Engineering:Volkswagen Crafter

Short description: Van manufactured by Volkswagen

Volkswagen Crafter
Overview
Manufacturer	Volkswagen Commercial Vehicles
Also called	MAN TGE Volkswagen Grand California Torsus Terrastorm
Production	2006–present
Assembly	From 2016: Poland, Września (Volkswagen Poznań Sp. z o.o., Września Plant) Previously: Germany, Düsseldorf (Daimler AG Werk Düsseldorf) Germany: Ludwigsfelde (Mercedes-Benz Ludwigsfelde)
Designer	Laurent Boulay
Body and chassis
Class	Light commercial vehicle (M)
Body style	Panel van Minibus Double cab Chassis cab
Layout	FF layout FR layout
Platform	MNB (Modular Light Commercial Vehicle platform) Second generation
Related	Mercedes-Benz Sprinter (First Gen)
Powertrain
Engine	2.0 L I4 TDI with DPF 2.5 L I5 TDI with DPF
Electric motor	100 kW (136.0 PS; 134.1 hp) synchronous permanent magnet AC motor
Transmission	6-speed manual 6-speed Shiftmatic automatic 8-speed Aisin automatic (FWD models)
Dimensions
Wheelbase	SWB: 3,250 mm (128.0 in) MWB: 3,665 mm (144.3 in) LWB: 4,325 mm (170.3 in)
Length	Chassis Double Cab LWB: 6,680 mm (263.0 in) 6,840 mm (269.3 in) 6,845 mm (269.5 in) Chassis Double Cab MWB: 5,870 mm (231.1 in) 6,085 mm (239.6 in) 6,140 mm (241.7 in) Chassis Double Cab SWB: 5,305 mm (208.9 in) 5,560 mm (218.9 in) Chassis Single Cab LWB: 6,680 mm (263.0 in) 6,845 mm (269.5 in) 6,930 mm (272.8 in) Chassis Single Cab MWB: 5,870 mm (231.1 in) 6,020 mm (237.0 in) 6,085 mm (239.6 in) Chassis Single Cab SWB: 5,305 mm (208.9 in) 5,570 mm (219.3 in) LWB: 7,345 mm (289.2 in) 6,940 mm (273.2 in) MWB: 5,910 mm (232.7 in) SWB: 5,245 mm (206.5 in)
Width	Vans: 1,993 mm (78.5 in) Pickup Trucks: 2,426 mm (95.5 in) 2,682 mm (105.6 in)
Height	Chassis Double Cab LWB: 2,420 mm (95.3 in) 2,405 mm (94.7 in) Chassis Double Cab MWB: 2,440 mm (96.1 in) 2,425 mm (95.5 in) Chassis Double Cab SWB: 2,365 mm (93.1 in) (also Chassis Single Cab SWB) 2,380 mm (93.7 in) Chassis Single Cab LWB: 2,385 mm (93.9 in) 2,395 mm (94.3 in) Chassis Single Cab MWB: 2,410 mm (94.9 in) 2,400 mm (94.5 in) LWB: 3,055 mm (120.3 in) (with roof) 3,050 mm (120.1 in) (with roof) 2,715 mm (106.9 in) 2,825 mm (111.2 in) 2,820 mm (111.0 in) MWB: 2,720 mm (107.1 in) (with roof) 3,050 mm (120.1 in) (with roof) 2,820 mm (111.0 in) (with roof) 2,435 mm (95.9 in) 2,535 mm (99.8 in) SWB: 2,435 mm (95.9 in) 2,725 mm (107.3 in) (with roof)
Chronology
Predecessor	Volkswagen Transporter LT

The Volkswagen Crafter, introduced in 2006, is the largest three- to five-ton van produced and sold by the Germany automaker Volkswagen Commercial Vehicles. The Crafter officially replaced the Volkswagen Transporter LT that was launched in 1975, although it is known as the LT3, its production plant code.

Like the second-generation LT, the first-generation Crafter is a rebadged Mercedes-Benz Sprinter, built by Daimler AG, with a powertrain by Volkswagen. The Daimler variant has been also sold by Daimler as the Freightliner Sprinter and Dodge Sprinter. An all-electric variant, the e-Crafter, was released in 2017.

Starting with the 2017 model year, the Crafter has been designed and built by Volkswagen, and no longer associated with the Sprinter. A version of the Crafter is also sold by MAN Truck & Bus as the MAN TGE.

First generation (Typ 2E/2F, 2006–2017)

Production plants

The first-generation Crafter was built in the Mercedes-Benz Ludwigsfelde and Düsseldorf plants, the same German factories where the Mercedes-Benz Sprinter is built.

