Service: Crafter 2006

Service
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Workshop Manual
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Crafter 2006 ➤
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Fuel supply system - Diesel engines
CKT CKT CKU CKU BJJ CEB
Engine ID BJK BJL BJM
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B C B C A
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CEB CEC CEC CSLB CSN CSL CSLA

B A B A C
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Edition 03.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply 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 D4B804563FF

Crafter 2006 ➤
Fuel supply system - Diesel engines - Edition 03.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . .e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number, engine data wag doe
olks . . . . . . . . . . . . . . . . . . s.n.ot.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3 General notes . . o.ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . . . . . . . . . . . . . . 6
th eo
4 Repair instructions
s au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c. . . . . . . . . . . . . . . . . . . . 7
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4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Procedure after filling with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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3.1 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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4 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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5 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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6.2 Removing and installing accelerator module with accelerator position sender G79 / G185
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7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
36
Contents i
Crafter 2006 ➤
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ii Contents
Crafter 2006 ➤
00 – Technical data
1 Safety instructions
(VRL008896; Edition 03.2016)
⇒ “1.1 Safety precautions when working on fuel supply system”,
page 1
⇒ “1.2 Safety precautions during work on fuel system”,
page 2
1.1 Safety precautions when working on

fuel supply system
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all types of lines so that the original routing is re‐
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♦ Ensure that there is sufficient
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♦ The fuel and the fuel
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♦ The fuel system is also under pressure! Before opening

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the system, place cloths around the connection. Then
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carefully loosen connection to release the pressure!

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♦ Wear eye and hand protection when performing any type

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of repair work on the fuel system!

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When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
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following:
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♦ Place the suction hose of an activated exhaust gas extraction

system close to the assembly opening of the fuel tank to ex‐
tract any fuel vapours that are released. If no exhaust gas
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extraction system is available, a radial fan with a displacement

greater than 15 m3/h can be used providing that motor is not
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

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1. Safety instructions 1
Crafter 2006 ➤
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1.2 Safety precautions during work on fuel
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WARNING un
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Danger of scalding due to very hot fuel!
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♦ In extreme cases the fuel lines and fuel can reach a tem‐
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after the engine has been switched off.
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♦ Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
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♦ Wear eye protection.
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Risk of injury due to highly-pressurised fuel.
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♦ Wrap a clean cloth around the connection before opening

the fuel system. Then release pressure by carefully loos‐
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♦ Wear protective gloves.
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♦ Wear eye protection.

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Risk of the electronic components being destroyed when bat‐
tery is disconnected!
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and

connecting battery .
2 Rep. gr.00 - Technical data

Crafter 2006 ➤
2 Identification
⇒ “2.1 Engine number, engine data”, page 3
2.1 Engine number, engine data

New four digit engine codes have been introduced since model
year 2009. The first 3 digits refer to the mechanical configuration
of the engine. These are stamped on the engine. The fourth digit
denotes the power output of the engine and depends on the en‐
gine control unit. The engine code can be found on the identifi‐
cation plate, the vehicle data sticker and on the engine control
unit.
The engine number (“engine code” and “serial number”) can be
found at the joint between engine and gearbox -arrow-.
Or:
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The engine number (“engine code” and “serial number”) is located
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on the left below the vacuum pump on the cylinder block.
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In addition, there is a sticker attached to the toothed belt guard
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showing the “engine code” and “serial number”. t to the co

The engine code is also included on the vehicle data sticker.
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The engine number consists of up to nine characters (alphanu‐

meric). The first part (maximum 4 characters) makes up the
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“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.
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Code BJJ BJK BJL BJM

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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, EU‐ EURO 4, EU 4 EURO 4, EU 4, EU‐

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RO 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 65/3500 80/3500 100/3500 120/3500
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rpm
Torque Nm 220/1750 … 2500 280/2000 … 2250 300/1750 … 2750 350/2000 … 3000
at
rpm
Bore Diam 81.0 81.0 81.0 81.0
eter,
mm
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 16.8 16.8 16.8 16.8
Fuel ac‐ DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
cord‐
ing to
Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
2. Identification 3
Crafter 2006 ➤
Code BJJ BJK BJL BJM

Turbocharging/su‐ yes yes yes yes
percharging
Particulate filter yes yes1) yes yes1)
Charge air cooler yes yes yes yes
Exhaust gas recircu‐ yes yes yes yes
lation
Lambda control yes yes1) yes yes1)
1) Not in EURO 3 or EU 3 engines
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 65/3300 80/3300 100/3500 120/3500
at
rpm
Torque Nm 250/1900 … 2300 300/1900 … 2300 330/2000 … 2800 360/2000 … 2800
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Bore Diam 81.0 81.0
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Stroke mm 95.5 95.5 95.5 95.5

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Compression ratio 16.8 16.8 16.8 16.8
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Fuel ac‐ 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
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Turbocharging/su‐ yes yes yes yes
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percharging
Particulate filter yes yes yes yes
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Reduction catalytic yes yes yes yes
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Exhaust gas recircu‐ yes yes yes yes
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Selective catalytic yes yes yes yes

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Engine code CKTB CKTC CKUB CKUC
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Manufactured from 05/11 ▶ 05/11 ▶ 05/11 ▶ 05/11 ▶
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Emissions fulfil EU 5 EU 5 EU 5 EU 5
EU 4 EU 4
EU 5 EU5
Capacity l 2.0 2.0 2.0 2.0
Output kW at 80 100 120 105
rpm 3500 3500 3600 3500
Torque Nm at 300 340 400 340
rpm 1500 … 2250 1575 … 2250 1800 1575 … 2250
Idling speed 1 rpm 830 ± 100 830 ± 100 830 ± 100 830 ± 100

Crafter 2006 ➤
Engine code CKTB CKTC CKUB CKUC

Capacity cm3 1968 1968 1968 1968
Bore Diameter, 81.0 81.0 81.0 81.0
mm
Stroke mm 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4
Compression ratio: 1 16.0 16.0 16.0 16.0
Fuel according DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
to
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module no no no no
Catalytic converter yes yes yes yes
Turbocharging/supercharg‐ Mono-turbo Mono-turbo Bi-turbo Bi-turbo
ing
Exhaust gas recirculation yes yes yes yes
Particulate filter yes, in the case of yes, in the case of yes, in the case of yes, in the case of
EU 5 EU 5 EU 5 EU 5
Selective catalytic reduction no no no no
(SCR system)
Engine code CSLB CSNA CSLA CSLC

