Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3

Turbocharging/super‐ yes yes yes yes

Particulate filter yes yes1) yes yes1)

Charge air cooling yes yes yes yes

1) Not in EURO 3 or EU 3 engines

Code CEBA CEBB CECA CECB

Charge air cooling yes yes yes yes

Exhaust gas recirculation yes yes yes yes

2 Rep. gr.00 - Technical data

⇒ “2.5 Safety precautions when working on injection system”,

⇒ “2.6 Safety precautions when working on the SCR system”,

2.1 Safety precautions when working on

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

fluid and vacuum) and electrical wiring in their original po‐

When removing and installing fuel gauge sender - G- or fuel pump

2.2 Safety precautions during road tests in

Danger of accidents due to distraction because of inadequately

2.3 Safety precautions when working on

vated charcoal filter system, coolant and refrigerant, brake

all moving or hot components.

4 Rep. gr.00 - Technical data

♦ When the engine is warm, the cooling system is under pres‐

When mechanical damage is found on the turbocharger, e.g.

2.5 Safety precautions when working on in‐

♦ Test and measuring instruments must always be secured