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Service
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Crafter 2006 ➤
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Brake systems
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Edition 09.2015
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
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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 © 2015 Volkswagen AG, Wolfsburg K0059031120

Crafter 2006 ➤
Brake systems - Edition 09.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .. V.o.lk.sw . a. g.e. . . . . . . . . . . . . . . . . . . . 2
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2.2 Checking vehicles with rear-wheel drive . . . .ol.ks.w.a.ge. . . . . . . . . . . . . . d.o.es.n.o . . . . . . . . . . . . 2
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2.3 General notes on brakes for Crafter 4MOTION ed
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45 - Anti-lock brake system . . . . . . . . .ss. . . .
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1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.1 General notes on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.3 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.1 Overview of fitting locations - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Assembly overview - control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 18
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3.3 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.3 Removing and installing speed sensor wire on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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4.4 Removing and installing speed sensor wire on rear axle, Crafter 3.0 t and 3.5 t . . . . . . . . 30
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4.5 Removing and installing speed sensor wire on rear axle, Crafter 5.0 t . . . . . . . . . . . . . . . . 31
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4.6 Removing and installing wire for brake pad wear indicator on front axle . . . . . . . . . . . . . . 32
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4.7 Removing and installing wire for brake pad wear indicator on rear axle . . . . . . . . . . . . . . 33
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4.8 Removing and installing yaw rate sender G202 and lateral acceleration sender G200 . . 33
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4.9 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Assembly overview - rear brake, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Assembly overview - brake shoes for handbrake, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . 44
2.4 Assembly overview - brake shoes for handbrake, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . 45
2.5 Removing and installing brake pads, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6 Removing and installing brake pads, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.7 Removing and installing brake caliper, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . 50
2.8 Removing and installing brake caliper, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.9 Removing and installing brake shoes for handbrake, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . 54
2.10 Removing and installing brake shoes for handbrake, Crafter 5.0 t . . . . . . . . . . . . . . . . . . 55
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Removing and installing front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.4 Note on adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.5 Adjusting front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
Crafter 2006 ➤
3.6 Adjusting brake shoes for handbrake and rear handbrake cables, Crafter 3.0 t and 3.5 t . . 61
3.7 Adjusting brake shoes for handbrake and rear handbrake cables, Crafter 5.0 t . . . . . . . . 62
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Removing and installing front brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1 Assembly overview - rear brake caliper, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . 69
2.2 Assembly overview - rear brake caliper, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3 Removing and installing rear brake caliper piston, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . 70
2.4 Removing and installing rear brake caliper piston, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . 72
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Removing and installing brake light switch F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.3 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Assembly overview - vacuum pump for vehicles with 5-cylinder diesel engine . . . . . . . . . . 80
4.2 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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5.1 Assembly overview - flanging tool . . . . . . . . . . . . . . s. w. a.g.en. A. G. .. . . . . .g.e.n .AG . .do. e.s. . . . . . . . . . 82
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5.2 Notes for repairs to brake lines . . . . . . . . . . . .d .by.V. . . . . . . . . . . . . . . . . . . . . . . . t.g.ua.r . . . . .
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5.3 Repairing brake lines . . . . . . . . . . . . . . . . h.or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.te.e . . 84
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5.4 Additional brake line on Crafter 4MOTION ss
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6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6.1 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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6.2 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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ii Contents
Crafter 2006 ➤
00 – Technical data
1 Technical data
(VRL008190; Edition 09.2015)
⇒ “1.1 Technical data for brakes”, page 1
1.1 Technical data for brakes

Brake master cylinder and brake servo
Brake master cylinder Diameter 25.4
in mm
Brake servo Diameter 10/10
in inches
Front brakes
Front brake Floating caliper disc brake
Piston diameter mm 2 x 48
Internally ventilated brake disc Diameter, 300
mm
Brake disc thickness mm 28
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Brake pad thickness (without backplate)
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Rear brake Floating caliper disc brake

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Piston diameter mm 51 47
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Brake disc Diameter, mm 298 303

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Ventilated brake disc mm 16 28

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Brake pad thickness (with‐ mm 13 15

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Handbrake Duo-Servo Duo-Servo

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Brake lining width mm 25 42

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1. Technical data 1
Crafter 2006 ➤
2 Brake test
⇒ “2.1 General information”, pagew2agen AG. Volkswagen AG does
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♦ For the test, ensure for vehicles with a manual gearbox that
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the gear lever is in neutral and for vehicles with an automated
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manual gearbox, that the selector lever is in “N”.
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♦ For test, observe specifications provided by manufacturer of
roller dynamometer.
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The brake regulation systems do not function when ignition is off.
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2.2 Checking vehicles with rear-wheel drive
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The brake test must be performed on a single-axle roller dyna‐

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The maximum test speed must not exceed 6 km/h.

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2.3 General notes on brakes for Crafter
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4MOTION with Achleitner four-wheel
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drive
Note
If the vehicle is tested on a single-axle roller dynamometer or

power-absorption roller, a two-axle roller dynamometer needs to
be used due to permanent four-wheel drive operation.
Note
Please always apply handbrake when parking. Make sure that the
transfer box is not in neutral position. This is important to prevent
the vehicle from rolling when parked on inclines/declines.
WARNING
Activating differential lock restricts ABS functionality.
2 Rep. gr.00 - Technical data

Crafter 2006 ➤
45 – Anti-lock brake system

1 General information
⇒ “1.1 General notes on ABS”, page 3
⇒ “1.2 Repair instructions for repair work on ABS”, page 3
⇒ “1.3 Fault display via warning lamps”, page 5
1.1 General notes on ABS

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Vehicles with ABS aress not fitted with a mechanical brake pressure
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regulator. Specially matched software in the control unit regulates
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the brake force distribution on the rear axle.
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Faults in the ABS do not influence the brake system and servo
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assistance. The conventional brake system remains functional
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even without ABS. A change in braking behaviour is to be reck‐
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oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
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The hydraulic unit -a- and control unit -b- form one component.
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They can be separated only when removed.
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If the ABS hydraulic unit - N55- with the ABS control unit - J104-
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is renewed, it must be recoded ⇒ Vehicle diagnostic tester.

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1.2 Repair instructions for repair work on
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ABS
♦ Before carrying out repair work on the anti-lock braking sys‐
tem, determine the cause of the fault using ⇒ Vehicle diag‐
nostic tester.
Note
is renewed, it must be recoded ⇒ Vehicle diagnostic tester.
♦ Disconnect battery earth strap with ignition switched off.

♦ Before carrying out welding work with an electric welding unit
⇒ Special information; Body No. 19; Notes on safety .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 88 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 88 .
1. General information 3
Crafter 2006 ➤
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. Auxiliary items containing mineral oil, e.g. oils,
greases, etc. must never be used.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours). Ensure that no brake fluid enters connectors.
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4 Rep. gr.45 - Anti-lock brake system

Crafter 2006 ➤
1.3 Fault display via warning lamps

Warning lamps
Item Description
1 Brake pad warning lamp - K32-agen AG. Volkswagen AG do
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2 ABS warning lamp - K47- olks ot g
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3 Brake system warning oris lamp - K118- tee
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4 Traction controlss system warning lamp - K86-
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ESP and TCS warning lamp - K155-

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Brake pad warning lamp - K32-
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♦ If brake pad warning lamp - K32- -1- does not go out after
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ignition is switched on and after completion of test run, or if it
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comes on during vehicle operation, the faults may be caused
spec
by the following:
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a - The brake pads/linings are worn.
– Check brake pads/linings on front and rear axles.
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b - There is a fault in the activation of the brake pad warning lamp
- K32- ⇒ Current flow diagrams, Electrical fault finding and Fitting
ss
locations.
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ABS warning lamp - K47-
form
mer
atio
♦ If the ABS warning lamp - K47- -2- does not go out after the
om
ignition has been switched on and test sequence has been
n
c
i
or
n
completed, then the fault may be:
thi
te
sd
va
a - The voltage supply is below 10 volts.

i
o
pr
cum
r
fo
en
ng
b - There is a fault in the ABS.

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Cop py
In the event of an ABS fault, the anti-lock brake system remains ht. rig
rig ht
switched off, but the brake system remains fully operational. py by
co Vo
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cted agen
c - Since the last time the vehicle was started there was a tem‐ Prote AG.
porary speed sensor fault.
In the event of a speed sensor fault, the ABS warning lamp - K47-
will extinguish after the engine is restarted and attains a speed
above 2.75 km/h.
d - The connection from dash panel insert to ABS control unit -
J104- is interrupted ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
ABS warning lamp - K47- and brake system warning lamp - K118-
♦ If ABS warning lamp - K47- -2- goes out but brake system
warning lamp - K118- -3- remains on, the causes of the fault
may be:
a - The handbrake is applied.
b - The brake fluid level is too low.
c - There is a fault in the activation of the brake pad warning lamp
- K118- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ If the ABS warning lamp - K47- -2- and the brake system
warning lamp - K118- -3- light up, the anti-lock brake system
and the EBD (electronic brake pressure distribution) system
have failed.
1. General information 5
Crafter 2006 ➤
WARNING
After the ABS warning lamp - K47-

wage
n AG. and
Volksthe brakedosystem
wagen AG
e n warn‐
ing lamp - K118- have Volit up, it is possible that the srear
lks ot g wheels
by ua
will lock up earlier.
ris
ed ran
t ee
ho
aut or
ac
ss
Traction control system warning lamp - K86-
ce
le
un
pt
an
d
itte
Only on vehicles equipped with traction control system.
y li
erm
ab
♦ If the traction control system warning lamp - K86- -4- does not
ility
ot p
go out after the ignition is switched on and completion of the
wit
is n
h re
test sequence, the fault causes may be:
ole,
spec
a - Short circuit to positive in TCS and ESP button - E256-
t to the co
b - Fault in activation of traction control system warning lamp -
K86- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
rrectne
- Traction control system has been switched off by ESP and TCS
button - E256-
ss o
cial p
f
There is a fault which affects only the TCS safety system. ABS
inform
and EBD safety systems of vehicle remain fully functional.
mer
atio
om
n
c
i
Note
or
n thi
te
sd
iva
o
r
If traction control system warning lamp - K86- flashes while the

p
cum
r
fo
vehicle is in motion, the TCS is in operation.

en
ng
t.
yi Co
Cop py
. rig
ESP and TCS warning lamp - K155-
t
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pyri by
Vo
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Only in vehicles with ESP.
by
cted agen
Prote AG.
♦ If the ESP and TCS warning lamp - K155- -4- does not go out
after ignition is switched on and the test sequence has been
completed, then the fault may be:
a - Short circuit to positive in TCS and ESP button - E256-
b - Fault in activation of stabilisation program warning lamp -
K155- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
c - TCS and ESP system has been switched off by TCS and ESP
button - E256- .
There is a fault affecting only the TCS/ESP. ABS and EBD safety
systems of vehicle remain fully functional ⇒ Read event memory.
Note
If ESP and TCS warning lamp - K155- flashes during travel, trac‐
tion control system (TCS) or ESP system is in operation.