Manufactured 45/13 ▶ 45/13 ▶ 11/15 ▶ 11/15 ▶
Emissions fulfil EU 6 EU 6 EU 6 EU 6
Capacity l 2.0 2.0 2.0 2.0
Output kW at rpm 84/3500 120/3600AG. Volkswage80/3500
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Torque Nm at 300/1500 … 225 by Vol400/1800 300/1500 n… ot g
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rpm 0 rised 2250 ran
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Idling speed 1 rpm 830 ± 50 au
t 830 ± 50 830 ± 50 830
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± 50
ss
Capacity cm3 1968 1968 1968 1968
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Bore Diameter, 81.0 81.0 81.0 81.0

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Stroke mm 95.5 95.5 95.5 95.5

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Valves per cylinder 4 4 4 4

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Compression ratio: 1 15.5 15.5 15.5 15.5

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Fuel according DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
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Balancer shaft module no no no no

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Catalytic converter yes yes yes yes

Exhaust gas recirculation yes yes yes yes
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Turbocharging/supercharg‐ Mono-turbo Bi-turbo Mono-turbo Mono-turbo

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Particulate filter yes yes yes yes

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Selective catalytic reduction yes yes yes yes

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2. Identification 5
Crafter 2006 ➤
3 General notes
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant,
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fluid and vacuum) and electrical wiring by Vin their original po‐
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♦ Ensure that there is sufficients auclearance to all moving or ra
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♦ When the engine is warm, the cooling system is under pres‐

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sure. If necessary, release pressure before beginning repair

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♦ Hoses are secured with spring-type clips. In case of repair,
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♦ When installing or removing spring-type clips, we recommend
using spring-type clip pliers - VAS 6340- or
♦ … hose clip pliers - VAS 6362- are recommended.
♦ When installing coolant hoses, route tension-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned with each other.

Crafter 2006 ➤
4 Repair instructions
⇒ “4.1 Rules for cleanliness”, page 7
4.1 Rules for cleanliness

When working on fuel supply and injection system, pay careful
attention to the following “rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ 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.
Caution
To prevent the high-pressure pump from running while it is

empty (very tight tolerances) and to ensure that the engine
starts quickly after parts have been renewed, it is important to
observe the following:
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♦ If fueldsystem
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pressure pump are removed or renewed, the tefuel system
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must be bled ⇒ Vehicle diagnostic tester Test electric
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♦ If the high-pressure pump is removed or renewed, the fuel

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system must be filled with fuel before engine is started for

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the first time ⇒ Rep. gr. 23 ; Injection system; Filling/

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General instructions:
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• Clean tools and workbench etc. before working on injection

system.
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• Thoroughly clean all unions and surrounding areas with en‐

gine or brake system cleanser before disconnecting. Dry
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cleaned area thoroughly.

• When removing components, plug all open connections im‐
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mediately with a suitable clean sealing cap.

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• Do not remove sealing caps from components until immedi‐

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reused in a new, sealable plastic bag.

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• The injectors and locations are to be checked before installa‐

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must be ensured that the injector shaft is clean. If necessary,
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clean injector bore.
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• Only the cleaning set - VAS 6811- may be used for cleaning
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the sealing surface of the injector bore.
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4. Repair instructions 7
Crafter 2006 ➤
• For detailed information on how to use the cleaning set as well

as the order in which its components
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• If high-pressure
au
th lines are not renewed, they must be labelled
or
a
on removal. High-pressure fuel lines must always be re-instal‐c
ss
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led in their original positions (i.e. on the same cylinder).

un
pt
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• Take care not to damage the injectors when removing the old
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copper seals.
pe
ility
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wit
• Check all new O-rings for damage before installing. Lubricate
, is n
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O-rings with engine oil or assembly oil before installing.
hole
spec
• Align high-pressure lines so that they are not subjected to
es, in part or in w
t to the co
stress . First tighten all unions hand-tight and then tighten to
torque.
• Never attempt to reshape high-pressure fuel lines.
rrectness of i
• When working on any part of the high-pressure fuel system,
l purpos
tools may be used only for loosening and tightening pipe un‐
ions. All other components must always be removed and
nform
ercia
installed by hand without using tools or other equipment.

m
• Press the fuel return lines onto the injectors by hand from
a
com
tio
above so that they engage audibly on each injector (do not
n in
r
press in the release pins when doing this). Then, press release
te o
thi
pin and pull fuel return hoses upwards by hand to check that
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they are firmly attached and are not leaking.

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• Disassembling individual common rail components is not per‐

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mitted. The components should be renewed as complete units
C py
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if faulty.
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• Do not carry out any installation work on common rail system
Prote
cted AG.
agen
whilst engine is running.
• Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
• All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
• When the system is open, do not work with compressed air.
Do not move vehicle.

Crafter 2006 ➤
20 – Fuel supply system

1 Procedure after filling with incorrect
fuel
Approach for engine code CKTB, CKTC, CKUB, CKUC, CSLB,
CSNA ⇒ page 9
Approach for engine code BJJ, BJK, BJL, BJM, CEBA, CEBB,
CECA, CECB ⇒ page 13
Note
AG. Volkswagen AG d
Observe different types. olksw
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not
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Engine code CKTB, CKTC, CKUB, CKUC, CSLB, CSNA hor eo
aut ra
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Special tools and workshop equipment required s
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nl
pt
du
♦ Torque wrench - V.A.G 1332-
an
itte
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ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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♦ Fuel extractor - VAS 5190-
rm
m
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n in
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thi
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♦ Vehicle diagnosis, testing and information system - VAS

5051B-
1. Procedure after filling with incorrect fuel 9

Crafter 2006 ➤
Caution
Irreparable damage to high-pressure components, especially

the high-pressure pump due to lack of lubrication though in‐
correct fuel (e.g. petrol) may occur when filling fuel tank with
incorrect fuel. Damage due to seizure and metal particles can
be expected. These metal particles will probably cause further
damage to pressure regulating valves and injectors.
Note
AG. Volkswagen A
These instructions are intended as a guide
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work steps by means of a flowchart,d bwith
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Here are the solutions for two different cases of filling with incor‐
ce
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rect fuel:
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♦ 1. scenario: engine was started with incorrect fuel. Impurities
rm
ab
or incorrect type of fuel has entered the fuel system and has
pe
ility
ot
reached the high-pressure system ⇒ page 10 .
wit
, is n
h re
♦ 2. scenario: engine was NOT started. The misfuelling was de‐
hole
spec
tected BEFORE the engine has been started ⇒ page 12 .
es, in part or in w
t to the co
Procedure for 1st case
rrectness of i
Caution
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• It is not permissible to completely empty the fuel tank with

the fuel suction device - VAS 5190- via the filler neck. nform
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♦ If the fuel tank is emptied with the fuel suction device - VAS
5190- via the filler neck, the non-return valve -arrow- will
m
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be damaged.
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Non-return valve -arrow- in filler neck

