VW Crafter

Volkswagen
VW Crafter panel van (2006-2016)
Crafter
Manufacturer:	Volkswagen commercial vehicles
Production period:	since 2006
Previous model:	VW LT
Successor:	none
Technical specifications
Designs:	Box trucks , flatbed trucks
Engines:	Diesel engines : 2.0–2.5 liters (64–120 kW) (first generation)
Length:	5244-7340 (first generation) mm
Width:	1993 (first generation) mm
Height:	2415-3045 (first generation) mm
Wheelbase:	3250-4325 (first generation) mm

VW Crafter Panel Van Facelift (2012)

Rear view

The new VW Crafter (since 2017)

The new VW e-Crafter (since 2017)

The VW Crafter is a small van from Volkswagen Commercial Vehicles that has been built since 2006. The second generation came on the market in 2016.

Variants (first generation)

Crafter	Wheelbase (mm)	Length (mm)	Station wagon (2415 mm)	Combi high roof (2705 mm)	Box (2415 mm)	Box high roof (2705 mm)	Box super high roof (2990 mm)	Cot	Flatbed with double cabin
30th	3250	5240	x		x			x	x
30th	3665	5905	x	x	x	x		x	x
35	3250	5240	x		x			x	x
35	3665	5940	x	x	x	x	x	x	x
35	4325	6940		x		x	x	x	x
50	3665	5940	x	x	x	x	x	x	x
50	4325	6940	x	x		x	x	x	x
50	4325	7340	x	x		x	x	x	x

First generation (2006-2016)

Volkswagen
VW Crafter panel van (2006-2016)
Crafter
Manufacturer:	Volkswagen commercial vehicles
Production period:	2006-2016
Previous model:	none
Successor:	none
Technical specifications
Designs:	Box trucks , flatbed trucks
Engines:	Diesel engines : 2.0–2.5 liters (64–120 kW)
Length:	5244-7340 mm
Width:	1993 mm
Height:	2415-3045 mm
Wheelbase:	3250-4325 mm

The 1st generation, which was produced from 2006 to November 2016, was largely identical to the Mercedes-Benz Sprinter except for the engines and the front of the vehicle . It was produced with this in the Ludwigsfelde and Düsseldorf plants.

landing gear

The chassis is essentially the same as that of the second generation VW LT, but some details have been revised.

Front axle

The front wheels are individually suspended on shock absorber struts and wishbones . The Crafter now has 16-inch wheels and a wider track . Like its predecessor, the transverse leaf spring is made of GRP and thus has a lower weight with improved stabilization. A stabilizer is now standard on the Crafter . The axle was acoustically decoupled from the vehicle body with rubber bearings. The driving behavior was designed to be slightly understeering to neutral.

Rear axle

The rigid rear axle is guided by two leaf springs installed lengthways. In the case of the panel van and station wagon variants , the body is acoustically decoupled via large rubber mounts. The suspension set-up has been improved and the shock absorbers have been relocated a little further outwards in order to better counteract the dangerous tendency to roll, for example when changing lanes quickly. A stabilizer is standard on the Crafter 50 and available at an additional cost on the Crafter 35.

Tires

The Crafter 30 is equipped as standard with 205 / 75R16C tires on 5.5J × 16-H2 rims. The tire size 235 / 65R16C with rim 6.5J × 16-H2 is standard equipment on the Crafter 35 and is available as an option for the Crafter 30. The rear axle of the Crafter 50 has twin tires in size 195 / 75R16C or 205 / 75R16C on 5.5J × 16-H2 rims. The Crafter 50 can also be equipped with so-called super-single tires instead of twin tires . Here, the permissible total weight is reduced to 4.6 t. The high load rating of 128 corresponds to a maximum tire load capacity of 1800 kg. The top speed is limited to 140 km / h. The advantage is the lower rolling resistance and the narrower wheel arches.

