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Crafter (2012)
Self Study Program
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Volkswagen Crafter (2012) Self Study Program

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Service Training
Self-Study Programme Technology 505
The Crafter 2012
Commercial
Vehicles
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The Crafter 2012 from Volkswagen Commercial Vehicles is a well known feature in its vehicle segment.
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It has set new benchmarks with its ingenious vehicle concept and wide range of models. The new 2.0 l 4-cylinder common rail engines are set to capture a leading position in terms of economy and reliability. Innovative technologies such as BlueMotion Technology and the start/stop system with energy recovery (recuperation) help to boost efficiency even more. The Crafter 2012 in the new brand design communicates high value and performance at first glance. It offers outstanding ergonomic features in a comfortable interior. The Crafter 2012 combines extraordinary functions with high utility value for an extremely wide range of applications. Every detail supports the driver in tackling the demands of his or her everyday job.
Its particular strengths are economy, comfort, driving properties as well as the wide range of variants.
The self-study programme presents the design and function of new developments! The content will not be updated.
Current testing, setting and repair instructions can be found in the provided service literature.
Important
note
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At a glance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Start/stop system in the Crafter 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Radio and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Introduction

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The Crafter 2012 in brand design

The newly designed front end of the new Crafter 2012 displays a powerful and self-assured appearance. The overall appearance is more slender, giving it an additionally dynamic appeal. The VW badges and letterings are adapted to the brand design.
Note the following features of the Crafter 2012:
• Wider radiator grille
• Continuous, one-piece trim in body colour
• New Volkswagen badges and letterings
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Features of body technology

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The new design of the Crafter 2012 means that changes to the body were necessary.
The front end of the Crafter 2012
The front end of the new Crafter 2012 has been adapted to the brand design.

Body

The radiator grille has been made wider and is now delimited by the headlights. There is a continuous trim fitted in the lower area. The lock carrier has been adapted to the modified attachments.
Attachment of the trim
Body
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Body
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Overview of galvanized components
Commercial vehicles are subject to elevated corrosion protection requirements during their tough everyday operation on construction sites and in haulage applications. The body structure of the Crafter 2012 has been further improved, in order to assist in achieving a long service life of the body. In particular, this includes galvanising additional surfaces of the body and the add-ons. The following graphics clarify which components in the new Crafter 2012 are galvanised in the open and closed designs.
Range of galvanised components in the closed design of the Crafter 2012
The closed design of the Crafter 2012 is used in the Crafter 2012 panel van or window van, for example.
Not galvanised
Electrolytically galvanised on one side
Electrolytically galvanised on both sides
Galvanised
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Range of galvanised components in the open design of the Crafter 2012
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The open designs have a single or double cab and are used as the body for the Crafter 2012 platform van, for example.
Not galvanised
Electrolytically galvanised on one side
Electrolytically galvanised on both sides
Galvanised
The illustrations of the galvanised components do not provide any information about the steel qualities used, but only about the galvanisation methods applied. For more information about the body of the Crafter 2012, please refer to Self-Study Programme 369 “The Crafter 2006”.
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Power units

