VW Crafter 2 Maintenance Eng

Service
Maintenance
Crafter 2017 ➤
TGE 2017 ➤
Edition 09.2018
Service Department. Technical Information

Service
Maintenance
Heading
1. Engine list
2. Service work
3. General information
4. Descriptions of work:
5. Exhaust emissions test
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.
Crafter 2017 ➤ , TGE 2017 ➤
Maintenance - Edition 09.2018
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Overview of engines - diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Information about flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Scopes of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 “Vehicle data” sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Entries in the Digital Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.9 Tyre pressure sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.10 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Swivel joints and suspension link mountings: Visual check . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 AdBlue® (reducing agent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 All-wheel drive coupling: Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4 Raising vehicle with lifting platform and trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5 Reading ash mass (saturation level) of diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . 48
4.6 8-speed automatic gearbox, AQ 450: Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7 8-speed automatic gearbox, AL 550: Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8 Battery: checking with battery tester (always refer to workshop manual) . . . . . . . . . . . . . . 49
4.9 Battery: checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 49
4.10 Checking tyres: condition, wear pattern, tyre pressure, tread depth . . . . . . . . . . . . . . . . . . 53
4.11 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 58
4.12 Brake system and clutch mechanism: Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . 59
4.13 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.14 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 63
4.15 Electric windows: initialising (activation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.16 Fault memory of all systems: reading with vehicle diagnostic tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.17 Bonnet catch: Cleaning, ensuring attachment is secure and lubricating . . . . . . . . . . . . . . 66
4.18 Bringing ERA GLONASS into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.19 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 68
4.20 Poly V-belt: check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.21 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.22 Fuel filter: renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.23 Fuel filter: drain water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.24 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 71
4.25 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.26 Engine and components in engine compartment: inspecting for leaks and damage (from
above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.27 Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.28 Engine oil: Draining or extracting and replenishing; renewing oil filter . . . . . . . . . . . . . . . . 77
4.29 Engine oil: capacities and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.30 Breakdown set: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.31 Carry out road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.32 Tyre Pressure Loss Indicator: calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.33 Spare wheel bracket: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.34 Wheel securing bolts: Tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contents i
Crafter 2017 ➤ , TGE 2017 ➤
4.35 Window wash/wipe system and headlight washer system: Checking function and settings;
replenishing to maximum level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.36 Headlight adjustment: check and adjust as necessary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.37 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.38 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.39 Check seat belts and belt buckles for external damage and function . . . . . . . . . . . . . . . . 100
4.40 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 101
4.41 Dust and pollen filter (interior filter): Cleaning housing and renewing filter element . . . . . . 102
4.42 Transportation mode: switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.43 Doors: grease door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.44 Vehicle underside (floor pan): visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.45 Camshaft drive toothed belt: check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.46 Camshaft drive toothed belt: renew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.1 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ii Contents
Crafter 2017 ➤ , TGE 2017 ➤
1 Engine list
(VIGG001209; Edition 09.2018)
⇒ “1.1 Overview of engines - diesel engines”, page 1
1.1 Overview of engines - diesel engines
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Engines ⇒ Diesel engine Diesel engine Diesel engine Diesel engine Diesel engine
Dis‐ I 2.0 2.0 2.0 2.0 2.0
place‐
ment
Type of Longitudinal Longitudinal Transverse Transverse Transverse
installa‐
tion
Engine code DASA DASB DAUA DAUB DAVA
Emission standard 5,6 EU 6 EU 3,4,5,6 EU 3,4,5,6 EU 6
No. of cylinders/ 4/4 4/4 4/4 4/4 4/4
valves per cylinder
Power kW at rpm 90/3250 103/3500 103/3500 75/3250 - 3500 130/3600
Torque Nm at 300/2000 340/2000 340/2000 300/2000 410/2000
rpm
Bore ∅ mm 81 81 81 81 81
Stroke mm 95.50 95.50 95.50 95.50 95.50
Compression ratio 15.5 15.5 15.5 15.5 15.5
Injection/ignition TDI TDI TDI TDI TDI
common rail common rail common rail common rail common rail
Diesel particle fil‐ Yes Yes Yes Yes Yes
ters
Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt Toothed belt
Engines ⇒ Diesel engine Diesel engine

Displacement I 2.0 2.0
Type of installation Longitudinal Longitudinal
Engine code DAWA DAWB
Emission standard EU 6 5,6
No. of cylinders/valves per cylinder 4/4 4/4
Power kW at rpm 130/3600 120/3500
Torque Nm at rpm 410/2000 410/2000
Bore ∅ mm 81 81
Stroke mm 95.50 95.50
Compression ratio 15.5 15.5
Injection/ignition TDI TDI
common rail common rail
Diesel particle filters Yes Yes
Camshaft drive Toothed belt Toothed belt
Volkswagen Technical Site: https://vwts.ru 1. Engine list 1

Crafter 2017 ➤ , TGE 2017 ➤
2 1. Engine list
Crafter 2017 ➤ , TGE 2017 ➤
2 Service work
⇒ “2.1 Information about flexible or fixed service”, page 3
⇒ “2.2 Service tables”, page 6
⇒ “2.3 Scopes of service”, page 7
2.1 Information about flexible or fixed serv‐

ice
⇒ “2.1.1 Service identification”, page 3
⇒ “2.1.2 Flexible service”, page 3
⇒ “2.1.3 Fixed service”, page 3
⇒ “2.1.4 Service interval display”, page 4
2.1.1 Service identification

– Referring to vehicle data sticker, check if vehicle is equipped
with following PR numbers.
The PR number is decisive for the service intervals.
Vehicle ID with PR number
Model year PR number Service
2017 ► VI4 Flexible service
2017 ► QI1, QI2, QI3, QI4, QI5 Fixed service
2.1.2 Flexible service

The flexible service enables long service intervals, depending on
individual driving style and the conditions under which the vehicle
is used.
Note
For the flexible service a special LongLife engine oil is required.
Vehicles with production control number “VI4” are set up for flex‐
ible service at the factory. This means that these vehicles have a
flexible service interval display and are fitted with the following
components:
♦ Flexible service interval display in dash panel insert
♦ Engine oil level sensor
♦ Brake pad wear indicator (if fitted)
For vehicles set up for flexible service, the service interval is de‐
termined by the control unit and is indicated on service interval
display.
Therefore the service intervals are flexible.
2.1.3 Fixed service

For vehicles with a fixed service, fixed services are calculated.
This means that the mileage or time values are already set by the
manufacturer. For normal operating conditions achieving these
service intervals is technically assured.
Therefore the service intervals are fixed.
2. Service work 3
Crafter 2017 ➤ , TGE 2017 ➤
Fixed service applies for vehicles that fulfil the following require‐
ments:
♦ Vehicles that have not been delivered with extended service
intervals (ESI) (PR numbers “QI1”, “QI2”, “QI3”, “QI4”, “QI5”)
♦ Vehicles for which extended service intervals (ESI) have been
stopped
♦ Vehicles for which no LongLife engine oil was used.
The fixed service intervals apply to all types of service events in‐
cluding engine oil change.
Therefore, these vehicles have a fixed service interval display and
for maintenance the fixed service intervals apply. These vehicles
are fitted with the following components:
♦ Fixed service interval display in dash panel insert
♦ Engine oil level sensor
♦ Brake pad wear indicator (if fitted)
2.1.4 Service interval display

Introduction of extended servicing intervals (ESI) ⇒ page 4
Flexible service interval display (only vehicles with a flexible serv‐
ice) ⇒ page 4
Fixed service interval display (only vehicles with a fixed service)
⇒ page 4
Service at service due ⇒ page 5
Service announcement ⇒ page 5
Retrieving service message from dash panel insert ⇒ page 5
Retrieving service information from Infotainment system
⇒ page 5
Introduction of extended servicing intervals (ESI)
Ask your importer if the extended servicing interval (ESI) is avail‐
able for your country.
Flexible service interval display (only vehicles with a flexible serv‐
ice)
Calculation of service intervals:
♦ The service intervals on vehicles with a flexible service is cal‐
culated. Input values such as, distance travelled, fuel con‐
sumption, oil temperature and loading on diesel particulate
filter are evaluated by the control unit.
♦ The result of the evaluation is a value for the deterioration of
the oil due to thermal loading.
♦ The oil deterioration is the deciding factor concerning the dis‐
tance that can still be driven to the next service.
Note
For vehicles with a flexible service but which are serviced ac‐
cording to fixed service intervals, the service interval display must
be recoded to “non-flexible” ⇒ page 98 .
Fixed service interval display (only vehicles with a fixed service)

Calculation of service intervals:
4 2. Service work
Crafter 2017 ➤ , TGE 2017 ➤
♦ The service interval for vehicles with a fixed service is calcu‐

lated in fixed service intervals. This means that the mileage or
time values have been previously determined and specified.
♦ For normal operating conditions achieving these service in‐
tervals is technically assured.
Service at service due
On vehicles with text messages in the display of the dash panel
insert, one of the following is shown depending on which event is
due:
♦ “Spanner symbol” and “Inspection now”.
♦ “Spanner symbol” and “Oil change service now”.
♦ “Spanner symbol” and “Oil change service and inspection
now”.
The service information disappears after a few seconds or if en‐
gine is running.
Service announcement
If a service is due, “Service announcement” appears on dash
panel insert display when ignition is switched on.
On vehicles with text messages in the display of the dash panel
insert, the following is shown:
♦ “Inspection in --- km or --- days”
♦ “Oil change service in --- km or --- days”
The service information disappears after a few seconds or if en‐
gine is running.
♦ The service announcement is displayed 30 days before the
next service due.
♦ The remaining distance displayed is always rounded to the
nearest 100 km or the remaining time rounded to full days.
Retrieving service message from dash panel insert
The current service information can be requested at any time with
the ignition switched on, the engine turned off and the vehicle at
a standstill.
– Press button 0.0 and hold it until the text “SERVICE” is shown
in the display.
– Release button 0.0 .
The current service message is shown in the display.
Retrieving service information from Infotainment system
The current service information can be requested at any time with
the ignition switched on, the engine turned off and the vehicle at
a standstill.
– Switch on ignition.
– Switch on infotainment system.
– Press Infotainment button CAR .
– Press Setup function button.
– In the menu, scroll to the Service function button.
– Press Service function button.
The service information is displayed in Infotainment system.
2. Service work 5
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2.2 Service tables

⇒ “2.2.1 Service tables”, page 6
Note
♦ The following chapter contains the common service tables for

commercial vehicles. In the past, individual service specifica‐
tions were introduced in several markets, usually on account
of challenging operating conditions. These are listed as “mar‐
ket-specific deviations” in the service tables.
♦ For combined kilometre and time display applies: whichever
occurs first.
♦ Depending on conditions under which the vehicle is used as
well as the equipment level of the vehicle, extra service work
must be performed in addition to the regular inspection or in‐
spection with extended scope.
♦ It is also possible to carry out additional work outside the serv‐
ice intervals, but such work must be entered in the Digital
Service Schedule (DSS).
2.2.1 Service tables

Service intervals ⇒ page 6
Service intervals
Vehicles from 2017
Service intervals
PR No. Service events: Indicated on
Intervals service interval display
and Infotainment system
2017 ► QI1 Oil change service (fixed): YES
every 5,000 km or 1 year
QI2 Oil change service (fixed): YES
QI6 Oil change service (flexible): YES
according to service interval
display in dash panel insert
max. 30,000 km / 2 years
VI4 Oil change service (flexible): YES
according to service interval
display in dash panel insert
max. 50,000 km / 2 years
Inspection: YES
initially after 2 years or
50,000 km
then after 1 year or 50,000 km
Extended inspection service: YES
after 3 years for the first time,
then every 2 years
6 2. Service work
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2.3 Scopes of service

⇒ “2.3.1 Scopes of service 2017 ►”, page 7
⇒ “2.3.2 Scopes of service, market specific deviations”,
page 11
⇒ “2.3.3 Additional work dependent on time/distance”,
page 11
2.3.1 Scopes of service 2017 ►

The following chapter contains the common scopes of service for
commercial vehicles. In the past, individual service specifications
were introduced in several markets, usually on account of chal‐
lenging operating conditions. These are listed as “market-specific
deviations” in the scopes of service ⇒ page 11 .
Delivery inspection ⇒ page 7
Scopes of service ⇒ page 9
Note
♦ Under certain circumstances, different types of service can be

performed at the same time. Doubly listed activities are charg‐
ed only once.
♦ Depending on the vehicle equipment and the conditions under
which the vehicle is used, additional service measures may be
necessary to supplement the service events.
♦ If faults requiring repair are found during servicing, the cus‐
tomer must be informed and, if necessary, the additional work
invoiced separately.
♦ Note any market-specific deviations for the delivery inspection
and the scopes of service ⇒ page 11 .
Delivery inspection
The sequence of the individual service tasks has been tested and
optimised. Therefore, it should be followed to avoid unnecessary
interruptions in the work.
Scope of work Page
Electrics
♦ Battery: Check battery terminal clamps by hand for tightness ⇒ page 49
♦ Battery: check with battery tester (always refer to workshop manual) ⇒ page 49
♦ Switch off transportation mode ⇒ page 102

• With ⇒ Vehicle diagnostic tester
♦ Reading event memory of all systems with ⇒ Vehicle diagnostic tester; rectify possible ⇒ page 66
faults according to repair guidelines
♦ Radio/radio navigation system: Store local radio stations to station buttons ⇒ Operating in‐
structions for In‐
fotainment sys‐
tem
Vehicle interior
♦ All switches, electrical consumers, sockets, gauges and other control elements: Check
function
2. Service work 7
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Scope of work Page

♦ Door handles, door locks, central locking and windows: check function and ease of
movement
♦ Front passenger airbag: check key switch and “ON/OFF function”; set switch to “ON” ⇒ Operating in‐
structions
♦ Electric windows: initialising (activation) ⇒ page 65
♦ Clock and date: setting ⇒ Operating in‐

structions
♦ Seat protective covers and protective foils: Remove
♦ Vehicle interior: Check for cleanliness (front and rear seats, interior trim, carpets/mats,
windows)
Vehicle exterior
♦ All equipment that has been packed inside the vehicle (floor mats, wiper arms, spoilers,
roof aerial, wheel trims/hub caps, covers): Install (if included)
♦ Edge protection on doors (plastic film): remove.
♦ Check vehicle exterior for cleanliness: Paintwork, decorative parts, windows, wiper
blades, surfaces
♦ Protective foil: Remove (if fitted)
♦ Towing eyes: Remove

• Place towing eye in vehicle tool kit and fit cover to bumper
Tyres
♦ Spare wheel: Check condition and inflation pressure (if fitted) ⇒ page 53
♦ Front left tyre: Check condition and inflation pressure ⇒ page 53
♦ Rear left tyre: Check condition and inflation pressure ⇒ page 53
♦ Rear right tyre: Check condition and inflation pressure ⇒ page 53
♦ Front right tyre: Check condition and inflation pressure ⇒ page 53
♦ Wheel securing bolts: Tightening to specified torque ⇒ page 85
Vehicle, bottom
♦ Vehicle from below (without removing engine noise insulation): Visual check for leaks
and damage.
♦ Mechanical units, steering, boots, hoses and receivers
♦ Vehicle underside (floor pan): visual check for damage ⇒ page 104
♦ Brake system and shock absorbers: inspecting for leaks and damage ⇒ page 58
Engine compartment
♦ Engine and components in engine compartment: inspecting for leaks and damage (from ⇒ page 75
above and below)
♦ Window wash/wipe system and headlight washer system: Check function and settings; ⇒ page 87
replenish to maximum level
♦ Engine oil level: checking ⇒ page 76

and
• Observe engine oil standards ⇒ page 80
8 2. Service work
Crafter 2017 ➤ , TGE 2017 ➤
Scope of work Page

♦ Cooling system: checking frost protection and coolant level ⇒ page 71
♦ Brake system and clutch mechanism: Changing brake fluid ⇒ page 59

• For stock vehicles and vehicles in storage whose standing period of 6 months or more,
the brake fluid must be renewed.
♦ Brake fluid level: checking ⇒ page 62
Documentation/final checks
♦ Number and function of keys: Check, wipe off grease if necessary
♦ Digital Service Schedule