Crafter 2006 ➤
2 Overview of fitting locations

⇒ “2.1 Overview of fitting locations - ABS/ESP”, page 7
2.1 Overview of fitting locations - ABS/ESP

⇒ “2.1.1 Components and fitting locations, ABS/TCS/ESP Bosch
8.1, Crafter 3.0 t and 3.5 t”, page 7
8.1, Crafter 5.0 t”, page 9
9i, Crafter 3.0 t and 3.5 t, 2012 ►”, page 10
9i, Crafter 5.0 t, 2012 ►”, page 12 gen AG
. Volkswagen AG
d a oes
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Vol
2.1.1 Components and ise
d b fitting locations, ABS/TCS/ESP
y gu
ara
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Bosch 8.1, Crafter 3.0 t
and 3.5 t aut or e
h or
a c
ss
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e
nl
pt
du
1 - ABS hydraulic unit - N55-
an
itte
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❑ Removing and installing
erm
ab
ility
up to week 27/2012
ot p
wit
⇒ page 33
, is n
h re
hole
spec
from week 27/2012
es, in part or in w
⇒ page 20
t to the co
❑ If the hydraulic control
unit is defective, it can
rrectness of i
be replaced only as a
complete unit.
l purpos
2 - ABS control unit - J104-

❑ If the hydraulic control nform
ercia

m
at
om
io
complete unit.
n
c
in t
or

his
ate
up to week 27/2012
do
priv
⇒ page 33
um
for
en
g

n
t.
yi Co
op
from week 27/2012 C py
t. rig
⇒ page 20
gh ht
pyri by
Vo
o
by c lksw
3 - ABS warning lamp - K47- cted agen
Prote AG.
❑ Fault display ⇒ page 5
4 - ESP and TCS warning lamp
- K155-
5 - Brake pad warning lamp -
K32-
6 - Brake system warning lamp
- K118-
7 - Brake light switch - F-
❑ Removing and installing ⇒ page 76
8 - TCS and ESP button - E256-
❑ Location: in centre of dash panel.
2. Overview of fitting locations 7

AG. Volkswagen AG d
agen oes
olksw not
Crafter 2006 ➤ d by
V gu
ara
e nte
Brake systems - Edition 09.2015 thoris
eo
au ra
ss c
9 - Steering angle sender - G85-
ce
le
un
pt
❑ Only on vehicles having ESP
an
d
itte
y li
❑ Location: on steering column between steering wheel and steering column switch
erm
ab
ility
ot p
10 - Lateral acceleration sender - G200- , longitudinal acceleration sender - G251- and yaw rate sender - G202-
wit
is n
h re
ole,
spec
❑ Combined in one housing.
t to the co
❑ Location: Under driver's seat.
rrectne
11 - Diagnostic connection
❑ Fitting location: driver footwell
ss o
12 - Front right speed sensor - G45- / front left speed sensor - G47-
cial p
f in
form
mer
atio
13 - Wheel bearing housing with wheel bearing/wheel bearing unit
om
n
c
❑ ABS sensor ring is installed in wheel bearing.
i
or
n thi
te
sd
a
14 - Rear right speed sensor - G44- / rear left speed sensor - G46-
iv
o
pr
cum
r

fo
en
ng
t.
yi Co
15 - Axle beam t. Cop py
rig
gh ht
yri
16 - Rear axle shaft with wheel bearing/wheel bearing unit p by
o Vo
by c lksw
cted agen
Prote AG.
Fitting location: the diagnostic connection is located on the left A-

pillar in the footwell.

Crafter 2006 ➤
2.1.2 Components and fitting locations, ABS/TCS/ESP Bosch 8.1, Crafter 5.0 t

up to week 27/2012
⇒ page 33
from week 27/2012
⇒ page 20
complete unit.
complete unit.
up to week 27/2012
⇒ page 33
from week 27/2012
⇒ page 20
3 - ABS warning lamp - K47-
- K155- n AG. Volkswagen AG do
swage es n
❑ Fault display ⇒ pagey V5olk ot g
u b ara
ed nte
5 - Brake pad warningtho
rislamp - e or
K32- au ac
ss
ce
e
nl
pt
du
an
6 - Brake system warning lamp

itte
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erm
- K118-
ab
ility
ot p

wit
, is n
h re

hole
spec

es, in part or in w
t to the co
8 - TCS and ESP button - E256-

rrectness of i

l purpos

nform
ercia
10 - Lateral acceleration sender - G200- , longitudinal acceleration sender - G251- and yaw rate sender - G202-
m
at

om
ion
c
❑ Combined in one housing.

in t
or
his
te
❑ Location: Under driver's seat.

a
do
priv

um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
12 - Front right speed sensor - G45- / front left speed sensor - G47- Prote
cted AG.
agen

Crafter 2006 ➤

⇒ “4.2.2 Assembly overview - speed sensor on rear axle, Crafter 5.0 t”, page 28
Volkswa
AG. gen AG
agen does
15 - Axle beam Volksw not
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by ara
ed
16 - Rear axle hub with wheel bearing/wheel bearing hunitris nte
t o eo
❑ ABS sensor ring is installed in rear axle hub.s au ra
c
s
ce
le
17 - Rear axle shaft
un
pt
an
d
itte
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erm
ab
ility
ot p
Fitting location: the diagnostic connection is located on the left A-
wit
is n
pillar in the footwell.
h re
ole,
spec
2.1.3 Components and fitting locations, ABS/TCS/ESP Bosch 9i, Crafter 3.0 t and
t to the co
3.5 t, 2012 ►
rrectne
s
up to week 27/2012
s o
cial p
⇒ page 33
f inform
mer
from week 27/2012
atio
m
⇒ page 20
o
n
c
i
or
n
thi
te
sd
a

iv
o
pr
c
um
r
fo
complete unit.
en
ng
t.
yi Co
op py
. C rig
ht ht
rig by
❑ With lateral acceleration copy Vo
by lksw
sender - G200- , longi‐ cted agen
Prote AG.
tudinal acceleration
sender - G251- and yaw
rate sender - G202- (on‐
ly on vehicles having
ESP)
complete unit.
up to week 27/2012
⇒ page 33
from week 27/2012
⇒ page 20
- K155-
Note
TCS only on Crafter 4MOTION with

Achleitner four-wheel drive.

Crafter 2006 ➤
5 - Brake pad warning lamp - K32-

6 - Brake system warning lamp - K118-
8 - ESP button - E256-
Note
Not on Crafter 4MOTION with


❑ Make sure it is installed in correct position:
❑ Removing and installing ⇒ page 25 .
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
Note
♦ Allocation ⇒ Electronic Parts

Catalogue “ETKA”
AG. Volkswagen AG d
♦ Modified wheel bearing housing agen oes
olksw not
on Crafter 4MOTION with d by
V gu
ara
Achleitner four-wheel drive. horise nte
eo
ut ra
Ensure correct installation posi‐
a
♦ ss c
tion of front speed sensors, be‐
ce
le
un
pt
cause malfunction may other‐

an
d
itte
wise occur ⇒ page 25 .

y li
erm
ab
ility
ot p

wit
is n
h re
❑ ⇒ Running gear, axles, steering; Rep. gr. 40

ole,
spec
❑ The ABS sensor ring on Crafter 4MOTION with Achleitner four-wheel drive is located on the outer con‐
stant velocity joint.

t to the co

rrectne

ss o
cial p
14 - Axle beam
inform
mer
15 - Rear axle shaft with wheel bearing/wheel bearing unit

atio
m

o
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
yri by
11
op Vo
by c lksw
Prote
cted AG. 2. Overview of fitting locations
agen
Crafter 2006 ➤
2.1.4 Components and fitting locations, ABS/TCS/ESP Bosch 9i, Crafter 5.0 t,
2012 ►
Volkswagen AG
1 - ABS hydraulic unit - N55- agen
AG. does
olksw not
❑ Removing and installing ed
by
V gu
ara
up to week 27/2012 ris nte
⇒ page 33 tho eo
s au ra
c
s
ce
e
nl
from week 27/2012
pt
du
an
itte
⇒ page 20
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
complete unit.
spec
es, in part or in w
t to the co
❑ With lateral acceleration
sender - G200- , longi‐
tudinal acceleration
rrectness of i
sender - G251- and yaw
l purpos
rate sender - G202- (on‐

ly on vehicles having
ESP)
nf
ercia
o
rm
m
atio
om
n in
or c
complete unit.
thi
te
sd
iva
o
r
rp
cu
up to week 27/2012
o
m
f
en
ng
⇒ page 33
t.
yi Co
op
C py
ht. rig
from week 27/2012
rig ht
py by
o Vo
⇒ page 20 by c lksw
cted agen
Prote AG.
- K155-
Note
TCS only on Crafter 4MOTION with

5 - Brake pad warning lamp - K32-

6 - Brake system warning lamp - K118-
8 - ESP button - E256-
Note
Not on Crafter 4MOTION with


Crafter 2006 ➤

❑ Make sure it is installed in correct position:
Note
♦ Allocation ⇒ Electronic Parts

Catalogue “ETKA”
♦ Modified wheel bearing housing
on Crafter 4MOTION with
♦ Ensure correct installation posi‐
wise occur ⇒ page 25 . AG. Volkswagen AG d
agen oes
olksw not
❑ ABS sensor ring is installed in wheel bearing. d by
V gu
ara
ise nte
❑ ⇒ Running gear, axles, steering; Rep. gr. 40 tho r eo
au ra
❑ The ABS sensor ring on Crafter 4MOTION with ss Achleitner four-wheel drive is located on the outer c con‐
stant velocity joint.
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
⇒ “4.2.2 Assembly overview - speed sensor on rear axle, Crafter 5.0 t”, page 28
hole
spec
es, in part or in w
t to the co
14 - Axle beam
15 - Rear axle hub with wheel bearing/wheel bearing unit
rrectness of i
❑ ABS sensor ring is installed in rear axle hub.
l purpos
16 - Rear axle shaft

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

Crafter 2006 ➤
3 Control unit and hydraulic unit

⇒ “3.1 Assembly overview - control unit and hydraulic unit”, page
14
⇒ “3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 ”, page 18
⇒ “3.3 Connecting brake lines to hydraulic unit”, page 24
3.1 Assembly overview - control unit and hy‐

draulic unit
⇒ “3.1.1 Assembly overview - ABS control unit J104 and ABS
hydraulic unit N55 up to week 27/2012”, page 14
⇒ “3.1.2 Assembly overview - ABS control unit J104 and ABS
hydraulic unit N55 , as of week 27/2012”, page 16
3.1.1 Assembly overview - ABS control unit - J104- and ABS hydraulic unit - N55-
up to week 27/2012 n AG. Volkswagen A ge G do
swa es n
Complete brake master cylinders and brake servos canbbey V re‐
olk ot g
ua
newed independently of each other. ris
ed ran
tee
tho or
s au ac
s
1 - Brake servo
ce
le
un
pt
❑ Diesel engines are fitted
an
d
itte
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with a vacuum pump to
erm
ab
generate the necessary
ility
ot p
vacuum.
wit
is n
h re
❑ A vacuum reservoir is
ole,
spec
additionally installed in
certain vehicle types.
t to the co
❑ Checking function
❑ With engine switched
rrectne
off, depress brake pedal
firmly several times (to
deplete vacuum in unit).
ss o
❑ Now step on and hold
cial p
f in
brake pedal with medi‐ form
mer
um pressure and start

atio
engine. If the brake ser‐

om
vo is functioning proper‐
c
i
or
ly, the brake pedal will

thi
te
sd
a
be felt to go down as the

iv
o
pr
servo takes effect.

um
r
fo
en
ng
❑ If faulty renew complete

t.
yi Co
op py
❑ Checking non-return
t. C rig
gh ht
yri
valve (in vacuum hose) p by
co Vo
⇒ page 80 .
by lksw
cted agen
Prote AG.
❑ Separating from brake
pedal ⇒ page 64 , Re‐
moving and installing
brake pedal.
brake servo
⇒ page 77 .
2 - Sealing ring
❑ Renew.

Crafter 2006 ➤
3 - Cap
4 - Brake fluid reservoir
5 - Sealing plug
❑ Moisten with brake fluid and press into brake master cylinder.
6 - Bolt
❑ To secure brake fluid reservoir to brake master cylinder.
7 - Nut
❑ Self-locking
❑ 20 Nm
8 - Brake master cylinder
❑ Cannot be repaired, renew complete when faulty.
9 - Sealing plug
AG. Volkswagen AG d
❑ Connection for vacuum hose. agen oes
olksw not
V gu
by ara
10 - Connection for brake line rised
nte
h o eo
❑ From hydraulic unit to front right
s aut brake caliper. ra
c
s
11 - Connection for brake line
ce
le
un
pt
an
d
❑ From hydraulic unit to rear left brake caliper.

itte
y li
rm
ab
pe
ility
ot
wit
❑ From hydraulic unit to rear right brake caliper.
, is n
h re
hole
spec
es, in part or in w
❑ From hydraulic unit to front left brake caliper.
t to the co
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
rrectness of i
l purpos
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.

16 - ABS control unit - J104- and ABS hydraulic unit - N55-
nform
ercia
❑ If the hydraulic control unit is defective, it can be replaced only as a complete unit.
m
a
com
tio

n in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
If the ABS hydraulic unit - N55- with

en
ng
t.
yi Co
the ABS control unit - J104- is re‐ Cop py
newed, it must be recoded in guided
t. rig
gh ht
yri
fault finding ⇒ Vehicle diagnostic
p by
o Vo
by c lksw
tester. Prote
cted AG.
agen
17 - Retaining plate
18 - Bolt
❑ 8 Nm
19 - Bump stop
3. Control unit and hydraulic unit 15

Crafter 2006 ➤
3.1.2 Assembly overview - ABS control unit - J104- and ABS hydraulic unit - N55- ,
as of week 27/2012
Complete brake master cylinders and brake servos can be re‐
newed independently of each other.
1 - Brake servo
with a vacuum pump to
generate the necessary n AG. Volkswagen AG do
swage es n
vacuum. byV
olk ot g
ua
ed ran
❑ A vacuum reservoir ishor is tee
additionally installedau in
t or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
brake pedal with medi‐
t to the co
rrectness of i
l purpos
servo takes effect.