The engine range of the Crafter 2012

The 2.0 l TDI engines of the Crafter 2012 are comparable with the 2.0 l engines in the Amarok and the Transporter T5. Following market launch, the Crafter 2012 will be available with four different engines:
- 2.0 l 80 kW TDI engine with turbocharger
- 2.0 l 100 kW TDI engine with turbocharger
- 2.0 l 105 kW TDI engine with biturbo unit
- 2.0 l 120 kW TDI engine with biturbo unit
For a certain period, the Crafter 2012 will continue to be offered with the 2.5 l 100 kW TDI engine in conjunction with Shiftmatic gearbox.
Common features of the 2.0 l TDI engines
The engines of the Crafter 2012 have the following features in common:
- Common rail injection system with solenoid valves
- Exhaust gas circulation through the cylinder head
- Controlled EGR cooling
- Piston with cooled ring groove
- Plastic suction pipe
- Diesel particulate filter (EU5)
- Subframe for holding optional ancillary units
What is EEV? EEV (Enhanced Environmentally Friendly Vehicle) is currently the strictest European exhaust standard for buses and trucks. These particularly environmentally friendly vehicles have emissions values that are well below those of the Euro 5 standard which came into force on October 2008 for all new buses and trucks.
yes: EU5
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Design 4-cylinder diesel engine
Cubic capacity 1968 cm
Bore 81 mm
Stroke 95.5 mm
Valves per cylinder 4
Compression ratio 16.0 : 1
Engine management EDC 17CP 20
Injection system Common rail
Diesel particulate filter no: EU4
change-over valve yes
Emissions standard EU4, EU5, EURO5, EEV
For more information about the technology of the 2.0 l diesel engines, refer to Self-Study Programmes 455 “2.0 l TDI engines in the T5 2010” and 463 “The Amarok 2011”.
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2.0 l TDI engines with turbocharger
s505_069
s505_025
1000 2000 3000 4000
40
70
100
130
160
190
220
250
280
310
[Nm]
[rpm]
[kW]
90
80
70
60
50
40
30
20
10
0
s505_026
1000 2000 3000 4000
40
70
100
130
160
190
220
250
280
310
[rpm]
90
80
70
60
50
40
30
20
10
0
[Nm]
[kW]
340
100
Technical features
• Exhaust turbocharger with variable turbine geometry (VTG exhaust tubocharger)
• At market launch of the Crafter 2012, available in two power levels with 80 kW and 100 kW
2.0 l 80 kW TDI engine
Technical data
Power and torque curve
Engine code CKTB
Max. power 80 kW at 3500 rpm
Max. torque 300 Nm at 1500
Turbocharging VTG exhaust turbocharger
2.0 l 80 kW TDI engine
Technical data
Engine code CKTC
Max. power 100 kW at 3500 rpm
Max. torque 340 Nm at 1576
Turbocharging VTG exhaust turbocharger
Power and torque curve
to 2250 rpm
to 2250 rpm
9
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Power units
s505_068
s505_027
1000 2000 3000 4000
40
70
100
130
160
190
220
250
280
310
[rpm]
90
80
70
60
50
40
30
20
10
0
[Nm]
[kW]
340
100
110
s505_028
1000 2000 3000 4000
100
130
160
190
220
250
280
310
340
370
[rpm]
110
100
90
80
70
60
50
40
30
20
[Nm]
[kW]
400
120
2.0 l TDI engines with bi-turbocharger
Technical features
• Bi-turbocharger with increased air flow volume
• At market launch of the Crafter 2012, available in two power levels with 105 kW and 120 kW
2.0 l 105 kW TDI engine
Technical data
Engine code CKUC
Max. power 105 kW at 3500 rpm
Max. torque 340 Nm at 1575
Turbocharging Bi-turbocharger
Power and torque curve
2.0 l 120 kW TDI engine
Technical data
Engine code CKUB
to 2250 rpm
Max. power 120 kW at 3600 rpm
Max. torque 400 Nm at 1800 rpm
Turbocharging Bi-turbocharger
Power and torque curve
10
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Engine technology of the 2.0 l TDI engines in the Crafter
s505_082
s505_083
2012
The design features and systems described below:
- Engine-mounted PTO
- Engine cooling system
- Exhaust gas recirculation system
- Fuel system are found on all four power variants of the 2.0 l TDI engine, and therefore apply both to engines with VTG exhaust turbocharger and to engines with bi-turbocharger.
Engine-mounted PTO
The ancillary unit carrier can be retrofitted, and in turn allows additional ancillary units to be fitted to all engine power levels. It is no longer necessary for this to be prepared at the factory. The ancillary units requested by the customer are installed by the service partner or a body
A spacer is mounted behind the large pulley of the ancillary unit drive.
manufacturer. The ancillary unit carrier is designed for various ancillary units.