– Enter pre-delivery inspection
– Complete vehicle data in Digital Service Schedule, see “Vehicle delivery documentation”
• For markets where the Digital Service Schedule does not apply, the respective data is
entered in the service history book
♦ Vehicle literature: check literature is complete and prepare for hand-over to customer
♦ Service interval display: Reset oil change service (flexible) ⇒ Vehicle diagnostic tester ⇒ page 97
“Service channel 1”
♦ Service interval display: Reset inspection ⇒ Vehicle diagnostic tester “Service channel ⇒ page 97
2”
♦ Carry out road test ⇒ page 81
Scopes of service
Change Inspection Extended in‐ Measure
oil spection service
Vehicle interior
X ♦ Interior lights, ambient lighting in storage compartment, ciga‐
rette lighter, sockets and warning lamps: Check function
X X ♦ Breakdown set (if fitted): Check (renew tyre inflation bottle with
sealant if expiry date has passed)
⇒ page 81
Vehicle exterior
X X ♦ Front lights – side lights, dipped beam, main beam, fog lights,
turn signals, hazard warning lights, horn: Check function
X X ♦ Tail light cluster – brake lights, tail light, reversing light, rear fog
light, number plate light, turn signals, hazard warning lights:
Check function
X ♦ Windscreen: inspect for damage.
X ♦ Bonnet catch: Cleaning, ensuring attachment is secure and

lubricating
⇒ page 66
X ♦ Interior and exterior body: inspecting for corrosion with doors
and flaps open
⇒ page 68
2. Service work 9
Crafter 2017 ➤ , TGE 2017 ➤

X ♦ Doors: grease door arrester
⇒ page 103
Underside of vehicle
X ♦ Engine oil: Drain for oil change
⇒ page 77
X ♦ Engine oil: Change / Engine oil filter: Renew
⇒ page 77
X ♦ Brake pads/linings: check thickness and condition of brake
discs, front and rear.
⇒ page 63
X ♦ Poly V-belt: Check condition and tension
⇒ page 68
X ♦ Brake system and shock absorbers: inspecting for leaks and
damage
⇒ page 58
X X ♦ Engine and components in engine compartment (from below),
gearbox, final drive and protective boots: Visual check for
leaks and damage
⇒ page 75
X ♦ CV joints, axial bearings, coupling rod bearings and anti-roll
bar rubber bushes: Visual check for damage
⇒ page 26
X ♦ Track rod ball joints: Check play, security and boots
⇒ page 101
X ♦ Exhaust system: inspect for leaks, firm seating and damage.
X ♦ Underbody: Visual check for damage to underbody protection

and underbody covers
⇒ page 104
X X ♦ Spare wheel bracket: Clean and lubricate
⇒ page 82
Tyres
X X ♦ Tread depth, condition, wear pattern, age, inflation pressure
(including spare wheel): Check, correct as necessary
⇒ page 53
Engine compartment
X X ♦ Engine oil level: checking
⇒ page 76
X ♦ Battery: Check (using battery tester)
⇒ page 49
X ♦ Brake fluid level (depending on lining wear): Check (observe
specification)
⇒ page 61
X X ♦ Engine and components in engine compartment: visual check
for leaks and damage (from above)
⇒ page 75
10 2. Service work
Crafter 2017 ➤ , TGE 2017 ➤

X X ♦ Cooling system: Check frost protection and coolant level and
correct as necessary. Frost-protection specification: -25°C (in
countries with an arctic climate: -35°C)
⇒ page 71
X X ♦ Window wash/wipe system, wiper blade and headlight washer
system: Check function, rest/park position and for damage,
replenish fluids
⇒ page 87
Final checks
X ♦ Service interval display: Reset oil change service (fixed/flexi‐
ble using ⇒ Vehicle diagnostic tester “Service channel 1”)
⇒ page 97
X X ♦ Service interval display: Reset inspection service (⇒ Vehicle
diagnostic tester “Service channel 2”)
⇒ page 97
X X ♦ Headlight adjustment: check and adjust as necessary.
⇒ page 91
X X ♦ Road test: Brake pedal, handbrake, selector mechanism,
steering, kick-down function, air conditioning system: Check
operation
⇒ page 81
2.3.2 Scopes of service, market specific devi‐

ations
This chapter only contains market-specific differences. This
means that all of the scopes of delivery inspection, service activ‐
ities or time and distance dependant additional work not listed
here are listed in the normal scope of service work.
Delivery inspection
Russia market
Scope of work Page
Electrics
♦ LED in emergency call button module: Check - it must be lit up green 2 minutes after ⇒ page 67
deactivation of the transport mode.
♦ ERA GLONASS system test: Perform, press button for 3 seconds, follow “voice prompt” ⇒ page 67
and perform test sequence
2.3.3 Additional work dependent on time/dis‐

tance
♦ Extra service work may need to be performed in addition to
the inspection service or oil change service/interval service.
This depends on the vehicle equipment and the conditions
under which the vehicle is used. These additional mainte‐
nance measures are invoiced separately and are marked as
extra work.
2. Service work 11
Crafter 2017 ➤ , TGE 2017 ➤
♦ Additional work based on time and distance 2017 ►

⇒ page 12
Additional work based on time and distance 2017 ►
Measure Interval
♦ Drain water from fuel filter; if vehicle runs on diesel According to drainage indicator in dash panel insert -
fuel: K-
♦ Diesel fuel not conform with standard “DIN EN 590”
• Valid in “dusty” regions
• With water level sensor
• Countries considered as dusty regions
⇒ page 20
⇒ page 69
♦ Dust and pollen filter (interior filter): Cleaning hous‐ Every 30,000 km or 1 year
ing and renewing filter element
⇒ page 20
⇒ page 102
♦ Camshaft drive toothed belt: check. Every 15 to 20,000 km
⇒ page 20
• Engine codes DASA, DASB, DAUA, DAUB, DAVA,
DAWA, DAWB
⇒ page 104
♦ Renew fuel filter; if vehicle runs on diesel fuel: Every 20,000 km
• Without water level sensor
⇒ page 20
⇒ page 69
♦ Air filter: cleaning housing and renewing filter ele‐ Every 30,000 km or 2 years
ment
⇒ page 20
⇒ page 74
• With water level sensor
⇒ page 20
⇒ page 69
12 2. Service work
Crafter 2017 ➤ , TGE 2017 ➤
Measure Interval
♦ Camshaft drive toothed belt: check. Every 50,000 km
DAWA, DAWB
⇒ page 104
♦ Poly V-belt: renewing Every 60,000 km
⇒ page 20
DAWA, DAWB
⇒ page 69
♦ Camshaft drive toothed belt: renew. Every 120,000 km
⇒ page 20
DAWA, DAWB
⇒ page 105
♦ Brake and clutch system: change brake fluid. Every 2 years
⇒ page 20
⇒ page 59
♦ Poly V-belt: check condition Every 50,000 km
DAWA, DAWB
⇒ page 68
♦ Dust and pollen filter (interior filter): Cleaning hous‐ Every 50,000 km or 2 years
ing and renewing filter element
⇒ page 102
♦ Diesel fuel conform with standard “DIN EN 590”
♦ With/without water level sensor
⇒ page 69
♦ Air filter: cleaning housing and renewing filter ele‐ Every 100,000 km or 4 years
ment
⇒ page 74
♦ Camshaft drive toothed belt: Renew (inc. tension‐ Every 200,000 km
ing roller)
DAWA, DAWB
⇒ page 105
♦ Automatic gearbox AQ/AL: Change oil
♦ Automatic gearbox AQ 450 ⇒ page 48
♦ Automatic gearbox AL 550 ⇒ page 48
2. Service work 13
Crafter 2017 ➤ , TGE 2017 ➤
Measure Interval
♦ Diesel particulate filter (if fitted): Read ash mass After 200,000 km for the first time, then every
(saturation level) 50,000 km
⇒ page 48
♦ All-wheel drive coupling: changing oil Every 3 years
⇒ page 37
♦ Brake and clutch system: change brake fluid. First time after 3 years, then every 2 years
⇒ page 59
14 2. Service work
Crafter 2017 ➤ , TGE 2017 ➤
3 General information
⇒ “3.1 Vehicle data sticker”, page 15
⇒ “3.2 Entries in the Digital Service Schedule”, page 15
⇒ “3.3 Vehicle diagnostic tester ”, page 16
⇒ “3.4 Vehicle identification number”, page 17
⇒ “3.5 Vehicle data sticker”, page 18
⇒ “3.6 Severe operating conditions”, page 18
⇒ “3.7 Engine code and engine number”, page 19
⇒ “3.8 Identification plate”, page 19
⇒ “3.9 Tyre pressure sticker”, page 20
⇒ “3.10 Countries with high levels of dust”, page 20
3.1 “Vehicle data” sticker

– Attach the upper of the two vehicle data stickers -arrow- in the
vehicle wallet.
3.2 Entries in the Digital Service Schedule

If a component having a change interval prescribed by the man‐
ufacturer is changed, the new change interval begins at the time
the component is changed.
• Therefore it is very important, every time a component is
changed, to document this in the Digital Service Schedule.
• For markets where the Digital Service Schedule does not ap‐
ply, the respective data is entered in the service history book.
• This also applies to components which were changed before
the regular change interval.
Note
♦ When using “Genuine parts kits” it must be taken into account

whether it is technically necessary to change all the compo‐
nents included in the genuine parts kits.
♦ If more components are renewed than is technically necessa‐
ry, inform the customer before repair!
3. General information 15
Crafter 2017 ➤ , TGE 2017 ➤
3.3 Vehicle diagnostic tester

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
WARNING
♦ During a road test, always secure test and measuring

equipment on the back seat.
♦ Only a passenger may operate these devices while the
vehicle is in motion.
Connecting vehicle diagnostic tester

Procedure
– Connect diagnostic cable connector -1- to diagnostic connec‐
tion -2-.
– Switch on ⇒ Vehicle diagnostic tester.
Now follow instructions on screen in order to start desired func‐
tions.
Left-hand drive vehicles
16 3. General information
Crafter 2017 ➤ , TGE 2017 ➤
Right-hand drive vehicles
3.4 Vehicle identification number

⇒ “3.4.1 Vehicle identification number on lower edge of wind‐
screen”, page 17
⇒ “3.4.2 Vehicle identification number in area of longitudinal
member”, page 17
⇒ “3.4.3 Vehicle identification number in area of A-pillar”,
page 18
⇒ “3.4.4 Significance of vehicle identification number”,
page 18
3.4.1 Vehicle identification number on lower

edge of windscreen
The vehicle identification number -arrow- is located on the left-
hand side of the vehicle behind the windscreen on the cowl panel
cross member. It is visible from the outside.
3.4.2 Vehicle identification number in area of

longitudinal member
The vehicle identification number -1- is located on the right in the
engine compartment on the longitudinal member.
Crafter 2017 ➤ , TGE 2017 ➤
3.4.3 Vehicle identification number in area of

A-pillar
The vehicle identification number -1- is on the right on the inner
panel of the front A-pillar.
To gain visual access to the vehicle identification number in this
position, the bumper cover must be removed.
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper; Removing and installing bumper cover .
3.4.4 Significance of vehicle identification number

123 456 78 9 10 11 000 1234
Manufacturer Filler charac‐ Model Filler charac‐ Model year Production lo‐ Serial number
code ters ters cation
3.5 Vehicle data sticker

The vehicle data sticker -1- is located in the vehicle on the side
of the open glove compartment.
The sticker contains the following data of the vehicle

1 - Vehicle identification number
2 - Vehicle type, engine output, gearbox
3 - Engine and gearbox codes, paint number, interior equipment
4 - Optional equipment, PR numbers
3.6 Severe operating conditions

If the vehicle is used under severe operating conditions some jobs
will have to be performed before the next service due or at shorter
service intervals.
Severe operating conditions
• Regular short trips or stop and go operation in urban traffic
• High percentage of cold starts
• Vehicle is used in areas with winter temperatures over a long
period
Crafter 2017 ➤ , TGE 2017 ➤
• Regular long periods of idling (e.g. taxis)

• Vehicle is often driven at full throttle with high payload or whilst
towing a trailer
• Using diesel with elevated sulphur content
• Regular operation in areas with high levels of dust
3.7 Engine code and engine number

The engine code and engine number are located in the following
positions:
♦ On vehicle data sticker ⇒ page 18
♦ On identification plate ⇒ page 19
Engine code and engine number are also located in engine work‐
shop manual ⇒ Rep. gr. 00 ; Label; Engine number/engine data .
3.8 Identification plate
Note
Vehicles for certain export countries have no type plate.
The type plate -1- or -2- is visible in the lower area of the B-pillar
when the driver door is opened.
Crafter 2017 ➤ , TGE 2017 ➤
3.9 Tyre pressure sticker

The tyre pressure sticker -1- can be found in the lower area of the
driver door when the door is open.
The tyre pressure sticker contains the tyre pressure data valid for
the vehicle.
3.10 Countries with high levels of dust

The countries with high levels of dust can be gleaned from this
chapter.
Country Dusty country
Abu Dhabi X
Afghanistan X
Egypt X
Algeria X
Angola X
Equatorial Guinea X
Argentina X
Armenia X
Azerbaijan X
Ethiopia X
Australia X
Bahrain X
Bangladesh X
Belize X
Benin X
Bhutan X
Bolivia X
Botswana X
Brazil X
Brunei X
Burkina Faso X
Chile X
China X
Costa Rica X
Democratic Republic X
of the Congo
Crafter 2017 ➤ , TGE 2017 ➤

Dominican Republic X
Djibouti X
Dubai X
Ecuador X
El Salvador X
Ivory Coast X
Eritrea X
Fiji X
French Guiana X
Gabon X
Gambia X
Georgia X
Ghana X
Guatemala X
Guinea-Bissau X
Guyana X
Honduras X
Hong Kong X
India X
Indonesia X
Iraq X
Iran X
Israel X
Yemen X
Jordan X
Cambodia X
Cameroon X
Cape Verde X
Kazakhstan X
Qatar X
Kenya X
Kyrgyz Republic X
Columbia X
Cuba X
Kuwait X
Laos X
Lesotho X
Lebanon X
Liberia X
Libya X
Macau X
Madagascar X
Malawi X
Maldives X
Mali X
Morocco X
Crafter 2017 ➤ , TGE 2017 ➤

Mauritania X
Mauritius X
Mexico X
Mongolia X
Mozambique X
Myanmar X
Namibia X
Nepal X
Nicaragua X
Niger X
Nigeria X
North Korea X
Oman X
Palestine X
Pakistan X
Panama X
Papua New Guinea X
Paraguay X
Peru X
Puerto Rico X
Qatar X
Rwanda X
Russia X
Zambia X
Saudi Arabia X
Senegal X
Sierra Leone X
Zimbabwe X
Singapore X
Somalia X
Sri Lanka X
Sudan X
South Sudan X
Surinam X
South Africa X
Swaziland X
Syria X
Tajikistan X
Tanzania X
Thailand X
Togo X
Chad X
Tunisia X
Turkmenistan X
Turkey X
Uganda X
Crafter 2017 ➤ , TGE 2017 ➤

Ukraine X
Uruguay X
USA X
Uzbekistan X
Venezuela X
United Arab Emirates X
Vietnam X
Belarus X
West Sahara X
Central Africa X
Crafter 2017 ➤ , TGE 2017 ➤
24 4. Descriptions of work:
Crafter 2017 ➤ , TGE 2017 ➤
4 Descriptions of work:
⇒ “4.1 Swivel joints and suspension link mountings: Visual check”,
page 26
⇒ “4.2 AdBlue® (reducing agent)”, page 31
⇒ “4.3 All-wheel drive coupling: Changing oil”, page 37
⇒ “4.4 Raising vehicle with lifting platform and trolley jack”,
page 37
⇒ “4.5 Reading ash mass (saturation level) of diesel particulate
filter”, page 48
⇒ “4.6 8-speed automatic gearbox, AQ 450: Changing oil”,
page 48
⇒ “4.7 8-speed automatic gearbox, AL 550: Changing oil”,
page 48
⇒ “4.8 Battery: checking with battery tester (always refer to work‐
shop manual)”, page 49
⇒ “4.9 Battery: checking battery terminal clamps for secure seat‐
ing”, page 49
⇒ “4.10 Checking tyres: condition, wear pattern, tyre pressure,
tread depth”, page 53
⇒ “4.11 Brake system and shock absorbers: inspecting for leaks
and damage”, page 58
⇒ “4.12 Brake system and clutch mechanism: Changing brake
fluid”, page 59
⇒ “4.13 Brake fluid level: checking”, page 62
⇒ “4.14 Brakes, front and rear: checking thickness of brake pads
and condition of brake discs”, page 63
⇒ “4.15 Electric windows: initialising (activation)”, page 65
⇒ “4.16 Fault memory of all systems: reading with vehicle diag‐
nostic tester , correcting possible faults according to repair guide‐
lines”, page 66
⇒ “4.17 Bonnet catch: Cleaning, ensuring attachment is secure
and lubricating”, page 66
⇒ “4.18 Bringing ERA GLONASS into operation”, page 67
⇒ “4.19 Interior and exterior body: inspecting for corrosion with
doors and flaps open”, page 68
⇒ “4.20 Poly V-belt: check condition”, page 68
⇒ “4.21 Poly V-belt: renewing”, page 69
⇒ “4.22 Fuel filter: renew”, page 69
⇒ “4.23 Fuel filter: drain water”, page 69
⇒ “4.24 Cooling system: checking frost protection and coolant
level”, page 71
⇒ “4.25 Air filter: cleaning housing and renewing filter element”,
page 74
⇒ “4.26 Engine and components in engine compartment: inspect‐
ing for leaks and damage (from above and below)”, page 75
⇒ “4.27 Engine oil level: checking”, page 76
⇒ “4.28 Engine oil: Draining or extracting and replenishing; re‐
newing oil filter”, page 77
4. Descriptions of work: 25
Crafter 2017 ➤ , TGE 2017 ➤
⇒ “4.29 Engine oil: capacities and specifications”, page 80

