Volkswagen Crafter

VW Crafter van

The VW Crafter is a van from Volkswagen, which is being build since 2006. Like its predecessor, VW LT (2nd generation ), it is identical to the Mercedes -Benz Sprinter and is - also produced with this in the works of Ludwig field and Dusseldorf - until 2016. On September 6, 2013, Daimler announced that co-operation will not continue after the expiry of the contract with VW, as these capacities would be needed for the Sprinter.

Technically, the Crafter, except for the built-in drive motors with the Sprinter is almost identical, while the optical similarities to the vehicle's front end. The VW Crafter has a large grille and unlike the Sprinter stacked twin headlights. This design is strongly reminiscent developed by VW in Brazil Trucks VW Constellation.

The Crafter is produced as the Sprinter in three wheelbases, four load compartment lengths and three roof heights. For the first time Volkswagen comes standard with a particulate filter and common rail injection in the engines ( 65 kW/89 hp and between 120 kW/163 hp). The revision of the already well-known 2.5 -liter engines were made jointly with Mercedes -Benz.

• 3.1 Engine Technology
• 3.2 lubrication
• 3.3 Cooling

• 4.1 Fuel Supply
• 4.2 common-rail injection
• 4.3 turbocharger
• 4.4 emission
• 4.5 Exhaust gas recirculation
• 4.6 Engine preheater

• 5.1 6 -speed manual transmission
• 5.2 Shiftmatic (SMC )

• 6.1 Power supply
• 6.2 lighting
• 6.3 Special Features

• 7.1 seats
• 7.2 occupant protection

Variants

Landing gear

The chassis corresponds substantially to that of the second generation VW LT, but has been revised in some details.

Front

The front wheels are independently suspended from damper struts and wishbones. The Crafter now has 16 "wheels and a wider track. The leaf spring transverse to its predecessor consists of GRP and thus has a lower weight with improved stabilization assets. As standard, the Crafter now also a stabilizer. The axis was acoustically decoupled from the vehicle body with rubber bearings. The ride was slightly understeer designed to neutral.

Rear axle

The rigid rear axle is guided on two longitudinally-mounted leaf springs. In the variants van or station wagon in the build oversized rubber bearing is acoustically decoupled. The suspension tuning was improved and the shocks have been moved slightly further outward to better counteract the dangerous body roll such as during fast lane changes. When Crafter 50, a stabilizer is fitted as standard, the Crafter 35 available at extra cost.

Tyres

The Crafter 30 has standard 205/75R16C-Reifen to 5.5 Jx16 H2 rims. The tire size 235/65R16C rim with 6.5 Jx16 -H2 heard the Crafter 35 standard equipment and is available as an optional extra for the Crafter 30. At the rear of the Crafter 50 there are twin wheels in size 195/75R16C or 205/75R16C on rim 5.5 Jx16 -H2. The Crafter 50 can be equipped with twin tires instead with the so-called super-single tires. Here, the total weight is lowered to 4.6 t. The high load index of 128 corresponds to a maximum tire load capacity of 1800 kg. The top speed is limited to 140 km / h. The advantage lies in a lower rolling resistance and the smaller wheel arches.

Brake system

The car has disc brakes on the front and rear axle, the front and from the Crafter 50 and the rear are ventilated. As with the LT2 is the parking brake from a small, integrated into the rear brake drum brake. The hydraulic dual-circuit system with diagonal split hydraulic brake assist and be assisted by a pneumatic 10 " brake booster. As standard, the Crafter with ABS, ASR traction control and an electronic stability program ESP equipped. Here is the latest generation of Bosch, which takes into account the vehicle load its control characteristics.

Steering

To achieve a high level of comfort, a hydraulically assisted rack- and-pinion steering is fitted. The steering column is designed telescoped for better crash safety and can be adjusted in height and angle as an option. The steering lock is no longer as hitherto constructed purely mechanical, but is locked by the electromechanical ignition lock with a servomotor.