Refer to the workshop manual regarding setting the timings in vehicles with an engine-mounted PTO.
11
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Power units
1
23
45
6
8
7
9
10
13
14
11
12
s505_035
The engine cooling system
The engine cooling system shown here is a simplified standard model of the cooling system of the Crafter 2012. The precise structure of the cooling system depends on the engine used as well as the equipment and thus the application of the Crafter 2012.
Expansion tank
1
Pump for exhaust gas recirculation cooler V400
2
Thermostat 1
3
Exhaust gas recirculation cooling bypass valve 2 N387
4
Exhaust gas recirculation cooling bypass valve N387
5
Coolant temperature sender G62
6
EGR cooler
7
Radiator
8
Radiator outlet coolant temperature sender G83
9
Coolant pump
10
Thermostat 2
11
Oil cooler
12
Coolant circulation pump V50
13
Heating heat exchanger
14
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Non-return valves and throttles in the cooling circuit
Choke
Non-return valves
s505_064
Non-return valves and throttles are used in the vent pipes within the cooling circuit. These purely mechanical components are permanently integrated in the hoses of the cooling system. The cooling system can no longer be bled If these components are missing or have been installed incorrectly.
Non-return valves
The non-return valves are intended to ensure that when the system is filled, the air escaping from the individual ventilation circuits cannot get into the other ventilation circuits. The direction of flow must always be towards the expansion tank. If the valves are installed the wrong way round, it will not be possible to fill the system properly.
Chokes
The chokes are used for reducing the coolant flow through the expansion tank. This means the necessary flow rate is reliably guaranteed in the main cooling circuit. Without chokes, the flow rate through the expansion tank would be too great, which could result in foaming of the coolant.
13
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Power units
s505_030
s505_029
Exhaust gas recirculation
All 2.0 l TDI engines of the Crafter 2012 have exhaust gas recirculation. A new feature is control of the cooling of the recirculated exhaust gas by means of a modified bypass structure.
Body
Intake air
1
Throttle flap
2
Exhaust gas recirculation valve N18
3
N345 change-over valve for cooler
4
of the exhaust gas recirculation
Radiator
5
EGR cooler
6
Exhaust gas recirculation cooling bypass valve N387
7
Exhaust gas recirculation cooling bypass valve 2 N387
8
Pump for exhaust gas recirculation cooler V400
9
Radiator outlet coolant temperature sender G83
10
Coolant temperature sender G62
11
Engine control unit J623
12
Exhaust
13
The exhaust gas recirculation cooler
The exhaust gas recirculation cooler of the 2.0 l TDI engine in the new Crafter 2012 does not have a built­in bypass which is opened and closed using a separate switching element.
The bypass function which continues to be required for cooling the recirculated exhaust gas is now achieved using the two exhaust gas recirculation cooling bypass valves N386 and N387.
This design measure simplifies the system structure of the exhaust gas recirculation.
14
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N386
V400
N387
s505_032
s505_031
V400
N386
N387
s505_034
s505_033
The exhaust gas recirculation cooling bypass valve N386
The exhaust gas recirculation cooling bypass valve N386 is mounted on the right of the radiator. It is a pneumatic 2/2-way valve with the two switching positions “open” and “closed”. It is controlled by the exhaust gas recirculation cooler change-over valve N345. It is open in the rest position. In this switching status, it allows coolant to flow from the radiator to the EGR cooler.
N386 and N387 must never be swapped over during repair work. Therefore, N387 has a grey housing and N386 has a black one.
The exhaust gas recirculation cooling bypass valve 2 N387
The exhaust gas recirculation cooling bypass valve 2 N387 is the counterpart to the valve N386. It is located above the radiator. It is closed in the rest position. In this switching status, it allows coolant to flow in from the cylinder head to the EGR cooler. Valve N387 is always controlled by the exhaust gas recirculation cooler change-over valve N345 so that it adopts the opposite switching status from that of the N386. If N386 is open, N387 must be closed. If N386 is closed, N387 must be open. This method achieves the bypass function for the exhaust gas recirculation cooler.