⇒ “4.31 Carry out road test”, page 81
⇒ “4.32 Tyre Pressure Loss Indicator: calibrating”, page 82
⇒ “4.33 Spare wheel bracket: checking”, page 82
⇒ “4.34 Wheel securing bolts: Tightening to specified torque”,
page 85
⇒ “4.30 Breakdown set: Checking”, page 81
⇒ “4.35 Window wash/wipe system and headlight washer system:
Checking function and settings; replenishing to maximum level”,
page 87
⇒ “4.36 Headlight adjustment: check and adjust as necessary.”,
page 91
⇒ “4.37 Service interval display: resetting”, page 97
⇒ “4.38 Service interval display: recoding”, page 98
⇒ “4.39 Check seat belts and belt buckles for external damage
and function”, page 100
⇒ “4.40 Track rod ends: checking clearance, firm seating and
boots”, page 101
⇒ “4.41 Dust and pollen filter (interior filter): Cleaning housing and
renewing filter element”, page 102
⇒ “4.42 Transportation mode: switching off”, page 102
⇒ “4.43 Doors: grease door arrester”, page 103
⇒ “4.44 Vehicle underside (floor pan): visual check for damage”,
page 104
⇒ “4.45 Camshaft drive toothed belt: check condition”,
page 104
⇒ “4.46 Camshaft drive toothed belt: renew.”, page 105
4.1 Swivel joints and suspension link

mountings: Visual check
⇒ “4.1.1 Swivel joints and suspension link mountings, front”, page
26
⇒ “4.1.2 Front coupling rod bearings and anti-roll bar rubber bush‐
es”, page 28
⇒ “4.1.3 Rear coupling rod bearings and anti-roll bar rubber bush‐
es”, page 29
⇒ “4.1.4 Rear rubber bush for leaf spring”, page 30
4.1.1 Swivel joints and suspension link

mountings, front
Crafter 2017 ➤ , TGE 2017 ➤
♦ Battery lamp - VAS 6901-
Procedure
Note
The following work on the vehicle must always be performed on

both sides of an axle on the relevant components.
– Check boots -1- of swivel joints for leaks and damage.
– Check front axle mountings -1- for large cracks, tears or cuts
in rubber material.
Crafter 2017 ➤ , TGE 2017 ➤
– Check rear axle mountings -1- for large cracks, tears or cuts
in rubber material.
– In addition, check axial bearings also for following damage:
♦ Complete separation of rubber and metal parts
♦ Large play between mounting and suspension link, which has
a considerably negative effect on the function of the mounting.
Note
♦ Superficial cracks and cuts as well as minor separations of the

rubber element from the metal part do not significantly affect
the operation of the elasto-kinematic bearing and are no cause
for complaint.
♦ Damage to the thin rubber skin over cavities due to construc‐
tion is also permissible.
♦ Play between bearing and axle component is permissible as
long as there is no negative effect on the function of the bear‐
ing.
4.1.2 Front coupling rod bearings and anti-roll

bar rubber bushes
Procedure
Note
The following work on the vehicle must always be performed on

both sides of an axle on the relevant components.
– Check boots -1- of coupling rod bearings for leaks and dam‐
age.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
Crafter 2017 ➤ , TGE 2017 ➤
– Check anti-roll bar rubber bushes -1- for damage.

– In addition, check coupling rod bearings and anti-roll bar rub‐
ber bushes for the following damage:
Note
♦ Neither surface cracks and splits nor smaller delaminations

between the moulded rubber part and metal have a significant
impact on the function of the elastokinematic bushes. They are
therefore not a reason for complaint.
ing.
– Install noise insulation ⇒ General body repairs, exterior; Rep.

gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation .
4.1.3 Rear coupling rod bearings and anti-roll

bar rubber bushes
Procedure
Note
♦ In isolated cases, the coupling rod bearings and the anti-roll

bar rubber bushes may differ from those illustrated here owing
to different axle versions. The work measures should be trans‐
ferred accordingly.
♦ The following work on the vehicle must always be performed
on both sides of an axle on the relevant components.
Crafter 2017 ➤ , TGE 2017 ➤
– Check anti-roll bar rubber bushes -1- for damage.
– Check boot -1- and bearings -2- of coupling rod for leaks and
damage.
– Also check anti-roll bar rubber bushes and coupling rod bear‐
ings for following damage:
Note
♦ Superficial cracks and cuts as well as minor separations of the

rubber element from the metal part do not significantly affect
the operation of the elasto-kinematic bearing and are no cause
for complaint.
ing.
4.1.4 Rear rubber bush for leaf spring

Procedure
Note
♦ In isolated cases, the rubber bushes of the leaf springs may

differ from those illustrated here owing to different axle ver‐
sions. The work measures should be transferred accordingly.
♦ The following work on the vehicle must always be performed
on both sides of an axle on the relevant components.
Crafter 2017 ➤ , TGE 2017 ➤
– Check all rubber bushes -1- of leaf springs for large cracks,
tears or cuts in rubber material.
– Check rubber bushes also for following damage:
Note
♦ Neither surface cracks and splits nor smaller delaminations

between the moulded rubber part and metal have a significant
impact on the function of the elastokinematic bushes. They are
therefore not a reason for complaint.
ing.
4.2 AdBlue® (reducing agent)

⇒ “4.2.1 General information”, page 31
⇒ “4.2.2 Health risk and cleaning”, page 33
⇒ “4.2.3 Disposal instructions”, page 34
⇒ “4.2.4 Filling reducing agent tank with AdBlue filling system VAS
6960 ”, page 34
⇒ “4.2.5 Filling the reducing agent tank from containers”,
page 35
⇒ “4.2.6 Filling the reducing agent tank from refill bottles”,
page 36
4.2.1 General information

Characteristics
♦ The reducing agent (AdBlue®/DEF) is not a diesel additive and
must not be poured into the diesel fuel tank.
♦ The reducing agent (AdBlue®/DEF) is used for exhaust treat‐
ment to reduce nitrogen oxides in the exhaust gas of diesel
powered vehicles.
♦ The reducing agent (AdBlue®/DEF) reduces these nitrogen
oxides to water and nitrogen.
♦ The reducing agent (AdBlue®/DEF) is a high-purity 32.5%
urea solution and is used in systems with exhaust treatment
(SCR catalytic converters) for diesel engines.
♦ The reducing agent (AdBlue®/DEF) is legally required for op‐
erating vehicles with SCR.
♦ AdBlue® is a registered trademark of the Verband der Auto‐
mobilindustrie e. V. (VDA) in the USA, Germany, the European
Union and other countries.
Application
♦ Do not mix additives with reducing agent (AdBlue®/DEF).
♦ Do not dilute the reducing agent (AdBlue®/DEF) with water.
Crafter 2017 ➤ , TGE 2017 ➤
♦ Do not use fluid that has already been used.

♦ Only use the reducing agent (AdBlue®) in the intended, origi‐
nal containers. Comply with the use-by date.
♦ Comply with the instructions of the reducing agent manufac‐
turer regarding use and storage.
Technical data
♦ “NOx reducing agent AUS 32” is the designation according to
ISO 22241-1.
♦ The reducing agent (AdBlue®/DEF) is filled in a separate tank
in the vehicle. It is NOT therefore mixed with diesel fuel.
♦ A refill container approved by the manufacturer must be used
to replenish the reducing agent (AdBlue®/DEF).
♦ The reducing agent tank has a capacity of approx. 18 litres.
Insufficient reducing agent
If the level of reducing agent is low, one of the following messages
appears on the dash panel insert:
♦ From a remaining distance of 2400 km, a gong sounds and
“Top up AdBlue (DEF)!” is displayed“ Remaining distance:
2400 km or 1400 miles”.
♦ From a remaining distance of 1000 km, a warning buzzer
sounds and “Top up AdBlue (DEF)!” is displayed“ 1000 km or
600 miles remaining until engine start no longer possible”.
♦ From a remaining distance of 0 km, a warning buzzer sounds
three times and “Top up AdBlue (DEF)!” is displayed“ Engine
start no longer possible”.
Note
♦ Depending on vehicle equipment, a symbol can also be shown

instead of a warning lamp in dash panel insert.
♦ In order to be able to restart the engine, the tank for reducing
agent must be replenished with a minimum of 9 litres of re‐
ducing agent (AdBlue®/DEF).
System malfunction or incorrect filling
Caution
The vehicle is damaged by filling with reducing agent (AdBl‐

ue®) that does NOT comply with the standard or by filling with
other fluids.
In case of system malfunction or incorrect filling, one of the fol‐

lowing messages appears on the dash panel insert:
♦ As of remaining range of 1000 km (600 mi): “Check AdBlue!
Remaining range 1050 km” or “Check AdBlue! Remaining dis‐
tance 600 mi”.
♦ From a remaining distance of 200 km (120 miles), a warning
buzzer sounds and “Check AdBlue!” is displayed“ 200 km re‐
maining until engine start no longer possible” or “Check AdBl‐
ue! No engine start possible in 120 mi”.
♦ As of a remaining range of 0 km, a three-fold warning buzzer
sounds and “Check AdBlue! Engine start no longer possible”.
Crafter 2017 ➤ , TGE 2017 ➤
Note
Depending on vehicle equipment, a symbol can also be shown

instead of a warning lamp in dash panel insert.
WARNING
♦ As soon as “Check AdBlue!” appears:“ No engine start

possible! ” is displayed and the engine is switched off; the
engine cannot be started again.
– Rectifying faults ⇒ Vehicle diagnostic tester.
4.2.2 Health risk and cleaning
WARNING
♦ AdBlue®/DEF is corrosive and an irritant that can cause

injury on contact with the skin, eyes and respiratory or‐
gans.
♦ In the event of AdBlue®/DEF coming into contact with the
eyes and skin, wash the affected area immediately with
plenty of water for at least 15 minutes and seek medical
assistance.
♦ In the event of skin contact with this fluid, immediately
wash off with plenty of water.
♦ In the event of AdBlue®/DEF ingestion, rinse out the
mouth immediately with plenty of water for at least 15 mi‐
nutes. Do not induce vomiting unless instructed to do so
by a doctor. Seek medical assistance without delay.
Caution
At all times, ensure that no reducing agent (AdBlue®/DEF) is

spilled on trim or body parts.
If this has happened, wash reducing agent (AdBlue®/DEF) out
again with clear water and a lint-free cotton cloth.
If the reducing agent (AdBlue®/DEF) has already crystallised,
use warm water and a sponge.
Reducing agent residues which are not removed crystallise af‐
ter a while and may damage the affected surface.
Crafter 2017 ➤ , TGE 2017 ➤
4.2.3 Disposal instructions
Caution
Information reference for storage and disposal ⇒ InfoNet, Op‐

eration, Strategy and deadlines, Environment, Handbook
Service Environmental Protection ! Request country-specific
information concerning storage and disposal from your import‐
er.
The refill container must be disposed of in accordance with
environmental regulations.
4.2.4 Filling reducing agent tank with AdBlue

filling system - VAS 6960-
♦ Filling device for AdBlue - VAS 6960-
Procedure
Note
♦ Ensure that the vehicle is on a hard, level standing and that

the ignition is switched off.
♦ Refer to the ⇒ Operating manual for the AdBlue filling system
- VAS 6960- .
♦ Use only demineralised water for cleaning any components of
the AdBlue®/DEF system. Do not use tap water for this.
– Switch off ignition.
Crafter 2017 ➤ , TGE 2017 ➤
– Open tank cap -1-.

– Clean reducing agent tank filler neck with a water-soaked, lint-
free cotton cloth.
– Insert filler nozzle of AdBlue filling system - VAS 6960- into
filler neck of reducing agent tank and start filling reducing
agent tank.
Note
The filler nozzle of the filling device for AdBlue - VAS 6960- stops
automatically when the required reducing agent level has been
attained.
– Remove filler nozzle.
– Screw in tank cap -1- until it engages.

– Close tank flap.
Note
After filling the reducing agent tank, switch on the ignition and
leave it switched on for at least 30 seconds so that the system
can detect the replenishment.
4.2.5 Filling the reducing agent tank from con‐

tainers
Procedure
Note
♦ Ensure that vehicle is at ground level.

the AdBlue® system. Do not use tap water for this.

free cotton cloth.
– Use the integrated pourer in the container for refilling with
AdBlue®.
Note
♦ Observe the product information and operating instructions

from the manufacturer.
♦ Do not overfill AdBlue® tank.
Crafter 2017 ➤ , TGE 2017 ➤

Note
4.2.6 Filling the reducing agent tank from refill

bottles
Procedure
Note
♦ Ensure that vehicle is at ground level.

the AdBlue® system. Do not use tap water for this.

free cotton cloth.
– Open the closure of the refilling bottle.
– Place neck of refilling bottle downwards onto filler neck and
screw it on until finger tight.
– Push refilling bottle towards filler neck and hold it pressed.
– Allow contents of refilling bottle to flow into reducing agent tank
(AdBlue®).
Note
♦ Observe the product information and operating instructions

from the manufacturer.
♦ Do not overfill AdBlue® tank.
♦ Make sure not to squeeze or damage the refill bottle.
– As soon as refilling bottle is empty, unscrew it and pull it out

upwards.
– Repeat procedure until reducing agent tank (AdBlue®) is full.
Crafter 2017 ➤ , TGE 2017 ➤

Note
4.3 All-wheel drive coupling: Changing oil

Work procedure in workshop manual ⇒ Rep. gr. 39 ; All-wheel
drive coupling; Draining and filling oil for all-wheel drive coupling
4.4 Raising vehicle with lifting platform and

trolley jack
⇒ “4.4.1 Safety information”, page 37
⇒ “4.4.2 Mounting point for lifting platform and workshop jack,
front of vehicle”, page 38
⇒ “4.4.3 Mounting point for lifting platform and workshop jack, rear
of vehicle”, page 38
⇒ “4.4.4 Additional securing of vehicle with tensioning straps
T10038 , front of vehicle”, page 40
⇒ “4.4.5 Additional securing of vehicle with tensioning strap
T10038 , front of vehicle, during removal of engine and subframe”,
page 41
⇒ “4.4.6 Additional securing of vehicle with tensioning straps
T10038 , rear of vehicle”, page 42
⇒ “4.4.7 Additionally supporting the vehicle with height-adjustable
stands”, page 44
⇒ “4.4.8 Raising vehicle on lifting platform”, page 45
⇒ “4.4.9 Raising vehicle with workshop jack”, page 46
4.4.1 Safety information

Risk of injury while vehicle is raised
If a drive wheel touches the ground while the vehicle is raised, the
vehicle could begin to move unintentionally. There is a risk of
parts of the body becoming trapped or drawn in.
– Always store the ignition key outside the vehicle.
Or
– Engage neutral.
Crafter 2017 ➤ , TGE 2017 ➤
4.4.2 Mounting point for lifting platform and

workshop jack, front of vehicle
Procedure
– Position mounting plate of lifting platform support arm in area
of side member marking at reinforcement of floor panel -1- on
both sides of vehicle.
Note
♦ Ensure that side member reinforcement seats centrally on

support plate of hoist mounting.
♦ Use a wide mounting plate if necessary, to ensure a safe sup‐
port.
4.4.3 Mounting point for lifting platform and

workshop jack, rear of vehicle
Depending on the type of vehicle there are different mounting
points for lifting the vehicle at the rear. Determine the mounting
point according to the type of vehicle as follows.
♦ Panel van, front-wheel drive, short wheelbase, with single
tyres
♦ Panel van, four-wheel drive, long wheelbase, with single tyres
♦ Panel van, front-wheel drive, long wheelbase, large body over‐
hang with single tyres
♦ Panel van, all-wheel drive, short wheelbase, with single tyres
♦ Panel van, all-wheel drive, long wheelbase, with single tyres
♦ Panel van, all-wheel drive, long wheelbase, large body over‐
Vehicles without stone deflector on leaf spring mounting
Procedure
– Bring support arm mounting plate of lifting platform into posi‐
tion in area of front leaf spring mounting -1- on each side of
the vehicle.
Note
♦ Make sure that the leaf spring mounting is located centrally on

the mounting plate of the lifting platform.
port.
Vehicles with stone deflector on leaf spring mounting
Crafter 2017 ➤ , TGE 2017 ➤
Procedure
– Fit support arm mounting plate of lifting platform to console
-1- on each side of the vehicle.
Note
♦ Make sure that the bracket is located centrally on the mounting

plate of the lifting platform.
port.