Braking system

Disc brakes are installed on the front and rear axles, with the front and, from the Crafter 50, also the rear brakes being internally ventilated. As with the LT2, the parking brake consists of a small drum brake integrated into the rear brake disc. The hydraulic dual-circuit system with diagonal division and hydraulic brake assist is supported by a pneumatic 10-inch brake booster . The Crafter was equipped as standard with an anti-lock braking system (ABS), traction control (ASR) and an electronic stability program ( ESP ). This is the latest generation of systems from Bosch , which takes the vehicle load into account in its control characteristics.

steering

To achieve a high level of comfort, a hydraulically assisted rack and pinion steering was installed. The steering column is designed to be telescopically displaceable for better crash safety and, as an option, can be adjusted in height and inclination. The steering lock is no longer constructed purely mechanically as before, but is locked via the electromechanical ignition lock with a servomotor.

drive

Initially, the Crafter was supplied exclusively with a five-cylinder diesel engine with a displacement of 2.5 liters. The engine was available in various power ratings from 65 to 120 kW (88 to 163 hp). Since 2012, the four-cylinder diesel engine with a displacement of 2.0 liters has been installed instead; the five-cylinder was completely painted. Advances in engine technology make it possible to generate the power necessary for a heavy van even with a displacement of 2.0 liters. Since then, the performance levels have ranged from 80 to 120 kW (109 to 163 hp). In Australia and New Zealand, the six-cylinder diesel engine from the identical Mercedes Sprinter was used in the Crafter .

Engine technology

Engine compartment of the VW Crafter

The longitudinally mounted in the direction of travel Crafter engines are based on the already used in the Volkswagen Transporter and VW LT 2 rows -Fünfzylindermotor with a displacement of 2.5 liters. In contrast to the left-turning 4 and 6-cylinders of the Sprinter, the 5-cylinders of the Crafters are right-turning like all older five-cylinders from Audi or VW. However, a common rail injection system and a soot particle filter are now being installed to improve the running smoothness and to meet the new, strict emission standards. A reinforced toothed belt is used to drive the camshaft , high-pressure pump and coolant pump. It has a change interval of 200,000 km. The drop-forged crankshaft with six bearings is located in a housing made of gray cast iron with lamellar graphite. It now has thicker crank pins to better absorb the torsional forces.

The pistons made of aluminum alloy, like those of the previous models, have an asymmetrical piston bowl for better swirling of the injected fuel. To increase the stability, it was a little larger and thus the compression reduced. In addition, the pistons are reinforced compared to the previous models and the connecting rods are trapezoidal. As with all other VW TDI engines, the piston crowns are also cooled from below by oil spray nozzles. The new five-layer metal cylinder head gasket enables a more stable sealing of the combustion chambers both from one another and from the outside. The engine's ancillary components such as the generator, refrigerant compressor, hydraulic pump and radiator fan are driven by a ribbed V-belt.

Technical specifications

model	Cylinders / valves per cylinder	Cubic capacity cm 3	Max. power	Max. Torque	Engine identification	Emission standard	Construction period
2.0 TDI	4/4	1968	80 kW (109 PS) at 3500 rpm	300 Nm at 1500-2250 rpm	CKTB	5 euro	since 2012
2.0 TDI	4/4	1968	100 kW (136 hp) at 3500 rpm	340 Nm at 1575-2250 rpm	CKTB	5 euro	since 2012
2.0 TDI	4/4	1968	105 kW (143 hp) at 3500 rpm	340 Nm at 1575-2250 rpm	CKUC	5 euro	since 2012
2.0 TDI	4/4	1968	120 kW (163 hp) at 3600 rpm	400 Nm at 1800 rpm	CKUB	5 euro	since 2012
2.5 TDI	5/2	2461	65 kW (88 PS) at 3500 rpm	220 Nm at 2000 rpm	BJJ	Euro 4	2006-2010
					CEBA	5 euro	2010–2012
2.5 TDI	5/2	2461	80 kW (109 PS) at 3500 rpm	280 Nm at 2000 rpm	BJK	Euro 4	2006-2010
					CEBB	5 euro	2010–2012
2.5 TDI	5/2	2461	100 kW (136 hp) at 3500 rpm	300 Nm at 2000 rpm	BJL	Euro 4	2006-2010
					CECA	5 euro	2010–2012
2.5 TDI	5/2	2461	120 kW (163 hp) at 3500 rpm	350 Nm at 2000 rpm	BJM	Euro 4	2006-2010
					CECB	5 euro	2010–2012

lubrication

The oil circulation is ensured by a sickle pump on the front of the crankshaft . An internal pressure relief valve protects the pump and motor from a possible high oil pressure. The oil filter module with paper insert is flanged upright on the side of the engine block. An oil pressure retention valve is provided for the cylinder head, which ensures residual lubrication when the oil pressure drops and thus protects the camshaft bearings from damage. The amount of oil in the engine is around 9 liters.

cooling

A coolant pump driven by the toothed belt is used to circulate the coolant. In addition, an electrically operated pump should prevent heat build-up when the engine is switched off; it also takes on the function of utilizing residual engine heat . The vehicle heating can be used for another 20 minutes after the engine has been switched off, depending on the outside temperature, via a button in the heating control. The flow through the water cooler is regulated by an expansion thermostat. The exhaust gas recirculation cooler and the engine oil cooler are also cooled via the cooling system .