15
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Power units
s505_063
s505_058
Mode of function of the exhaust gas recirculation cooling
The cooling of the recirculated gases is controlled according to the coolant temperature which is measured by the engine control unit via the radiator outlet coolant temperature sender G83. Further influencing parameters are the outside temperature and the “Ignition on” and “Engine running” information.
Control intervention is performed by the two exhaust gas recirculation cooling bypass valves N386 and N387.
In a control cycle, it is possible to differentiate between the following three control statuses.
Control status 1
Condition:
- Coolant temperature is < 60 °C
- Outdoor temperature is > 17 °C
- Ignition is “on”
After the ignition has been switched on, the exhaust gas recirculation cooling bypass valve 2 N387 is opened by the engine control unit, and valve N386 is closed. The exhaust gas recirculation cooling is switched to “Warm supply”.
Engine control unit J623
1
Radiator outlet coolant temperature sender G83
2
Radiator
3
Thermostat 1
4
Coolant pump/water pump
5
Exhaust gas recirculation cooling bypass valve N387
6
Exhaust gas recirculation cooling bypass valve 2 N387
7
N345 change-over valve for cooler
8
of the exhaust gas recirculation
Pump for exhaust gas recirculation cooler V400
9
Thermostat 2
10
Coolant temperature sender G62
11
EGR cooler
12
16
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s505_059
s505_060
Control status 2
Condition:
- Coolant temperature is < 60 °C
- Outdoor temperature is > 17 °C
- Engine running
After the engine starts, the exhaust gas recirculation cooling remains set to “Warm supply” until the coolant temperature reaches 60 °C. The electric pump for exhaust gas recirculation cooler V400 is activated and is operating continuously. The switching status of both valves remains unchanged.
Control status 3
Condition:
- Coolant temperature is > 60 °C
- Outdoor temperature is > 17 °C
- Engine running
If the coolant temperature rises above 60 °C, valve N387 is closed and valve N386 is opened. The pump for exhaust gas recirculation cooler V400 now supplies the coolant from the radiator.
The system is now in “Cold supply”.
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Power units
Practical notes on troubleshooting
Diagnostic capability of the pneumatic switch elements Exhaust gas recirculation cooling bypass valve N386 and N387
It is possible to check the function of valves N386 and N387 by electronic diagnosis, even if these are not electrically activated but are actuated by the vacuum system. By evaluating the temperature sensor G83 and G62, it is possible to draw conclusions about the function of the corresponding mechanical components.
Component
Fault code
Fault description
Notes on troubleshooting
N386 Exhaust gas recirculation cooling change-over valve
P30D500
Exhaust gas recirculation cooling bypass valve 2 malfunction
Depending on the EGR cooler temperature, the engine control unit demands a changeo­ver of the bypass valves to the low tem­perature circuit. As a result, the temperatures at the radiator outlet coolant temperature sender must change accordingly.
If the expected temperature is not reached within the desired time window then the fault is set.
- Defective vacuum hoses to the valves.
- Valve sticking in the low temperature circuit (N386); Actuator test: Use the exhaust gas recirculation cooler change-over valve in order to check the valve switching by a finger test.
- Rule out the possibility that valve 1 (N386) and valve 2 (N387) are swapped over, by checking the part numbers and colour coding.
N387 Exhaust gas recirculation cooling change-over valve
P30D600
Exhaust gas recirculation cooling bypass valve 2 malfunction
Depending on the EGR cooler temperature, the engine control unit demands a changeover of the bypass valves to the high temperature circuit. As a result, the temperatures at the radiator outlet coolant temperature sender must change accordingly.
If the expected temperature deviates from the measured temperature then the fault is set.
- Defective vacuum hoses to the valves.
- Valve sticking in the low temperature circuit (N387); Actuator test: Use the exhaust gas recirculation cooler change-over valve in order to check the valve switching by a finger test.