♦ Panel van, long wheelbase, large body overhang, with twin
tyres
♦ Panel van, short wheelbase, with twin tyres
♦ Panel van, long wheelbase, with twin tyres
Procedure
– Bring support arm mounting plate of lifting platform into posi‐
tion in area of front leaf spring mounting -1- on each side of
the vehicle.
Note
♦ Make sure that the leaf spring mounting is located centrally on

port.

♦ Double cab, front-wheel drive, short wheelbase
Procedure
– Attach lifting platform-specific prism mounting -2- on rear sup‐
port arms.
– Position prism mounting -2- on console -1- in direction of
-arrow- in such a way that prism mounting -2- engages in con‐
sole support next to leaf spring.
♦ Single cab, long wheelbase
♦ Double cab, long wheelbase
Crafter 2017 ➤ , TGE 2017 ➤
Procedure
– On each side of vehicle, bring mounting plate of lifting platform
support arm in position in area of longitudinal member
-arrow-.
Note
♦ Make sure that the longitudinal member is located centrally on

port.
4.4.4 Additional securing of vehicle with ten‐

sioning straps - T10038- , front of vehicle
♦ Tensioning strap - T10038-
Note
♦ Vehicles with a heavy body, panel vans and Kombi models

with a long wheelbase must be supported additionally.
♦ When removing large components such as the engine, sub‐
frame or gearbox, the vehicle needs to be secured to the
platform.
♦ If the vehicle is not strapped down, there is a great danger that
the vehicle will slip off the lifting platform.
Procedure
– Secure vehicle on both sides to lifting platform using tension‐
ing straps - T10038- .
– Sling tensioning strap - T10038- -1- around subframe -3- and
lifting platform support arm -2-.
– Tighten tensioning strap - T10038- .
Note
When slinging tensioning strap - T10038- , ensure that neither

fuel, brake and coolant lines nor wiring connections are crushed
or damaged by the tensioning strap.
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sioning strap - T10038- , front of vehicle,
during removal of engine and subframe
Note

platform.
Procedure
Left-hand side
– Remove front left underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing underbody cladding .
– Guide tensioning strap - T10038- -2- through bracket -1- and
around lifting platform support arm -3-.
Note

Crafter 2017 ➤ , TGE 2017 ➤
Right-hand side
– Remove front right underbody cladding ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing
and installing underbody cladding .
Note


sioning straps - T10038- , rear of vehicle
Note

platform.
Depending on the type of vehicle there are different lashing points

for securing the vehicle at the rear. Determine the lashing points
according to the type of vehicle as follows.
♦ Panel van, front-wheel drive, short wheelbase, with single
tyres
♦ Panel van, four-wheel drive, long wheelbase, with single tyres
♦ Panel van, front-wheel drive, long wheelbase, large body over‐
♦ Panel van, all-wheel drive, short wheelbase, with single tyres
♦ Panel van, all-wheel drive, long wheelbase, with single tyres
♦ Panel van, all-wheel drive, long wheelbase, large body over‐
Crafter 2017 ➤ , TGE 2017 ➤
Vehicles without stone deflector on leaf spring mounting

Procedure
– Secure vehicle on both sides of lifting platform using tension‐
ing strap - T10038- .
Note

Vehicles with stone deflector on leaf spring mounting
Procedure
Note


♦ Single cab, front-wheel drive, long wheelbase
♦ Double cab, front-wheel drive, short wheelbase
♦ Double cab, front-wheel drive, long wheelbase
Procedure
– Sling tensioning strap - T10038- -2- around console -1- and
♦ Panel van, short wheelbase, with twin tyres
♦ Panel van, long wheelbase, with twin tyres
♦ Panel van, long wheelbase, large body overhang, with twin
tyres
Crafter 2017 ➤ , TGE 2017 ➤
Procedure
– Sling tensioning strap - T10038- -2- around leaf spring -3- and
Note


♦ Single cab, long wheelbase
♦ Double cab, long wheelbase
Procedure
– Sling tensioning strap - T10038- -1- around longitudinal mem‐
ber -3- and support arm of lifting platform -2-.
Note

4.4.7 Additionally supporting the vehicle with

height-adjustable stands
Note
♦ Vehicles with heavy body, Vans and estate cars with a long
wheelbase must be supported additionally.
♦ Depending on assembly condition of vehicle, it can be secured
using commercially available, height-adjustable stands in ad‐
dition to lashing it to support arms of lifting platform with
tensioning straps - T10038- .
♦ To avoid damage, make sure that no electrical cables, brake
lines or fuel lines become trapped.
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Procedure
– To support vehicle, place height-adjustable stands -1- under
rear longitudinal member -arrows-.
– Alternatively, height-adjustable stands -2- can be positioned

under rear leaf spring brackets -1- on rear axle tube.
4.4.8 Raising vehicle on lifting platform
Note
Before driving a vehicle onto a lifting platform it must be ensured

that the vehicle weight does not exceed the permissible lifting ca‐
pacity of the platform.
Lifting platform with access ramps

Procedure
– Laden vehicles must be unloaded before being raised.
– Before driving onto the lifting platform, ensure that there is
sufficient clearance between low-lying components and lifting
platform.
– When on the lifting platform, switch off the engine.
– Engage parking brake.
– Activate the means for securing the vehicle to the lifting plat‐
form ⇒ Operating instructions for the lifting platform .
Lifting platform with support arms
Procedure
– Laden vehicles must be unloaded before being raised.
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– Before raising the vehicle on the lifting platform, ensure that

there is sufficient clearance between low-lying components
and lifting platform.
Clean contact surfaces of the support arm mounting plates from
dirt, grease, wax and dust.
– Unscrew mounting plates of lifting platform far enough to en‐
sure sufficient clearance between support arm and side mem‐
ber.
– Position support arms of lifting platform beneath mounting
points on underbody, front mounting points ⇒ page 38 and rear
mounting points ⇒ page 38 .
– Operate lifting platform, and raise vehicle slightly.
– Visually inspect all mounting points to ensure that mounting
plates of support arms are located correctly underneath the
mounting points. If not, bring the vehicle back to the ground,
and adjust the position of the support arms.
– Raise vehicle.
– Always strap the vehicle down on the lifting platform at the front
⇒ page 40 and rear ⇒ page 42 .
Note

platform.
– Depending on assembly condition of vehicle, support it on

commercially available, height-adjustable stands in addition to
securing with tensioning straps - T10038- ⇒ page 44 .
Lifting platform with wheel lift supports
Procedure
– Re-equip lifting platform so that existing 4 mounting plates are
replaced by 4 wheel lift supports -1-.
– Adjust spacing of lifting platform arms in relation to each other.
– Drive vehicle onto lifting platform until vehicle is located ex‐
actly in wheel lifts -2-.
– The vehicle can now be raised and lowered to the desired as‐
sembly height.
4.4.9 Raising vehicle with workshop jack

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♦ VAS 741007
♦ VAS 741009
Procedure
Note
♦ The workshop jack may only be positioned at the dedicated

lifting points at the front ⇒ page 38 and rear ⇒ page 38 .
♦ To prevent damage always use a suitable rubber or wooden
block.
Under no circumstances should the vehicle be raised at the fol‐

lowing point as serious damage could otherwise ensue:
♦ Sump
♦ Gearbox
♦ Rear axle
♦ Front axle
♦ Sill panels
– Clean contact surface of mounting plate from dirt, grease, wax
and dust.
– Bring jack in position beneath respective mounting point on
underbody.
– Operate trolley jack, and raise vehicle slightly.
– Visually inspect the lifting point to ensure that mounting plates
of the jack are located correctly underneath the lifting point. If
not, bring the vehicle back to the ground, and adjust the posi‐
tion of the jack.
– Raise vehicle.
– To provide additional support for the vehicle, use suitable jack
stands.
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4.5 Reading ash mass (saturation level) of

diesel particulate filter
Note
♦ The ash mass test provides information on the saturation level

of the particulate filter volume.
♦ After a certain running time diesel particulate filters must be
exchanged, because of ash deposits.
♦ If the limit is reached, renew diesel particulate filter ⇒ Rep. gr.
26 ; Emission control; Removing and installing emission con‐
trol module .
Procedure
– Apply handbrake.
– Automatic gearbox: move selector lever to position “P”.
– Manual gearbox: gear lever in neutral
Note
If the display is not as shown in the procedure: ⇒ Operating in‐

structions for diagnostic tester
ODIS Service
– Connect ⇒ Vehicle diagnostic tester ⇒ page 16 .
– Carry out identification of vehicle.
– Enter task data, or select “Without task”.
– Select “Control units”.
– “01 - Systems capable of self-diagnosis”.
– Select “01 - Diesel direct injection and glow plug system”.
– Select “01 - Engine electronics functions”.
– Select “01 - Check ash deposit mass of diesel particulate filter”.
– Follow instructions on display.

– End the test.
– Switch off ignition and disconnect ⇒ Vehicle diagnostic tester
from vehicle.
4.6 8-speed automatic gearbox, AQ 450:

Changing oil
Procedure in workshop manual ⇒ Rep. gr. 37 ; ATF; Changing
ATF .
4.7 8-speed automatic gearbox, AL 550:

Changing oil
Procedure in workshop manual ⇒ Rep. gr. 37 ; ATF; Changing
ATF .
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4.8 Battery: checking with battery tester (al‐

ways refer to workshop manual)
The starter battery is located under the floor, in front of the front
left seat.
The second battery is located on left side of engine compartment.
– The work procedure can be found in the Workshop Manual ⇒
Electrical system, General information; Rep. gr. 27 ; Starter,
current supply, CCS; Battery; Checking battery .
4.9 Battery: checking battery terminal

clamps for secure seating
⇒ “4.9.1 Battery: Checking battery terminal clamps for secure
seating, starter battery”, page 49
⇒ “4.9.2 Battery: Checking battery terminal clamps for secure
seating, second battery”, page 51
4.9.1 Battery: Checking battery terminal

clamps for secure seating, starter bat‐
tery
♦ Torque wrench - V.A.G 1331-
♦ Ratchet wrench - V.A.G. 1331/1-
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Note
♦ A securely seated battery terminal clamp ensures trouble-free

function and long service life of the battery.
♦ When securing the terminal clamp, ensure it is located fully on
the battery terminal.
♦ The second battery is installed in the engine compartment, the
starter battery is installed in the interior.
Procedure
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Remove battery cover -1- ⇒ Electrical system; Rep. gr. 27 ;
Battery; Removing and installing battery .
– Remove battery terminal cover.
– Loosen NEGATIVE battery clamp -1-, and remove in

-direction of arrow-.
– Loosen nut on POSITIVE battery clamp -1-.

– Tighten nut on POSITIVE battery clamp -1- to specified torque
using torque wrench - V.A.G 1331- and ratchet - V.A.G.
1331/1- .
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– Reconnect NEGATIVE battery clamp -1-, and tighten it to

specified torque using torque wrench - V.A.G 1331- and ratch‐
et - V.A.G. 1331/1- .
– Install battery cover.
Note
If the battery has been reconnected, observe procedures descri‐

bed in ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .
Specified torques
Component Specified torque

Nut for battery terminal 6 Nm
4.9.2 Battery: Checking battery terminal

clamps for secure seating, second bat‐
tery
♦ Ratchet wrench - V.A.G. 1331/1-
Crafter 2017 ➤ , TGE 2017 ➤
Note
♦ A securely seated battery terminal clamp ensures trouble-free

function and long service life of the battery.
♦ When securing the terminal clamp, ensure it is located fully on
the battery terminal.
♦ The second battery is installed in the engine compartment, the
starter battery is installed in the interior.
Procedure
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Open bonnet.
– Remove battery terminal cover.
– Loosen NEGATIVE battery clamp -1-, and remove.
– Loosen nut from POSITIVE battery clamp -1-.

– Tighten nut from POSITIVE battery clamp -1- to specified tor‐
que using torque wrench - V.A.G 1331- and ratchet - V.A.G.
1331/1- .
– Reconnect NEGATIVE battery clamp -1-, and tighten it to

specified torque using torque wrench - V.A.G 1331- and ratch‐
et - V.A.G. 1331/1- .
– Reinstall battery terminal cover
Note
If the battery has been reconnected, observe procedures descri‐

bed in ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .
Specified torques
Component Specified torque

Nut for battery terminal 6 Nm
Crafter 2017 ➤ , TGE 2017 ➤
4.10 Checking tyres: condition, wear pattern,

tyre pressure, tread depth
⇒ “4.10.2 Checking tyre age”, page 54
⇒ “4.10.3 Tyres: checking condition”, page 55
⇒ “4.10.4 Wear pattern: checking”, page 55
⇒ “4.10.5 Checking tyre tread depth (including spare wheel)”,
page 55
⇒ “4.10.6 Checking tyre pressure (including spare wheel), cor‐
recting if necessary”, page 55
⇒ “4.10.7 Tyre Pressure Monitoring System”, page 58
WARNING
For safety reasons, only tyres of same type and tread pattern
should be fitted on a vehicle!
For information on approved wheel and tyre combinations, re‐
fer to ⇒ Wheels and tyres guide; Rep. gr. 44 ; Wheels, tyres,
vehicle geometry; Wheel and tyre combinations .
On vehicles with all-wheel drive, tyres of the same type and
tread profile must be used as otherwise damage to the self-
locking centre differential may ensue.
Note
♦ Tyre pressures for the relevant model can also be found on a

sticker. The sticker is attached to the inside of the driver door.
♦ Please note that the pressures indicated on the sticker apply
to cold tyres. Do not reduce increased pressures of warm
tyres.
♦ Depending on the vehicle, the sticker may also contain infor‐
mation on the comfort tyre pressure. The comfort tyre pressure
facilitates improved driving comfort.
♦ Adjust the tyre pressure to suit the vehicle load. For delivery
inspections or repairs, the partial load tyre pressure is to be
used.
♦ If no inflation pressure is shown for the spare wheel, then in‐
flate the spare wheel to the highest inflation pressure for the
vehicle.
Crafter 2017 ➤ , TGE 2017 ➤
M+S tyres
Note
♦ Important information on recommended winter tyres can be

found in ⇒ Wheels and tyres guide; Rep. gr. 44 ; Wheels,
tyres, vehicle geometry; Wheel and tyre combinations .
♦ If winter tyres are fitted, a sticker indicating the speed limit
must be attached in the interior where it is visible for the cus‐
tomer.
♦ For winter tyres, the tyre pressure does not have be increased.
However, this only applies if the winter tyre used corresponds
exactly to the standard summer tyre size and the speed index
is no higher than “H”. If this is not the case, please refer to the
recommendation of the tyre manufacturer.
All-wheel drive vehicles (additional notes)

♦ The vehicle must be fitted with tyres of the same brand. Oth‐
erwise, the speed difference between the axles will cause the
all-wheel drive coupling to increase the portion of drive to the
rear wheels unnecessarily. This may cause damage.
♦ A differing tread depth between front and rear axle tyres, e.g.
due to wear, is of no consequence. However it is recommen‐
ded that the tyres with the greater tread depth are fitted on the
front.
♦ If the front tyres are noticeably more worn than the rear tyres,
they have a smaller rolling circumference and therefore turn
faster. This causes wind-up in the drive train and the tyres
wear in a shorter period.
4.10.2 Checking tyre age
Note
We recommend not to use any summer or winter tyres older than