Fuel system

Fuel supply

There is an electric pre-feed pump in the plastic fuel tank for continuous fuel delivery. From there, the mechanically driven high-pressure pump is supplied via the fuel filter and the fuel reservoir. This provides the pressure required for injection. The fuel filter has an electric heater, which prevents the formation of paraffin crystals and thus clogging of the filter at low outside temperatures . Fuel not required by the injection valves is returned to the fuel tank via a pressure holding valve and a return line.

Common rail injection

The piezoelectric injection valves , which work with a maximum pressure of 1600 bar, enable several pre- and post-injections and thus a low-noise and low-emission engine run. The injection of the 2.5 TDI engines until 2010 was regulated by a Bosch EDC-16C system (Electronic Diesel Control). The injection of the 2.5 TDI engines from 2010–2012, as well as the 2.0 TDI models available from 2012, is controlled by a Bosch EDC-17C system.

Exhaust gas turbocharger

The exhaust gas turbocharger with adjustable guide vanes is controlled by a vacuum unit. The engine control unit regulates the optimum boost pressure depending on the load condition. The control unit also limits the maximum boost pressure. Since the air in the turbocharger heats up, a charge air cooler is connected downstream.

Exhaust gas cleaning

The exhaust gases are cleaned with a soot particle filter. In this oxidation are catalyst and particulate filter combined into one unit and mounted directly behind the turbocharger. This enables the operating temperature to be reached quickly and optimal regeneration. The use of an additive is not necessary here. If the engine is mainly operated in the partial load range, the filter is regenerated by increasing the exhaust gas temperature.

Exhaust gas recirculation

Exhaust gas recirculation (EGR) is also installed in the Crafter to reduce nitrogen oxide emissions. Some of the exhaust gases are fed back into the combustion process, which lowers the oxygen content of the mixture. This can slow down the combustion and reduce the combustion chamber temperature. This is supported by the EGR cooler. The EGR valve on the Crafter is electrically operated and can therefore better regulate the amount of exhaust gas that is returned. A lambda probe installed in front of the soot particle filter serves as a sensor to determine the residual oxygen content in the exhaust gas. An electrically operated intake manifold flap is used in front of the EGR valve, which can reduce the amount of air drawn in if necessary. This is required to switch off the engine and to regenerate the particulate filter and supports exhaust gas recirculation.

Glow plug system

The quick-start glow system with ceramic glow plugs enables an immediate start at temperatures down to −24 ° C. The control unit supplies the glow plugs with a time-delayed pulse-width modulated current in order to relieve the electrical system. It monitors each glow plug, signaling faults in the system by lighting the pilot light for annealing.

Power transmission

All of the transmission variants used in the Crafter were developed by Daimler-Benz .

6-speed manual transmission

The Crafter uses 6-speed manual transmissions in three-shaft design as standard, which transfer the power to the rear axle via a multi-part cardan shaft . The gearbox with a housing made of die- cast aluminum is available in two versions for a maximum torque of 330 or 350 Nm, the stronger version being used with the 120 kW motor. The gearshift is operated via cables with a joystick-like lever in the control panel. A power take-off that can be activated from the driver's seat is available for special bodies (tipper, crane, tow truck, etc.). A permanent output of 28 kW and a torque of 140 Nm at an engine speed of 1200 rpm can be provided. Subsequent installation in a standard gear unit is not possible.

Shiftmatic (SMC)

To improve comfort and to relieve the driver, the Crafter can be equipped with the Shiftmatic (SMC) automated gearbox as an option . This is available for the 80 kW and 100 kW motors. The internal structure essentially corresponds to that of the 6-speed manual transmission. The gears can be switched manually by tapping the joystick or fully automatically. Although a conventional single-plate dry clutch is installed, this transmission does not have a clutch pedal. The clutch and the individual gear steps are operated hydraulically and monitored by the transmission control unit. The Shiftmatic has its own hydraulic pump, a pressure accumulator, a hydraulic control unit and a separate hydraulic oil supply. If individual components fail, an emergency program is activated and automatic mode is switched off. It is only possible to shift manually up to third gear. The transmission oil only needs to be replaced after ten years or 320,000 kilometers.

Electrical system

With the Crafter, the individual control units are networked with one another via CAN and MOST bus systems.