- Rule out the possibility that valve 1 (N386) and valve 2 (N387) are swapped over, by checking the part numbers and colour coding.
18
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The fuel system of the Crafter 2012
s505_044
A Bosch common rail injection system is installed in the Crafter 2012. Depending on the operating status, the injection pressure is 230 to 1800 bar. Solenoid valve injectors are used for the fuel injection. There is no electric heating of the fuel filter in the fuel preheating. The fuel preheating is achieved by the warm fuel from the return flow.
Key
G6
G81
G247
N30
N31
N32
N33
N276
N290
Fuel system pressurisation pump
Fuel temperature sender
Fuel pressure sender
Injector, cylinder 1
Injector, cylinder 2
Injector, cylinder 3
Injector, cylinder 4
Fuel pressure regulating valve
Fuel metering valve
1
2
3
4
5
High-pressure fuel pump
Choke
Fuel filter
Fuel tank
High-pressure accumulator (fuel rail)
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Power units
F36 Clutch pedal switch
F71 Clutch pedal switch for
stop/start system
G28 Engine speed sender
G31 Charge air pressure sender G42 Intake air temperature sender
G39 Lambda probe
G40 Hall sender
G62 Coolant temperature sender
G69 Throttle valve potentiometer
G70 Air mass meter
G79 Accelerator position sender G185 Accelerator position sender 2
G71 Intake manifold pressure sender
G81 Fuel temperature sender
G83 Coolant temperature sender on the
radiator outlet
G212 Exhaust gas recirculation potentiometer
G235 Exhaust gas temperature sender 1
G247 Fuel pressure sender
G266 Oil level and oil temperature sender
G495 Exhaust gas temperature sender 3
G581 Position sender for charge pressure
positioner
G648 Exhaust gas temperature sender 4
J623
Engine control unit
G450 Exhaust gas pressure sensor 1
System overview for 2.0 l TDI engines with VTG turbocharger
20
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J17 Fuel pump relay G6 Fuel system pressurisation pump
J338 Throttle valve module V157 Intake manifold flap motor
J179 Automatic glow period control unit Q10-Q13 Glow plugs 1 - 4
N18 Exhaust gas recirculation valve
N30- N33 Injectors, cylinders 1 - 4
N75 Charge pressure control solenoid valve
N79 Heater element for
crankcase breather (cold country only)
N276 Fuel pressure regulating valve
N290 Fuel metering valve
N345 Exhaust gas recirculation cooler
change-over valve
V50 Coolant circulation pump
V400 Coolant circulation pump
Z19 Lambda probe heater
J285
Control unit in dash panel insert
K29
Glow period warning lamp
K83
Exhaust emissions warning lamp
K231
Diesel particulate filter warning lamp
J17
J179
s505_052
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Power units
F36 Clutch pedal switch
F71 Clutch pedal switch for
stop/start system
G28 Engine speed sender
G31 Charge air pressure sender G42 Intake air temperature sender
G39 Lambda probe
G40 Hall sender
G62 Coolant temperature sender
G69 Throttle valve potentiometer
G70 Air mass meter
G79 Accelerator position sender G185 Accelerator position sender 2
G71 Intake manifold pressure sender
G81 Fuel temperature sender
G83 Coolant temperature sender on the
radiator outlet
G212 Exhaust gas recirculation potentiometer
G235 Exhaust gas temperature sender 1
G247 Fuel pressure sender
G266 Oil level and oil temperature sender
G447 Charge pressure sender 2
G495 Exhaust gas temperature sender 3
G584 Regulating flap potentiometer
G648 Exhaust gas temperature sender 4
J623
Engine control unit
G450 Exhaust gas pressure sensor 1
System overview for 2.0 l TDI engines with bi-turbocharger
22
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J17 Fuel pump relay G6 Fuel system pressurisation pump
J338 Throttle valve module V157 Intake manifold flap motor
J179 Automatic glow period control unit Q10-Q13 Glow plugs 1 - 4
N18 Exhaust gas recirculation valve
N30- N33 Injectors, cylinders 1 - 4
N75 Charge pressure control solenoid valve
N79 Heater element for
crankcase breather (cold country only)
N276 Fuel pressure regulating valve
N290 Fuel metering valve
N345 Exhaust gas recirculation cooler
change-over valve
V50 Coolant circulation pump
V400 Coolant circulation pump
Z19 Lambda probe heater
J285
Control unit in dash panel insert
K29
Glow period warning lamp
K83
Exhaust emissions warning lamp
K231
Diesel particulate filter warning lamp
J17
J179
N220 Exhaust flap valve
s505_053
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Start/stop system in the Crafter 2012