Design

France car designer Laurent Boulay is responsible for the frontal design of the Crafter, which takes cues from the Volkswagen Constellation.

Engines

From launch in 2006 up to 2010, all internal combustion engines were based upon Volkswagen Group's re engineered 2.5 litre R5 TDI. This turbodiesel is an inline five-cylinder (R5) Turbocharged Direct Injection (TDI) diesel engine.

It displaces 2,459 cubic centimetres (150.1 cu in), and uses what was the latest common rail fuel system, with piezoelectric actuated injectors for the cylinder-direct fuel injection. It also utilises a diesel particulate filter (DPF), allowing all engine variants to comply with Euro IV European emission standards.

The 2010 version of the 2.5 TDI CR engine was redesigned, correcting the previous problems of turbo failure. An engine update was also released under the guise of "Blue TDI", which used AdBlue – or diesel exhaust fluid (DEF) – in combination with a DPF to attain the more stringent Euro V EEV European emission standards.

Engines (2006–2011)
Model	Engine type	Power	rpm	Torque	rpm	European emission standards
2.5 TDI CR	2,459 cc (150 cu in) I5 turbo	88 PS (65 kW; 87 hp)	3500	220 N⋅m (162 lb⋅ft)	2000	Euro 4
		88 PS (65 kW; 87 hp)	3300	250 N⋅m (184 lb⋅ft)	1900–2300	Euro 5 EEV
		109 PS (80 kW; 108 hp)	3500	280 N⋅m (207 lb⋅ft)	2000	Euro 4
		109 PS (80 kW; 108 hp)	3300	300 N⋅m (221 lb⋅ft)	1900–2300	Euro 5 EEV
		136 PS (100 kW; 134 hp)	3500	300 N⋅m (221 lb⋅ft)	2000	Euro 4
		136 PS (100 kW; 134 hp)	3500	330 N⋅m (243 lb⋅ft)	2000	Euro 5 EEV
		163 PS (120 kW; 161 hp)	3500	350 N⋅m (258 lb⋅ft)	2000	Euro 4
		163 PS (120 kW; 161 hp)	3500	360 N⋅m (266 lb⋅ft)	2200	Euro 5 EEV

Features

The Crafter is available in three wheelbase options; 3,250 millimetres (128.0 in), 3,665 millimetres (144.3 in) and 4,325 millimetres (170.3 in). It is equipped with front airbags as standard, and side and curtain airbags as options, along with anti-lock braking system (ABS), load adapting electronic stability programme (ESP), anti-slip regulation (traction control) (ASR), and electronic differential lock (EDL).

The electronic differential lock (EDL) employed by Volkswagen is not, as the name suggests, a differential lock at all. Sensors monitor both roadwheel speeds across a driven axle, and if one is rotating substantially faster than the other (i.e. slipping) the EDL system momentarily brakes it. This effectively transfers the torque to the other driven wheel which is deemed to still have grip.

Payloads and gross vehicle weights

The Crafter Chassis and Double Cabs models have payloads ranging from 1,472 to 3,026 kilograms (3,245 to 6,671 lb), and come in gross vehicle weights (GVW) of either 3.5 or 5.3 tonnes.

Conversions based on the Volkswagen Crafter

The Crafter is an ideal base vehicle for minibus conversions, and Volkswagen have a list of accredited vehicle conversion specialists.

Awards

The Crafter has won a number of motor industry awards, including:

• 2006 What Van? – Overall Van of the Year (United Kingdom )
• 2006 What Van? – Large Van of the Year (UK)
• 2007 Professional Van and Light Truck Magazine – Large Van of the Year (UK)
• 2007 Van Fleet World – Best Large Panel Van (UK)
• 2007 Delivery Magazine – Large Van of the Year (Australia )
• 2008 Professional Van and Light Truck Magazine – Best Van derived Chassis Cab of the Year (UK)

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  Front (Europe; pre facelift)

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  Rear (Europe; pre facelift)

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  Volkswagen Crafter Minibus (Europe; pre facelift)

First generation facelift (2011–2017)

Volkswagen Commercial Vehicles released a revised Crafter in April 2011. The design of the grille was changed to the current design language of the Volkswagen brand. New power trains based on the 2.0L TDI producing 80 kW/109 PS, 100 kW/136 PS and BiTDI 120 kW/163 PS with the engine revised the payload was increased by up to 10% on some models. The facelift appeared 2 years before the Sprinter on which its based got its own facelift.

