VOLKSWAGEN Crafter CR28 2.

5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

General information: Common rail, Diesel

General
Always read the general guidelines before working on high-pressure fuel systems. Common rail diesel injection systems
operate at very high pressure. Caution! Do not repair the common rail system when the engine is running.

Before starting work, depressurise the fuel system.

Wait for at least five minutes after turning off the engine.

Warning: Always wear protective gloves and eye protection when carrying out this work.

Before working on the fuel system, clean the area thoroughly. Dirt particles in the fuel system can cause faulty engine
operation. Open fuel connections must be sealed off with appropriate covers or plugs. Note: Never disassemble fuel
injectors. Always renew the injector copper sealing ring.

After injector renewal. Reprogram the engine control unit.

After engine control unit renewal: All existing injector compensation codes in the new engine control unit must be set with a
diagnostic tool.

Caution! Do not bend or fit high-pressure fuel lines under stress. If there is evidence of leakage, renew the fuel line and
fittings. High-pressure fuel lines are specific to each vehicle and are not interchangeable.

The common rail system can vary the injection pressure and timing over a wide range. The injection pressure is
independent of the engine speed and injected fuel quantity. The high-pressure pump is separated from the injectors by a
pressure accumulator, the common rail.

To calculate the injection pressure, timing and fuel quantity, the engine control unit uses signals from the following
components:
- Accelerator pedal position sensor
- Crankshaft position sensor
- Engine temperature sensor
- Boost pressure sensor

There are three types of common rail system

Solenoid valve injector. Fuel pressure control valve (1350 bar).

Solenoid valve injector. A metering unit controls the fuel delivery at the high-pressure pump side (1600 bar).

Piezo injector. A metering unit controls the fuel delivery at the high-pressure pump side (1600 - 2000 bar).

Common rail system design

All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

Image call-out
1. Fuel tank
1. Fuel pre-filter
1. Low-pressure fuel pump
1. Fuel filter
1. Fuel temperature sensor:
1. High-pressure fuel pump:
1. Metering unit
1. Fuel rail
1. Fuel rail pressure sensor
1. Fuel pressure control valve
1. Injector
Low-pressure pump
The low-pressure fuel pump delivers fuel from the fuel tank to the high-pressure fuel pump
Low-pressure fuel pump:
1. In-tank fuel pump
1. In-line pump

Electric fuel pump (< 200l/h, 6 bar)

Image call-out
1. Pump element
1. Electric motor
1. Pump end cover
All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

1. Fuel pressure limiter

1. Non-return valve
Function. The pump permanently delivers fuel to the injection system, independently of engine load. An overflow valve
allows excess fuel to flow back to the fuel tank. The electric fuel pump can cut off fuel delivery when necessary. When the
ignition is turned on (engine stopped). A safety circuit prevents fuel delivery.

The roller cell pump (RCP) is the most commonly used pump element. The roller cell pump is a positive-displacement
pump with free-moving slotted rotors in the eccentric base plate. When the rotor rotates, the movable rollers are forced
outwards to the pump housing. The combined effects of centrifugal force and fuel pressure determine roller movement. The
rollers act as rotating seals, creating a chamber. The slotted rotor is electrically driven. When the kidney-shaped inlet
opening closes, the chamber volume continuously reduces. The end cover contains the electrical connections and the
pressure-side fuel outlet. A non-return valve prevents the fuel lines from emptying when the fuel pump switches off.

1. Slotted rotor
1. Eccentric base plate
1. Movable rollers

Gear fuel pump (< 400l/h, < 7 bar). Location: The pump is attached to the engine. or. The pump is integrated into the high-
pressure pump. The gear fuel pump is driven via a coupling, gearwheel or toothed belt. Fuel delivery depends on engine
speed. The fuel flow rate is controlled by the following components: Throttle. Overflow valve.

1. Suction throttle valve

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companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

1. Primary gearwheel
1. Secondary gearwheel

The pump has two engaging rotating gearwheels. The fuel is moved from the suction to the pressure side in the tooth
spaces. The contact surface between the gearwheels functions as a seal, preventing the fuel from flowing back. When the
engine has run dry or before the first start, the fuel system must be bled. To bleed the system: Fit a hand pump directly on
the gear pump or on the low-pressure lines.

High-pressure pump
The high-pressure pump generates a constant pressure for the fuel rail. During injection, the fuel is not compressed. The
pump and conventional injection pump locations are identical. The gear fuel pump is driven via a coupling, gearwheel or
toothed belt. The pump speed is proportional to the engine speed. When the engine is idling or running at partial load, the
high-pressure pump delivers excess fuel.

Early systems: A pressure control valve on the fuel rail returns excess fuel to the tank. The overall injection efficiency is
low.

Later systems: A metering unit controls the fuel delivery at the high-pressure pump side. The fuel pump load and maximum
fuel temperature are reduced.