Power supply

A two-battery concept is optionally available, in which a second battery is installed for additional components. This relieves the load on the starter battery, which is decoupled via an isolating relay. A special feature is that the starter battery is installed under the footwell on the driver's side and the additional battery is in the engine compartment. A positive pole connection near the air filter is provided for jumpstarting the engine.

lighting

The onboard power supply control unit is the central control unit for all main functions. The light switch only forwards switching commands to this control unit via the data bus. Automatic driving lights and daytime running lights are also optionally available. Like the car models, the turn signal system has a lane change function in which a single tap on the turn signal switch causes the turn signal lights to light up three times. If the airbag is triggered in an accident, the hazard warning lights switch on automatically.

Optional extras

A large number of additional equipment is available for the Crafter:

• rain sensor
• heated windshield
• central locking system
• Anti-theft alarm system with interior monitoring and towing protection
• Parking aid
• Tire pressure control
• Radio and navigation systems
• phone
• Tachograph
• radio
• Cruise control system
• Auxiliary heating
• Seat heating
• backup camera

body

In the box and station wagon versions, the Crafter has a self-supporting all-steel body in an integral construction. Compared to the LT, the construction has been improved in some details in order to optimize stability and crash behavior. The pillars have been reinforced and laser soldering and welding processes are used. Some parts are bonded to one another using adhesive processes to increase torsional rigidity. The side members have energy-absorbing deformation elements that absorb the impact in the event of a frontal crash.

Seats

The driver and front passenger seats are equipped with three-point seat belts with belt force limiters. The passenger seat can be equipped with a double bench seat as an option. The station wagon has two rows of seats with double bench seats in the passenger compartment, the third bench seat has three seats. There are 3-point belts on all seats, and if desired, the double bench seats can be fitted with Isofix brackets for child seats.

Occupant protection

Compared to the LT, the floor structure has been reinforced to better protect the passengers. A driver airbag is fitted as standard in the Crafter, while the front passenger and head airbags are available as special equipment. There are pyrotechnic belt tensioners for the driver's cab.

Second generation (since 2017)

Second generation crafter (2018)

Rear view

A Crafter that was completely redeveloped by Volkswagen has been manufactured in a plant in Września (Poland) built exclusively for this van since 2016 . This is also offered by the Group's sister company MAN, but as the MAN TGE . The vehicle, which has been available to order since November 2016, has been delivered since March 2017.

In contrast to its predecessor, the Crafter II is much closer to the VW design line.

Visually, the modified and now much more homogeneous vehicle front, which corresponds to the current VW design line, is particularly striking.

Both a 6-speed manual transmission and an 8-speed automatic converter transmission are available. The 3.0 and 3.5 t versions are available with front-wheel drive, rear-wheel drive or 4Motion (all-wheel drive), the 5-t version with rear-wheel drive or 4Motion.

The Crafter II is offered as a panel van, panel van with double cab, flatbed, flatbed with double cab and as a tipper. It is offered in four lengths and three heights.

In 2019 a camper variant called the VW Grand California came onto the market.

Others

Optional extras

The cutting of the cord in the 2nd generation of the Crafter from Mercedes-Benz (Sprinter) is also noticeable in the cruise control, which is now typically used for VW at the end of the turn signal lever.

body

Subfloor

Used models of the first generation often suffered from rust in the rear on the seam between the wheel arch and the side wall. The factory body mass, which was supposed to protect the seam, was worn away over time, allowing access for harmful substances (e.g. road salt). In the advanced stage, the rust penetrated into the hold. The new model clearly shows that this fold has been removed.

MOIA +6

MOIA +6 at the IAA 2019

At the TechCrunch Disrupt in December 2017 in Berlin, an electric vehicle based on the VW Crafter (Type 7C0) was presented for the Volkswagen mobility service MOIA . It will initially be used for an app-based collection service starting in Hamburg in 2018. It was built by Volkswagen Commercial Vehicles and the Volkswagen factory in Osnabrück . The vehicle was initially known simply as the MOIA vehicle and has now been christened MOIA +6 after the six passenger seats .

Web links

Commons : Volkswagen Crafter  - collection of pictures, videos and audio files

• Official website

Individual evidence

1. ↑ Markus Bauer: MAN Transporter based on Crafter - MAN and VW cooperate. 2015.
2. ↑ Volkswagen subsidiary Moia presents electric vehicles for collective trips. heise.de, December 4, 2017, accessed December 6, 2017 . 
3. ↑ Our vehicle: The MOIA +6 , moia.io, accessed on February 10, 2020.