❑ If faulty renew complete
nform
ercia
m
valve (in vacuum hose)

a
com
ti
⇒ page 80 .
on in
r
te o

thi
s
iva

do
r
rp

um
fo
brake pedal.
en
ng
t.
yi Co
op
❑ Removing and installing C py
t. rig
brake servo.
gh ht
pyri by
Vo
co lksw
by
2 - Sealing ring Prote
cted AG.
agen
❑ Renew.
3 - Cap
5 - Sealing plug
6 - Bolt
❑ To secure brake fluid reservoir to brake master cylinder.
7 - Nut
❑ Self-locking
❑ 20 Nm
❑ Cannot be repaired, renew complete when faulty.
9 - Sealing plug
❑ Connection for vacuum hose.

Crafter 2006 ➤

❑ From hydraulic unit to front right brake caliper.
❑ 14 Nm
❑ From hydraulic unit to rear left brake caliper.
❑ 14 Nm
❑ From hydraulic unit to rear right brake caliper.
❑ 14 Nm
❑ From hydraulic unit to front left brake caliper.
❑ 14 Nm
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
❑ 14 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
❑ 14 Nm wage
n AG. Volkswagen AG do
e ks s no
Vol t
16 - ABS control unit - J104- and ABS hydraulic
db
y unit - N55- gu
ara
rise nte
❑ If the hydraulic control unit isuthdefective,
o it can be replaced only as a completee o unit.
ra
a
❑ Removing and installing ⇒s page 20
s c
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
If the ABS hydraulic unit - N55- with
ot p
wit
the ABS control unit - J104- is re‐
, is n
h re
newed, it must be recoded in guided
hole
spec
fault finding⇒ Vehicle diagnostic
es, in part or in w
tester.
t to the co
17 - Bracket rrectness of i
❑ Removing ⇒ page 23 .
l purpos
18 - Bump stop
19 - Washer
nform
ercia
20 - Nut
m
at
❑ 8 Nm
om
ion
c
in t
r
21 - Nut
o
his
ate
❑ 8 Nm
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
Crafter 2006 ➤ d byV gu
ara
e
Brake systems - Edition 09.2015 ho ris nte
eo
aut ra
ss c
3.2 Removing and installing ABS control
ce
e
nl
pt
du
unit - J104- and ABS hydraulic unit -
an
itte
y li
erm
N55-
ab
ility
ot p
wit
, is n
⇒ “3.2.1 Removing and installing ABS control unit J104 and ABS
h re
hydraulic unit N55 , up to week 27/2012”, page 18
hole
spec
es, in part or in w
⇒ “3.2.2 Removing and installing ABS control unit J104 and ABS
t to the co
hydraulic unit N55 , as of week 27/2012”, page 20
3.2.1 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
rrectness of i
N55- , up to week 27/2012
l purpos
Special tools and workshop
nform
ercia
equipment required
m
at
♦ Torque wrench - V.A.G
om
ion
1331-
c
in t
or
his
te
♦ Open ring spanner insert,

a
do
riv
AF 11 mm - V.A.G 1410/6-
p
cum
for
en
g
♦ Universal joint - V.A.G

n
t.
yi Co
op
1410/7- C py
ht. rig
rig ht
by
♦ Torque wrench - VAS copy Vo
by lksw
6854- cted agen
Prote AG.
♦ Brake pedal depressor -

V.A.G 1869/2-
♦ Assembly tool - V.A.G
1410/8-

Crafter 2006 ➤
Sealing plugs from repair kit, part number 1 H0 698 311 A

2 - Sealing plug M10
Removing
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit - gen AG. Volkswagen AG d
N55- and is located on the left in the engine compartment. Volkswa oes
not
g y ua
db ran
If problems are reported, the hydraulic unit and the control
ris unit
e
tee
ho
must be renewed together. au
t or
ac
ss
ce
le
un
pt
WARNING
an
d
itte
y li
erm
ab
Do not bend the brake lines in the area of the hydraulic unit!
ility
ot p
wit
is n
h re
ole,
– Note or request radio code on vehicles with coded radio if
spec
necessary.
t to the co
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
rrectne
– Connect bleeder bottle hose to front left brake caliper bleed
valve and open bleed valve.
ss
– Use brake pedal depressor - V.A.G 1869/2- to depress brake
o
cial p
f i
pedal.
nform
mer
– Close front left bleed valve.
atio
om
n
– Place sufficient lint-free cloths under the control unit and hy‐
c
i
or
n thi
draulic unit.
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Note
t.
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Ensure no brake fluid gets onto contacts. rig ht
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cted agen
Prote AG.
– Unscrew brake lines -1- to -4-, -A- and -B- from ABS hydraulic
unit - N55- .
– Seal brake lines and threaded holes using sealing plugs - 1H0
698 311 A- from repair kit.

Crafter 2006 ➤
AG. Volkswagen AG d
Brake systems - Edition 09.2015 agen oes
olksw not
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d b ara
– Release retainer -1- for connector -2- on control
rise unit in direc‐ nte
ho eo
tion of -arrow A- and pull connector froms a control unit in direc‐
ut ra
c
tion of -arrow B-. s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove ABS hydraulic unit - N55- together with ABS control
l purpos
unit - J104- -1-.

To do this, first pull ABS hydraulic unit - N55- with ABS control
nf
ercia
o
unit - J104- out of rubber buffers -4- beneath control unit and then
rm
m
beneath hydraulic unit.
atio
om
n in
c
– Remove bolt -3- from retaining plate -2-.

or
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Installing
iv
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Note t. Cop py
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If the ABS hydraulic unit - N55- with the ABS control unit - J104- cop Vo
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is renewed, it must be recoded in guided fault finding⇒ Vehicle
cted agen
Prote AG.
diagnostic tester.
Install in reverse order. Note the following points:

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be installed.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
Caution
Brake line nuts must be screwed to end of threads into ABS

hydraulic unit - N55- by hand.
Only then may the nuts be tightened to the specified torque.
– Bleed brake system ⇒ page 88 .

– Carry out a road test.
– Perform road test at more than 40 km/h for at least 80 seconds.
– Read event memory after road test ⇒ Vehicle diagnostic test‐
er.
Specified torques
♦ ⇒ “3.1 Assembly overview - control unit and hydraulic unit”,
page 14
3.2.2 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
N55- , as of week 27/2012

Crafter 2006 ➤
Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
♦ Open ring spanner insert,
AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G
1410/7-
♦ Torque wrench - VAS
6854-
♦ Brake pedal depressor -
V.A.G 1869/2-
♦ Assembly tool - V.A.G
1410/8-
AG. Volkswagen AG d
agen oes
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un
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ab
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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Cop py
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pyri by
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by
cted agen
Prote AG.

Crafter 2006 ➤
Sealing plugs from repair kit, part number 1 H0 698 311 A

Removing
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
If problems are reported, the hydraulic unit and the control unit
must be renewed together.
WARNING
Do not bend the brake lines in the area of the hydraulic unit!
– Note or request radio code on vehicles with coded radio if

necessary.
– Connect bleeder bottle hose to front left brake caliper bleed
valve and open bleed valve.
– Use brake pedal depressor - V.A.G 1869/2- to depress brake
pedal.
– Close front left bleed valve.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
Note
Ensure no brake fluid gets onto contacts. agen

AG. Volkswagen AG d
oes
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– Unscrew brake lines -1- to -4-,tho-A- and -B- from ABS hydraulic
r eo
u
unit - N55- . ss a ra
c
ce
le
– Seal brake lines and threaded holes using sealing plugs - 1H0
un
pt
an
d
698 311 A- from repair kit.

itte
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rm
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es, in part or in w
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22
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cted
Rep. gr.45 - Anti-lock brake system
agen
Prote AG.
Crafter 2006 ➤
– Release retainer -1- for connector -2- on control unit in direc‐

tion of -arrow A- and pull connector from control unit in direc‐
tion of -arrow B-.
– Remove nuts -2- and remove rubber buffer with washer
– Pull ABS hydraulic unit - N55- with ABS control unit - J104-
-1- upwards out of bracket.
– Set ABS hydraulic unit - N55- with ABS control unit - J104- on
a clean surface.
AG. Volkswagen AG d
Removing bracket agen oes
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ab
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– Remove nuts -1- and remove bracket -1- for ABS hydraulic
h re
unit - N55- with ABS control unit - J104- upwards.
ole,
spec
Installing
t to the co
Note
rrectne
s
is renewed, it must be recoded in guided fault finding⇒ Vehicle

s o
diagnostic tester.
cial p
f inform
mer

atio
om
n
c
♦ Remove sealing plugs from new hydraulic unit only when the
i
or
n thi
corresponding brake line is to be installed.

te
sd
iva
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♦ If sealing plugs are removed too early from the hydraulic unit,
p
cum
r
fo
brake fluid can escape, and it can then no longer be guaran‐

en
ng
t.
yi
teed that the unit can be sufficiently filled and bled.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Caution
c by lksw
cted agen
Prote AG.
Brake line nuts must be screwed to end of threads into ABS

hydraulic unit - N55- by hand.
Only then may the nuts be tightened to the specified torque.
Specified torques ⇒ page 16

– Perform road test at more than 40 km/h for at least 80 seconds.
– Read event memory after road test ⇒ Vehicle diagnostic test‐
er.

Crafter 2006 ➤
3.3 Connecting brake lines to hydraulic unit

On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit. Volkswa AG. gen AG
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On hydraulic unit:
, is n
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hole
A - From hydraulic unit to primary piston circuit of brake master
spec
cylinder.
es, in part or in w
t to the co
- Marked on hydraulic unit with -HZ1-.
B - From hydraulic unit to secondary piston circuit of brake master
rrectness of i
cylinder.
l purpos
- Marked on hydraulic unit with -HZ2-.

1 - From hydraulic unit to front left brake caliper.
nform
ercia
- Marked on hydraulic unit with -VL-.

m
a
com
tio
2 - From hydraulic unit to front right brake caliper.
n in
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- Marked on hydraulic unit with -VR-.
s
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3 - Hydraulic unit, rear left brake caliper.
um
fo
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t.
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- Marked on hydraulic unit with -HL-.
Co
Cop py
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4 - Hydraulic unit, rear right brake caliper.
ht
pyri by
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cted
- Marked on hydraulic unit with -HR-.
agen
Prote AG.

AG. Volkswagen AG d
agen oes
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ara Crafter 2006 ➤
e
horis nte
eo Brake systems - Edition 09.2015
aut ra
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ce
le
4 Sensors
un
pt
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itte
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rm
⇒ “4.1 Assembly overview - speed sensor on front axle”,
ab
pe
ility
page 25
ot
wit
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⇒ “4.2 Assembly overview - speed sensor on rear axle”,
h re
hole
page 26
spec
es, in part or in w
⇒ “4.3 Removing and installing speed sensor wire on front axle”,
t to the co
page 28
⇒ “4.4 Removing and installing speed sensor wire on rear axle,
rrectness of i
Crafter 3.0 t and 3.5 t”, page 30
l purpos
⇒ “4.5 Removing and installing speed sensor wire on rear axle,

Crafter 5.0 t”, page 31
nform
ercia
⇒ “4.6 Removing and installing wire for brake pad wear indicator
on front axle”, page 32
m
a
com
tion in
⇒ “4.7 Removing and installing wire for brake pad wear indicator
r
te o
on rear axle”, page 33
thi
s
iva
do
r
⇒ “4.8 Removing and installing yaw rate sender G202 and lateral
rp
cum
fo
acceleration sender G200 ”, page 33

en
ng
t.
yi Co
op
⇒ “4.9 Removing and installing steering angle sender G85 ”, page
C py
ht. rig
34 rig ht
py by
co Vo
by lksw
4.1 Assembly overview - speed sensor on front axle
cted agen
Prote AG.
4. Sensors 25
Crafter 2006 ➤
1 - Front right speed sensor -