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Procedure
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– Do not switch ignition on.
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– Remove fuel tank ⇒ page 18 .
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– Remove fuel delivery unit and replace with a new one
⇒ page 23 .
– Use fuel suction device - VAS 5190- to completely empty fuel
tank via fuel delivery unit ⇒ page 21 .
– Check fuel tank for dirt and filings.
– If necessary, clean fuel tank.
Procedure - no filings in fuel tank
– Fill fuel tank with 5 litres of diesel fuel.
– Completely empty fuel tank again as described above
⇒ page 21 .
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure
pump: Removing and installing high-pressure pump .
10 Rep. gr.20 - Fuel supply system

AG. Volkswagen AG d Crafter 2006 ➤
agen
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o s
ol not
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– Unscrew bolts -arrows- and remove
ut
ho metering unit -1- from the eo
OLD high-pressure pump. ss a ra
c
ce
le
– Check metering unit and high-pressure pump for filings.
un
pt
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If there are filings in the high-pressure pump, renew the following
erm
ab
components:
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wit
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail): is n
h re
Removing and installing high-pressure lines .
ole,
spec
urposes, in part or in wh
♦ fuel rail (fuel rail) including fuel pressure regulating valve -
t to the co
N276- and fuel pressure sender - G247- ⇒ Rep. gr. 23 ;
Injectors/fuel rail (fuel rail): Removing and installing fuel rail
♦ Injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail); Removing
rrectne
and installing injectors
s
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
s o
units/fuel rail; Assembly overview - injectors .
cial p
f inform
♦ Fuel filter
mer
atio
m
– Fill up vehicle.
o
n
c
i
or
n thi
– Bleed fuel system ⇒ Rep. gr. 23 ; Injection system; Filling/
te
sd
va

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pr
cum
r
fo
– Perform road test.
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ng
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op
End
C py
t. rig
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If there are no filings in high-pressure pump:
op Vo
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– Renew fuel filter.
– Fill up vehicle and perform road test.
End
Procedure - filings in fuel tank
– Renew all high-pressure components:
♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump:
Removing and installing high-pressure pump .
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail):
Removing and installing high-pressure lines .
♦ fuel rail (fuel rail) including fuel pressure regulating valve -
N276- and fuel pressure sender - G247- ⇒ Rep. gr. 23 ;
Injectors/fuel rail (fuel rail): Removing and installing fuel rail
♦ Injectors ⇒ Rep. gr. 23 ; Injectors/fuel rail (fuel rail); Removing
and installing injectors
♦ Fuel return lines (overflow oil lines) ⇒ Rep. gr. 23 ; Injector
units/fuel rail; Assembly overview - injectors .
– Install fuel delivery unit ⇒ page 23 .
– Install fuel tank ⇒ page 18 .
– Renew fuel filter ⇒ page 32 .
To prevent the high-pressure pump from running while it is empty
and to ensure that the engine starts quickly after parts have been
renewed, it is important to observe the following:
– Fill fuel tank with 5 litres of diesel fuel. Then, perform the func‐
tion “Bleeding fuel system” in “guided functions”.

Crafter 2006 ➤
♦ If fuel system components located between the fuel tank and

the high-pressure pump are renewed or removed, the fuel
system must be bled.
♦ To bleed fuel system with ⇒ Vehicle diagnostic tester, use
“Bleed fuel system” function ⇒ Rep. gr. 23 ; Injection system;
Bleeding/filling fuel system .
♦ This process takes 130 seconds. Fuel pumps are actuated a
total of 3 times in this case. The process must not be termi‐
nated prematurely.
– Fill fuel tank completely with diesel fuel.
Procedure for 2nd case
Procedure
– Remove fuel delivery unit and drain ⇒ page 23 .
– Check strainer and clean if soiled.
Note
♦ The lint-free cloth can be ordered from the ⇒ ServiceNet;

Workshop Equipment; Techno equipment catalogue; BMK
consumables .
♦ Always work carefully and ensure cleanliness when working
on the fuel system. The fuel system reacts sensitively to the
ingress of dirt.
– Use the fuel suction device - VAS 5190- to completely empty

n AG. Volkswagen AG do
the fuel tank via the fuel delivery
lkswageunit. es n
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by ua
Fuel tank completely empty:
ris
ed ran
tee
tho or
– Clean inside of sfuel
au tank with lint-free cloth. ac
s
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nl
pt
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itte

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ility

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hole
spec
– Fill fuel tank with 5 litres of diesel fuel.

es, in part or in w
t to the co

rrectness of i
♦ If fuel system components located between fuel tank and high-

pressure pump are renewed or removed, fuel system must be
l purpos
bled. To do this, perform “Bleed fuel system” function on ve‐

hicle diagnostic tester in “Guided Functions” ⇒ Rep. gr. 23 ;
nf
ercia
Injection system; Filling/bleeding fuel system .

orm
m

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or c
nated prematurely.
thi
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Cop py
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12
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Rep. gr.20 - Fuel supply system Prote
cted AG.
agen
Crafter 2006 ➤
Engine code BJJ, BJK, BJL, BJM, CEBA, CEBB, CECA, CECB
Caution
Irreparable damage to high-pressure components, especially

the high-pressure pump due to lack of lubrication through die‐
sel can occur when the fuel tank is filled with incorrect fuel.
Damage due to seizure and metal particles can be expected.
These metal particles will probably cause further damage to
pressure regulating valves and injectors.
olks
wage es n
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db ara
rise nte
tho eo
Here are the solutions for stwo
au different cases of filling with incor‐ ra
c
rect fuel: s
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nl
pt
du
♦ 1st scenario: filling with incorrect fuel was detected BEFORE
an
itte
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starting the engine and the engine was NOT started
erm
ab
⇒ page 13 .
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wit
, is n
♦ 2nd scenario: filling with incorrect fuel was detected AFTER
h re
starting the engine. Impurities or incorrect type of fuel has en‐
hole
spec
tered the fuel system and has reached the high-pressure
es, in part or in w
system ⇒ page 14 .
t to the co
Procedure for 1st case
rrectness of i
Caution
l purpos

the fuel suction device - VAS 5190- via the filler neck.
nf
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orm
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atio
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c
be damaged.
or
thi
te
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iva
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Cop py
– Do not switch ignition on. ht. rig
rig ht
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cted agen
Prote AG.
– Disengage and detach connector for fuel system pressurisa‐

tion pump - G6- and fuel gauge sender - G- in centre left of
underbody -A-.
– Remove fuel delivery unit and drain ⇒ page 23 .
the fuel tank via the fuel delivery unit.
– Installing fuel tank ⇒ page 18

AG. Volkswagen AG d
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Crafter 2006 ➤ horis
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ss a- Edition 03.2016 ra
c
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nl
pt
– Attach connector for fuel system pressurisation pump - G6-
du
an
itte
and fuel gauge sender - G- in centre left of underbody -A-.
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erm
ab
ility
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wit
, is n
Note
h re
hole
spec
For models in which the fuel pump is activated when the door is
es, in part or in w
t to the co
opened, the fuel filter must be renewed.
rrectness of i
l purpos
– Fill fuel tank with 5 litres of diesel fuel. Then carry out function
“Bleeding fuel system” ⇒ Vehicle diagnostic tester.
nform
ercia
♦ If fuel system components located between the fuel tank and

m
at
om
ion
c
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or
his
ate
do
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um
for
en
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♦ This process takes 130 seconds. Fuel pumps are actuated a t. C rig
gh ht
total of 3 times in this case. The process must not be termi‐ yri
p by
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by c
nated prematurely.
lksw
cted agen
Prote AG.
Procedure for 2nd case
Caution

the fuel suction device - VAS 5190- via the filler neck.
be damaged.