Drive units

Engine technology

The aggregates used in the Crafter series based on the five-cylinder engine already used in the VW Transporter and VW LT 2 with a displacement of 2.5 liters. In contrast to the left-handed 4 - and 6- cylinders of the Sprinter 5-cylinder of the crafters are like all older Audi/VW-5-Zylinder dextrorotatory. To improve the smoothness and to the new strict emissions standards to take account of a common-rail fuel injection and a particulate filter, however, are now installed. The engines are mounted longitudinally in the direction of travel Crafter. A reinforced toothed belts used for driving the camshaft, the high pressure and the coolant pump. He has a change interval of 200,000 km. The six -bearing crankshaft is drop forged in a housing made ​​of gray cast iron with lamellar graphite. She now has thicker crank pins to accommodate the torsional forces better.

The aluminum alloy pistons, as well as the previous models, an asymmetric piston bowl for better turbulence of the fuel injected. To increase the stability of the compression was reduced by a slightly larger piston bowl compared to previous models. In addition, the pistons are compared with the previous models, strengthened and equipped with Trapezpleueln. As with all other VW TDI engines also here the piston crowns are additionally cooled by oil jets from below. The new five-layer metal head gasket allows for better sealing of the combustion chambers, both with each other and to the outside. The engine accessories such as the alternator, refrigerant compressor, hydraulic pump and radiator fan are driven by a wedge -ribbed belt.

Lubrication

The oil circulation is ensured by a front seat on the crankshaft crescent pump. An internal pressure relief valve protects the pump and motor from a possibly too high oil pressure. The oil filter module with paper insert is standing sideways flanged to the engine block. For the cylinder head oil pressure control valve is provided, which protects at sedimenting oil pressure still ensures a residual lubrication and as the bearing of the cam shaft against damage. The amount of oil in the engine is about 9 liters.

Cooling

For circulating the cooling medium via the toothed belt a driven coolant pump is used. In addition, to prevent an accumulation of heat when the engine is an electrically operated pump; she also takes on the function of the residual engine heat utilization. Here, using a button in the heating regulation, the vehicle heating even after the engine has stopped, depending on the outside temperature, can be used for a further 20 minutes. The flow through the radiator is controlled by an expansion thermostat. About the cooling system of the cooler for exhaust gas recirculation and the engine oil cooler is additionally cooled.

Fuel system

Fuel supply

The plastic fuel tank is an electric feed pump for continuous fuel delivery. From there, the mechanically driven high-pressure pump is supplied via the fuel filter and the fuel reservoir. This provides the necessary pressure for injection. The fuel filter has an electrical heater that at low ambient temperatures to prevent the formation of wax crystals and therefore the clogging of the filter. Of the injectors are not needed, fuel is supplied again to a pressure-holding valve and a return line to the fuel tank.

Common - rail injection

The piezoelectric injectors that operate at a maximum pressure of 1600 bar, allowing multiple pre-and post-injections, and thus a low-noise and low-emission engine running. The injection is controlled by a Bosch EDC 16C system (Electronic Diesel Control ).

Turbocharger

The exhaust gas turbocharger with adjustable guide vanes is controlled by a vacuum unit. From the engine control unit that the optimum charge pressure is adjusted depending on the load condition. Also the maximum charging pressure is limited by the control unit. Since the air in the turbocharger heats him an intercooler downstream.

Emission control

The exhaust gases are cleaned with a particulate filter. In this oxidation catalyst and particulate filter are combined into one unit and placed directly behind the turbocharger. So one up faster and optimal recovery is possible. The use of an additive is not necessary here. The engine is operated mostly in the part-load range, the filter is regenerated by raising the exhaust gas temperature.

Exhaust gas recirculation

Even the Crafter exhaust gas recirculation (EGR) system is installed to reduce nitrogen oxide emissions. Here, a part of the exhaust gases is supplied to the combustion process again, which reduces the oxygen content of the mixture. Thereby, the combustion slows down and the combustion chamber temperature can be reduced. This is supported by the EGR cooler. The EGR valve is actuated electrically in Crafter and can better control the amount of recirculated exhaust gas. A sensor installed in front of the particulate filter, a lambda probe for determining the residual oxygen content is used in the exhaust gas. Before the EGR valve electrically actuated intake manifold is used, which can reduce the amount of air drawn if necessary. This is the engine shut down and the regeneration of the particle filter requires and supports the exhaust gas recirculation.