G45- / front left speed sensor -
G47-
⇒ page 28 .
2 - Wheel bearing housing with
wheel bearing/wheel bearing
unit
❑ Allocation ⇒ Electronic
Parts Catalogue “ETKA”
❑ ABS sensor ring is in‐
stalled in wheel bearing.
❑ ⇒ Running gear, axles,
steering; Rep. gr. 40 ;
Wheel bearing; Assem‐
bly overview - wheel
bearing
❑ The ABS sensor ring on
Crafter 4MOTION with
Achleitner four-wheel
drive is located on the
outer constant velocity
joint.
steering; Rep. gr. 40 ;
Drive shaft; Assembly
overview - drive shaft .
Note

tion of front speed sensors, be‐ AG. Volkswagen AG d
cause malfunction may other‐ agen oes
olksw not
wise occur ⇒ page 25 . ed by
V gu
ara
ris nte
ho eo
ut
3 - Brake disc ss a ra
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ce
le
4 - Bolt
un
pt
an
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itte
❑ 22 Nm
y li
erm
ab
5 - Bolt
ility
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❑ 8 Nm
h re
ole,
spec
t to the co
4.2 Assembly overview - speed sensor on

rear axle
rrectne
⇒ “4.2.1 Assembly overview - speed sensor on rear axle,

ss o
⇒ “4.2.2 Assembly overview - speed sensor on rear axle,

cial p
f in

form
mer
atio
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c
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or
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted
26
agen
Prote AG.
Rep. gr.45 - Anti-lock brake system
Crafter 2006 ➤
4.2.1 Assembly overview - speed sensor on rear axle, Crafter 3.0 t and 3.5 t
1 - Rear right speed sensor -

G44- / rear left speed sensor -
G46-
⇒ page 30 .
2 - Bolt, 8 Nm
3 - Bolt
steering; Rep. gr. 42
4 - Axle beam
5 - Splash plate
6 - Rear axle shaft with wheel
bearing/wheel bearing unit
stalled in wheel bearing.
AG. Volkswagen AG d
agen oes
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ara
ed
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aut ra
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nl
pt
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Sensors 27
Crafter 2006 ➤
4.2.2 Assembly overview - speed sensor on rear axle, Crafter 5.0 t
1 - Bolt, 8 Nm
2 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
3 - Axle beam
4 - Splash plate
5 - Rear axle hub
stalled in rear axle hub.
6 - Rear axle shaft n AG. Volkswagen AG do
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spec
t to the co
rrectness o
cial p
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mer
atio
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c
i
or
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te
sd
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4.3 Removing and installing speed sensor

en
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t.
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wire on front axle
Cop py
t. rig
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pyri by
Removing speed sensor wire from control unit to wheel housing
co Vo
by lksw
cted
⇒ page 28
agen
Prote AG.
Installing speed sensor wire from control unit to wheel housing

⇒ page 29
Removing speed sensor wire from wheel bearing housing to
wheel housing ⇒ page 29
Installing speed sensor wire from wheel bearing housing to wheel
housing ⇒ page 30
Removing speed sensor wire from control unit to wheel housing
Special tools and workshop equipment required

Crafter 2006 ➤
♦ Wiring harness repair set - VAS 1978 B-
AG. Volkswagen A
– Disconnect batteryolk⇒swElectrical
agen system; Rep.
G do
esgr.
not 27 ; Battery;
Disconnectingd band
y V reconnecting battery. gu
ar
e an
ris te
– Release uretainer
tho -1- for connector -2- on control unit in edirec‐
or
tion of s-arrow
sa A- and pull connector from control unit in direc‐
ac
tion of -arrow B-.
ce
e
nl
pt
du
an
– Release cover cap from multi-pin connector using screwdriver,
itte
y li
erm
and remove it.
ab
ility
ot p
Contact assignment of 38-pin connector - T38- for wiring harness
wit
, is n
on control unit -J104- ⇒ Current flow diagrams, Electrical fault
h re
hole
finding and Fitting locations.
spec
es, in part or in w
– Use release tool wiring harness repair set - VAS 1978 B- to

remove relevant contacts. t to the co
– Remove front wheel housing liner ⇒ General body repairs,
rrectness of i
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and

installing front wheel housing liner .
l purpos
– In wheel housing, disconnect connector -1- from speed sensor

nform
ercia
wire and speed sensor.

m
at
♦ Connector colour on left side of vehicle: black

om
ion
c
in t
r
♦ Connector colour on right side of vehicle: colourless

o
his
ate
do
riv
2 - Connector for brake pad wear indicator (blue)

p
cum
for
en
– Remove defective speed sensor wire.

ng
t.
yi Co
op py
Installing speed sensor wire from control unit to wheel housing t. C rig
gh ht
pyri by
– Install new speed sensor wire.
o Vo
by c lksw
cted agen
Prote AG.
Removing speed sensor wire from wheel bearing housing to
wheel housing
– Remove front wheel housing liner ⇒ General body repairs,
– In wheel housing, disconnect connector -1- from speed sensor

wire and speed sensor.
4. Sensors 29
Crafter 2006 ➤
– Unclip speed sensor wire -1- from clips -arrows A- on shock

absorber.
Crafter 4MOTION with Achleitner four-wheel drive
Note
♦ Modified wheel bearing housing on Crafter 4MOTION with

Achleitner four-wheel drive. AG. Volkswagen AG d
agen oes
olksw not
V gu
♦ Ensure correct installation position of front speed sensors, ised by ara
nte
since otherwise malfunction may occur. thor eo
au ra
ss c
– Unbolt speed sensor wire from frame.
ce
le
un
pt
an
d
itte
– Separate cable ties.
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rm
ab
pe
ility
– Mark installation position of speed sensor.
ot
wit
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Continuation for all vehicles
h re
hole
spec
es, in part or in w
– Unscrew bolt -1- and remove speed sensor -2- from wheel
t to the co
bearing housing.
Installing speed sensor wire from wheel bearing housing to wheel
housing
rrectness of i
Install in reverse order.
l purpos
Specified torques
nform
ercia
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page

m
25
a
com
tion in
♦ ⇒ “4.2.1 Assembly overview - speed sensor on rear axle,
r
te o
thi
s
iva
do
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rp
c
um
fo
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t.
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Cop py
t. rig
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pyri by
Vo
co
wire on rear axle, Crafter 3.0 t and 3.5 t
by lksw
cted agen
Prote AG.

♦ Torque wrench - V.A.G 1331-
Removing speed sensor wire

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

Crafter 2006 ➤
– On right side of underbody, disconnect connector -1- from

speed sensor wire and speed sensor.
– Separate all speed sensor wire connections to handbrake ca‐
ble and axle beam.
– Unscrew bolt -1- and remove speed sensor -2- from wheel axle
beam.
Installing speed sensor wire
wage
Specified torques olks es n
ot g
byV ua
ed ran
♦ ⇒ “4.2.1 Assembly overview - speed sensor
horis on rear axle, tee
Crafter 3.0 t and 3.5 t”, page 27 aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
wire on rear axle, Crafter 5.0 t
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
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
Removing speed sensor wire pyri by
Vo
co lksw
by
cted agen
– Raise vehicle ⇒ Maintenance ; Booklet 10.2 . Prote AG.
– On right side of underbody, disconnect connector -1- from

speed sensor wire and speed sensor.
– Separate all speed sensor wire connections to handbrake ca‐
ble and axle beam.
4. Sensors 31
Crafter 2006 ➤
– Unscrew bolt -1- and remove speed sensor -2- from wheel axle
beam.
Installing speed sensor wire
Specified torques
4.6 Removing and installing wire for ebrake

pad wear indicator on fronty Vaxle
olks
wag es n
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u b ara
ed
Removing wire for brake pad wear indicator
tho
ris nte
e or
au ac
– Remove front wheel housing liner s⇒ s General body repairs,
ce
e

nl
pt
du
an
itte
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erm
ab
– In wheel housing, disconnect connector -2-.
ility
ot p
wit
♦ Connector colour on left and right sides of vehicle: blue
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Unplug connector -arrow-.

o
n in
or c
– Unscrew bolt -1- and remove connector -2- from brake caliper.
thi
te
sd
iva
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rp
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m
f
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ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
– Unclip wire -2- from clips -arrows B- on shock absorber.

Installing wire for brake pad wear indicator
Continue installation in reverse order.
Specified torques
Component Specified torque
Connector to brake caliper 8 Nm

Crafter 2006 ➤
4.7 Removing and installing wire for brake

pad wear indicator on rear axle
Removing wire for brake pad wear indicator

– Disconnect connector -2- on right side of underfloor.
♦ Connector colour on left and right sides of vehicle: blue
1 - Connector for speed sensor wire to speed sensor (black or
colourless)
– Separate all wiring connections for brake pad wear indicator
to handbrake cable and axle beam.
lkswage es n
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ir se tee
tho
u or
a ac
ss
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– Disconnect connector -arrow-.

un
pt
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itte
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– Unscrew bolt -1- and remove connector -2- from brake caliper.
rm
ab
pe
ility
Installing wire for brake pad wear indicator
ot
wit
, is n
h re
hole
spec
Specified torques
es, in part or in w
t to the co
Connector to brake caliper 8 Nm
rrectness of i
l purpos
nform
ercia
4.8 Removing and installing yaw rate send‐

m
er - G202- and lateral acceleration send‐

a
com
tion in
er - G200-
r
te o
thi
s
iva
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rp
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fo
Note
en
ng
t.
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♦ Not relevant for vehicles equipped with Bosch ESP9i.
t. C rig
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pyri by
Vo
♦ The yaw rate sender - G202- and lateral acceleration sender
co lksw
by
cted agen
- G200- are integrated in ABS control unit - J104- . Prote AG.
4. Sensors 33
Crafter 2006 ➤
WARNING
Severe shocks (e.g. dropping, impact) may destroy the yaw

rate sender - G202- and the lateral acceleration sender -
G200- . agen
AG. Volkswagen AG d
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Removing yaw rate sender - G202- and lateral
tho acceleration send‐ or
er - G200- au ac
ss
ce
e
nl
The yaw rate sender - G202- and the lateral acceleration sender
pt
du
an
- G200- are combined in one housing. This is installed under the
itte
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driver seat.
erm
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ility
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– Move driver seat to foremost position.
wit
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h re
– Pull off connector -1-.
hole
spec
es, in part or in w
– Remove bolts -arrows-.
t to the co
– Remove yaw rate sender - G202- and lateral acceleration
sender - G200- -2-.
rrectness of i
Installing yaw rate sender - G202- and lateral acceleration sender
- G200-
l purpos
nf
ercia
o
Specified torques
rm
m
atio
m

o
n in
or c
thi
Bolt yaw rate sender - G202- and 6 Nm
te
sd
a
lateral acceleration sender -

iv
o
r
rp
cu
G200- to base plate.
o
m
f
en
ng
t.
yi Co
op py
4.9 Removing and installing steering angle
t. C rig
gh ht
yri by
sender - G85-
op Vo
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cted agen
Prote AG.
The steering angle sender - G85- is located between the steering
wheel and steering column switch.
Removing and installing
Remove steering column combination switch ⇒ Electrical system;
Rep. gr. 94 ; Steering column switch module; Removing and in‐
stalling steering column combination switch .

Crafter 2006 ➤
46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brakes”, page 35
⇒ “1.2 Removing and installing brake pads/linings”, page 36
⇒ “1.3 Removing and installing brake caliper”, page 38
1.1 Assembly overview - front brakes
Note
♦ After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that
the brake pads/linings are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).
1 - Protective cap
2 - Bolt
❑ Always renew after re‐
moving.
❑ 35 Nm AG. Volkswagen AG d
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3 - Brake hose byV
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❑ Bolted to brake caliper. horis nte
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❑ 35 Nm ss a c
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4 - Brake caliper
un
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⇒ page 38 .
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❑ Repairing ⇒ page 66 .
wit
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5 - Brake pads
hole
spec
❑ Thickness: 13.5 mm not
es, in part or in w
t to the co
including backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let 10.2 . rrectness of i
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❑ Always replace on both

sides
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⇒ page 36 .
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❑ Pad wear limit: 2 mm

ion in
without backplate (re‐

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maining pad thickness)

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❑ Always renew when
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changing pads.
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1. Front brakes 35
Crafter 2006 ➤
8 - Brake carrier
9 - Brake disc
❑ Brake disc, 300 mm in diameter
❑ Internally ventilated.
❑ Thickness: 28 mm
❑ Wear limit: 25 mm.
❑ Always renew on both sides of an axle.
10 - Bolt
❑ 22 Nm
Note

wise occur ⇒ page 25 .
12 - Bolt
❑ 170 Nm
1.2 Removing and installing brake pads/lin‐

ings
♦ Piston resetting appliance - T10145- AG. Volkswagen AG d
agen oes
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es, in part or in w
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Removing
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Note
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Mark brake pads when removing if they are to be reused. Fit in

nform
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same position when installing, or braking will be uneven.

m
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– Remove wheels.
at
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Cop py
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36 Rep. gr.46 - Brakes - mechanism

Crafter 2006 ➤
– Disconnect connector -1- for brake pad wear indicator.