Crafter 2006 ➤
– Disengage and detach connector for fuel system pressurisa‐

tion pump - G6- and fuel gauge sender - G- in centre left of
underbody -A-.
– Remove fuel delivery unit and replace with a new one
⇒ page 23 .
the fuel tank via the fuel delivery unit. gen AG
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a does
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– Check fuel tank for dirt and filings. Vol gu
d by ara
e nte
ris
– If necessary, clean fuel tank. tho eo
s au ra
c
Procedure - no filings in fuel tank
s
ce
e
nl
pt
du
– Replace high-pressure pump ⇒ Rep. gr. 23 ; High-pressure
an
itte
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pump: Removing and installing high-pressure pump .
erm
ab
ility
ot p
– Remove fuel pressure regulating valve - N276- of »old« high-
wit
, is n
pressure pump and check for particles.
h re
hole
spec
If particles are found in the fuel pressure regulating valve - N276- ,
es, in part or in w
renew all other high-pressure components:
t to the co
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injection system; Assem‐
bly overview - fuel system
rrectness of i
♦ High-pressure accumulator (fuel rail) including fuel pressure
l purpos
regulating valve - N276- and fuel pressure sender - G247- ⇒

Rep. gr. 23 ; Injection system; Assembly overview - fuel sys‐
tem
nform
ercia
♦ Injectors (piezo injectors) ⇒ Rep. gr. 23 ; Injectors/fuel rail;

m
at
Removing and installing injectors
om
ion
c
in t
r
♦ Fuel return lines ⇒ Rep. gr. 23 ; Injection system; Assembly

o
his
e
overview - fuel system

at
do
priv
cum
Procedure - filings in fuel tank
for
en
ng
t.
yi Co
– Renew all high-pressure components: t. Cop py
rig
gh ht
♦ High-pressure pump ⇒ Rep. gr. 23 ; High-pressure pump: yri
p by
o Vo
Removing and installing high-pressure pump .
by c lksw
cted agen
Prote AG.
♦ High-pressure lines ⇒ Rep. gr. 23 ; Injection system; Assem‐
bly overview - fuel system
♦ High-pressure accumulator (fuel rail) including fuel pressure
regulating valve - N276- and fuel pressure sender - G247- ⇒
Rep. gr. 23 ; Injection system; Assembly overview - fuel sys‐
tem
♦ Injectors (piezo injectors) ⇒ Rep. gr. 23 ; Injectors/fuel rail;
Removing and installing injectors
♦ Fuel return lines ⇒ Rep. gr. 23 ; Injection system; Assembly
overview - fuel system
Continuation for all
– Installing fuel tank ⇒ page 18
– Renew fuel filter ⇒ page 32 .

Crafter 2006 ➤
– Attach connector for fuel system pressurisation pump - G6-

and fuel gauge sender - G- in centre left of underbody -A-.
Note
For models in which the fuel pump is activated when the door is
opened, the fuel filter must be renewed.

renewed, it is important to observe the following: n AG. Volkswagen A ge G do
swa es n
– Fill fuel tank with 5 litres of diesel fuel. Then carry
by out function
Vol
k ot g
ua
“Bleeding fuel system” ⇒ Vehicle diagnosticristester.
ed ran
tee
tho or
♦ If fuel system components located between
ss
au the fuel tank and ac
ce
le
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
nated prematurely.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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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 ➤
2 Fuel tank
⇒ “2.1 Assembly overview - fuel tank”, page 17
⇒ “2.2 Removing and installing fuel tank”, page 18
⇒ “2.3 Emptying fuel tank”, page 21
2.1 Assembly overview - fuel tank
Caution
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
1 - Cap
❑ Renew seal if damaged.
2 - Tank flap unit
Removing and installing ⇒
. Volkswagen AG
Rep. gr. 55 swa
gen AG does
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3 - Bolt ris
ed
ara
nte
ho eo
❑ 2.5auNm
t ra
c
ss
4 - Cover
ce
le
un
pt
an
d
❑ For filler neck

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rm
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5 - Supply line
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6 - Return line
h re
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7 - Union nut
spec
es, in part or in w
❑ Remove and install us‐

t to the co
ing special wrench -

T50014- or special
wrench - T40283- .
rrectness of i
❑ 50 Nm
l purpos
8 - Fuel delivery unit

❑ With fuel system pres‐
nform
ercia
surisation pump - G6-

m
and fuel gauge sender -

a
com
tio
G- .
n in
r
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❑ Removing and installing

thi
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iva
⇒ page 23
do
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9 - Seal
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❑ Renew if damaged ht. Cop py
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❑ Moisten with fuel when rig ht
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installing
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10 - Fuel tank
❑ When removing, sup‐
port using engine and gearbox jack - V.A.G 1383 A- .
❑ Emptying ⇒ page 21
❑ Removing and installing ⇒ page 18
11 - Securing strap
❑ Note installation position
2. Fuel tank 17
Crafter 2006 ➤
12 - Bolt
❑ 56 Nm agen
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13 - Breather line ed by ara
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14 - Cover aut h
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15 - Earth wire
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16 - Panel nut
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17 - Bolt
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❑ 7 Nm
is n
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ole,
spec
t to the co
2.2 Removing and installing fuel tank
rrectne
Caution
s
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cial p
f inform
mer
atio
om
n
c
i
or
Special tools and workshop equipment required n thi

te
sd
iva
♦ Torque wrench (5…50 Nm) - V.A.G 1331-

pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.

Crafter 2006 ➤
♦ Vehicle diagnosis, testing and information system - VAS

5051B-
AG. Volkswagen AG d
agen oes
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ility
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♦ Engine and gearbox jack - V.A.G 1383 A-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
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c
Removing
or
thi
te
sd
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– Note safety precautions before starting installation work

o
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⇒ page 1 .
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f
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– Observe rules for cleanliness ⇒ page 7 .
Co
Cop py
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rig ht
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Note cted agen
Prote AG.
Before carrying out further work, disconnect battery earth strap.