6 years.
Note
The DOT number -arrow- is a sequence of digits that is stamped

onto at least one side wall of vehicle tyres; it indicates the date
the tyre was manufactured.
The first two digits represent the week; for example “09” as shown
in the illustration.
The last two end digits represent the year of manufacture; for ex‐
ample “15” as shown in the illustration.
“0915” in this case means that the tyre was manufactured in the
ninth week of the year 2015.
Crafter 2017 ➤ , TGE 2017 ➤
4.10.3 Tyres: checking condition
WARNING
If damage is determined, always check to see if a new tyre

should be fitted.
Tests at delivery inspection:

– Check tyre side walls and treads for damage and foreign bod‐
ies such as, for example, nails or broken glass.
Tests at service:
– Check tyre side walls and treads for damage and foreign bod‐
ies such as, for example, nails or broken glass.
– Check tyres for cupping, one-sided wear, porous side walls,
cuts and punctures.
– Check for appropriate direction of rotation, or make sure that
the inner and outer sides have not been interchanged.
4.10.4 Wear pattern: checking

The wear pattern on the front tyres will indicate e.g. whether toe
and camber settings need to be checked.
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is mainly attributed to incorrect camber.
If wear of this nature is detected, determine cause by checking
alignment (repair measure).
4.10.5 Checking tyre tread depth (including

spare wheel)
Procedure
– Check tyre tread depth.
Minimum tread depth: 1.6 mm
Note
♦ This figure may vary according to legislation in individual coun‐

tries. Request details from importer.
♦ The minimum tread depth is reached when the tyres have
worn down level with the 1.6 mm high tread wear indicators
-arrows- positioned at intervals around the tyre.
♦ If the tread depth is approaching the minimum allowed depth,
inform the customer.
4.10.6 Checking tyre pressure (including spare

wheel), correcting if necessary
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♦ Tyre inflator - VAS 5216-
Note
♦ For the delivery inspection, check the presence of the tyre in‐
flation pressure sticker. If the sticker is missing, order a new
one ⇒ Electronic parts catalogue (ETKA) or for MAN TGE ⇒
webMANTIS .
♦ “Checking tyre pressure” also applies to the spare wheel, if a
spare wheel with standard tyres is fitted.
♦ The tyre pressures in the table apply to cold tyres. Do not re‐
duce increased pressures of warm tyres.
♦ Winter tyres and summer tyres may be used with the same
tyre sizes - check suitability for use with chains.
♦ Tyre pressures for the relevant model can also be found on a
sticker attached to the inside of driver door.
♦ Values for pressure are indicated in “bar”.
♦ Adjust the tyre pressure to suit the vehicle load.
♦ Tyre pressures apply for all tyre sizes fitted in the factory.
♦ The tyre pressures indicated are valid when towing a trailer up
to a speed of 130 km/h (if permitted).
♦ The tyre pressure sensors are secured to special aluminium
valves on the wheel. These valves are fixed rigidly by a threa‐
ded connection. When inflating and checking the tyre pres‐
sure, do not bend the valves »into position«.
♦ If valve caps are missing, damage to the valve and Tyre Pres‐
sure Monitoring System sensors may ensue. Therefore, al‐
ways use valve caps that are of the same factory standard. Do
not use metal valve caps.
♦ Do not use »convenience« valve caps as these do not have
sealing properties and can cause damage to the tyre pressure
sensors.
♦ If changing to different tyres, do not damage the valves and
sensors ⇒ Running gear, axles, steering; Rep. gr. 44 ; Tyre
Pressure Monitoring System; Removing and installing tyre
pressure sensor G222/G223/G224/G225 .
♦ Note that a basic setting of the Tyre Pressure Loss Indicator
is to be performed on vehicles with Tyre Pressure Loss Indi‐
cator each time the pressure is changed ⇒ page 82 .
Explanation of speed indexes used in the table:

♦ Q: up to 160 km/h
♦ R: up to 170 km/h
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♦ S: up to 180 km/h
♦ T: up to 190 km/h
♦ H: up to 210 km/h
♦ V: up to 240 km/h
Applies to all factory-fitted tyre sizes
Spare wheel with standard tyres
The spare wheel should have the highest tyre pressure deter‐
mined for the vehicle.
Tyre pressure table
Maximum Drive type Front axle Tyre size Wheel size Tyre pres‐ Tyre pres‐
permissible Engine installa‐ Load index Rim offset sure sure
weight tion type Front axle Rear axle
3 t - 3.5 t Front-wheel VV0 205/75R16C 6.5Jx16 4 bar 4.9 bar
drive 113/111R ET60
All-wheel drive 235/65R16C 6.5Jx16 3.4 bar 4.2 bar
Transverse 115/113R ET60
235/60R17C 6.5Jx17 3.5 bar 4.3 bar
117/115R ET60
3 t - 3.5 t Front-wheel VV8 205/75R16C 6.5Jx16 4.8 bar 4.9 bar
drive 113/111R ET60
235/60R17C 6.5Jx17 4.2 bar 4.3 bar
117/115R ET60
3.88 t Front-wheel VV0 235/65R16C 6.5Jx16 3.3 bar 4.7 bar
drive 121/119R ET60
3.88 t - 4 t Front-wheel VV8 235/65R16C 6.5Jx16 4.0 bar 4.7 bar
drive 121/119R ET60
3.5 t Rear wheel VV0 235/65R16C 6.5Jx16 3.4 bar 4.6 bar
drive with sin‐ 115/113R ET60
gle tyres 235/60R17C 6.5Jx17 3.5 bar 4.7 bar
Longitudinal 117/115R ET60
drive with sin‐ 115/113R ET60
gle tyres 235/60R17C 6.5Jx17 4.2 bar 4.7 bar
Longitudinal 117/115R ET60
drive with twin 113/111R HMA 121.5
tyres
Longitudinal
tyres
Longitudinal
tyres
Longitudinal
Volkswagen Technical Site: https://vwts.ru
Crafter 2017 ➤ , TGE 2017 ➤
Maximum Drive type Front axle Tyre size Wheel size Tyre pres‐ Tyre pres‐
permissible Engine installa‐ Load index Rim offset sure sure
weight tion type Front axle Rear axle
tyres
Longitudinal
3.88 t - 4 t Rear wheel VV8 205/75R16C 5.5Jx16 4.8 bar 3.5 bar
tyres
Longitudinal
3.88 t - 4 t Rear wheel VV8 205/70R17C 5.5Jx17 4.5 bar 3.2 bar
tyres
Longitudinal
5t Rear wheel VV8 205/75R16C 5.5Jx16 5.1 bar 4.0 bar
tyres
Longitudinal
5t Rear wheel VV8 205/70R17C 5.5Jx17 4.8 bar 3.7 bar
tyres
Longitudinal
tyres
Longitudinal
4.10.7 Tyre Pressure Monitoring System

The Tyre Pressure Monitoring System uses tyre pressure sensors
to measure the inflation pressure in each wheel.
These are indicated in the dash panel insert - KX2- by way of
indicator lamps or, on some models, graphic displays in the dash
panel insert - KX2- .
The Tyre Pressure Monitoring System informs the driver if the tyre
pressure is too low.
After changing the tyre pressures or one or more of the wheels,
the tyre pressure values are adapted automatically.
If changing wheels, e.g. summer tyres to winter tyres, ensure that
there are tyre pressure sensors on the newly fitted wheels as well.
4.11 Brake system and shock absorbers: in‐

specting for leaks and damage
Crafter 2017 ➤ , TGE 2017 ➤
Procedure
– Check following components for leaks and damage:
♦ Brake servo, for anti-lock brake system (hydraulic unit)
♦ Brake caliper
♦ Brake master cylinder and shock absorber for inspection
– Make sure that brake hoses are not twisted ⇒ Brake hydraulic
system, regulator, booster; Rep. gr. 47 .
– In addition, make sure that brake hoses do not contact other
components across entire steering range.
– Check brake hoses for abrasion and brittleness.
– Check brake lines for signs of abrasion.
– Check brake connections and fastenings for correct seating,
leaks and corrosion.
WARNING
Faults found must always be rectified (repair measure).
4.12 Brake system and clutch mechanism:

Changing brake fluid
⇒ “4.12.1 Brake fluid: change”, page 59
⇒ “4.12.2 Brake fluid specification”, page 61
4.12.1 Brake fluid: change

♦ Brake filling and bleeding equipment - VAS 6860-
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♦ Brake bleeding tool - VAS 6564-
♦ Upgrade kit and extraction unit - V.A.G 1869/4-

♦ Torque wrench - VAS 6854-
WARNING
♦ Never allow brake fluid to come into contact with fluids that
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐
eral oils damage the seals and boots in the brake system.
♦ Brake fluid is poisonous. In addition, due to its corrosive
nature, it must not come into contact with paint.
♦ Brake fluid is hygroscopic, which means it absorbs mois‐
ture from the ambient air and should therefore always be
stored in air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
♦ Do not reuse extracted (used) brake fluid!
♦ Observe relevant disposal regulations.
Procedure
Caution
When replenishing, ensure to not spill any liquids in the engine

compartment.
Spilled liquids may cause damage to the paintwork and to
components in the engine compartment.
Toothed belts, V-belts and poly V-belts which came into con‐
tact with oil, brake fluid, coolant or fuel must always be re‐
newed.
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– Using suction hose from brake filling and bleeding equipment

- VAS 6860- or a suction bottle with a built-in strainer, extract
as much brake fluid as possible from brake fluid reservoir.
– Connect adapter to brake fluid reservoir.
– Connect filler hose from brake filling and bleeding unit - VAS
6860- to adapter.
Note
Observe the ⇒ operating instructions for the brake filling and

bleeding unit - VAS 6860- .
– One after other, open breather valves on brake callipers, and

let appropriate quantity of brake fluid run out.
Used brake fluid is pushed out of the system by pumping in new
fluid.
– Open breather valve on clutch slave cylinder.
– Keep breather valve open until new brake fluid escapes with‐
out bubbles.
– Close breather valve on clutch slave cylinder.
Sequence: Brake fluid quantity which must
Wheel brake cylinders, flow out of wheel brake cylinders
brake calipers or brake calipers
Rear right 0.4 … 0.5 litre
Rear left 0.4 … 0.5 litre
Front right 0.4 … 0.5 litre
Front left 0.4 … 0.5 litre
– Switch off brake filling and bleeding equipment.
– Detach connection on brake fluid reservoir.
– Check pedal pressure and brake pedal free play. Free play:
max. 1/3 of pedal travel.
– Depress clutch pedal several times.
– Fill brake fluid into reservoir up to max. mark.
4.12.2 Brake fluid specification

Brake fluids are available as replacement parts ⇒ Electronic parts
catalogue (ETKA) or ⇒ webMANTIS for MAN TGE.
Permissible brake fluid specifications for vehicles
♦ The manufacturer recommends using new genuine brake fluid
to ensure that the brake system functions optimally.
♦ Alternatively, a brake fluid acc. to requirements of US standard
FMVSS 116 DOT4 or DIN ISO 4925 Class 4 can be used.
♦ Specification is stated on brake fluid packaging.
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4.13 Brake fluid level: checking

⇒ “4.13.1 Checking brake fluid level at delivery inspection”, page
62
⇒ “4.13.2 Checking brake fluid level at inspection service”,
page 62
4.13.1 Checking brake fluid level at delivery in‐

spection
Note
♦ On right-hand drive vehicles, the brake fluid reservoir is loca‐

ted on the right side in engine compartment at plenum cham‐
ber bulkhead.
♦ Genuine brake fluid must be used.
WARNING
♦ Never allow brake fluid to come into contact with fluids that
contain mineral oils (e.g. oil, petrol, cleaning agents). Min‐
eral oils will damage seals and rubber grommets of brake
system.
♦ Brake fluid is poisonous. In addition, due to its corrosive
nature, it must not come into contact with paint.
♦ Brake fluid is hygroscopic, which means it absorbs mois‐
ture from the ambient air and should therefore always be
stored in air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
– At delivery inspection, the fluid level must be at MAX. marking

-1-.
Note
To prevent brake fluid from flowing out of the reservoir, the max.
marking -1- must not be exceeded.
4.13.2 Checking brake fluid level at inspection

service
Note
♦ On right-hand drive vehicles, the brake fluid reservoir is loca‐

ted on the right side in engine compartment at plenum cham‐
ber bulkhead.
♦ Genuine brake fluid must be used.
♦ The brake fluid is dependent on pad wear.
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The fluid level must always be judged in conjunction with lining/

pad wear.
When vehicle is in use, fluid level tends to drop slightly due to
lining/pad wear and automatic adjustment.
Recommended brake fluid level, if brake pads are almost at wear
limit:
When the brake fluid level is at min. marking -2- or just above,
replenishment is not necessary.
Recommended brake fluid level when brake pads are new or well
within pad wear limit:
Between min. marking -2- and max. marking -1-.
Note
If the fluid level is below the min. marking -2-, the brake system
must be checked for leaks before fluid is topped up ⇒ Brake sys‐
tem; Rep. gr. 47 ; Hydraulic system; Leakage test .
4.14 Brakes, front and rear: checking thick‐

ness of brake pads and condition of
brake discs
⇒ “4.14.1 Front and rear brake pads/linings: Checking thickness”,
page 63
⇒ “4.14.2 Condition of brake discs: checking”, page 64
4.14.1 Front and rear brake pads/linings:

Checking thickness
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♦ Fluorescent lamp, 13 watts - VAS 6485-

♦ Mirror
Procedure
– Measure outer and inner brake pad thickness by inspecting
through the holes of wheel rim (depending on type).
– If necessary, remove the wheel to make it easier to assess or
measure the remaining thickness of the pads.
– Mark position of wheel in relation to brake disc, in order to
avoid imbalances on vehicle wheel.
– Unbolt wheel bolts and remove wheel.
– Assess or measure inner and outer brake pad thickness.
Front brake pads
a - Brake pad thickness “without” backplate
Wear dimension: 2 mm
Rear brake pads/linings

a - Brake pad thickness “without” backplate
Wear dimension: 2 mm
Note
♦ The brake pads have reached their wear limit at a brake pad
thickness of 2 mm (without backplate) and must be renewed
(repair measure). Inform the customer. Renewing the brake
pads is a repair measure.
♦ When renewing brake pads, always check the brake discs for
wear and proper condition ⇒ page 64 . Checking and re‐
placing the brake discs is a repair measure.
– If necessary, reinstall wheel at marked position.

– Push on wheel trims if necessary.
Torque settings
♦ Wheels, tyres; Specified torque for wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres; Specified
torque for wheel bolts
4.14.2 Condition of brake discs: checking

Crafter 2017 ➤ , TGE 2017 ➤

♦ Mirror
♦ Vernier gauge
Procedure
– Check all brake discs for the following damage patterns:
♦ Cracks
♦ Scoring
♦ Rust (no surface rust)
♦ Degree of wear at the ridge along the circumference
– Check thickness of brake discs using a commercially available
vernier gauge or a micrometer.
Notes about wear limit of brake discs: ⇒ Brake system; Rep. gr.
00 ; Technical data; Technical data of brakes .
Note
Inform the customer about damaged or worn out brake discs. Re‐
newing the brake discs is a repair measure.
4.15 Electric windows: initialising (activation)
Note
The automatic opening and closing features for the electric win‐
dows do not function after disconnecting and reconnecting the
battery. Therefore, before a new vehicle is delivered, the window
regulators must be reactivated. Once the windows have been re‐
activated, the battery must not be disconnected again.
WARNING
After batteries have been disconnected and reconnected the

roll-back function of the electric window regulators is disabled.
Severe pinching injuries could result!
Procedure
– Close all doors and windows completely.
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– Pull both buttons of electric windows in driver door upwards

and hold for at least a second.
The one-touch opening and closing function of the electric win‐
dows is now ready for use.
4.16 Fault memory of all systems: reading

with vehicle diagnostic tester , correct‐
ing possible faults according to repair
guidelines
Procedure
Note

ODIS Service
– Select “Event memory list”.
– Repair all faults according to repair guidelines.
Note
The vehicle must always be delivered to the customer with event

memory cleared.
Static faults
If one or more static faults are found in the event memory, we
recommend seeking agreement from the customer to rectify
these faults using Guided Fault Finding.
Sporadic faults
If only sporadic faults or messages are stored in the event mem‐
ory and the customer has no complaints in conjunction with the
electronic vehicle system, clear event memory.
4.17 Bonnet catch: Cleaning, ensuring at‐

tachment is secure and lubricating
♦ Cleaning solution and lubricating paste ⇒ Electronic parts
catalogue (ETKA) or ⇒ webMANTIS for MAN TGE
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Procedure
– Clean bonnet lock -3- and striker -1- with cleaning solution and
a lint-free cloth.
– If necessary, clean with »compressed air«.
– Lubricate striker pin -1- at bearing position -2- with lubricating
paste.
– Lubricate moving mechanism -4- on bonnet lock -3- with lu‐
bricating paste.
– Remove covers -3- from bonnet lock -2-.