– Remove cover caps -arrows- and unscrew bolts for securing
brake caliper.
lkswage es n
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– Insert screwdriver into notch -arrow A- on abrake
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ac
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– Press screwdriver in direction of -arrow B- to pull guide pin out
ce
le
un
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of brake carrier.
an
d
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– Remove brake caliper, guiding wire for brake pad wear indi‐
ility
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cator through opening in brake caliper.
wit
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– Secure brake caliper with wire so that the weight of the brake
ole,
caliper does not stress or damage the brake hose.
spec
– Remove brake pads from brake carrier sideways.
t to the co
– Clean brake caliper housing.
rrectne
Note
ss o
cial p
f
Only use methylated spirits to clean brake caliper housing.
inform
mer
atio
Installing
om
n
c
i
Before inserting new brake pads, press piston back into cylinder
or
n thi
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using piston resetting tool - T10145- . Before pressing piston

t
sd
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back, draw off brake fluid from brake fluid reservoir with bleeder
i
o
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bottle. Otherwise, fluid can overflow and cause damage, particu‐

fo
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larly if reservoir has been topped up.

t.
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Cop py
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– Press both pistons back with piston resetting tool - T10145- p by
co Vo
lksw
-1-.
by
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Prote AG.
1. Front brakes 37
AG. Volkswagen AG d
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Crafter 2006 ➤ d byV gu
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Brake systems - Edition 09.2015 horis nte
eo
aut ra
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– Insert brake pads -1-.
ce
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nl
pt
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an
Ensure that brake pads -1- are seated correctly in pad retainers
itte
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-arrows-.
erm
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– Insert brake caliper housing. Make sure that guide pins en‐
wit
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gage correctly in brake carrier.
h re
hole
spec
– Tighten new securing bolts to specified torque.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
– Insert cover caps -arrows-.
for
en
ng
t.
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– Connect connector -1- for brake pad wear indicator. . Cop py
rig
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– Fit wheels.
rig by
copy Vo
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cted
♦ After replacing brake pads/linings, depress brake pedal firmly
agen
Prote AG.
several times with vehicle stationary so that the brake pads/
linings are properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.
Specified torques
♦ ⇒ “1.1 Assembly overview - front brakes”, page 35
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Connector for brake pad wear in‐ 8 Nm
dicator to brake caliper
1.3 Removing and installing brake caliper

♦ Brake pedal depressor - V.A.G 1869/2-

Crafter 2006 ➤
Removing
Note
This procedure applies only to exchanging the brake caliper or

the following repair work on the brake caliper.

– Remove wheels.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve. gen AG
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d a oes
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– Apply brake pedal depressor - V.A.G
db
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Vo . gu
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ris
– Close bleed valve and removeutbleed
ho bottle. eo
ra
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ss
– Unscrew brake hose.
ce
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nl
pt
du
an
itte
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erm
ab
– Remove cover caps -arrows- and unscrew bolts for securing
ility
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brake caliper.
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Insert screwdriver into notch -arrow A- on brake carrier.

m
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om
– Press screwdriver in direction of -arrow B- to push guide pin

ion
c
out of brake carrier. in t

or
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ate
– Pull brake caliper from brake carrier.

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Installing
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• Piston is pressed back. C py
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• The brake pads are seated on the brake carrier. copy Vo
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– Insert brake caliper housing and make sure that guide pins
AG.
engage correctly in brake carrier.

– Tighten new securing bolts to specified torque.
1. Front brakes 39
Crafter 2006 ➤
– Insert cover caps -arrows-.

– Connect connector -1- for brake pad wear indicator.
– Bolt brake hose to brake caliper.
– Remove brake pedal actuator - V.A.G 1869/2- .
– Fit wheels.
Note
♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
Specified torques
♦ ⇒ “1.1 Assembly overview - front brakes”, page 35
AG. Volkswagen AG d
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nl
pt
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ab
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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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orm
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or c
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Crafter 2006 ➤
2 Rear brakes
⇒ “2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t”,
page 41
⇒ “2.2 Assembly overview - rear brake, Crafter 5.0 t”, page 43
⇒ “2.3 Assembly overview - brake shoes for handbrake,
⇒ “2.4 Assembly overview - brake shoes for handbrake,
⇒ “2.5 Removing and installing brake pads, Crafter 3.0 t and 3.5 t”,
page 45
⇒ “2.6 Removing and installing brake pads, Crafter 5.0 t”,
page 47
⇒ “2.7 Removing and installing brake caliper, Crafter 3.0 t and
3.5 t”, page 50
⇒ “2.8 Removing and installing brake caliper, Crafter 5.0 t”, page
52
⇒ “2.9 Removing and installing brake shoes for handbrake,
AG. Volkswagen AG d
Crafter 3.0 t and 3.5 t”, page 54 ksw
agen oes
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⇒ “2.10 Removing and installing brake ed shoes for handbrake,
b ran
ris
Crafter 5.0 t”, page 55 ut
ho tee
or
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ss
2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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wit
, is n
♦ After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that
h re
hole
the brake pads/linings are properly seated in their normal operating position.
spec
es, in part or in w
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
t to the co
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Rear brakes 41
Crafter 2006 ➤
1 - Splash plate
2 - Rear axle shaft
3 - Brake disc
❑ Brake disc, 288 mm in
diameter
❑ When worn, renew on
both sides of axle.
❑ Combined with drum for AG. Volkswagen AG d
handbrake (Duo-Ser‐ agen oes
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vo). byV gu
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4 - Bolt aut
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❑ 22 Nm s
ce
le
un
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5 - Brake carrier
an
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ab
6 - Pad retainer
pe
ility
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wit
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changing pads.
h re
hole
spec
❑ Always set in place with
es, in part or in w
angled lug pointing out‐
t to the co
wards.
7 - Protective cap
rrectness of i
❑ Check for damage
l purpos
8 - Guide pin
9 - Brake pads
nform
ercia
❑ Thickness without back‐

m
a
plate: 13 mm
com
tion in
❑ Pad wear limit: 2 mm
r
te o
thi
without backplate (re‐
s
iva
do
maining pad thickness)
r
rp
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fo
❑ Checking thickness
en
ng
t.
⇒ Maintenance ; Booklet 10.2 .
yi Co
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❑ Always replace on both sides ht. rig
rig ht
py by
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Prote AG.
10 - Brake pad wear indicator
❑ Only on outer brake pad
11 - Brake caliper
12 - Bolt
❑ Renew after removing
❑ 35 Nm
13 - Bolt
❑ 80 Nm +45°

Crafter 2006 ➤
2.2 Assembly overview - rear brake,

Crafter 5.0 t
Note

♦ Use the brake filling and bleeding equipment - VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
this, release pressure in system).
1 - Splash plate
2 - Rear axle shaft
3 - Brake disc
❑ Brake disc, 303 mm in
diameter
both sides of axle.
❑ Combined with drum for
handbrake wage
es n
olks ot g
4 - Flange byV ua
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5 - Bolt auth or
ac
ss
ce
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un
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❑ 80 Nm +40°
an
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itte
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6 - Brake carrier
ab
pe
ility
ot
7 - Pad retainers
wit
, is n
h re

hole
spec
changing pads.
es, in part or in w
❑ Always set in place with

t to the co
angled lug pointing out‐

wards.
rrectness of i
8 - Protective cap
l purpos
❑ Check for damage

9 - Guide pin
nform
ercia
10 - Brake pads
m
a
com

ion in
⇒ page 47 .
r
te o
thi
❑ Thickness without back‐

s
iva
do
plate: 16 mm
r
rp
cum
fo
❑ Pad wear limit: 2 mm without backplate (remaining pad thickness)

en
ng
t.
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op
❑ Checking thickness ⇒ Maintenance ; Booklet 10.2 . C py
t. rig
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❑ Always replace on both sides p by
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11 - Brake pad wear indicator Prote AG.
❑ Only on inner brake pad
2. Rear brakes 43
Crafter 2006 ➤
12 - Brake caliper
13 - Bolt
❑ 35 Nm
14 - Bolt
❑ 260 Nm
2.3 Assembly overview - brake shoes for handbrake, Crafter 3.0 t and 3.5 t
1 - Handbrake cable
2 - Pin
AG. Volkswagen AG d
3 - Brake shoes for handbrake agen oes
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❑ Removing and installing d b ara
ise nte
⇒ page 54 . thor eo
au ra
c
4 - Retaining spring ss
ce
le
un
pt
5 - Expander
an
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itte
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❑ Check for freedom of
erm
ab
movement.
ility
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is n
❑ Before installing brake
h re
shoes, attach to hand‐
ole,
spec
brake cable with pin
⇒ Item 2 (page 44) .
t to the co
6 - Brake disc
rrectne
both sides of axle.
ss
handbrake
o
cial p
f in
7 - Bolt
form
mer
❑ 22 Nm
atio
om
n
c
8 - Rear return spring

i
or
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te
sd
a
9 - Front return spring

iv
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pr
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10 - Setting pinion for brake

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shoes
Co
Cop py
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movement. cop Vo
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11 - Brake caliper
AG.
12 - Bolt
❑ Always renew after re‐
moving.
❑ 80 Nm +45°

Crafter 2006 ➤
2.4 Assembly overview - brake shoes for handbrake, Crafter 5.0 t
1 - Upper return spring

2 - Brake shoes for handbrake
⇒ page 55 .
3 - Retaining spring
4 - Return spring
5 - Return spring
6 - Retaining plate
7 - Brake disc
both sides of axle.
handbrake
8 - Flange
9 - Bolt
❑ 80 Nm +40°
10 - Handbrake cable
11 - Expander
movement.
❑ Attach to handbrake ca‐ lkswage es n
o ot g
ble ⇒ Item 10 (page 45) ed
byV ua
ran
before installing brake horis tee
shoes au
t or
ac
ss
12 - Brake caliper
ce
le
un
pt
an
d

itte
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⇒ page 52 .
erm
ab
ility
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wit
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ole,
spec
2.5 Removing and installing brake pads,

t to the co
Crafter 3.0 t and 3.5 t

rrectne
♦ Piston resetting appliance - T10145-

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
2. Rear brakes 45
Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
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ara
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nl
Removing
pt
du
an
itte
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erm
ab
ility
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Note
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Remove wheels.
rrectness of i
l purpos
– Unscrew securing bolts -arrows- for brake caliper.

nf
ercia
o
rm

m
atio
om
n in
c
or
thi

te
sd
iva
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rp

cu
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m
f
en
ng
t.
– Clean brake carrier and brake caliper.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Note
by lksw
cted agen
Prote AG.
Installing
Install in reverse order of removal, observing the following:

Crafter 2006 ➤
– Press pistons back with piston resetting tool - T10145- -1-.

-arrows-.
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gen AG
– Insert brake caliper housing. Volkswa does
not
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pt
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ab
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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– Tighten new securing bolts -arrows- to specified torque.

nf
ercia
or
– Fit wheels.
m
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atio
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n in
or c

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te

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cu

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f
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ng
t.
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Specified torques Cop py
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♦ ⇒ “2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t”, p by
co Vo
page 41
by lksw
cted agen
Prote AG.
2.6 Removing and installing brake pads,

Crafter 5.0 t
2. Rear brakes 47
Crafter 2006 ➤
AG. Volkswagen AG d
♦ Piston resetting appliance - T10145- agen oes
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tho eo
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un
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an
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ab
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spec
es, in part or in w
t to the co
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tion in
r
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thi
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ng
t.
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Cop py
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pyri by
Vo
o
Removing
c by lksw
cted agen
Prote AG.
Note


– Remove wheels.