For this reason, first check whether a coded radio is fitted. Obtain
anti-theft coding first if necessary.
– Disconnect battery earth strap with ignition switched off ⇒

Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
– Draining fuel tank ⇒ page 21
– Remove tank flap unit ⇒ Rep. gr. 55 .
2. Fuel tank 19
AG. Volkswagen AG d
agen oes
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Crafter 2006 ➤ by
Vol not
gu
d ara
oris - Edition 03.2016
e nte
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aut ra
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– Unscrew bolts -arrows- and remove
s filler neck cover -1-.
s
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
c
– Undo bolt -arrows- from filler neck -1-.
um
for
en
ng
t.
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Cop py
WARNING
t. rig
gh ht
pyri by
Vo
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by c lksw
Fuel supply line may be pressurised. Wear eye protection and cted agen
Prote AG.
protective clothing to avoid eye injuries and skin contact. Be‐
fore loosening hose connections, wrap a cloth around the
connection. Then release pressure by carefully pulling hose off
connection.
– Remove noise insulation (if fitted).
– Disconnect fuel lines -1 and 2- from fuel filter.

– Collect any escaping fuel in a cloth.

Crafter 2006 ➤
– Detach connector -arrow- and fuel line -1-.

– Remove cover ⇒ Item 14 (page 18) .
– Detach earth wire ⇒ Item 15 (page 18) .
– Pull breather line ⇒ Item 13 (page 18) out of body.
– Support fuel tank with engine and gearbox jack - V.A.G 1383
A- .
– Undo and remove bolts of securing straps and carefully lower
fuel tank.
Installing AG. Volkswagen AG d
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Install in reverse order. In the process, d bnote
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spec
♦ Note installation position of securing straps.
es, in part or in w
t to the co
♦ Connections for breather and fuel lines must engage audibly
when joined.
rrectness of i
♦ Do not interchange supply and return hoses.
l purpos
♦ Install breather and fuel hoses free of kinks.

♦ Ensure that line connections are tight.
nf
ercia
o
♦ Check fuel tank/body earth connection on filler neck.
rm
m
atio
m
Specified torques
o
n in
or c
thi
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 17
te
sd
iva
o
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♦ Tank flap unit ⇒ Rep. gr. 55 .

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2.3 Emptying fuel tank Cop py
t. rig
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Special tools and workshop equipment required
co Vo
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cted agen
Prote AG.
♦ Fuel extractor - VAS 5190-
Procedure
– Note safety precautions before starting installation work
⇒ page 1 .
– Observe rules for cleanliness ⇒ page 1 .
2. Fuel tank 21
Crafter 2006 ➤
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.
– At a distance of -a- = 815 mm from end of extraction hose, use

insulating tape to mark -arrow- the hose of the fuel extractor -
VAS 5190- .
– Remove cap from fuel filler neck. agen
AG. Volkswagen AG d
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Screw shaft -1- of fuel extractor - VAS 5190- onto fuel tank
hole
spec
filler neck.
es, in part or in w
t to the co
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
rrectness of i
Note
l purpos
A ball valve is located at the lower end of the filler neck in the fuel
nform
ercia
tank, which must not be damaged by the extraction hose. You

must therefore push the hose into the filler neck only as far as the
m
at
om
marking.
ion
c
in t
or
his
e
– Drain fuel tank as far as possible.

at
do
priv
cum
or
– Carefully pull out extraction hose of fuel extractor - VAS 5190- .

f
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
When no more fuel is extracted, the tank is emptied just enough
Prote AG.
for the sender flange to be opened without danger.

Crafter 2006 ➤
AG. VolFuel
kswagsupply
en AG system - Diesel engines - Edition 03.2016
agen does
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is nte
3 Fuel delivery unit and fuel gauge or eo
h
aut ra
sender ss c
ce
le
un
pt
an
d
⇒ “3.1 Removing and installing fuel delivery unit, fuel gauge send‐ itte
y li
er”, page 23
erm
ab
ility
ot p
⇒ “3.2 Removing and installing fuel gauge sender G ”,
wit
is n
page 25
h re
ole,
spec
3.1 Removing and installing fuel delivery
t to the co
unit, fuel gauge sender
rrectne
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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
♦ Wrench - T50014-
AG.
Or
♦ Wrench - T40283-
3. Fuel delivery unit and fuel gauge sender 23

Crafter 2006 ➤
Removing
Note
♦ Note safety precautions before starting installation work

⇒ page 1 .
♦ Observe rules for cleanliness ⇒ page 7 .

– Loosen union nut -1- with special wrench - T50014- or special
wrench - T40283- .
– Carefully pull fuel supply unit together with seal out of fuel tank.
– When removing the fuel delivery unit, ensure that the float arm
of the fuel gauge sender is not bent.
– Place a cloth underneath the fuel delivery unit to catch any
escaping fuel.
Note
♦ If delivery unit is to be renewed, old delivery unit must be

drained before disposal.
♦ Observe environmental regulations for disposal.
♦ Check fuel tank for foreign bodies and dirt.
Installing
Install in reverse order. In the process, note the following: n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
Note utho
or
a ac
ss
When inserting fuel delivery unit, ensure that fuel gauge sender -
ce
le
un
pt
G- is not bent.
an
d
itte
y li
rm
ab
pe
– Insert seal for fuel delivery unit dry into opening of fuel tank. ility
ot
wit
, is n
– Coat inner side of seal with fuel.

h re
hole
spec
– When inserting fuel delivery unit, ensure that fuel gauge send‐
es, in part or in w
er is not bent.
t to the co
– When sealing flange is inserted, ensure that seal is not dam‐

aged or squashed.
rrectness of i
• Arrow on fuel delivery unit -1- points to recess -B- on fuel tank.
l purpos
• Lug on fuel delivery unit -A- must align with recess -B- on fuel
nform
tank.
mercia
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
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Tighten union nut -1- with special wrench - T50014- or special

wrench - T40283- .
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 17 wagen AG. Volkswagen AG doe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
3.2 Removing and installing fuel gauge
ot p
wit
, is n
sender - G-
h re
hole
spec
Removing
es, in part or in w
t to the co
Note
rrectness of i
♦ Note safety precautions before starting installation work
l purpos
⇒ page 1 .
♦ Observe rules for cleanliness ⇒ page 7 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Remove fuel delivery unit ⇒ page 23 .
o
r
rp
cu
o
m
f
en
– Empty fuel delivery unit and place down on a clean surface.
ng
t.
yi Co
op py
– Unplug connector -arrow- from regulating flap potentiometer - t. C rig
gh ht
G- and lay cable aside. pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disengage catch -arrows- and withdraw fuel gauge sender -