Engine preheater

The Schnellstartglühanlage with ceramic glow makes an immediate start at temperatures down to -24 ° C. The control device supplies the glow plug with a time-shifted pulse-width- modulated current, in order to relieve the electrical system. It monitors each glow plug and signals faults in the system by the warning lamp annealing time.

Power transmission

All gear types used in the Crafter developed by Daimler -Benz.

6 -speed manual transmission

6- speed manual transmission standard used in three-shaft design in the Crafter, which pass through a multi-piece propeller shaft, the force at the rear axle. The transmission having a housing made of die-cast aluminum is available in two variants for a maximum torque of 330 Nm or 350, with the more powerful variant is used in the 120 - kW motor. The circuit is operated by cables with a joystick -like lever in the control panel. For special structures ( dump truck, crane, tow truck etc.) from the driving position switchable PTO is available. Permanently may also be provided at an engine speed of 1200 rpm, a power of 28 kW and a torque of 140 Nm. Subsequent installation in a standard transmission is not possible.

Shiftmatic (SMC )

To improve comfort and to relieve the driver of the Crafter as an option with the automated manual transmission Shiftmatic (SMC ) can be provided. This is available from 80 kW and the 100 kW engine. The internal structure essentially corresponds to that of the 6-speed manual transmission. The gears can be manually switched to one by tapping the joystick or automatically. Although a conventional single-plate dry clutch is installed, eliminating the clutch pedal in this gear. The clutch and the individual gears are hydraulically operated and monitored by the gearbox control unit. The Shiftmatic has its own hydraulic pump, an accumulator, a hydraulic control unit and a separate hydraulic oil supply. In case of failure of individual components an emergency program is activated and switched off the automatic mode. There is only manual shifting up to third gear possible. The transmission fluid must be replaced after ten years or 320,000 kilometers.

Electrical System

When Crafter the individual control units are networked via CAN - and MOST bus systems.

Power supply

Optionally two batteries concept is possible in which a second battery for auxiliary components is installed. The decoupled via an interface relay starter battery is so relieved. A special feature is that the starter battery is installed under the footwell on the driver's side and the auxiliary battery is in the engine compartment. Jump-starting the engine, a positive pole terminal is provided in the vicinity of the air filter.

Lighting

Central control unit of the main functions is the onboard supply control unit. The light switch is on the data bus only switching commands to this control unit. An optional automatic headlights and daytime running lights are available. The warning system as that of the car models a lane change function in which a single tap of the turn signal switch has a three times flashing of the direction indicators result. Event of an accident, the airbag has been triggered, automatically turns on the hazard warning flashers.

Special Features

For the crafter a lot of additional equipment is available:

• Rain sensor
• Heated windscreen
• Central
• Anti-theft alarm system with interior monitoring and tow-away protection
• Parking sensors
• Tire pressure monitoring system
• Radio and navigation systems
• Phone
• Tachograph
• Radio
• Cruise control
• Heater
• Automatic
• Heated seats
• Reversing camera

Body

The Crafter has in the box and combi versions of a self-supporting all -steel body with an integral structure. Compared to the LT, the design is improved in some detail in order to optimize the stability and crashworthiness. Thus, the columns were strengthened and laser soldering and welding processes are used. Some parts may be connected by gluing process with each other to increase the torsional stiffness. The longitudinal beams have energy-absorbing deformation elements, which absorb the impact force during a frontal crash.

Seats

Driver and passenger seat are equipped with three- point safety belts with force limiters. The passenger seat can be fitted as optional with a double seat. The station wagon was in the passenger compartment two rows of seats with double bench, the third seat has three positions. Are located on all seats, 3- point seat belts, on request, the two-seater benches can be fitted with Isofix mountings for child seats.

Occupant protection

The soil structure has been strengthened compared to LT, to better protect the passengers. A standard driver's airbag is mounted in the Crafter, front passenger and head airbag is available as an optional extra. For the cab there are pyrotechnic belt tensioners.