Crafter 2006 ➤

– Clean brake carrier and brake caliper.
Note
Installing
– Press both pistons back with piston resetting tool - T10145-

-1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
– Carefully press brake pad wear indicator -2- onto stop in new
spec
brake pad -1-.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Prote AG.
2. Rear brakes 49
Crafter 2006 ➤

-arrows-.
– Insert brake caliper housing.
AG. Volkswagen AG d
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un
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an
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– Fit wheels.
wit
is n
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ole,
spec
t to the co
Specified torques
rrectne
♦ ⇒ “2.2 Assembly overview - rear brake, Crafter 5.0 t”,
s
page 43
s o
cial p
f in
form
mer
atio
om
n
c
i
or
n thi
e

t
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i
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fo
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t.
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2.7 Removing and installing brake caliper, Cop py
ht. rig
Crafter 3.0 t and 3.5 t

rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.
♦ Brake pedal depressor - V.A.G 1869/2-

Crafter 2006 ➤
Removing
Note
This procedure applies only to exchanging the brake caliper or

the following repair work on the brake caliper.
– Raise vehicle ⇒ Maintenance ; Booklet 10.2 . lkswage es n
o ot g
byV ua
d
– Remove wheels. o
ir se
ran
tee
th or
u
– Connect bleeder bottle hose to brake caliper bleed
ss
a valve and ac
open bleed valve.
ce
e
nl
pt
du
an
– Apply brake pedal depressor - V.A.G 1869/2- .
itte
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erm
ab
– Close bleed valve and remove bleed bottle.
ility
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– Unscrew brake hose.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Installing
nform
ercia

m
at
• Piston is pressed back.
om
ion
c
in t
r
• The brake pads are seated on the brake carrier.

o
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ate
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p
cum
for
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.
2. Rear brakes 51
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
e d
Crafter 2006ho➤ ris nte
eo
t
Brake systems
s au - Edition 09.2015 ra
c
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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– Screw brake line to brake caliper.
wit
, is n
h re
hole
spec
es, in part or in w
– Fit wheels.
t to the co
Note
rrectness of i
l purpos
operating position.
nform
ercia

m
a
com
tion in
Specified torques
r
te o
thi
s
iva
♦ ⇒ page 41
do
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rp
cum
fo
en
ng
t.
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Co
Cop py
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ht
rig by
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by lksw
Brake hose to brake caliper 35 Nm
cted agen
Prote AG.
2.8 Removing and installing brake caliper,

Crafter 5.0 t

Crafter 2006 ➤
Removing
Note
This procedure applies only to exchanging or the following repair

work on the brake caliper.

– Remove wheels.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
AG. Volkswagen AG d
agen
– Close bleed valve and remove
Vol
ksw bleed bottle.
oes
not
gu
y
db ara
– Unscrew brake hose. rise nte
tho eo
au ra
– Disconnect connector
ss -1- for brake pad wear indicator. c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Installing
t to the co
• The pistons are pressed back.
• The brake pads are seated on the brake carrier. rrectne

ss o
cial p
f in
– Tighten securing bolts -arrows- to specified torque.

form
mer
atio

om
n
c
– Screw brake line to brake caliper.

or
n thi
te
sd
va

i
o
pr
cum
r
fo
– Fit wheels.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note op Vo
by c lksw
cted agen
Prote AG.
operating position.
Specified torques
♦ ⇒ page 43
Brake hose to brake caliper 35 Nm
2. Rear brakes 53
Crafter 2006 ➤
2.9 Removing and installing brake shoes for

handbrake, Crafter 3.0 t and 3.5 t
♦ Hook - 3438-
lkswage es n
o ot g
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d ran
ir se tee
tho
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Removing
rrectne
Note
Brake shoes may come apart, fall and be damaged.

ss o
cial p
f inform

mer
atio
– Remove wheels.
om
n
c
i
or
– Remove brake caliper together with brake carrier and secure

thi
te
with wire so that weight of brake caliper does not stress or

sd
iva
o
r
damage brake hose.

p
cum
r
fo
en
ng
– Reset brake in order to be able to remove brake disc.

t.
yi Co
Cop py
.
– To do this, insert a screwdriver through hole in brake disc and
t rig
gh ht
yri by
position it on setting pinion for brake shoes -1-. cop Vo
by lksw
cted agen
Prote
– Turn setting pinion for brake shoes -1- by moving screwdriver
AG.
in direction of -arrow-.
– Remove brake discs.
– Turn nut -1- to relieve rear handbrake cables.

– Detach handbrake cables -arrows-.

AG. Volkswagen AG d
agen
Volksw
oes
not Crafter 2006 ➤
by gu
ised ara
nte Brake systems - Edition 09.2015
or eo
h
ut ra
– Unhookss return springs with hook - 3438- .
a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Press retaining spring -1- with pliers -2- in direction of

-arrow A- and turn so that hook -3- can be removed through
nf
ercia
slot -arrow B- on rear side of cover plate.
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
Only the lower retaining spring is shown on the illustration. A re‐
o
r
rp
cu
taining spring is also installed in the upper section of the brake
o
m
f
en
ng
shoes; this also has to be removed.

t.
yi Co
Cop py
t. rig
gh ht
yri
– Pull brake shoes apart as far as necessary and remove for‐ p by
o Vo
by c
wards (in direction of travel).
lksw
cted agen
Prote AG.
Installing
– Preassemble brake shoes.

A - Setting pinion
B - Front return spring
C - Brake shoes
F - Direction of travel
– Pull brake shoes apart as far as necessary and insert back‐
wards (opposite direction of travel).
Specified torques
2.10 Removing and installing brake shoes for

handbrake, Crafter 5.0 t
2. Rear brakes 55
Crafter 2006 ➤
♦ Hook - 3438-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
Note
rrectness of i
Brake shoes may come apart, fall and be damaged.
l purpos
nform
ercia
– Remove wheels.
m
a
com
ti
– Remove brake caliper together with brake carrier and secure
on in
with wire so that weight of brake caliper does not stress or
r
te o
damage brake hose. thi

s
iva
do
r
rp
Reset brake in order to be able to remove brake disc.

um
fo
en
ng
t.
yi
– To reset brake, turn adjuster screw -1- of adjustment jig -2- in
Co
op py
direction of -arrow B- using a commercially available spanner.
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
The brake shoes are not shown to improve the illustration clarity
of the adjustment jig -2-.
– Remove brake discs.
– Turn nut -1- to relieve rear handbrake cables.

– Detach handbrake cables -arrows-.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
– Unhook return springs
Vol with hook - 3438- .
ksw not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press retaining spring -1- with pliers -2- in direction of
rrectness of i
-arrow A- and turn so that hook -3- can be removed through
slot -arrow B- on rear side of cover plate.
l purpos
nf
Note
ercia
orm
m
atio
Only one retaining spring is shown on the illustration. The other
om
n in
brake shoe is also fitted with a retaining spring that must be re‐
or c
moved as well.
thi
te
sd
iva
o
r
rp
cu
– Pull brake shoes apart as far as necessary and remove for‐
o
m
f
en
ng
wards (in direction of travel).

t.
yi Co
Cop py
. rig
Installing
ht ht
rig by
copy Vo
lksw
by
cted agen
Prote AG.
– Preassemble brake shoes.

A - Return spring with “longest length”
B - Return spring with “middle length”
C - Return spring with “shortest length”
D - Brake shoes
E - Retaining plate
Pfeil - Direction of travel
– Pull brake shoes apart as far as necessary and insert back‐
wards (opposite direction of travel).
Specified torques
2. Rear brakes 57
Crafter 2006 ➤
3 Handbrake
⇒ “3.1 Assembly overview - handbrake lever”, page 58
⇒ “3.2 Removing and installing handbrake lever”, page 59
⇒ “3.3 Removing and installing front handbrake cable”,
page 60
⇒ “3.4 Note on adjusting handbrake”, page 60
⇒ “3.5 Adjusting front handbrake cable”, page 60
⇒ “3.6 Adjusting brake shoes for handbrake and rear handbrake
cables, Crafter 3.0 t and 3.5 t”, page 61
⇒ “3.7 Adjusting brake shoes for handbrake and rear handbrake
cables, Crafter 5.0 t”, page 62
3.1 Assembly overview - handbrake lever
1 - Front trim
2 - Rear trim
3 - Bolt
❑ 60 Nm
wage es n
4 - Bolt yV
olks ot g
ua
d b
❑ 10 Nm o
ir se
ran
tee
th or
u
5 - Handbrake warning switch ss
a ac
- F9-
ce
le
un
pt
an
d
6 - Handbrake cable, front

itte
y li
rm
ab
❑ Adjusting ⇒ page 60 .
pe
ility
ot
wit
, is n
⇒ page 60 .
h re
hole
spec
7 - Retaining clip
es, in part or in w
t to the co
8 - Pin
9 - Handbrake lever
rrectness of i
⇒ page 59 .
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
3.2 Removing and installing handbrake lev‐

er
Removing
– Pull front trim -1- off handbrake lever in -direction of arrow-.
– Remove rear trim -2- from handbrake lever.
• The handbrake lever is in its lowest position, and is not applied.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Disconnect connector -1- on handbrake warning switch - F9- .
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove retaining clip -1- and pull out securing pin for front
handbrake cable out of handbrake lever.
m
a
com
tio
– Press both lugs -arrows- together and slide front handbrake
n in
r
te o
cable -2- out of handbrake lever -3-.
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.
– Separate connection -1-.

– Unscrew bolts -arrows- and remove handbrake lever -2-.
Installing
– Adjusting front handbrake cable ⇒ page 60 .
Specified torques
♦ ⇒ “3.1 Assembly overview - handbrake lever”, page 58
3. Handbrake 59
Crafter 2006 ➤
3.3 Removing and installing front hand‐

brake cable
Removing
– Remove rear trim -2- from handbrake lever.
AG . Volkswage
• The handbrake lever is in its lowest position,
ksw
agenand is not applied.
n AG d
oes
n
Vol ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove retaining clip -1- and pull out securing pin for front
handbrake cable out of handbrake lever.
– Press both lugs -arrows- together and slide front handbrake
rrectness of i
cable -2- out of handbrake lever -3-.
l purpos
– Push boot of handbrake cable and handbrake cable out

through underbody.
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
– Detach front handbrake cable from lever -1- -arrow-.
Co
Cop py
t. rig
gh
– Pull out front handbrake cable through underbody, in direction
ht
pyri by
Vo
o
of travel.
c by lksw
cted agen
Prote AG.
Installing
– Adjusting front handbrake cable ⇒ page 60 .
3.4 Note on adjusting handbrake
Note
Before adjusting handbrake, first adjust brake shoes for hand‐

brake, then adjust front handbrake cable.
3.5 Adjusting front handbrake cable

– Release handbrake lever.

Crafter 2006 ➤
– Unscrew nuts -2- from bracket -3-, and push bracket in direc‐
tion of travel.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Push bracket backwards until there is 6 mm clearance be‐
ility
ot p
tween lever -1- and bracket -3-.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
A 6 mm drill may be used as gauge.
rrectness of i
– Tighten nuts of bracket.
l purpos
– Pull handbrake lever on 4 notches.

nf
ercia
orm
– Check that both wheels turn freely.
m
atio
om
Specified torques
n in
or c
thi
te
sd
iva
o
r
rp
cu
Nut for bracket to body 40 Nm
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
3.6 Adjusting brake shoes for handbrake
op Vo
by c lksw
cted agen
and rear handbrake cables, Crafter 3.0 t
Prote AG.
and 3.5 t
– Unscrew and remove one wheel bolt from each of the rear axle
wheels.
– Release handbrake.
– Unscrew nuts -2- from bracket -3-, and push bracket in direc‐
tion of travel.
3. Handbrake 61
lkswage es n
o ot g
byV ua
d ran
ir se
Crafter 2006 ➤ tho tee
or
u
ss
a ac
ce
le
un
pt
– Turn wheel until setting pinion -1- can be seen through hole
an
d
itte
y li
for wheel bolt.
erm
ab
ility
ot p
– Use screwdriver to turn setting pinion -1- counter to direction
wit
is n
of -arrow- until wheel is fixed.
h re
ole,
– Turn back setting pinion by 3 teeth in direction of -arrow-.
spec
t to the co
– Adjust front handbrake cable ⇒ page 60 .
rrectness o
cial p
f inform
– Loosen lock nut, and tighten nut -1- until rear handbrake ca‐
mer
bles no longer sag.
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Lock loosened nuts again. C py
t. rig
gh ht
yri
– Install removed wheel bolts.
p by
co Vo
by lksw
cted agen
Specified torques
Prote AG.

3.7 Adjusting brake shoes for handbrake

and rear handbrake cables, Crafter 5.0 t
– Release handbrake.
– Loosen nuts -2- of bracket -3-.
– Push bracket -3- in direction of travel.

Crafter 2006 ➤
– Turn adjuster screw -1- of adjustment jig -2- in direction of

-arrow A- using a commercially available spanner until wheel
is fixed.
Note
The brake shoes are not shown to improve the illustration clarity
of the adjustment jig.
– Loosen adjustment jig by approx. 3 notches in direction of

-arrow B-.
– Tighten nut -1- until rear handbrake cables no longer sag.

– Tighten lock nut.
– Adjust front handbrake cable ⇒ page 60 .
Specified torques
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris 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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Handbrake 63
Crafter 2006 ➤
4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 64
⇒ “4.2 Removing and installing brake pedal”, page 64
4.1 Assembly overview - brake pedal
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.

⇒ page 76 .
2 - Brake pedal with mounting
bracket
⇒ page 64 . agen
AG. Volkswagen AG d
oes
olksw not
V
3 - Cap ed by gu
ara
ris nte
o eo
4 - Nut aut
h
ra
s c
❑ Always renew after re‐ s
ce
le
moving.
un
pt
an
d
itte
y li
❑ 25 Nm
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.2 Removing and installing brake pedal

Removing
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Assembly overview -
steering column trim .