Radial-piston pump: The pump plungers compress the fuel. The radial-piston pump produces overlapping delivery strokes,
even load on the pump drive, and low drive peak. In passenger cars, the radial-piston pump is fuel-lubricated. Passenger
cars can also have oil-lubricated in-line piston pumps. The low-pressure pump delivers the fuel to the high-pressure pump
inlet via a filter. A safety valve is located behind the inlet. When the delivery pressure from the low-pressure pump exceeds
the safety valve opening pressure: The fuel flows into the high-pressure pump lubrication circuit. The eccentric on the drive
shaft moves the pump plunger up and down. The fuel flows through the inlet valve into the element chamber. The pump
plunger moves downwards. When the bottom dead centre (BDC) position of the plunger is exceeded, the inlet valve closes.
The pressure will rise above the low-pressure pump delivery pressure. The rising pressure opens the outlet valve when the
fuel rail pressure is reached. The pressurised fuel then flows to the high-pressure circuit. When the top dead centre (TDC)
position is reached: The pressure drops and the outlet valve closes. The remaining fuel is depressurised and the plunger
moves downwards. The inlet valve reopens when the element chamber pressure exceeds the delivery pressure.

1. Fuel inlet
1. Safety valve
1. Lubrication and cooling circuit

All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

1. Pump plunger
1. Inlet valve
1. Pump element chamber
1. Outlet valve
The process begins again
Fuel rail
The fuel rail is a high-pressure accumulator which maintains the fuel at high pressure. This accumulator damps the
pulsating effect of the fuel pump and the injection cycles. The injection pressure remains constant when the injector opens.

The fuel from the high-pressure pump enters the fuel rail. The rail-pressure sensor measures the fuel pressure. The
pressure control valve limits the fuel pressure in the rail to the maximum permissible pressure. The valve closes when the
rail pressure is too low.

1. Fuel rail
1. Pressure control valve
1. At the inlet
1. Fuel return line
1. Fuel rail pressure sensor
1. Fuel line to injector

The common rail system has two methods of controlling the fuel pressure:
1. A pressure control valve combined with a metering unit on the high-pressure pump
1. A metering unit combined with a mechanical pressure relief valve at the end of the fuel rail
The pressure relief valve only opens when the fuel rail pressure rises above the maximum allowable pressure

All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

Image call-out
1. Fuel rail
1. Pressure relief valve
1. At the inlet
1. Fuel return line
1. Fuel rail pressure sensor
1. Fuel line to injector
Injector
The fuel is delivered to the injectors via the high-pressure lines. The injectors are fitted into the cylinder head with taper
locks. The injectors are sealed to the combustion chamber by copper gaskets. The injector incorporates the nozzle.

There are three types of injectors

1. Solenoid valve injectors with one-piece armature
1. Solenoid valve injectors with two-piece armature
1. Piezo injector

The fuel injector is an electronically controlled valve. The control unit determines the quantity of fuel required. A signal is
used to control the injection timing. The control unit sends a low-current signal to activate the injector. Solenoid valve
injector. Piezo injector. The piezo injector has fewer moving parts and less internal friction. The piezo injector can have high
needle speeds together with extremely small and precisely injected fuel quantities.

1. Solenoid

All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

1. Hydraulic control valve

1. Injector nozzles

1. Piezo actuator
1. Hydraulic coupling
1. Injector control valve
1. Injector nozzles
Diagnostics
Exhaust gas emissions have to fulfil increasingly higher standards. Additional software functions, like injector delivery
compensation, have been introduced. Each injector has different fuel injection characteristics. The engine control unit
compensates for these differences by adjusting the fuel injection duration for each injector separately. This is based on the
unique, 30-digit, alphanumeric compensation code. Injector compensation codes are printed on top of each injector.

After injector renewal. Reprogram the new compensation code into the engine control unit. To ensure that every cylinder
provides the same torque to the crankshaft: The smooth-running control adapts the injected fuel quantity per injector. If a
particular cylinder's speed is too low, the injected fuel quantity is increased and vice-versa. If one cylinder has a lower
torque than the others, its injector has a longer triggering period. The remaining cylinders receive a shorter injector-
triggering period. These deviations in the injection times can be read with a diagnostic tool. By comparing the readings with
the programmed values, any injectors not functioning correctly can be identified. The smooth-running control is limited to
the compensation value (Injector delivery compensation) and is make/type dependent. If the correction value is higher than
this limit, the torque of the specific cylinder will be insufficient. This causes poor running and reduced engine efficiency.

All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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VOLKSWAGEN Crafter CR28 2.5 TDI (BJM) 2006 - 2012 March 28, 2024

Repair Manuals

Poor engine performance. Possible cause: Injector programming failure.

After injector renewal. Reprogram the new compensation code into the engine control unit.

Cavitation. Local pressure variations may cause temporary vapour bubble formation. The vapour bubbles will then implode
in the subsequent high-pressure phase, causing cavitation damage to any surface they contact. Renew the components
which do not conform to specification.

Injector contamination. Fuel contamination can result in deposits on the injector nozzle. Increased resistance during nozzle
opening/closing. Solution: Clean the injectors.

Pressure relief valve contamination. Fuel contamination can result in deposits on the return valve. The outlet will not close
completely. The fuel rail pressure will not reach its maximum value. Solution: Clean the pressure relief valve.

Injector nozzles. Damaged injector nozzles due to worn metallic parts. or. Fuel with very low lubrication characteristics.
Renew the components which do not conform to specification.

All trademark names mentioned herein are for reference purpose only and are not intended to suggest any connection between HaynesPro and such
companies. All trademarks are the property of their respective owners.

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