G- upwards in -direction of arrow-.
Installing
Installation is carried out in the reverse order; note the following:
– Insert fuel gauge sender - G- into guides on fuel pump and
press downwards until it engages.
Specified torques
♦ ⇒ “2.1 Assembly overview - fuel tank”, page 17
3. Fuel delivery unit and fuel gauge sender 25

Crafter 2006 ➤
4 Plug-in connectors
⇒ “4.1 Separating plug-in connectors”, page 26
4.1 Separating plug-in connectors

AG. Volkswagen AG d
Special tools and workshop equipment required agen oes
olksw not
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ara
♦ Lever - T10468- rised
nte
ho eo
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
Assignment of plug-in connectors
l purpos
Note
nform
mercia
at
♦ The plug-in connectors for fuel, vacuum and breather lines are
om
ion
colour coded. There is either a coloured dot on the plug-in
c
in t
or
connector or the release button is of the respective colour
his
ate
⇒ page 26 .
do
priv
cum
or
♦ Plug-in connectors for fuel lines must engage »audibly« when

f
en
ng
t.
yi
joined.
Co
Cop py
ht. rig
♦ Ensure plug-in connector is secured properly by pulling. rig ht
py by
co Vo
by lksw
cted agen
Prote
Colour assignment
AG.
Plug-in connector Colour code on plug-in connector

Fuel supply Black
Fuel return line Blue
Breather White, beige
Vacuum Green
WARNING
The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.
Wear eye protection and protective clothing to avoid eye inju‐
ries and skin contact. Before loosening hose connections,
wrap a cloth around the connection. Then release pressure by
carefully opening the connection point.

Crafter 2006 ➤
Variant 1
Plug-in connector with release buttons -arrows- on right and left
AG. Volkswagen AG d
agen oes
olksw not
V gu
Opening d by ara
ise nte
or e
h
Counterhold at the
s aut coupling point for fuel -1- in the engine com‐ or a
c
partment. s
ce
e
nl
pt
du
– Insert lever between heat shield and stop - T10468- -arrow- of
an
itte
y li
fuel line -2- and counterhold.
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
r
Continued for all coupling points in fuel system:

o
his
ate
do
riv
– Push plug-in connector -1- in -direction of arrow A-.

p
cum
for
– Press and hold release buttons.

en
ng
t.
yi Co
op py
– Pull plug-in connector -1- off fuel line -2- in t. C rig
gh ht
-direction of arrow B-. yri
p by
o Vo
by c lksw
cted
Note colour assignment during installation ⇒ page 26 .
agen
Prote AG.
Plug-in connectors for fuel lines must engage »audibly« when

joined.
– Ensure plug-in connector is secured properly by pulling.
4. Plug-in connectors 27
Crafter 2006 ➤
Variant 2
Plug-in connector with pull-release mechanism -arrow-.
Opening
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction of arrow B-.
– Pull plug-in connector -1- off fuel line -3- in
-direction of arrow B-.
Note colour assignment during installation ⇒ page 26 . lkswage es n
o ot g
byV ua
d ran
Plug-in connectors for fuel lines must engage »audibly« wheno
ir se tee
joined. auth or
ac
ss
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
Variant 3
rrectne
Plug-in connector with button in front -arrow-
s
Opening
s o
cial p
f i
– Press release button -arrow- and pull off plug-in connectors.
nform
mer

atio
om
n
c
i
or
n thi
joined.
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
Variant 4
ht
pyri by
Vo
co lksw
by
Plug-in connector with release button -arrows- on right and left:
cted agen
Prote AG.
Opening
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
joined.

Crafter 2006 ➤
Variant 5
Plug-in connector with release buttons -arrows- on right and left:
Opening
joined.
Variant 6
Plug-in connector with release buttons -arrows- on right and left:
Opening
– Push plug-in connector -1- in -direction of arrow- and maintain
pressure.
Note colour assignment during
agen
Ainstallation
G. Volkswagen⇒AG
page
do 26 . w es n
olks o
Plug-in connectorsd bfor
y V fuel lines must engage »audibly«
t gu
arawhen
joined. orise nte
eh
ut or
ac
sa
– Ensure splug-in connector is secured properly by pulling.
ce
le
un
pt
an
d
Variant 7
itte
y li
erm
ab
Plug-in connector -1- with release buttons -2- on right and left:
ility
ot p
wit
is n
Opening
h re
ole,
– Press plug-in connector -1- in -direction of arrow A- and main‐

spec
tain pressure.
t to the co
– Press release button -2- in -direction of arrow B- and pull off

plug-in connector -1-.
rrectne

ss
joined.
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
o
by c lksw
cted agen
Prote AG.
4. Plug-in connectors 29
Crafter 2006 ➤
5 Fuel filter
⇒ “5.1 Assembly overview - fuel filter”, page 30
⇒ “5.2 Removing and installing fuel filter”, page 32
5.1 Assembly overview - fuel filter
5.1.1 Assembly overview - fuel filter - with re‐

placeable filter element
Vehicles with 2.5 l common rail engine
Note
♦ To guarantee immediate engine starting after renewing theVolkswa

fuel filter, the fuel system must be bled using vehicle wadiagnostic
gen AG
. gen AG
does
tester ⇒ Vehicle diagnostic tester. Volks not
gu
by d ara
ise nte
♦ To do this, perform the routine “Initial fuel
tho filling after installing
r eo
high-pressure pump” ⇒ Rep. gr. 23ss;auInjection system; Filling/ ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
1 - Fuel supply line
ility
ot p
wit
❑ From fuel tank
is n
h re
ole,
❑ Do not kink.
spec
❑ Ensure secure seating
t to the co
❑ To pull off flange, press
release buttons on con‐
necting piece.
rrectne
❑ Disconnect plug-in con‐
nectors ⇒ page 26
❑ Push-fit couplings must ss o
cial p
f i
engage »audibly« when
nform
joined.
mer
atio
m
❑ Ensure plug-in connec‐

o
n
c
tor is secured properly

i
or
n thi
by pulling it.
te
sd
iva
o
pr
2 - Connector
um
r
fo
en
ng
❑ For fuel filter heater -

t.
yi Co
op
Z57- . C py
t. rig
gh ht
yri
3 - Upper part of fuel filter
p by
co Vo
by lksw
cted
❑ With fuel filter heater -
agen
Prote AG.
Z57- .
❑ To fuel accumulator
❑ Do not kink.
necting piece.
nectors ⇒ page 26
❑ Push-fit couplings must
joined.