Crafter 2006 ➤
– Remove brake light switch - F- from mounting bracket

⇒ page 76 .
Volkswa
– Remove securing spring -arrow-agenon pin for connecting
AG. gen AG
does fork
ksw
head to brake pedal. by Vol not
gu
a d ran
se
– Remove pin for connecting
tho
ri fork head to brake pedal. tee
or
au ac
– Unscrew nutsss-1- on both sides of mounting bracket.
ce
le
un
pt
– Remove brake pedal together with mounting bracket -2-.
an
d
itte
y li
rm
ab
Installing
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Brake pedal 65
Crafter 2006 ➤
47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - front brake caliper”, page 66
⇒ “1.2 Removing and installing front brake caliper piston”,
page 67
1.1 Assembly overview - front brake caliper
Note
♦ When carrying out repairs, install all parts supplied in repair kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake cylinder, piston and seal.
1 - Brake caliper housing

2 - Brake hose lkswage es n
o ot g
yV ua
❑ Tighten at brake caliper ir se
d b ran
to 35 Nm. utho tee
or
a ac
3 - Bleeder valve ss
ce
le
un
pt
❑ 14 Nm
an
d
itte
y li
4 - Dust cap
rm
ab
pe
ility
ot
5 - Protective cap
wit
, is n
h re
❑ Take care not to dam‐
hole
age when inserting. spec

es, in part or in w
t to the co
6 - Guide pin
WARNING
rrectness of i
Two different types of

l purpos
guide bushes are instal‐

led. Always ensure that
the guide bush with the
nform
ercia
moulded insert is instal‐

m
led »on top« (on bleeder

a
com
tio
valve).
n in
r
te o
thi
s
iva
do
r
7 - Sealing ring
rp
cum
fo
en
g

n
t.
yi Co
⇒ page 67 . t. Cop py
rig
gh ht
yri
8 - Piston p by
co Vo
by lksw
cted agen
Prote AG.
⇒ page 67 .
9 - Protective cap
❑ Take care not to dam‐
age when inserting pis‐
ton.
10 - Connector for brake pad wear indicator
11 - Bolt
❑ 8 Nm
66 Rep. gr.47 - Brakes - hydraulics

Crafter 2006 ➤
1.2 Removing and installing front brake cal‐

iper piston
♦ Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
Removing
du
an
itte
y li
erm
– Press piston out of brake caliper housing using compressed
ab
ility
air.
ot p
wit
, is n
Place a piece of wood in the recess to prevent damage to the
h re
hole
piston.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Remove seal using removal wedge - 3409- .

atio
om
n in
c
When removing ensure that the surface of the cylinder is not

or
thi
e
damaged.
t
sd
iva
o
r
rp
cu
Installing
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Note opyri
gh by
Vo
ht
by c lksw
cted
agen
Prote AG.
– Apply thin coat of assembly paste - G 052 150 A2- to piston

and seal before installing.
– Insert oil seal in brake caliper housing.
1. Front brake caliper 67

Crafter 2006 ➤
– Place protective cap with outer sealing lip on piston.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
t to the co
inder groove.
When doing this, hold piston in front of brake caliper housing.
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
– Press piston into brake caliper housing using piston resetting
f
en
ng
t.
tool - T10145- -1-.
yi Co
Cop py
t. rig
The outer sealing lip on the protective cap will then slip into the
gh ht
pyri by
piston groove.
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
2 Rear brake caliper

⇒ “2.1 Assembly overview - rear brake caliper, Crafter 3.0 t and
3.5 t”, page 69
⇒ “2.2 Assembly overview - rear brake caliper, Crafter 5.0 t”, page
70
⇒ “2.3 Removing andwainstalling
gen AG
. Volrear
kswagbrake
en AG caliper piston,
does
Crafter 3.0 t and
y V3.5
o t”, page 70
lks not
gu
b ara
ed
⇒ “2.4 Removing
ris and installing rear brake caliper piston,
nte
tho eo
Crafters a5.0 t”, page 72
u ra
c
s
ce
2.1
e
Assembly overview - rear brake caliper, Crafter 3.0 t and 3.5 t

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
♦ When carrying out repairs, install all parts supplied in repair kit.
hole
spec
es, in part or in w
t to the co
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake cylinder, piston and seal.
rrectness of i
l purpos
1 - Protective cap
2 - Bleeder valve nform
ercia
❑ Before screwing in, ap‐

ply thin coat of assembly
m
at
om
paste - G 052 150 A2- to

ion
c
thread.
in t
or
his
te
❑ 14 Nm
a
do
priv
cum
or

f
en
ng
t.
yi Co
4 - Sealing ring t. Cop py
rig
gh
ht
pyri by
Vo
⇒ page 70 .
co lksw
by
cted agen
Prote AG.
5 - Piston
⇒ page 70 .
6 - Dust boot for piston
⇒ page 70 .
7 - Connector for brake pad
wear indicator
8 - Bolt
❑ 8 Nm
9 - Brake hose
❑ Secured to brake cali‐
per.
❑ 35 Nm
2. Rear brake caliper 69

Crafter 2006 ➤
2.2 Assembly overview - rear brake caliper,

Crafter 5.0 t
Note
♦ When carrying out repairs, install all parts supplied in repair

kit.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake
cylinder, piston and seal.
1 - Dust cap
2 - Bleeder valve AG. Volkswagen AG d
agen
❑ Before screwing in, ap‐ olksw
oes
not
yV gu
ply thin coat of assembly ed b ara
nte
is
paste - G 052 150 A2- to thor eo
thread. s au ra
c
s
❑ 14 Nm
ce
le
un
pt
an
d
3 - Sealing ring
itte
y li
erm
ab
ility
ot p
⇒ page 72 .
wit
is n
h re
4 - Protective cap
ole,
spec
5 - Piston
t to the co
⇒ page 72 .
rrectne
7 - Connector for brake pad
ss
wear indicator
o
cial p
f in
8 - Bolt
form
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❑ 8 Nm
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n
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9 - Brake hose
i
or
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❑ Secured to brake cali‐

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2.3 Removing and installing rear brake cal‐

iper piston, Crafter 3.0 t and 3.5 t

Crafter 2006 ➤
♦ Removal wedge - 3409-
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♦ Piston resetting appliance - T10145- hor eo
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♦ Assembly tool for protective caps - T10146/3-
ss o
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Removing
air.
piston.

Crafter 2006 ➤

damaged.
Installing
Note

and seal before installing. gen AG
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– Insert oil seal in brake caliper
db
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– Place protective caps with
au outer sealing lip on piston. ra
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Hold piston in front of brake caliper housing.

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tool - T10145- -1-. nform
ercia
A - Vice clamp
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– Using assembly tool for protective caps - T10146/3- -1- and

piston resetting appliance - T10145- , press protective cap into
brake caliper so that cap is fitted correctly all round.
piston groove.
2.4 Removing and installing rear brake cal‐

iper piston, Crafter 5.0 t

Crafter 2006 ➤
AG. Volkswagen AG d
♦ Removal wedge - 3409- ksw
agen oes
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Removing cop Vo
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AG.
air.
piston.

damaged.
Installing
Note

and seal before installing.
– Insert oil seal in brake caliper housing.

Crafter 2006 ➤
– Place protective cap with outer sealing lip on piston.
– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper housing.

tool - T10145- -1-.
piston groove.
AG. Volkswagen AG d
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Crafter 2006 ➤
3 Brake servo and brake master cylin‐

der
⇒ “3.1 Assembly overview - brake servo/brake master cylinder”,
page 75
⇒ “3.3 Removing and installing brake servo”, page 77
⇒ “3.4 Removing and installing brake master cylinder”,
page 78
⇒ “3.2 Removing and installing brake light switch F ”, page 76
3.1 Assembly overview - brake servo/brake master cylinder
1 - Brake servo
with a vacuum pump to AG. Volkswagen AG d
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generate the necessary by
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❑ A vacuum reservoir is aut ra
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s in
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brake pedal with medi‐
rrectness of i
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servo takes effect.
nform
ercia
❑ If faulty, renew as a
complete unit.
m
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com
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on in
valve (in vacuum hose)

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⇒ page 80 .
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brake pedal.
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brake servo
agen
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⇒ page 77 .
2 - Sealing ring
3 - Cap
❑ With switch for brake fluid level
5 - Sealing plug
6 - Nut
❑ 20 Nm
3. Brake servo and brake master cylinder 75

Crafter 2006 ➤
7 - Brake line
8 - Bolt
❑ Removing and installing ⇒ page 78 . AG. Volkswagen AG d
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❑ Cannot be repaired, renew complete when faulty. olksw not
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10 - Sealing plug horis
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❑ Connection for vacuum hose. ss a c
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3.2 Removing and installing brake light
ab
pe
ility
switch - F-
ot
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hole
⇒ “3.2.1 Removing and installing brake light switch F ▶ 05.2011”,
spec
page 76
es, in part or in w
t to the co
⇒ “3.2.2 Removing and installing brake light switch F 06.2011 ▶”,
page 76
rrectness of i
3.2.1 Removing and installing brake light
l purpos
switch - F- ▶ 05.2011
Removing
nform
ercia
– Pull connector -1- off brake light switch - F- -2-.

m
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– Press lever -3- in direction of -arrow A- and turn brake light
n in
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switch - F- -2- to stop in direction of -arrow B-.
thi
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– Remove brake light switch - F- -2- from recess -arrow-.
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Install in reverse order. ht. rig
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3.2.2 Removing and installing brake light

switch - F- 06.2011 ▶
Removing
– Pull brake light switch - F- -1- out of mounting in direction of
arrow -2-.

Crafter 2006 ➤
– Pull connector -1- off brake light switch - F- -2-.

Installing
• Brake pedal in rest position (not depressed).
AG. Volkswagen AG d
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– Connect connector -1- to brake light switch - F- -2-. itte
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nf
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o
– Insert brake light switch - F- -1- from behind and through de‐
rm
m
tents of mounting -2- in -direction of arrow- until switch con‐
atio
m
tacts brake pedal (in rest position). Other adjustments are not
o
n in
c
required.
or
thi
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In the figure the brake pedal is shown depressed for clarity
o
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Prote AG.
3.3 Removing and installing brake servo

Removing
– Remove brake master cylinder ⇒ page 78 .
– Remove driver footwell cover ⇒ General body repairs, interior;
Rep. gr. 70 .

Crafter 2006 ➤
– Remove securing spring -arrow- on pin for connecting fork

head to brake pedal.
– Remove pin for connecting fork head to brake pedal.
– Unscrew nuts -1- on both sides of mounting bracket.
– Remove brake servo.
Installing
3.4 Removing and installing brake master

cylinder
Removing
– Pull connector -1- off brake fluid level sender.
– Place sufficient lint-free cloths in area of plenum chamber, en‐
gine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234-
or extraction unit - V.A.G 1869/4- .
– Pull off supply hose for clutch master cylinder -1-.

AG. Volkswagen AG d
– Mark and unscrew brake lines -2- and -3- from brake master olks
wage
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not
cylinder. Seal brake lines using sealing plugs from repair
db
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1H0 698 311 A- . or
ise nte
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t to the co
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cial p
f inform
mer
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78
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Rep. gr.47 - Brakes - hydraulics Prote
cted AG.
agen
Crafter 2006 ➤
– Unscrew nuts -arrows- from brake master cylinder -1-.
Note
For ease of illustration, brake master cylinder is shown without

brake fluid reservoir.
– Carefully take brake master cylinder out of brake servo.

Installing
Specified torques
♦ ⇒ “3.1 Assembly overview - brake servo/brake master cylin‐
der”, page 75
AG. Volkswagen AG d
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mer
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Cop py
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Prote AG.

Crafter 2006 ➤
4 Vacuum system
⇒ “4.1 Assembly overview - vacuum pump for vehicles with 5-
cylinder diesel engine”, page 80
⇒ “4.2 Checking non-return valve”, page 80
⇒ “4.3 Removing and installing vacuum pump”, page 81
4.1 Assembly overview - vacuum pump for vehicles with 5-cylinder diesel en‐
gine
1 - Vacuum pump
⇒ page 81 .
2 - Vacuum hose
❑ Before connecting, ap‐
ply lubricant (e.g. tyre fit‐
ting lubricant) to con‐
nection on vacuum
pump.
3 - Nut
❑ 20 Nm
4 - Sealing ring
❑ Check for correct seat AG. Volkswagen AG d
agen oes
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when installing by Vol not
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5 - Plunger thor eo
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nform
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at
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ion
c
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4.2 Checking non-return valve

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for
The non-return valve is installed directly at brake servo vacuum

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connection.
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ran
ho
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ut or
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ss
– Check non-return valve -A-.
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The air must pass through the valve in the direction of -arrow-.
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The valve must remain closed in the opposite direction.
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Observe correct installation position. Arrow must point in direction
is n
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of vacuum pump or engine.
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4.3 Removing and installing vacuum pump
cial p
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mer
Removing
atio
om
– Pull vacuum hose -A- off vacuum pump.
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– Unscrew nuts -arrows- and remove vacuum pump -A-.