– Check that bolts -1- on bonnet lock -2- are seated securely.
– Check that bolts -2- on striker pin -1- are seated securely.
Torque settings
♦ Bonnet; Assembly overview - bonnet ⇒ General body repairs,
exterior; Rep. gr. 55 ; Bonnet; Assembly overview - bonnet
4.18 Bringing ERA GLONASS into operation

This chapter only applies for the Russian market.
Procedure
Note
ERA GLONASS cannot be commissioned until certain criteria

have been fulfilled and the status LED lights up green.
If the status LED in the emergency assistance call button - E276-

lights up red, proceed as follows:
• Data for “Guided Fault Finding” is current
Crafter 2017 ➤ , TGE 2017 ➤
– Select emergency call module control unit and communication

unit - J949- to bring ERA GLONASS into operation ⇒ Vehicle
diagnostic tester, Guided Functions , Emergency call
module control unit and communication unit 2 , Sub-
systems framework conditions , J949 Bringing ERA
GLONASS into operation .
Various functions of the ERA GLONASS system are checked or

executed in the program:
♦ Check GPS reception
♦ Check GSM/UMTS reception
♦ Check DTCs
♦ Perform terminal 30 reset
still lights up red after 10 minutes, proceed as follows:
– Generate “DISS” report via “ELSA”.
– Proceed as instructed by the “NSC”.
Note

lights up green and the test call fails, e.g. by redialling, submit a
“DISS” note and proceed as per the instructions from the “NSC”
as well.
4.19 Interior and exterior body: inspecting for

corrosion with doors and flaps open
Test locations
♦ Sliding roof frame
♦ Inner and outer door frame
♦ Area around trim strips
♦ Windscreen roof edge
♦ Outer and inner A-pillar
♦ Bonnet
♦ Wheel arches
♦ Inner and outer tailgate
4.20 Poly V-belt: check condition

Procedure
insulation .
– Use a socket spanner to turn engine at vibration damper on
pulley.
– Check poly V-belt -1- for the following:
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♦ Sub-surface cracks (cracks, core ruptures, cross sectional

breaks)
♦ Layer separation (top layer, cord strands)
♦ Base break-up
♦ Frayed cord strands
♦ Flank wear (material wear, frayed flanks, flank brittleness -
glassy flanks-, surface cracks)
♦ Traces of oil and grease
Caution
• If faults are found, it is absolutely necessary to renew the

poly V-belt.
• This can avoid breakdowns and malfunctions.
• The replacement of a poly V-belt is a repair measure.
4.21 Poly V-belt: renewing

– For procedure, see Workshop Manual ⇒ Rep. gr. 13 ; Cylinder
block, pulley end; Removing and installing poly V-belt .
4.22 Fuel filter: renew

– Procedure is described in Workshop Manual ⇒ Rep. gr. 20 ;
Fuel filter; Removing and installing fuel filter .
4.23 Fuel filter: drain water

Procedure
– Move gear lever on manual gearbox to neutral.
– Move selector lever on automatic gearbox to position “P”.
– Stop engine and switch off ignition.
– Secure vehicle to prevent it from rolling away.
– Prepare a suitable and sealable container to collect the fuel/
water mixture.
– Open bonnet.
– Fit a suitable hose to the water drain plug connection -1- on
the fuel filter -2-.
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– Insert hose -2- from fuel filter -1- in container -3-.

– Start the engine.
– Loosen water drain plug -1- 1/2 to 3/4 turn in direction of

-arrow-.
– Drain about 200 ml of fuel/water mixture or drain until it is evi‐
dent that just diesel is escaping.
– Tighten water drain plug again.
– Switch off engine.
– Pull off hose from connection of water drain plug and empty
into container.
– Remove container and seal.
Note
♦ Ensure that no components come into contact with diesel fuel.

Clean immediately, if necessary.
♦ Remove leaked fuel.
– Start engine and check system for leaks (visual check).
Note
If »Drain water from fuel filter« warning lamp in dash panel insert
lights up, drain water from fuel filter again. Should the warning
lamp remain lit after this measure, perform fault finding in the
electrical system ⇒ Vehicle diagnostic tester.
Torque settings
♦ Fuel filter; Assembly overview - fuel filter ⇒ Rep. gr. 20 ; Fuel
filter; Assembly overview - fuel filter .
Crafter 2017 ➤ , TGE 2017 ➤
4.24 Cooling system: checking frost protec‐

tion and coolant level
⇒ “4.24.1 Notes”, page 71
⇒ “4.24.2 Frost protection: checking, replenishing coolant additive
if necessary”, page 72
⇒ “4.24.3 Coolant level: checking, replenishing coolant if neces‐
sary”, page 73
⇒ “4.24.4 Mixing ratio”, page 73
4.24.1 Notes
Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. As the water quality differs from coun‐
try to country and even from region to region, the quality of the
water to be used in the cooling system has been specified by
Volkswagen. Distilled water fulfils all requirements. For this
reason, distilled water must be used when mixing coolant for
topping up or replacing coolant.
♦ Only use coolant additives as per ⇒ Electronic parts catalogue
(ETKA) or ⇒ webMANTIS for MAN TGE. Other coolant ad‐
ditives may reduce corrosion protection substantially. The
resulting damage could lead to loss of coolant and subsequent
severe damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. Therefore, the cooling system
must be filled all year round with a coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ ONLY refractometer - T10007A- may be used for determining
current anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Crafter 2017 ➤ , TGE 2017 ➤
4.24.2 Frost protection: checking, replenishing

coolant additive if necessary
♦ Refractometer - T10007 A-
Note
Read precise value for the following tests at bright/dark boundary.

Using a pipette, place a drop of water on the glass to improve the
readability of the bright/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
Procedure
– Check concentration of coolant additive using refractometer -
T10007 A- (refer to operating instructions).
The scale -1- of the refractometer is calibrated for coolant addi‐
tives G12; G12 Plus, G12 Plus Plus and G11.
The scale -2- is only calibrated for coolant additive G13.
– If frost protection is insufficient, drain some coolant, and top
up with coolant additive.
Caution

compartment.
newed.
Note
♦ If the currently used coolant additive cannot be determined

precisely, use the scale -2- for coolant additive G13.
♦ Please observe disposal instructions!
– Check coolant additive concentration after road test again.
Crafter 2017 ➤ , TGE 2017 ➤
4.24.3 Coolant level: checking, replenishing

coolant if necessary
Procedure
– Check coolant level in expansion tank with engine cold.
Recommended coolant level at delivery inspection:
♦ Coolant level above MIN marking -arrow-
Recommended coolant level at inspection service
• Slightly above hatched area -arrow-.
Note
If the inspection service checks show that the fluid loss is greater
than can be expected through normal use, inform the customer
of the required repair measure.
– If coolant is too low, add required amount according to mixture

ratio.
Caution

compartment.
newed.
4.24.4 Mixing ratio
Caution
Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
The total amount of coolant is approx. 14 litres on average de‐

pending on the equipment.
Frost protection to Engine Amount of coolant addi‐ Amount of water in litres
tive in litres
-25°C 2.0 l TDI 75 kW 5.6 8.4
-40°C 2.0 l TDI 75 kW 7 7
-25°C 2.0 l TDI 90 kW 5.6 8.4
-40°C 2.0 l TDI 90 kW 7 7
-25°C 2.0 l TDI 5.6 8.4
103 kW / 120 kW /
130 kW
-40°C 2.0 l TDI 7 7
103 kW / 120 kW /
130 kW
Crafter 2017 ➤ , TGE 2017 ➤
4.25 Air filter: cleaning housing and renewing

filter element
♦ Torque screwdriver - V.A.G 1624-
Removing
– If the air filter housing is soiled, clean it from the outside.
– Loosen clamp of intake hose with torque screwdriver - V.A.G
1624- and pull off intake hose -1-.
– Release spring retainers -1-.
Crafter 2017 ➤ , TGE 2017 ➤
– Raise upper part of air filter, and remove air filter -1- upwards.
Installing
Install in reverse order of removal, observing the following:
– If the air filter housing is soiled, clean it from the inside.
Note
♦ When installing, ensure that the air filter element sits correctly
in the housing.
♦ Check that the seal is in full contact.
♦ Make absolutely sure that the “lugs” of the upper part of the
air filter are correctly inserted in the “mountings” of the lower
part of air filter.
Reset programmed values for the air filter in engine control unit
⇒ Vehicle diagnostic tester:
– Select Engine/motor control unit - J623- with Guided Func-
tions .
– Select Resetting learnt values in engine/motor con-

trol unit .
– Select and perform Resetting air filter function af-

ter air filter replacement .
4.26 Engine and components in engine com‐

partment: inspecting for leaks and dam‐
age (from above and below)
Procedure
– If fitted, remove the engine cover panel.
– Check engine and components in engine compartment for
leaks and damage.
– Check lines, hoses and connections of the following systems
for leaks, abrasion, porosity and brittleness.
♦ Fuel type
♦ Cooling and heating system
♦ Oil circuit
♦ Air conditioning system
♦ Intake system
♦ Brake system
Note
♦ Arrange for defects to be rectified as repair measures.

♦ If fluid loss is greater than can be expected through normal
use, determine source and rectify (repair measure).
Crafter 2017 ➤ , TGE 2017 ➤
4.27 Engine oil level: checking

Procedure
– After shutting off engine, wait at least 3 minutes so that the oil
can flow back into the sump.
– Pull out dipstick, wipe with a clean cloth and push dipstick in
again to limit stop.
– Pull dipstick out again and read oil level.
Note
♦ The oil level must always be in the upper third of area -A- for
the pre-delivery inspection.
♦ The oil-change quantity in the maintenance table was deter‐
mined experimentally and is sufficient for the technical func‐
tionality of the engine in all operating conditions. During all
other service events, the oil level must be checked corrected
as necessary if the customer requests this. This enables an
additional topping-up to the specified oil quantity to the upper
limit of the dip stick. Due to tolerances, the oil temperature and
the drip time, various quantities may be required for topping
up.
A - Do not top up oil.

B - Oil can be replenished up to the max. mark -A-.
C - Oil must be replenished. The oil level must then be at least in
the upper third of the measuring area -B-.
– If oil level is above max. mark -A-, drain or extract excess oil
to prevent damage to catalytic converter.
– If the oil level is below the minimum mark -C-, replenish with
oil accordingly.
Caution

compartment.
newed.
Oil capacities and engine oil specifications ⇒ page 80 .
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4.28 Engine oil: Draining or extracting and re‐

plenishing; renewing oil filter
⇒ “4.28.1 Engine oil: draining or extracting”, page 77
⇒ “4.28.2 Oil filter: renewing”, page 78
⇒ “4.28.3 Engine oil: replenishing”, page 79
The engine oil should be changed more often in the case of se‐
vere operating conditions, e.g.:
♦ operation with fuel containing sulphur
♦ with frequent short trips,
♦ in areas with high levels of dust,
♦ with frequent trips carrying a full load or pulling a trailer,
♦ with a high number of cold starts,
♦ and when the vehicle is used for a long time in areas with ex‐
tremely low temperatures,
Stopping and starting, such as in urban traffic, also puts vehicles
with diesel particulate filter under greater stress (severe operating
conditions). Use, in these conditions is an additional load on the
engine oil which is taken into account by the flexible service in‐
terval system.
4.28.1 Engine oil: draining or extracting

♦ Used oil collection and extraction unit - VAS 6622A-
♦ Oil filter strap wrench

♦ Oil spill cloth - VAS 6204/1-
Procedure
Option 1:
– Extract engine oil using used oil collection and extraction unit
- VAS 6622A- .
Option 2:
insulation .
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– Unscrew oil drain plug -1- from sump -2-.

– Let engine oil drain.
Note
The oil drain plug and seal are one unit and must be renewed
together.
– Screw in oil drain plug together with seal hand-tight and then
tighten to specified torque.
WARNING
♦ Torque specifications must not be exceeded.

♦ Excessive torque can cause leaks in the area of the oil
drain plug or even damage.
Torque settings
♦ Sump/oil pump; Assembly overview - sump/oil pump ⇒ Rep.
gr. 17 ; Sump/oil pump; Assembly overview - sump/oil pump
4.28.2 Oil filter: renewing

♦ Used oil collection and extraction unit - VAS 6622A-
Removing
Note
Observe relevant disposal regulations.
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insulation .
– Unscrew pump for exhaust gas recirculation cooler - V400- on
cylinder block and lay aside with hoses still connected ⇒ Rep.
gr. 26 ; Exhaust gas recirculation; Removing and installing
pump for exhaust gas recirculation cooler - V400- .
– Unscrew oil drain plug -2- of cap -1- and allow engine oil to
drain.
– Removing cap -1-.

– Pull out filter element.
Installing
Install in reverse order of removal, observing the following:
– Insert O-ring -2- in groove of oil drain plug for cap -1-. Screw
in oil drain plug and tighten to specified torque.
– Moisten new O-ring -4- with engine oil and renew oil filter el‐
ement -5-.
– Clean sealing surfaces on sealing cap and oil filter housing.
– Install cap -3- and tighten with tightening torque.
Torque settings
♦ Oil filter/oil pressure switch; Assembly overview - oil filter
housing/oil pressure switch ⇒ Rep. gr. 17 ; Oil filter/oil pres‐
sure switch; Assembly overview - oil filter housing/oil pressure
switch
4.28.3 Engine oil: replenishing

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♦ Oil filler funnel - VAS 6842-
– When adding oil, use oil filler funnel - VAS 6842- as appropri‐
ate.
Oil capacities and engine oil specifications ⇒ page 80 .
Caution

compartment.
newed.
It is absolutely essential for the engine to perform the final oil level
check while the engine is warm to ensure correct assessment of
the oil level.
4.29 Engine oil: capacities and specifications
Caution
Only engine oils approved by the manufacturer may be used,

up-to-date information ⇒ ServiceNet, Technical information,
Inspection and maintenance, Approved oils , or ask your im‐
porter.
Vehicles from 2017

Diesel engines Oil quantity with Engine oil standards
Engine code Capacity / out‐ filter (I) With flexible With fixed serv‐ Without diesel
put service ice particulate filter
with diesel par‐ with diesel par‐
ticulate filter ticulate filter
DASA 2.0 l / 90 kW 9.4 VW 507 00 VW 507 00 VW 505 01
DASB 2.0 l / 103 kW 9.4 VW 507 00 VW 507 00 VW 505 01
DAUA 2.0 l / 103 kW 7.2 VW 507 00 VW 507 00 VW 505 01
DAUB 2.0 l / 75 kW 7.2 VW 507 00 VW 507 00 VW 505 01
DAVA 2.0 l / 130 kW 7.2 VW 507 00 VW 507 00 VW 505 01
DAWA 2.0 l / 130 kW 9.4 VW 507 00 VW 507 00 VW 505 01
DAWB 2.0 l / 120 kW 9.4 VW 507 00 VW 507 00 VW 505 01
Crafter 2017 ➤ , TGE 2017 ➤
4.30 Breakdown set: Checking

Depending on the equipment level, the vehicles are equipped with
a breakdown set.
The breakdown set -1- is in the front passenger door.
The breakdown set -1- includes a bottle of tyre sealant -3- and a
compressor -2-.
The tyre sealant in the bottle has a limited shelf life.
The expiry date is therefore specified on the bottle -3-.
– Enter expiry date in maintenance table.
– If the expiry date has been reached, replace tyre sealant. (The
tyre sealant must not be more than 4 years old).
Observe regulations for disposal.
4.31 Carry out road test