s505_036
s505_054

The start/stop system with recuperation and energy management

An effective measure to reduce consumption and, with it, CO2 emissions, is to switch off the internal combustion engine automatically when the vehicle is stationary; the engine is restarted automatically only when required. The start/stop system in the Crafter 2012 has been expanded for all four power variants of the 2.0 l TDI engine.
The start/stop system in the Crafter 2012 comprises the following functions:
- Start/stop function
- Energy management
- Recuperation function
The start/stop function is activated automatically when the ignition is switched on.
Deactivation by the driver:
When the start/stop function is active, it can be switched off manually by pressing the engine start/ stop button in the control unit for middle of dash panel J819.
Activation by the driver:
If the start/stop function has been switched off, the function can be activated by the driver by once again pressing the engine start/stop button in the control unit for middle of dash panel J819. The display of system messages distinguishes between the Lowline and Highline equipment of the instrument cluster (control unit for dash panel insert).
Display of the start/stop function in Lowline equipment (top) and Highline equipment (bottom) of the instrument cluster
24
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s505_037
s505_073
Battery regulation control unit J840
The battery regulation control unit under the driver seat
The battery regulation control unit is located in the substructure of the seat on the driver side.
It is clipped into a holder on the base of the seat substructure. It forms the interface to the vehicle electrical system, and coordinates the energy management. J840 has the following tasks:
- Assessment of electrical power requirement in the vehicle electrical system
- Processing of the alternator load signal and controlling the alternator via LIN data bus
- Evaluating the battery status information from the battery monitor control unit J367
- Requesting the engine start due to elevated electrical power consumption when the start/stop function is active
In vehicles with a Lowline instrument cluster, a start request by the energy management is indicated by the battery symbol flashing on the instrument cluster after the start/stop symbol has gone out. Here too, there is also a gong sound.
A detailed list of the necessary operating conditions for the start/stop function and information on operating the start/stop function can be found in the owner's manual of the Crafter 2012 as well as in Self-Study Programme 426 “The start/stop system 2009”.
Energy management
If a manual engine start is necessary in stop mode due to the energy management of the vehicle electrical system then a prompt for manual engine start is displayed for the driver on the multifunction display of the instrument cluster (Highline only). In addition, a gong sounds as an acoustic signal as well.
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Start/stop system in the Crafter 2012
s505_038
s505_050
Battery monitor control unit J367
The battery monitor control unit is connected to the battery instead of the battery earth strap. It is mounted on the negative battery terminal and is connected to the battery regulation control unit together with the alternator via LIN bus. The battery monitor control unit has a built-in resistor (shunt) located between the negative battery terminal and the earth cable, and therefore registers the entire battery current.
The control unit supplies the following information:
- Instantaneous charge status of the vehicle electrical system battery
- Instantaneous battery voltage
- Instantaneous battery current
- Instantaneous battery temperature
Voltage stabiliser J532
The voltage stabiliser is a DC/DC voltage converter.