Crafter 2006 ➤
❑ Ensure plug-in connector is secured properly by pulling it.
5 - O-ring
❑ Renew
6 - Filter insert
❑ Bleed fuel system after replacing filter ⇒ Rep. gr. 23 ; Injection system; Filling/bleeding fuel system
7 - Lower part of fuel filter
❑ Loosen and tighten with fuel filter wrench - T50011- .
❑ 15 Nm gen AG
. Volkswagen AG
d wa oes
olks not
8 - Seal db
yV gu
ara
ise nte
❑ Renew if damaged
tho
r eo
au ra
c
9 - Water drain screw
ss
ce
e
nl
❑ Loosen and allow approx. 100 cm3 fluid to drain
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
5.1.2 Assembly overview - fuel filter - without
, is n
h re
replaceable filter element
hole
spec
es, in part or in w
t to the co
Vehicles with 2.0 l common rail engine
rrectness of i
Note
l purpos
♦ To guarantee immediate engine starting after renewing fuel

filter, fuel system must be bled using ⇒ Vehicle diagnostic
tester.
nf
ercia
orm
♦ To do this, perform the routine “Initial fuel filling after installing
m
atio
m
high-pressure pump” ⇒ Rep. gr. 23 ; Injection system; Filling/

o
n in
c

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Fuel filter 31
Crafter 2006 ➤
1 - Fuel filter
❑ Bleed fuel system after
replacing filter ⇒ Rep.
gr. 23 ; Injection sys‐
tem; Filling/bleeding
fuel system
❑ From fuel tank
❑ Do not kink.
necting piece.
nectors ⇒ page 26
joined.
tor is secured properly
by pulling it.
❑ To engine.
❑ Do not kink.
❑ Ensure secure seating n AG. Volkswagen AG do
swage es n
❑ To pull off flange, press byV
olk ot g
ua
release buttons on con‐ ir se
d ran
tee
necting piece. utho
or
a ac
❑ Disconnect plug-in con‐ ss
ce
e
nectors ⇒ page 26
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
joined.
wit
, is n

h re
hole
tor is secured properly by pulling it.

spec
es, in part or in w
t to the co
5.2 Removing and installing fuel filter

rrectness of i
l purpos
Note
Applies to both variants

nf
ercia
orm
m
atio
m

o
n in
or c
♦ Drip tray for workshop hoist - VAS 6208-

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
ksw
agen Fuel supply
oes
not
system - Diesel engines - Edition 03.2016
ol
byV gu
ara
ed
Removing oris nte
eo
h
aut ra
ss c
WARNING
ce
le
un
pt
an
d
itte
y li
Fuel supply line may be pressurised. Wear eye protection and
rm
ab
pe
ility
ot
wit
, is n
h re
hole
connection.
spec
es, in part or in w
t to the co
– Place drip tray for workshop hoist - VAS 6208- under fuel filter.
– Disconnect fuel lines -1 and 2- from fuel filter -3-. To do this,
rrectness of i
press quick-release couplings ⇒ page 26 .
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
– Push fuel filter -1- upwards in direction of -arrow- out of retainer co Vo
by lksw
-2- and remove downwards.
cted agen
Prote AG.
Installing
– Install in reverse order of removal.
5. Fuel filter 33
Crafter 2006 ➤
6 Accelerator mechanism
⇒ “6.1 Assembly overview - accelerator module”, page 34
⇒ “6.2 Removing and installing accelerator module with acceler‐
ator position sender G79 / G185 ”, page 35
6.1 Assembly overview - accelerator mod‐

ule
⇒ “6.1.1 Assembly overview - accelerator module”, page 34
⇒ “6.1.2 Function of the electronic throttle”, page 34
6.1.1 Assembly overview - accelerator module
1 - Connector
2 - Accelerator position sender lkswage es n
o ot g
- G79- byV ua
d ran
ir se tee
❑ Not adjustable. utho
or
a ac
❑ The accelerator position ss
ce
e
sender - G79- transmits

nl
pt
du
an
the driver's input to the
itte
y li
engine control unit.
erm
ab
ility
ot p
3 - Bolt
wit
, is n
h re
❑ 8 Nm
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.1.2 Function of the electronic throttle

With the EPC system, the throttle valve is not operated by a cable
from the accelerator There is no mechanical connection between
the accelerator and the throttle valve.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.

Crafter 2006 ➤
The position of the accelerator (driver's requirement) is a main

input value for the engine control unit .
The throttle valve is actuated by a control motor (throttle valve
positioner) in the throttle valve module over the full range of en‐
gine speeds and load conditions.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit .
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender . This means that when
the accelerator is depressed half way, the throttle valve positioner
opens the throttle valve to the same extent. The throttle valve is
then approx. half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender .
This means that the throttle valve can already be completely open
even though the accelerator is only depressed half way. This has
the advantage of preventing throttling losses at the throttle valve.
After evaluating the torque requirements of the various compo‐
nents (e.g. air conditioning system, automatic gearbox, ABS/
ESP, etc.), the engine control unit calculates the optimal throttle
valve opening angle for the respective situation.agen
AG. Volkswagen AG d
o w es n
olks ot g
This also results in significantly improveded
by consumption and ex‐
V ua
ran
haust emission values under certain ho
risload conditions. tee
t or
au ac
“EPC” is a system comprising allss components which contribute to
determining, controlling or monitoring the position of the throttle
ce
e
nl
pt
du
valve (e.g. accelerator position sender , throttle valve control
an
itte
y li
module , EPC warning lamp , engine control unit ).
erm
ab
ility
ot p
6.2 Removing and installing accelerator

wit
, is n
module with accelerator position sender

h re
hole
-G79- / -G185- spec

es, in part or in w
t to the co
Removing
– Disconnect connector -1-.
rrectness of i
– Undo bolts -arrows- and remove accelerator mechanism -2-

l purpos
from the console.