Installing
– If necessary, continue turning engine until plunger -A- is flush

with cylinder head.
Specified torques
♦ ⇒ “4.1 Assembly overview - vacuum pump for vehicles with 5-
cylinder diesel engine”, page 80
4. Vacuum system 81
Crafter 2006 ➤
5 Brake lines
⇒ “5.1 Assembly overview - flanging tool”, page 82
⇒ “5.2 Notes for repairs to brake lines”, page 83
⇒ “5.3 Repairing brake lines”, page 84
⇒ “5.4 Additional brake line onwaCrafter
gen AG 4MOTION
. Volkswagen AGwith Achleitner
does
four-wheel drive”, page 86
yV
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5.1 Assembly overview - flanging tool
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1 - Flanging tool upper part
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❑ Unbolt to change flang‐
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ing jaws .
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2 - Fastening for handle
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❑ Must be unbolted to ac‐
spec
cess securing bolt for
es, in part or in w
t to the co
upper part
3 - Securing bolt
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❑ For flanging tool upper
part
l purpos
4 - Grub screws for flanging

jaws
nform
ercia
❑ Centring and holding

m
flanging jaws .
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tion in
❑ Hexagon socket head

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bolt, 2 mm
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❑ Various
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❑ Assembly instructions
C py
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⇒ page 83
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Crafter 2006 ➤
Flanging jaw assembly instructions:

♦ -VAS 6056/6- (dark) for black brake lines
♦ -VAS 6056/7- (light) for green brake lines
Note
The arrow on the rounded side of the flanging jaws must point to
the edge of the housing, and the straight side of the flanging jaws
must be installed towards the spindle, or the flange will not be
formed correctly.
5.2 Notes for repairs to brake lines

The flanging tool for brake lines - VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this allows sections of brake lines
to be renewed at less expense.
The use of flanging tool - V.A.G 1356- is not permitted due to the
coating and the diameter of the black brake lines.
Note
♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict
agen the cross-section
olksw
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♦ Preferably separate brakethlines
or
i
at underbody. tee
or
au ac
♦ The positions of the intermediate
ss pieces must be selected so
ce
e
that they cannot chafe on moving parts.

nl
pt
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♦ Do not grease spindle; merely clean with methylated spirits.

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♦ Flanging tool for brake lines - VAS 6056-

spec
es, in part or in w
t to the co
rrectness of i
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orm
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by lksw
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Prote AG.
5. Brake lines 83
Crafter 2006 ➤
♦ Brake filling and bleeding equipment - VAS 5234-
List of individual tools:
1 - Flanging tool - VAS 6056/1-

❑ Flanging jaws - VAS
6056/6- are installed n AG. Volkswagen AG do
agein
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flanging toolby-VVAS
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6056/1- r.ised ran
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2 - Pipe cutter
ss
au - VAS 6056/2- ra
c
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3 - Brake line scraper - VAS

nl
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6056/3-
itte
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❑ Grub screws (in shaft

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wit
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ted and must not be

h re
readjusted!
hole
spec
4 - Set of grips with plastic jaws

es, in part or in w
t to the co
- VAS 6056/4-
5 - Pipe bending tool - VAS
6056/5-
rrectness of i
6 - Special wrench, 6 mm
l purpos
7 - Flanging jaws - VAS

6056/7-
nform
mercia
at
om
ion
c
in t
or
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ate
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5.3 Repairing brake lines

– Unbolt respective brake line from brake caliper or wheel brake
cylinder. Catch escaping brake fluid and dispose of this as per
regulations.

Crafter 2006 ➤
– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.
– Clamp brake line in a grip wrench -4- so that approx. 50 mm

project from plastic jaws.
– Clamp scraper -3- into drill and position on brake line.
– At slow drill speed and with gentle pressure on brake line,
scrape coating off brake line.
Note
Length of scraping is determined by stop in scraper.
– Remove scraper from brake line and remove scraping resi‐

dues.
– Remove set of grips and slide union nut -D- onto brake line.
AG. Volkswagen AG d
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– Slide brake line -B- to stop -A- in flanging tool.

ole,
spec
t to the co
Note
Brake line must be positioned against stop when the hexagon

rrectne
socket head bolts are tightened, or the flange will not be formed
correctly.
ss o
cial p
f i
– Pre-tension brake line in flanging tool until brake line can no

nform
longer be moved. Then fold up stop -A- and use angled driver
mer
atio
-C- to tighten hexagon socket head bolts in diagonal se‐

om
quence.
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5. Brake lines 85
Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
– Turn spindle to stop in flanging tool. olksw not
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– Turn spindle back again. horis nte
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– Release hexagon socket head bolts diagonally. ss c
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un
– Remove brake line from flanging tool. Clean and check brake
pt
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line and flange.
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Briefly flush the section of brake line remaining in the vehicle:
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– Connect brake filling and bleeding equipment - VAS 5234- ,
h re
hole
connect bleeder bottle hose to brake line flange and allow
spec
brake filling and bleeding equipment - VAS 5234- to run briefly
es, in part or in w
until a little brake fluid has run through.
t to the co
– Blow out new brake line to be inserted with compressed air.
rrectness of i
– Join brake lines using connector -E-.
l purpos
– Install brake line.

nform
mercia
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tion in
r
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cted
5.4 Additional brake line on Crafter 4MO‐
agen
Prote AG.
TION with Achleitner four-wheel drive

Note
♦ Crafter 4MOTION with Achleitner four-wheel drive is equipped

with extended brake line to front brake calipers.
♦ When e.g. removing subframe of Crafter 4MOTION with
Achleitner four-wheel drive, this extended brake line needs to
be removed and reinstalled accordingly.
Note
The connecting piece of the brake line can be found on the right
side, behind the heat shield.

Crafter 2006 ➤
Removing
Note
Observe safety notes when handling brake fluid ⇒ page 88 .
– Extract brake fluid using brake filling and bleeding equipment

- VAS 5234- .
– Unbolt brake lines -1- from brake hose -arrow-, and seal brake
lines using sealing plugs from repair kit - 1H0 698 311 A- .
– Disconnect brake line -1- from connecting piece -2-.
– Seal brake lines on connecting piece -2- using sealing plugs
from repair kit - 1H0 698 311 A- .
– If necessary, unbolt heat shield on right side.
AG. Volkswagen AG d
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– Unclip brake
s au line -1- by releasing clips -3- and remove it. r ac
s
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Brake pipes may only be bent up to max. 90°. They otherwise kink
wit
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or reveal deformations which impermissibly constrict the pipe

h re
cross-section.
hole
spec
es, in part or in w
t to the co
Installing
rrectness of i
– Bleed brake system using brake filling and bleeding equip‐

ment - VAS 5234- ⇒ page 88 .
l purpos

nform
mercia
Note
at
om
ion
c
in t
or
Perform controlled brake test during road test (pulsations must be

his
ate
felt at brake pedal).

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5. Brake lines 87
Crafter 2006 ➤
6 Hydraulic system
⇒ “6.1 Bleeding hydraulic system following standard procedure”,
page 88 AG. Volkswagen AG d
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⇒ “6.2 Testing for leaks”, page 89 d by
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6.1 Bleeding hydraulic system following ho eo
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standard procedure
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Note
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Bleeding the brake system is described for brake filling and bleed‐
h re
ing equipment VAS 5234. hole
spec
es, in part or in w
t to the co
♦ Bleeding brake system on vehicles with ABS is performed in
the same way as on vehicles with a conventional brake sys‐
tem.
rrectness of i
♦ While bleeding rear wheel brake, move lever of brake pressure
l purpos
regulator.
♦ Only use new brake fluid - B 000 700 A- (please specify the
nform
ercia
container index for the point).

m
a
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
com
tion in
fluid must not come into contact with paintwork.
r
te o
thi
♦ Brake fluid is hygroscopic, which means it absorbs moisture
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iva
do
r
from the ambient air and should therefore always be stored in

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air-tight containers.
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♦ Rinse off spilled brake fluid using plenty of water. C py
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Special tools and workshop equipment required op Vo
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Bleeding brake system on vehicles with ABS is performed in same

way as vehicles with a conventional brake system.
– Connect brake filling and bleeding equipment - VAS 5234- .
– Open bleeder valves in specified order and bleed brake cali‐
pers.
Bleeding sequence
1 - Rear right brake caliper
2 - Rear left brake caliper
3 - Front right brake caliper
4 - Front left brake caliper

Crafter 2006 ➤
– Leave bleeder valve open with bleeder bottle hose connected

until brake fluid free of air bubbles flows out.
Changing brake fluid ⇒ Maintenance ; Booklet 10.2 ; Work se‐
quences; Changing brake fluid
6.2 Testing for leaks

♦ Tester for brake pressure regulator - V.A.G 1310 A-
♦ Adapter M10 - V.A.G 1310/6-

Test prerequisites:
• Brake system (hydraulic unit, brake hoses, brake lines and
brake calipers) operating properly and free of leaks.
Checking n AG. Volkswagen AG do
lkswage es n
– Remove bleeder valve at one of front brake calipers. by V Connect
o ot g
ua
d
tester for brake pressure regulator - V.A.G 1310 o
ir seA- and bleed.
ran
tee
th or
u
– Apply pressure to brake pedal until gaugesindicates
s a a pressure ac
of 50 bar. The pressure must not drop by more than 4 bar
ce
e
nl
pt
within the test period of 45 seconds. Renew brake master cyl‐
du
an
itte
inder if drop in pressure exceeds specification.
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
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om
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ate
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Prote AG.
6. Hydraulic system 89

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0059031120

4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.2 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.1 Technical data for brakes

Type Crafter 3.0 t and 3.5 t Crafter 5.0 t

Rear brake Floating caliper disc brake

Brake disc Diameter, mm 298 303

Ventilated brake disc mm 16 28

Brake pad thickness (with‐ mm 13 15

Handbrake Duo-Servo Duo-Servo

Brake lining width mm 25 42

2.1 General information

The brake regulation systems do not function when ignition is off.

2.2 Checking vehicles with rear-wheel drive

The brake test must be performed on a single-axle roller dyna‐

The maximum test speed must not exceed 6 km/h.

If the vehicle is tested on a single-axle roller dynamometer or

Activating differential lock restricts ABS functionality.

2 Rep. gr.00 - Technical data

45 – Anti-lock brake system

1.1 General notes on ABS

the brake force distribution on the rear axle.

even without ABS. A change in braking behaviour is to be reck‐

They can be separated only when removed.

is renewed, it must be recoded ⇒ Vehicle diagnostic tester.

♦ Disconnect battery earth strap with ignition switched off.

4 Rep. gr.45 - Anti-lock brake system

1.3 Fault display via warning lamps

ESP and TCS warning lamp - K155-

ignition is switched on and after completion of test run, or if it

comes on during vehicle operation, the faults may be caused

ignition has been switched on and test sequence has been

a - The voltage supply is below 10 volts.

b - There is a fault in the ABS.

After the ABS warning lamp - K47-

Only on vehicles equipped with traction control system.

go out after the ignition is switched on and completion of the

a - Short circuit to positive in TCS and ESP button - E256-

If traction control system warning lamp - K86- flashes while the

vehicle is in motion, the TCS is in operation.

6 Rep. gr.45 - Anti-lock brake system

2 Overview of fitting locations

2.1 Overview of fitting locations - ABS/ESP

1 - ABS hydraulic unit - N55-

2 - ABS control unit - J104-

unit is defective, it can

❑ Removing and installing

❑ Removing and installing

2. Overview of fitting locations 7

❑ ABS sensor ring is installed in wheel bearing.

❑ Removing and installing ⇒ page 30

Fitting location: the diagnostic connection is located on the left A-

8 Rep. gr.45 - Anti-lock brake system

1 - ABS hydraulic unit - N55-

6 - Brake system warning lamp

❑ Fault display ⇒ page 5

7 - Brake light switch - F-

❑ Removing and installing ⇒ page 76

8 - TCS and ESP button - E256-

9 - Steering angle sender - G85-