DC/DC (DC = Direct Current) means converting direct current into direct current. It is located under the cover of the fuse box on the left-hand side of the body. The high current consumption of the starter means there is a voltage dip in the vehicle electrical system voltage every time the engine starts. In order to avoid cut-outs of the infotainment components, the roof electronics and the digital tachograph when the engine is restarted, the electrical power supply to the engine is stabilised by J532 during the engine restart.
The battery monitor control unit on the negative terminal of the vehicle electrical system battery.
26
The voltage stabiliser
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An AGM battery is used as the starter battery in the Crafter 2012 with BlueMotion Technology.
s505_039
(AGM = absorbent glass mat) Optionally, a wet battery is fitted as a second battery. Please bear the following aspects in mind when recharging or jump-starting: As far as the negative terminal is concerned, the charging cable is not allowed to be connected directly to the negative terminal of the battery. Make the connection exclusively to the body earth. This ensures that the battery monitor control unit is not bypassed.
Advanced features of the start/stop function
Driver detection
For safety reasons, it is essential for the presence of the driver to be detected without ambiguity in order to achieve an automatic engine stop as part of the start/stop function, and for the engine to be restarted. An engine stop is only performed if the driver has his or her seat belt fastened, and the vehicle doors are closed.
The following behaviour applies in stop mode:
If the driver unfastens his or her seat belt or if the tailgate or one of the doors is opened then the engine control unit deactivates the start/stop function. The engine can be started manually all the same.
Deactivated start/stop function in the Highline display
If the time period of 30 seconds is exceeded, the engine control unit switches the start/stop function off. The engine can now only be started manually. If the driver is unambiguously detected as being present again within 30 seconds then the engine control unit activates the start/stop function again, which means the engine can once again be started automatically.
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Start/stop system in the Crafter 2012
Charge voltage
s505_024
Charge voltage
s505_023
Recuperation
Recuperation is a technical process of energy recovery. An interplay between various vehicle systems achieves a reduction in fuel consumption by means of recuperation. The following functions are required for this:
- Alternator control
- Registering the battery status
- Registering the energy requirement in the vehicle electrical system
- Registering the current engine operation
This is how it works
The battery regulation control unit J840 specifies a nominal voltage for the alternator when the engine is running, via the LIN interface. This nominal voltage depends, amongst other things, on the energy requirement in the vehicle electrical system, the status of the battery (temperature, charge status) and the requirements of the engine control unit.
The engine control unit J623 calculates a recommendation for a voltage increase or reduction of the alternator, and sends this recommendation to the battery regulation control unit via the CAN data bus. This then specifies a corresponding nominal voltage for the alternator.
Reduction in the alternator voltage: A voltage reduction leads to a reduction in the power output of the alternator, and therefore a lower fuel consumption.
Increase in the alternator voltage: A voltage increase results in an increase in the power output of the alternator, and is preferably requested in operating phases with low specific fuel consumption. The lowest fuel consumption is achieved during deceleration or braking, by means of the overrun cut-off.
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Radio and navigation

