Service

Workshop Manual
Crafter 2006 ➤
Brake systems
Edition 09.2015

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics

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 2006 ➤
Brake systems - Edition 09.2015

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Checking vehicles with rear-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 General notes on brakes for Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . 2

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General notes on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Overview of fitting locations - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Assembly overview - control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 18
3.3 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Removing and installing speed sensor wire on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4 Removing and installing speed sensor wire on rear axle, Crafter 3.0 t and 3.5 t . . . . . . . . 30
4.5 Removing and installing speed sensor wire on rear axle, Crafter 5.0 t . . . . . . . . . . . . . . . . 31
4.6 Removing and installing wire for brake pad wear indicator on front axle . . . . . . . . . . . . . . 32
4.7 Removing and installing wire for brake pad wear indicator on rear axle . . . . . . . . . . . . . . 33
4.8 Removing and installing yaw rate sender G202 and lateral acceleration sender G200 . . 33
4.9 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Assembly overview - rear brake, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Assembly overview - brake shoes for handbrake, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . 44
2.4 Assembly overview - brake shoes for handbrake, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . 45
2.5 Removing and installing brake pads, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6 Removing and installing brake pads, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.7 Removing and installing brake caliper, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . 50
2.8 Removing and installing brake caliper, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.9 Removing and installing brake shoes for handbrake, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . 54
2.10 Removing and installing brake shoes for handbrake, Crafter 5.0 t . . . . . . . . . . . . . . . . . . 55
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Removing and installing front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.4 Note on adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.5 Adjusting front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Contents i
 Crafter 2006 ➤
Brake systems - Edition 09.2015

3.6 Adjusting brake shoes for handbrake and rear handbrake cables, Crafter 3.0 t and 3.5 t . . 61
3.7 Adjusting brake shoes for handbrake and rear handbrake cables, Crafter 5.0 t . . . . . . . . 62
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Removing and installing front brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1 Assembly overview - rear brake caliper, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . . . . . . . . . 69
2.2 Assembly overview - rear brake caliper, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3 Removing and installing rear brake caliper piston, Crafter 3.0 t and 3.5 t . . . . . . . . . . . . . . 70
2.4 Removing and installing rear brake caliper piston, Crafter 5.0 t . . . . . . . . . . . . . . . . . . . . . . 72
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Removing and installing brake light switch F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.3 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Assembly overview - vacuum pump for vehicles with 5-cylinder diesel engine . . . . . . . . . . 80
4.2 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.3 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2 Notes for repairs to brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.4 Additional brake line on Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . 86
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

ii Contents
 Crafter 2006 ➤
Brake systems - Edition 09.2015

00 – Technical data
1 Technical data
(VRL008190; Edition 09.2015)
⇒ “1.1 Technical data for brakes”, page 1

1.1 Technical data for brakes

Brake master cylinder and brake servo
Brake master cylinder Diameter 25.4
in mm
Brake servo Diameter 10/10
in inches

Front brakes
Front brake Floating caliper disc brake
Piston diameter mm 2 x 48
Internally ventilated brake disc Diameter, 300
mm
Brake disc thickness mm 28
Brake pad thickness (without backplate) mm 13.5

Rear brakes
Type Crafter 3.0 t and 3.5 t Crafter 5.0 t
Rear brake Floating caliper disc brake
Piston diameter mm 51 47
Brake disc Diameter, mm 298 303
Ventilated brake disc mm 16 28
thickness No Yes
Brake pad thickness (with‐ mm 13 15
out backplate)
Handbrake Duo-Servo Duo-Servo
Brake lining width mm 25 42

1. Technical data 1
 Crafter 2006 ➤
Brake systems - Edition 09.2015

2 Brake test
⇒ “2.1 General information”, page 2
⇒ “2.2 Checking vehicles with rear-wheel drive”, page 2
⇒ “2.3 General notes on brakes for Crafter 4MOTION with Achleit‐
ner four-wheel drive”, page 2

2.1 General information

♦ The drive is provided by the test rig.
♦ For the test, ensure for vehicles with a manual gearbox that
the gear lever is in neutral and for vehicles with an automated
manual gearbox, that the selector lever is in “N”.
♦ For test, observe specifications provided by manufacturer of
roller dynamometer.

Note

The brake regulation systems do not function when ignition is off.

2.2 Checking vehicles with rear-wheel drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.

2.3 General notes on brakes for Crafter

4MOTION with Achleitner four-wheel
drive

Note

If the vehicle is tested on a single-axle roller dynamometer or

power-absorption roller, a two-axle roller dynamometer needs to
be used due to permanent four-wheel drive operation.

Note

Please always apply handbrake when parking. Make sure that the
transfer box is not in neutral position. This is important to prevent
the vehicle from rolling when parked on inclines/declines.

WARNING

Activating differential lock restricts ABS functionality.

2 Rep. gr.00 - Technical data

 Crafter 2006 ➤
Brake systems - Edition 09.2015

45 – Anti-lock brake system

1 General information
⇒ “1.1 General notes on ABS”, page 3
⇒ “1.2 Repair instructions for repair work on ABS”, page 3
⇒ “1.3 Fault display via warning lamps”, page 5

1.1 General notes on ABS

The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.

Note

Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.

The hydraulic unit -a- and control unit -b- form one component.
They can be separated only when removed.

Note

If the ABS hydraulic unit - N55- with the ABS control unit - J104-
is renewed, it must be recoded ⇒ Vehicle diagnostic tester.

1.2 Repair instructions for repair work on

ABS
♦ Before carrying out repair work on the anti-lock braking sys‐
tem, determine the cause of the fault using ⇒ Vehicle diag‐
nostic tester.