Which of the following can be checked depends on vehicle equip‐
ment and local conditions (urban/country).
Check the following during a road test
– Engine: output, misfiring, idling speed, acceleration
– Clutch: pulling away, pedal pressure, odours
– Gear selection: ease of operation, stick position
– Automatic gearbox: selector lever position, shift lock/ignition
key removal lock, shift behaviour, dash panel insert display.
– Foot brake and parking brake: function, free travel and effec‐
tiveness, pulling to one side, juddering, squeal.
– ABS function: pulsing must be felt at the brake pedal during
ABS-regulated braking
– Steering: function, steering free clearance, steering wheel
centred when vehicle is travelling straight ahead
– Tilting roof: function
– Radio/radio navigation system: function, reception, GALA, in‐
terference noise
– Air conditioner: check function (at low temperatures the func‐
tion of air conditioner must be checked in a workshop)
– Vehicle: pulling to one side when travelling straight-ahead
(level road)
– Wheels, drive shafts, prop shaft: imbalance
– Wheel bearings: noises
– Engine: hot starting behaviour
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4.32 Tyre Pressure Loss Indicator: calibrat‐

ing
Note
♦ The calibration of the Tyre Pressure Loss Indicator must only

be performed “after” the tyre pressure has been corrected to
the prescribed values.
♦ If no pressure loss and tyre damage are found after a tyre
pressure warning, the incorrect warning can be rectified by
calibrating.
Tyre Pressure Loss Indicator compares the speed and thus the
rolling circumference and vibrations of the individual wheels via
the ABS sensors. If the tyre pressure changes on one or several
wheels, the Tyre Pressure Loss Indicator will indicate this in the
dash panel insert and the Infotainment system.
The rolling circumference of tyre changes if:
♦ The tyre pressure is too low.
♦ The tyre has structural damage.
♦ The vehicle is loaded more heavily on one side.
♦ The wheels on one axle are loaded more heavily (e.g. when
towing a trailer or when driving in mountains).
♦ Snow chains are fitted.
♦ The temporary spare wheel is fitted.
♦ One wheel per axle has been changed.
The Tyre Pressure Loss Indicator is a yellow warning lamp in the
dash panel insert.
♦ A “PERMANENT LIGHTING-UP” in conjunction with a warn‐
ing tone, means “WARNING”, pressure loss has been detec‐
ted, check tyre pressure and carry out calibration.
Calibration for vehicles as of 06.2018
– Switch on infotainment system.
– Press Home function button.
– Press Vehicle function button.
– Press Setup function button.
– Press Tyres function button.
– Press Set function button.
– Press Confirm function button.
4.33 Spare wheel bracket: checking

Access to the spare wheel winch varies depending on the equip‐
ment level ⇒ Owner's Manual .
♦ Pentagon socket from vehicle tool kit
Procedure
– Unclip cap for spare wheel winch if fitted.
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– Reach through body aperture and turn pentagon -1- on spare

wheel winch as far as stop in anti-clockwise direction.
When turning pentagon, a resistance must be overcome.
Spare wheel is lowered while suspended on cable of spare wheel
bracket.
Dropside and chassis
– Reach through body aperture -1- and turn pentagon as far as

stop in anti-clockwise direction.
When turning pentagon, a resistance must be overcome.
Spare wheel -2- is lowered while suspended on cable of spare
wheel bracket.
Vehicles 2017 ►
– Unscrew nut -2- of tether -1- from bracket -3-.

Continuation for all vehicles
– Loosen rim holder -4- from spare wheel -1-, tilt at an angle and
push through hole -2- in centre of rim along with cable -3-.
– Lay spare wheel aside.
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– Check cables -1- and -2- as well as wheel bracket -3- for dam‐
age.
Note
If the spare wheel winch is damaged, inform the customer imme‐

diately about necessary repair work.
– Prepare spare wheel for re-installation.

– Turn rim holder of cable at an angle and push through hole in
centre of rim along with cable.
– Position rim holder in rim hole, ensuring when doing so that
rim holder is located centrally in rim hole and not canted.
Vehicles 2017 ►
– Tighten nut -2- of tether -1- in bracket -3-.

Dropside and chassis
– Position spare wheel so that cable can be wound freely onto
spare wheel winch.
– Reach through body aperture -1- and turn pentagon on spare

wheel winch as far as stop in clockwise direction.
Spare wheel -2- is thereby pulled up under vehicle floor while
suspended on cable of spare wheel bracket.
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– Reach through body aperture and turn pentagon -1- on spare

wheel winch as far as stop in clockwise direction.
Spare wheel is thereby pulled up under vehicle floor while sus‐
pended on cable of spare wheel bracket.
Note
♦ While winding up the spare wheel, make sure that the tether
is not trapped between the wheel and the vehicle body or
frame.
♦ On vehicles with underbody cladding, make sure that the
spare wheel is not canted during winding up and that it is pulled
up properly into its end position.
The loud clicking noise comes from the excessive torque of the
spare wheel winch and can be heard when the spare wheel is
wound up to stop and beyond.
– Fit cap for spare wheel winch if present.
– Finally, check that spare wheel is seated correctly in spare
wheel bracket.
Specified torques
♦ Spare wheel bracket; Assembly overview - spare wheel brack‐
et ⇒ General body repairs, exterior; Rep. gr. 66 ; Spare wheel
bracket; Assembly overview - spare wheel bracket
4.34 Wheel securing bolts: Tightening to

specified torque
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♦ Adapter set for tamper-proof wheel bolts - T10101 A-
The adapter for loosening and tightening the anti-theft wheel bolts
and nuts can be found in the vehicle tool kit. As an alternative,
use the adapter set for tamper-proof wheel bolts - T10101 A- .
Perform the following procedure on all wheels
With anti-theft wheel bolts
– Loosen anti-theft wheel bolts -1-.
Note
To loosen the anti-theft wheel securing bolt, a special adapter is

required which can be found in the vehicle tool kit. Alternatively,
the master kit for wheel bolts - T10101A- or the master kit for
wheel bolts - T10190- can be used.
– Push adapter -2- into anti-theft wheel bolt -1- onto stop.
– Push wheel brace with extension onto adapter -2- onto stop.
Continuation for all vehicles:
– Unscrew all wheel bolts/nuts by about one turn.
– Tighten wheel bolts and nuts again diagonally to final specified
torque.
Note
On the “delivery inspection”, do not fit a tag to the interior mirror

indicating the necessity for tightening the wheel bolts to the final
torque since the wheels have already been tightened to the speci‐
fied torque at the factory. The wheels must only be tightened to
the prescribed torque setting for “Delivery inspection”.
Torque settings
♦ Wheels, tyres; Specified torque for wheel bolts ⇒ Running
gear, axles, steering; Rep. gr. 44 ; Wheels, tyres; Specified
torque for wheel bolts
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4.35 Window wash/wipe system and head‐

light washer system: Checking function
and settings; replenishing to maximum
level
⇒ “4.35.1 Checking Windscreen: Clearing with antifreeze for
windscreen wash/wipe system, replenishing with fluid if neces‐
sary”, page 87
⇒ “4.35.2 Window wash/wipe system: checking spray jet settings
and adjusting if necessary”, page 89
⇒ “4.35.3 Headlight washer system: Check spray jet settings, ad‐
just if necessary”, page 90
4.35.1 Checking Windscreen: Clearing with an‐

tifreeze for windscreen wash/wipe sys‐
tem, replenishing with fluid if necessary
Procedure
♦ Refractometer - T10007 A-
– Check concentration of anti-freeze additive using refractome‐

ter - T10007 A- .
– When doing this, observe the ⇒ operating instructions for the
refractometer .
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The scale -1- of the refractometer is calibrated for the concentra‐

ted window cleaning fluid with anti-freeze protection ⇒ Electronic
parts catalogue (ETKA) or ⇒ webMANTIS for MAN TGE.
The scale -2- is calibrated for commercially available windscreen
washer fluid as well as a mixture of commercially available wind‐
screen washer fluid and concentrated window cleaning fluid with
anti-freeze protection ⇒ Electronic parts catalogue or ⇒ web‐
MANTIS for MAN TGE.
Read precise value for the following tests at bright/dark boundary.
Using a pipette, place a drop of water on the glass to improve the
readability of the bright/dark boundary. The bright/dark boundary
can be clearly recognised on the “WATERLINE”.
Mixing ratio
Frost protection to Concentrated win‐ Water
dow cleaning fluid
with anti-freeze pro‐
tection
⇒ Electronic parts
catalogue (ETKA)
or ⇒ webMANTIS
for MAN TGE
-17/-18°C 1 part 3 parts
-22/-23 °C 1 part 2 parts
-37/-38 °C 1 part 1 part
Replenishing with fluid
The washer fluid reservoir must be filled completely.
With immediate effect, use only the concentrated window clean‐
ing fluid with all-year-round anti-freeze protection to replenish the
window wiper and washer system ⇒ Electronic parts catalogue
or ⇒ webMANTIS for MAN TGE.
Note
♦ On vehicles with fan jets, the reservoir must be filled with con‐
centrated window cleaning fluid with anti-freeze protection, as
this fluid has a low viscosity at temperatures below freezing.
Otherwise the complicated spray jet system can become
blocked by the crystallised washer fluid, which affects the
spray pattern of the spray jet. Using concentrated window
cleaning fluid with anti-freeze ensures that the fan jets remain
fully functional even at low temperatures ⇒ Electronic parts
catalogue (ETKA) or ⇒ webMANTIS for MAN TGE.
♦ Concentrated window cleaning fluid with anti-freeze protects
the spray jets, washer fluid reservoir and connecting hoses
from freezing.
♦ Even in warmer seasons, use concentrated window cleaning
fluid with anti-freeze protection ⇒ Electronic parts catalogue
(ETKA) or ⇒ webMANTIS for MAN TGE. The powerful cleans‐
er removes wax and oil residue from the glass.
♦ Frost protection must be guaranteed to approx. -25°C (approx.
-35°C in countries with an arctic climate) in the windscreen
wash/wipe system.
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4.35.2 Window wash/wipe system: checking

spray jet settings and adjusting if nec‐
essary
♦ Adjusting tool - T40187-
Note
♦ The spray jets may be cleaned in both directions, also opposite

to direction of spray with compressed air or water.
♦ Never use a needle or similar object, as otherwise the water
passage in washer spray jets will be damaged!
♦ If stream of water is uneven or cannot be adjusted to specified
dimensions, renew washer jet (repair measure).
♦ The spray patterns of an RHD vehicle are a mirror image of
those of an LHD vehicle.
♦ Close the bonnet before switching on the ignition.
♦ Risk of trapping: When the ignition is switched back on, the
front wiper arms might start moving unintentionally.
♦ Risk of damaging the bonnet when moving wipers back into
the park position.
♦ Do not manoeuvre the vehicle with wiper arms folded out.
♦ The wipers automatically move back to the park position when
the wiper switch is operated or when road speed exceeds
6 km/h.
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Windscreen spray jet settings

Procedure
– Actuate window washer system and check spray pattern.
The spray pattern must meet the following standard:
♦ Equally distributed, symmetrical spray pattern
♦ Uniform, precise jets of water
♦ Spray jet unit on right side: points at which water jets strike the
window for entire wiper range -illustration-
♦ Spray nozzle unit on left side. Spray pattern as mirror image
to spray nozzle unit on right side
– Actuate window washer system and check spray pattern.
– If the spray pattern does not meet the standard: Adjust spray
nozzles with adjusting tool - T40187- so that the jets of water
hit the windscreen at the indicated points.
Rear window spray jet setting:
Procedure
– Remove cap -1- above drive shaft -2-.

– Using adjusting tool - T40187- or adjusting tool - T10564- ,
adjust spray jets so that the washer jets spray onto rear win‐
dow in area of spray fields -1-.
Dimension a = 350 mm
4.35.3 Headlight washer system: Check spray

jet settings, adjust if necessary
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The following jet setting figures are for the left-hand headlight
(right-hand mirror image).
Procedure
– Switch on dipped headlight.
– Operate windscreen washing system.
The headlights are washed if the windscreen wiper lever is hold
in »Wipe position« for at least 1.5 seconds.
The spray jets are extended.
– Using adjusting tool - T10167- , align spray direction of re‐
spective jet to centre of headlight.
4.36 Headlight adjustment: check and adjust

as necessary.
⇒ “4.36.1 Test requirements”, page 91
⇒ “4.36.2 Halogen headlights: adjusting”, page 93
⇒ “4.36.3 Adjusting LED headlights”, page 94
⇒ “4.36.4 Adjusting fog lights”, page 96
⇒ “4.36.5 Adjusting auxiliary headlights”, page 96
4.36.1 Test requirements

Test and adjustment conditions
♦ Tyre pressure OK
♦ Lenses must not be damaged or dirty.
♦ Reflectors and bulbs OK.
♦ Vehicles with manual headlight range control: thumb wheel to
zero position
♦ Weight specifications have been set
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♦ The vehicle must be rolled forward and backward several me‐

tres or front and rear springs must be bounced fully several
times so that springs settle.
♦ Vehicle and headlight adjuster must be on a level surface.
♦ Vehicle and headlight adjuster must be aligned.
♦ Inclination must be set.
Load: with one person or 75 kg on the driver seat and the vehicle
otherwise unloaded (unladen weight)
The unladen weight is the weight of the vehicle ready for operation
including the weight of all equipment normally carried (e.g. spare
wheel, tools, jack, fire extinguisher etc.).
The vehicle must be rolled forward or backward several metres
or front and rear springs must be bounced fully several times so
that springs settle.
Note
Within the scope of the test conditions for headlight adjustment,

a fuel tank that is only partially full need not be compensated for
with additional weight.
Procedure
Vehicles with manually regulated headlight range control
– Set thumb wheel of headlight range control to zero position.
– Check headlight height adjustment by setting the headlight
range control from zero position to maximum level.
– When doing this, observe the light in the headlight adjustment
unit . It must adjust accordingly.
– Then, set the thumb wheel of headlight range control to zero
position again.
If the headlight range control does not work as described, it must
be repaired prior to headlight adjustment. Otherwise it is impos‐
sible to ensure that the headlights are set to the basic position for
the adjustment. Inform the customer. the required repair meas‐
ures.
Vehicle -2- and headlight adjustment unit -1- must be aligned rel‐
ative to one another.
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The inclination information -1- in “%” is stamped into the trim

above the headlight. Headlights must be adjusted according to
this information. Percentage given is based on a projection dis‐
tance of 10 metres. Example: Converting a dip setting of e.g.
1.0 % is equivalent to 10 cm.
4.36.2 Halogen headlights: adjusting

♦ Headlight adjustment unit - VAS 5046-
♦ Headlight adjustment unit - VAS 5047 A-
♦ Headlight adjustment unit - VAS 5209 B-
Note
♦ Prior to performing any adjustment work, consult the ⇒ oper‐

ating instructions for the headlight adjustment units .
♦ The adjustment is described for the left headlight. Proceed in
the same manner when adjusting the right headlight.
Procedure
Test prerequisites ⇒ page 91 .
– Checking headlight adjustment:
♦ When the dipped beam headlight is switched on, the horizontal
light-dark border must make contact with the dividing line -1-
of the display zone.
♦ The breaking point -2- between the horizontal part of the light-
dark border of the light on the left and the slope on the right
should be on the vertical line passing through the centre mark.
The bright core of the light beam must be to the right of the vertical
line.
– Adjust the headlight if the current adjustment does not meet
the requirements.
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♦ Lateral adjustment screw -1-

♦ Height adjustment screw -2-
– Turn height adjustment screw -4- on headlight -1- until setting

is correct. To do this, insert screwdriver through hole in rein‐
forcement -2- until it reaches the adjuster screw.
– Turn height/lateral adjustment screw -3- until setting is correct.
Note
♦ Adjustment of the right headlight is carried out in the same

sequence.
♦ The adjustment screws for the right headlight are a mirror im‐
age.
4.36.3 Adjusting LED headlights

Note
♦ Prior to performing any adjustment work, consult the ⇒ oper‐

ating instructions for the headlight adjustment units .
♦ The adjustment is described for the left headlight. Proceed in
the same manner when adjusting the right headlight.
Procedure
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– Checking headlight adjustment:

– With the dipped beam switched on, the lowest part of the hor‐
izontal light-dark border must be aligned with the dividing line
-1- of the test area.
– The breaking point -2- between the horizontal part of the light-
dark border on the left and the slope on the right should be on
the vertical line passing through the centre mark.
– Adjust the headlight if the current adjustment does not meet
the requirements.
– Carry out basic setting of headlight range control ⇒ Vehicle
diagnostic tester.
ODIS Service
– Select “Systems capable of self-diagnosis”.
– Select “0009 - Electronic central electrics”.
– Select “0009 - Electronic central electrics, functions”.
– Select “0009 - Basic setting, headlights”.
Note