Engines

In 2011, the 2.5 litre engine was replaced by the 2.0 litre TDI, which utilises exhaust gas recirculation (EGR) in conjunction with a diesel particulate filter (DPF), allowing all engine variants to comply with Euro 5b (Euro V) European emission standards, which came into force in September 2011.

Engines (2011–2017)
Model	Engine type	Power	rpm	Torque	rpm	European emission standards
2.0 TDI CR	1,968 cc (120 cu in) I4 turbo	109 PS (80 kW; 108 hp)	3500	300 N⋅m (221 lb⋅ft)	1500–2250	Euro 5b
		136 PS (100 kW; 134 hp)	3500	340 N⋅m (251 lb⋅ft)	1500–2250	Euro 5b
2.0 BiTDI CR		163 PS (120 kW; 161 hp)	4000	400 N⋅m (295 lb⋅ft)	1500–2250	Euro 5b

In March 2012 the Crafter 4Motion variant was released as an option with one engine BiTDI 120 kW (163 PS; 161 hp). The four wheel drive system is supplied and fitted by Austrian specialists Achleitner.

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  Facelift front (2011)

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  Facelift rear (2011)

Second generation (Typ SY/SZ, 2017–present)

The second generation of the Volkswagen Crafter was developed entirely by Volkswagen, after the end of their collaboration with Mercedes-Benz. The new design corresponds with the current design line of Volkswagen, and comes in Startline or Trendline trim. The motorhome variant, called the Volkswagen Grand California, was first shown at the 2018 Caravan Salon Düsseldorf. The Grand California comes in two lengths; the 6.0 metre (600) and the 6.8 metre (680) and went on sale at the beginning of 2019.

The second generation Crafter is built in Września, Poland , with a new factory being built specifically for its production. Planned volume is 85,000 vehicles per year, on a 220 ha sized site (300,000 square metres under roof). The cost of the new plant was about 800 million EUR.

Engines

Engines (2017–)
Model	Engine type	Power	rpm	Torque	rpm	European emission standards
2.0 TDI CR	1,968 cc (120 cu in) I4 turbo	109 PS (80 kW; 108 hp)	3500	300 N⋅m (221 lb⋅ft)	1500–2250	Euro 6
		114 PS (84 kW; 112 hp)	3500	300 N⋅m (221 lb⋅ft)	1500–2250	Euro 6
		140 PS (103 kW; 138 hp)	3500	340 N⋅m (251 lb⋅ft)	1575–2250	Euro 6
2.0 BiTDI CR		163 PS (120 kW; 161 hp)	3600	400 N⋅m (295 lb⋅ft)	1800	Euro 6

e-Crafter

In September 2016, Volkswagen unveiled the e-Crafter all electric van at the IAA Commercial Vehicles show in Hanover. The concept e-Crafter has a 43 kWh battery that delivers an estimated range of 208 km (129 mi). The van payload is rated at 1,709 kg, and cargo space is listed at 11.3 cubic meters. The e-Crafter has a 100 kW (136 PS; 134 hp) and 290 N⋅m (214 lb⋅ft) electric motor, and top speed is limited to 80 km/h (50 mph). The electric van is production ready, and retail deliveries were slated for 2017.

Grand California

At the 2017 IAA Frankfurt Motor Show, Volkswagen presented the California XXL motorhome concept, based on the Crafter. The 6.2 m long vehicle has a standing height of 2.2 m and is equipped with underfloor heating. The production version was named Grand California and the model went on sale in 2019. It is the larger version of the Volkswagen Transporter based Volkswagen California.

MAN TGE

The second generation Crafter is also sold by MAN Truck & Bus as the MAN TGE. MAN is a brand of TRATON, which is the Volkswagen Group's heavy commercial vehicle division. The MAN TGE has a wide range of body types, with the van primarily being sold as a panel van, but also available as a tipper, dropside or crew cab variant.

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  MAN TGE 5.180, as Public light bus in Hong Kong

MAN eTGE

The all-electric MAN eTGE was unveiled in March 2018 and entered series production in July that year. It can carry up to 1,700 kg (3,700 lb) of load. The maximum power of its permanently excited synchronous motor is 100 kW (130 hp), the maximum torque over the entire speed range is 290 N⋅m (210 lbf⋅ft). The maximum speed is limited to 90 km/h, and the purchase price was around 69,500 euros in 2018.

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  Second generation Crafter front

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  Second generation Crafter rear

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  Second generation Crafter dashboard

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  MAN TGE

External links

• Official Site (in German)