s505_045
s505_046

The range of equipment

At present, the following radios and navigation units are available for the Crafter 2012:
- RCD 2001 radio
- RCD 3002 radio
- RCD 4002 radio
- RNS 4010 navigation unit
- RNS 5010 navigation unit
The Crafter 2012 is designed for the new generation of radio and navigation units, therefore the MOST data bus has been discontinued. Connecting an external CD changer or an external telephone control unit via MOST data bus is not necessary, because of the new unit functions.
RCD 2001 radio
•1-DIN radio
• AM/FM single tuner
•Single CD player
• MP3/WMA-capable
RCD 3002 radio
• 5-inch colour display
• AM/FM single tuner
•Single CD player
• MP3/WMA-capable
• Internal Bluetooth telephony
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Radio and navigation
s505_047
s505_048
s505_049
RCD 4002 radio
• 5-inch colour display
• AM/FM single tuner
•CD player
•6 CD changer
•MP3/WMA-capable
• Internal Bluetooth telephony
Navigation unit RNS 4010
• 5-inch colour display
• AM/FM double tuner
• 6 DVD changer
•MP3/WMA-capable
• Internal Bluetooth telephony
•Arrow navigation
Navigation unit RNS 5010
• 6.5-inch colour display
• AM/FM double tuner
• Internal hard disk
• 6 DVD changer
•SD card reader
•MP3/WMA-capable
• Internal Bluetooth telephony
• Video input
• Music database
•Map navigation
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Unit connections, taking the example of the RNS 5010:
AM/FM, FM2
1
video
2
GPS
3
Bluetooth
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MOST databus
5
Unit connections
The two navigation units RNS 4010 and RNS 5010 have an AM/FM double tuner. Only one AM/FM aerial is installed in the Crafter 2012 for the radio reception. This means no aerial diversity or phase diversity is possible. As a result, the two aerial inputs AM/FM1 and FM2 are connected via an aerial splitter. On the rear of the unit, there is also a connection for an external Bluetooth aerial. The possibility of a MOST databus connection on the unit is not used for the Crafter 2012.
The aerial splitter behind the radio installation frame
The aerial splitter
The Crafter 2012 has an aerial splitter for connecting radio and navigation units with a double tuner. It is located behind the radio installation frame and makes it possible to connect the two aerial inputs AM/ FM1 and FM2.
By means of the aerial splitter, the unit can search in the background for alternative reception frequencies of the same station.
Bluetooth aerial
The Bluetooth aerial is installed in all radio and navigation units with internal telephone function outside the unit. It is attached to the centre dash panel (right air nozzle) by means of an adhesive pad on the rear of the air nozzle.
The Bluetooth aerial on the heating duct to the right air nozzle
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Radio and navigation
2
1
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a
s505_065
s505_079

Telephone preparation

The mobile phone preparation is available in various versions:
- for vehicles without radio
- for vehicles with radio preparation
- for vehicles with RCD 2001 radio
- for vehicles with RCD 3002 or RCD 4002 radio
- for vehicles with RNS 4010 or RNS 5010 radio/navigation system
The mobile phone preparation for vehicles for vehicles without radio or with radio preparation (Fig. a) consists of a cradle on the dash panel. It has a Bluetooth hands-free device, a built-in amplifier and an external microphone for the hands-free device.
The amplifier is connected to the standard loudspeakers at the front. There is no separate control unit for the telephone, the necessary electronics are installed in the cradle. Operation is by means of the cradle. This hands-free device is also suitable for audio streaming.
Start call
1
Volume louder (+) / quieter (-)
2
End call
3
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The mobile phone preparation for vehicles with radio RCD 2001 (Fig. b) consists of the cradle on the dashboard which has a Bluetooth hands-free device as well as an external microphone for the hands-free device. There is no separate control unit for the telephone, the necessary electronics are installed in the cradle. In this variant, voice reproduction is amplified by means of the radio. This hands-free device is also suitable for audio streaming.
Start call
1
Quick dial
2
Breakdown call
3
End call
4
The mobile phone preparation for the radios RCD 3002 and RCD 4002 as well as for radio/navigation systems RNS 4010 and RNS 5010 is completely built into the radio. Only the microphone for the hands-free device is fitted outside the radio in these units. There is no separate control unit for the telephone. This mobile phone preparation has a Bluetooth hands-free device. For communication between the mobile phone and the radio/radio/navigation system, these units have a Bluetooth aerial connected on the rear of the unit. This hands-free device is not suitable for audio streaming.
33
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© VOLKSWAGEN AG, Wolfsburg All rights reserved. Subject to technical modifications.
000.2812.62.20 Technical status 09/2011
Volkswagen AG After Sales Qualifizierung Service Training VSQ-1 Brieffach 1995 D-38436 Wolfsburg
❀ This paper was manufactured using pulp bleached without the use of chlorine.
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