Installing
nf
ercia
or
Installation is carried out in the reverse order; note the following:

m
m
atio
m
Specified torques
o
n in
or c
thi
e
♦ ⇒ “6.1 Assembly overview - accelerator module”, page 34

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Accelerator mechanism 35
Crafter 2006 ➤
Fuel supply system - nDiesel
wage
AG. Volkengines - Edition
swagen AG
doe 03.2016
ks s no
Vol t gu
d by ara
e nte
ris
7 Fuel pump
au
tho eo
ra
ss c
⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
ce
le
un
pt
page 36
an
d
itte
y li
erm
7.1 Checking fuel system pressurisation
ab
ility
ot p
pump - G6-
wit
is n
h re
ole,
⇒ “7.1.1 Checking delivery pressure of fuel system pressurisation
spec
pump G6 ”, page 36
t to the co
7.1.1 Checking delivery pressure of fuel sys‐
tem pressurisation pump - G6-
rrectness
Note
o
cial p
f inform
Observe different engine variants
mer
atio
om
n
c
i
or
n thi
te
♦ Drip tray for workshop hoist - VAS 6208-
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.
♦ Pressure tester - VAS 6550-
♦ Hose adapter set - VAS 6550/3-

Crafter 2006 ➤
Test prerequisites
• Fuses must obe OK.
lksw
age es n
ot g
byV ua
• Battery ir sevoltage at least 12 V
d ran
tee
tho
or
• Ignition
ss
au
switched off ac
ce
e
• There must be at least 10 l of fuel in the fuel tank.

nl
pt
du
an
itte
y li
• All electrical consumers, e.g. lights and rear window heating,
erm
ab
must be switched off.
ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
Fuel supply lines are under pressure! Wear eye protection and
t to the co
rrectness of i
connection.
l purpos
nform
ercia
WARNING
m
at
om
io
♦ Read rules for cleanliness and the instructions for working
n
c
in t
r
on the fuel system ⇒ “4.1 Rules for cleanliness”, page 7 .

o
his
ate
do
riv
♦ Always follow these rules for cleanliness and instructions

p
cum
before starting work and while working on the fuel system.

for
en
ng
t.
yi Co
♦ Wrap a clean cloth around the connection before opening
Cop py
the fuel system, then carefully loosen the connection to
t. rig
gh ht
yri
release the pressure.
p by
co Vo
by lksw
cted agen
Prote AG.
Procedure
– Place drip tray for workshop hoist - VAS 6208- under fuel filter.
– Pull off fuel supply line -2- to engine from fuel filter -3-. To do
this, press quick-release couplings ⇒ page 26 .
7. Fuel pump 37
Crafter 2006 ➤
– Attach connection -A- of pressure tester - VAS 6550- with suit‐

able line to open end of fuel filter.
– Attach connection -B- of pressure tester - VAS 6550- with suit‐
able line to open line of high-pressure pump.
– Switch on pressure tester - VAS 6550- by pressing On/Off
button.
– Close shut-off tap -C- of pressure tester - VAS 6550- .
– Carefully open shut-off valves -A- and -B-.
– Start engine.
Read off specified value:
• 5-cylinder engine: approx. 0.5 bar on pressure tester - VAS
6550-
6550-
If the specified value is attained, the fuel system is OK.
If the specification is not attained:
– Connect fuel line -2- to fuel filter again -3-.
– Release fuel supply line -1- from fuel tank to fuel filter -3- and
pull off ⇒ page 26 . wage
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– Collect any escaping fuel in a
ed cloth.
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Crafter 2006 ➤
– Attach connection -A- of pressure tester - VAS 6550- with suit‐

able line to open line of fuel tank.
able line to open end of fuel filter.
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– Close shut-off tap -C- of pressure tester
ris
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– Carefully open shut-off valves -A- sand
au -B-. ac
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– Start engine.
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6550-
es, in part or in w
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If specification is attained:
– Renew fuel filter.
rrectness of i
l purpos
– A measurement must be performed directly on the fuel deliv‐

ery unit.
nform
ercia
Carry out the following work:

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– Lower fuel tank ⇒ page 18 .
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– First check that connector -arrow- is fitted securely without
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pressing catch. The connector can cause a fault if it has not
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been fitted correctly.

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– Pull off fuel supply line (black or black marking) from fuel de‐
t. C rig
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livery unit ⇒ page 26 . p by
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7. Fuel pump 39
Crafter 2006 ➤
– Fit connection -A- of pressure tester - VAS 6550- with suitable

line to open end of fuel delivery unit flange.
able line to open end of line.
button.
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– Close shut-off tap -C- of pressure tester - VAS 6550- . y Volksw not
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– Carefully open shut-off valves -A- and -B-. rise nte
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– Start engine. ss c
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un
pt
an
d
itte
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rm
ab
pe
ility
6550-
ot
wit
, is n
h re
hole
6550-
spec
es, in part or in w
If specification is attained:
t to the co
– Renew fuel line.
rrectness of i
– Remove fuel delivery unit ⇒ page 23 .
l purpos
– Fuel delivery unit filter strainer soiled. In order to check it, re‐
move the fuel delivery unit ⇒ page 23 .
nform
mercia
– Quick-release coupling in the fuel delivery unit defective. In
a
com
ti
order to check it, remove the fuel delivery unit ⇒ page 23 .
on in
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te o
thi
If no fault can be found.
s
iva
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– Renew fuel delivery unit ⇒ page 23 .
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Service: Crafter 2006

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Service

CEB CEC CEC CSLB CSN CSL CSLA

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D4B804563FF

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.1 Safety precautions when working on

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

♦ The fuel system is also under pressure! Before opening

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 or fuel pump

♦ Place the suction hose of an activated exhaust gas extraction

extraction system is available, a radial fan with a displacement

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

Risk of injury due to highly-pressurised fuel.

♦ Wrap a clean cloth around the connection before opening

♦ Wear protective gloves.

♦ Wear eye protection.

– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and

2 Rep. gr.00 - Technical data

2.1 Engine number, engine data

The engine number (“engine code” and “serial number”) is located

on the left below the vacuum pump on the cylinder block.

showing the “engine code” and “serial number”. t to the co

The engine number consists of up to nine characters (alphanu‐

“engine code”, and the second part (6 characters), the “serial

Code BJJ BJK BJL BJM

Manufactured 03.06 ► 03.06 ► 03.06 ► 03.06 ►

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

Code BJJ BJK BJL BJM

Code CEBA CEBB CECA CECB

Stroke mm 95.5 95.5 95.5 95.5

Compression ratio 16.8 16.8 16.8 16.8

Turbocharging/su‐ yes yes yes yes

Charge air cooler yes yes yes yes

Selective catalytic yes yes yes yes

4 Rep. gr.00 - Technical data

Engine code CKTB CKTC CKUB CKUC

Engine code CSLB CSNA CSLA CSLC

Bore Diameter, 81.0 81.0 81.0 81.0

Stroke mm 95.5 95.5 95.5 95.5

Valves per cylinder 4 4 4 4

Compression ratio: 1 15.5 15.5 15.5 15.5

Balancer shaft module no no no no

Catalytic converter yes yes yes yes

Turbocharging/supercharg‐ Mono-turbo Bi-turbo Mono-turbo Mono-turbo

Charge air cooler yes yes yes yes

Particulate filter yes yes yes yes

Selective catalytic reduction yes yes yes yes

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

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

sure. If necessary, release pressure before beginning repair

6 Rep. gr.00 - Technical data

4.1 Rules for cleanliness

To prevent the high-pressure pump from running while it is

♦ If the high-pressure pump is removed or renewed, the fuel