♦ Height adjustment screw -1-

♦ Lateral adjustment screw -2-
– Turn height adjustment screw -3- on headlight -1- until setting

is correct.
– Turn lateral adjustment screw -2- until setting is correct.
Note
♦ Adjustment of the right headlight is carried out in the same

sequence.
♦ The adjustment screws for the right headlight are a mirror im‐
age.
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4.36.4 Adjusting fog lights

Procedure
– Check headlight adjustment.
♦ Inclination of fog lights: 2.0 %
– Check whether the upper light-dark border of the light touches
the setting line -1- and runs horizontally over the entire width
of the display zone.
– To adjust the fog light range, adjust the adjuster screw through
opening -1- in bumper.
Note
♦ Adjustment of the right fog light is carried out in the same se‐
quence.
♦ The location of the adjuster screw for the right fog light is a
mirror image.
♦ There is no provision for lateral adjustment.
4.36.5 Adjusting auxiliary headlights

Additionally retrofitted lights of other systems must be checked
and set according to valid guidelines.
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4.37 Service interval display: resetting

⇒ “4.37.2 Resetting service interval display using ODIS vehicle
diagnostic tester software”, page 97
⇒ “4.37.3 Resetting service interval display without vehicle diag‐
nostic tester”, page 98

The service interval display must be reset for:
♦ Delivery inspection
♦ Each oil change service (fixed/flexible)
♦ Each inspection
Note
Observe the current operating instructions for the vehicle diag‐

nostic system that are shown on the display when the Adminis‐
tration and Operating Manual functions are selected.
4.37.2 Resetting service interval display using

ODIS vehicle diagnostic tester software
Note
♦ It is not necessary to log in in order to enter or call up vehicle

data.
♦ If the display is not as shown in the procedure: ⇒ Operating
instructions for diagnostic tester
Procedure
– Automatic gearbox: move selector lever to position “P”.
– Manual gearbox: move gear lever to neutral.
ODIS service
– Select “Dash panel insert”.
– Select “Guided Functions”.
– Select the respective service which is to be reset.
– Follow instructions in “Guided functions” mode.
Crafter 2017 ➤ , TGE 2017 ➤
Note
If the vehicle battery was disconnected for a long period on vehi‐

cles with flexible service, it is not possible to calculate the period
until the next service is due. The service interval displays may
therefore indicate inaccurate calculations. In this case, observe
the maximum permissible service intervals stated in the service
tables.
4.37.3 Resetting service interval display with‐

out vehicle diagnostic tester
The service interval display must be reset for:
♦ delivery inspection
♦ Every oil change service (fixed/flexible)
♦ Every interval service (fixed/flexible)
♦ Every inspection
Procedure
– Press and hold button 0.0 in dash panel insert.
– Release button 0.0 in dash panel insert if one of the following
messages appears in the display of the dash panel insert:
♦ Reset oil change service?
♦ Reset inspection service?
– Press button 0.0 in dash panel insert to confirm.
Note
♦ If the oil change service was manually reset, the service in‐
terval display will then also change to a fixed service interval
on vehicles with flexible oil change service.
♦ If the vehicle battery was disconnected for a long period on
vehicles with flexible service, it is not possible to calculate the
period until the next service is due. The service interval dis‐
plays may therefore indicate inaccurate calculations. In this
case, observe the maximum permissible service intervals sta‐
ted in the service tables.
4.38 Service interval display: recoding
Note
♦ It is not necessary to log in in order to enter or call up vehicle

data.
♦ If the display is not as shown in the procedure: ⇒ Operating
instructions for diagnostic tester

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Recoding from flexible to fixed intervals

ODIS Service
– Connect ⇒ Vehicle diagnostic tester.
– Select “Change flexible/fixed intervals”.
Recoding from fixed to flexible intervals

ODIS Service
– Select “Change flexible/fixed intervals”.
Changing values for maximum distance to be driven (km) until

next oil change service (fixed) during delivery inspection
ODIS Service
– Select “Oil change service (fixed)”.
– Reset “-1- Oil change service (fixed)”.
The current values for maximum distance to be driven (km) are shown on ⇒ Vehicle diagnostic tester.
– Select “No”.
– Select value for maximum distance to be driven until next oil change service, according to specifications
valid in your country.
Volkswagen Technical Site: https://vwts.ru
Crafter 2017 ➤ , TGE 2017 ➤
4.39 Check seat belts and belt buckles for

external damage and function
Procedure
– Pull out belt webbing -1- completely, and check it for cut fibres,
chafing or other damage.
– Rectify any twists -arrow- of the belt webbing.

– Check locking mechanism of belt inertia reel by abruptly pull‐
ing belt webbing.
– Engage latch plate -1- in belt buckle, and pull latch plate -1-
abruptly to make sure that the belt buckle latch -arrow- is
securely engaged.
– Check belt buckle for following possible damage:

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♦ Buckle tongue guide is flush with upper edge of housing -1-

♦ Release button protrudes too far -2-
♦ Loose buckle housing -3-
– Check belt buckle anchorages for proper condition and exte‐

rior damage. Abrasive areas -arrow- on the seat trim may be
signs that wires are broken and belt buckle anchorages are
deformed.
– Check belt buckle anchorages for broken and/or deformed

wires -1- as well as for other damage to the housing -2-.
Note
♦ Always renew the affected seat belt or belt buckle if damaged,

malfunctioning etc.
♦ If the customer does not wish to renew the damaged seat belt,
make a note on the repair order.
4.40 Track rod ends: checking clearance,

firm seating and boots

♦ Mirror

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Procedure
– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free).
There must be no noticeable clearance.
– Check if track rods are properly secured.
– Check that boots -arrow- are not damaged and are seated
correctly.
– Check bellows of track rod on the steering rack -arrow- for

leaks and damages.
Note
If faults are found, always renew the affected track rod or boot.
Inform the customer. Renewing the track rods/boot is a repair
measure.
4.41 Dust and pollen filter (interior filter):

Cleaning housing and renewing filter el‐
ement
For procedure, see Workshop Manual ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Front heater and air conditioning unit; Removing
and installing dust and pollen filter .
4.42 Transportation mode: switching off


Crafter 2017 ➤ , TGE 2017 ➤
Note
♦ The transportation mode is responsible for assuring the start‐

ing capability of vehicle.
♦ Battery discharging is reduced by the transportation mode,
because electrical consumers are switched off.
♦ Certain functions of the vehicle are dispensable when the ve‐
hicle is being transported These are deactivated when the
transport mode is activated to preserve life of battery.
♦ These are especially all functions in the vehicle which can re‐
duce the battery capacity when being misused.
♦ Examples are radios, electronically operated flaps and attach‐
ments and anti-theft alarm systems which can produce faults
during transportation.
Procedure
ODIS Service
– Select “Data bus diagnostic interface”.
– Select “Identify control unit”.
– Select “Switch transportation mode off/on”.
Procedure for event entry “Loading mode active”

– Switch transport mode on again.
– Switch off ignition for 10 seconds.
– Switch transport mode off again.
– Switch on ignition again for 10 seconds.
After this procedure has been carried out, the event entry “Load‐
ing mode active” is no longer stored.
4.43 Doors: grease door arrester

♦ Lubricating paste and lock cylinder lubricating spray ⇒ Elec‐
tronic parts catalogue (ETKA) or ⇒ webMANTIS for MAN TGE

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Procedure
– Lubricate door arrester -1- at positions marked with -arrows-
on top and bottom.
– Use lubricating paste or lock cylinder lubricating spray.
4.44 Vehicle underside (floor pan): visual

check for damage

♦ Mirror
Procedure
– Visually check the underbody for damage and corrosion.
During the visual check of the underbody, also check the wheel
housings and side members.
Note
Faults found must always be rectified (repair measure). This in‐

hibits corrosion and rusting through.
4.45 Camshaft drive toothed belt: check con‐

dition
⇒ “4.45.1 Camshaft drive toothed belt: Checking condition, 2.0 l
diesel engines”, page 104
4.45.1 Camshaft drive toothed belt: Checking

condition, 2.0 l diesel engines
Procedure
– Remove toothed belt guard ⇒ Rep. gr. 15 ; Toothed belt drive;
Assembly overview - toothed belt guard .

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– Turn crankshaft at least one full turn and check toothed belt
for the following:
♦ Cracks, cross sectional breaks
♦ Layer separation (toothed belt body, tensile cords)
♦ Toothed belt body breakup
♦ Frayed cord strands
♦ Surface cracks (synthetic coating)
When checking condition, search for the following particular dam‐
age:
♦ -A- Cracks, cross-sectional breaks, cracks (coating)
♦ -B- Side contact
♦ -C- Fraying of cord strands
♦ -D- Cracks (in teeth base)
♦ Layer separation (toothed belt body, tensile cords)
♦ Surface cracks (synthetic coating)
Note
If faults are found, always renew toothed belt. This can avoid
breakdowns and malfunctions. The replacement of a toothed belt
is a repair measure.
4.46 Camshaft drive toothed belt: renew.

Work procedure as per Workshop Manual ⇒ Rep. gr. 15 ; Tooth‐
ed belt drive; Removing and installing toothed belt .

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5 Exhaust emissions test

⇒ “5.1 Exhaust emissions test for diesel engines”, page 106
5.1 Exhaust emissions test for diesel en‐

gines
Note
♦ Observe legal regulation according to country.

♦ The exhaust emissions test described below has been created
according to the legal regulations valid in Germany.
Emissions test intervals:

Vehicles with diesel engine:
♦ 3 years after initial registration and then every 2 years
♦ Vehicles for commercial passenger transport, e.g. taxis: every
12 months
♦ Exhaust gas testing station L - VAS 7320 A-
Note
♦ The following description refers to vehicles fitted with “On‐

board diagnosis” OBD.
♦ The OBD monitors all components and part systems influenc‐
ing the exhaust emissions quality.
♦ It is possible to carry out an exhaust emissions test only when
all units of the emissions testing station are connected prop‐
erly and joined to each other according to the operating in‐
structions.
♦ All work to be performed is displayed by the emissions testing
station .
Test requirements
• All test conditions and data required for exhaust emissions test
are found on EET data sheet for the respective engine.
• For bar code reading of specified data for EET, the EET data
sheet must be printed out.
• Automatic gearbox: selector lever in position “P” or “N”.
• Manual gearbox: gear lever in neutral
• Parking brake applied
– Perform exhaust emission test according to instructions on
display.
Vehicle data input
– Enter the following data:
♦ Registration number
♦ Key numbers
♦ Vehicle identification number
106 5. Exhaust emissions test

Crafter 2017 ➤ , TGE 2017 ➤
♦ Fuel type
♦ Mileage
The following vehicle data can be found in the vehicle registration
certificate part 1:
♦ Registration number: “e.g. WOB-HH 1234”
♦ Emission key No. “field 14.1 (code for field 14)”
♦ Vehicle manufacturer: “Field 2”, “Field 2.1 (code for field 2)”
♦ Vehicle identification number “field E”
♦ Type and version “Field D2 (type only)”, “Field 2.2 (code for
field D.2)”
Specified data input for EET
There are different ways to enter the specified data:
♦ 1. By manual input
♦ 2. By bar code input from EET data sheet
♦ 3. Through ELSA web service
Note
♦ If there is no ESP to deactivate the engine speed limiter, the

rev limit can be measured using the engine speed limited by
the control unit. To do this, all the EET specifications must be
entered manually.
♦ To use the ELSA web service, the exhaust gas testing station
L which is used for the exhaust emissions test must be inte‐
grated in the workshop network.
♦ The ELSA web service automatically transmits the data for the
specific vehicle via the network to the respective mask.
Manual specified data input for EET:
Note
♦ All test conditions and data required for exhaust emissions test
⇒ Data sheets for exhaust emissions test for respective en‐
gine.
♦ If the engine speed limiter cannot be deactivated, enter the
value 2500 ± 200 rpm in the box for rev limit and 2500 in the
box for engine speed for conditioning.
5. Exhaust emissions test 107

Crafter 2017 ➤ , TGE 2017 ➤
– Perform manual data input according to instructions on dis‐

play.
– Enter displayed values on EET data sheet under “Test values
for exhaust emissions test” on display in following sequence:
1- Speed for conditioning
2- Number of throttle bursts for conditioning
3- Engine oil temperature (min. value)
4- Select method for engine oil temperature measurement
5- Idling speed
6- Governed speed
7- Rev limit measuring period (1 second)
8- Type plate value
9- Select probe type (number of probe)
10 - Select measuring mode
11 - Measured period portion
Note
♦ When performing the exhaust emissions test, the respective

technician must always use the vehicle-specific exhaust emis‐
sions limit value indicated on the type plate.
♦ If no value is indicated on the type plate, the opacity figure
specified by the manufacturer and indicated in ELSA must be
used.
♦ If no value is indicated on the type plate and no opacity figure
has been specified by the manufacturer, the statutory opacity
figures (2.5 m -1 or 1.5 m -1, depending on date of initial reg‐
istration) must be used.
♦ For all Euro-6-vehicles an opacity figure of max. 0.5 m -1 ap‐
plies.
– Proceed by pressing the button arrow .

Specified data input for EET as bar code:
– If EET nominal data is present in bar code format then read in
bar code of EET data sheet using reader pen.
If the opacity figure on the EET data sheet is different from the
value indicated on the type plate, enter the type plate value man‐
ually.
Inspection
– Perform visual check of any components which are relevant
for exhaust emissions.
– Check if exhaust system is fitted and complete and check for
leaks and damage.
Procedure
– Follow instructions of emissions testing station .
108 5. Exhaust emissions test

Crafter 2017 ➤ , TGE 2017 ➤
Evaluation
Note
♦ If the exhaust emissions test was performed with an active rev

limiter, enter the following in the test log:
♦ “The governed speed test was performed with an automatic
engine speed limit of 2500 rpm. ”
5. Exhaust emissions test 109

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Service

Service Department. Technical Information

1.1 Overview of engines - diesel engines

Engines ⇒ Diesel engine Diesel engine

Volkswagen Technical Site: https://vwts.ru 1. Engine list 1

2.1 Information about flexible or fixed serv‐

2.1.1 Service identification

2.1.2 Flexible service

For the flexible service a special LongLife engine oil is required.

2.1.3 Fixed service

2.1.4 Service interval display

Fixed service interval display (only vehicles with a fixed service)

♦ The service interval for vehicles with a fixed service is calcu‐

2.2 Service tables

♦ The following chapter contains the common service tables for

2.2.1 Service tables

2.3 Scopes of service

2.3.1 Scopes of service 2017 ►

♦ Under certain circumstances, different types of service can be

♦ Switch off transportation mode ⇒ page 102

Scope of work Page

♦ Clock and date: setting ⇒ Operating in‐

♦ Edge protection on doors (plastic film): remove.

♦ Protective foil: Remove (if fitted)

♦ Towing eyes: Remove

♦ Front left tyre: Check condition and inflation pressure ⇒ page 53

♦ Rear left tyre: Check condition and inflation pressure ⇒ page 53

♦ Rear right tyre: Check condition and inflation pressure ⇒ page 53

♦ Front right tyre: Check condition and inflation pressure ⇒ page 53

♦ Wheel securing bolts: Tightening to specified torque ⇒ page 85

♦ Engine oil level: checking ⇒ page 76

Scope of work Page

♦ Brake system and clutch mechanism: Changing brake fluid ⇒ page 59

♦ Brake fluid level: checking ⇒ page 62

♦ Digital Service Schedule

♦ Carry out road test ⇒ page 81

X ♦ Windscreen: inspect for damage.

X ♦ Bonnet catch: Cleaning, ensuring attachment is secure and

Change Inspection Extended in‐ Measure

X ♦ Underbody: Visual check for damage to underbody protection

Change Inspection Extended in‐ Measure

2.3.2 Scopes of service, market specific devi‐

2.3.3 Additional work dependent on time/dis‐

♦ Additional work based on time and distance 2017 ►

3.1 “Vehicle data” sticker

3.2 Entries in the Digital Service Schedule

♦ When using “Genuine parts kits” it must be taken into account

3.3 Vehicle diagnostic tester

♦ During a road test, always secure test and measuring

Connecting vehicle diagnostic tester

Right-hand drive vehicles

3.4 Vehicle identification number

3.4.1 Vehicle identification number on lower

3.4.2 Vehicle identification number in area of

3.4.3 Vehicle identification number in area of

3.4.4 Significance of vehicle identification number

3.5 Vehicle data sticker

The sticker contains the following data of the vehicle

3.6 Severe operating conditions

• Regular long periods of idling (e.g. taxis)

3.7 Engine code and engine number

3.8 Identification plate

Vehicles for certain export countries have no type plate.