Note

If the ABS hydraulic unit - N55- with the ABS control unit - J104-
is renewed, it must be recoded ⇒ Vehicle diagnostic tester.

♦ Disconnect battery earth strap with ignition switched off.

♦ Before carrying out welding work with an electric welding unit
⇒ Special information; Body No. 19; Notes on safety .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 88 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 88 .

1. General information 3
 Crafter 2006 ➤
Brake systems - Edition 09.2015

♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. Auxiliary items containing mineral oil, e.g. oils,
greases, etc. must never be used.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours). Ensure that no brake fluid enters connectors.

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 Crafter 2006 ➤
Brake systems - Edition 09.2015

1.3 Fault display via warning lamps

Warning lamps
Item Description
1 Brake pad warning lamp - K32-
2 ABS warning lamp - K47-
3 Brake system warning lamp - K118-
4 Traction control system warning lamp - K86-
ESP and TCS warning lamp - K155-
Brake pad warning lamp - K32-
♦ If brake pad warning lamp - K32- -1- does not go out after
ignition is switched on and after completion of test run, or if it
comes on during vehicle operation, the faults may be caused
by the following:
a - The brake pads/linings are worn.
– Check brake pads/linings on front and rear axles.
b - There is a fault in the activation of the brake pad warning lamp
- K32- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
ABS warning lamp - K47-
♦ If the ABS warning lamp - K47- -2- does not go out after the
ignition has been switched on and test sequence has been
completed, then the fault may be:
a - The voltage supply is below 10 volts.
b - There is a fault in the ABS.
In the event of an ABS fault, the anti-lock brake system remains
switched off, but the brake system remains fully operational.
c - Since the last time the vehicle was started there was a tem‐
porary speed sensor fault.
In the event of a speed sensor fault, the ABS warning lamp - K47-
will extinguish after the engine is restarted and attains a speed
above 2.75 km/h.
d - The connection from dash panel insert to ABS control unit -
J104- is interrupted ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
ABS warning lamp - K47- and brake system warning lamp - K118-
♦ If ABS warning lamp - K47- -2- goes out but brake system
warning lamp - K118- -3- remains on, the causes of the fault
may be:
a - The handbrake is applied.
b - The brake fluid level is too low.
c - There is a fault in the activation of the brake pad warning lamp
- K118- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ If the ABS warning lamp - K47- -2- and the brake system
warning lamp - K118- -3- light up, the anti-lock brake system
and the EBD (electronic brake pressure distribution) system
have failed.

1. General information 5
 Crafter 2006 ➤
Brake systems - Edition 09.2015

WARNING

After the ABS warning lamp - K47- and the brake system warn‐
ing lamp - K118- have lit up, it is possible that the rear wheels
will lock up earlier.

Traction control system warning lamp - K86-

Only on vehicles equipped with traction control system.
♦ If the traction control system warning lamp - K86- -4- does not
go out after the ignition is switched on and completion of the
test sequence, the fault causes may be:
a - Short circuit to positive in TCS and ESP button - E256-
b - Fault in activation of traction control system warning lamp -
K86- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
- Traction control system has been switched off by ESP and TCS
button - E256-
There is a fault which affects only the TCS safety system. ABS
and EBD safety systems of vehicle remain fully functional.

Note

If traction control system warning lamp - K86- flashes while the

vehicle is in motion, the TCS is in operation.

ESP and TCS warning lamp - K155-

Only in vehicles with ESP.
♦ If the ESP and TCS warning lamp - K155- -4- does not go out
after ignition is switched on and the test sequence has been
completed, then the fault may be:
a - Short circuit to positive in TCS and ESP button - E256-
b - Fault in activation of stabilisation program warning lamp -
K155- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
c - TCS and ESP system has been switched off by TCS and ESP
button - E256- .
There is a fault affecting only the TCS/ESP. ABS and EBD safety
systems of vehicle remain fully functional ⇒ Read event memory.

Note

If ESP and TCS warning lamp - K155- flashes during travel, trac‐
tion control system (TCS) or ESP system is in operation.

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 Crafter 2006 ➤
Brake systems - Edition 09.2015

2 Overview of fitting locations

⇒ “2.1 Overview of fitting locations - ABS/ESP”, page 7

2.1 Overview of fitting locations - ABS/ESP

⇒ “2.1.1 Components and fitting locations, ABS/TCS/ESP Bosch
8.1, Crafter 3.0 t and 3.5 t”, page 7
⇒ “2.1.2 Components and fitting locations, ABS/TCS/ESP Bosch
8.1, Crafter 5.0 t”, page 9
⇒ “2.1.3 Components and fitting locations, ABS/TCS/ESP Bosch
9i, Crafter 3.0 t and 3.5 t, 2012 ►”, page 10
⇒ “2.1.4 Components and fitting locations, ABS/TCS/ESP Bosch
9i, Crafter 5.0 t, 2012 ►”, page 12

2.1.1 Components and fitting locations, ABS/TCS/ESP Bosch 8.1, Crafter 3.0 t
and 3.5 t

1 - ABS hydraulic unit - N55-

❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
2 - ABS control unit - J104-
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
3 - ABS warning lamp - K47-
❑ Fault display ⇒ page 5
4 - ESP and TCS warning lamp
- K155-
❑ Fault display ⇒ page 5
5 - Brake pad warning lamp -
K32-
❑ Fault display ⇒ page 5
6 - Brake system warning lamp
- K118-
❑ Fault display ⇒ page 5
7 - Brake light switch - F- Volkswagen Technical Site: http://vwts.ru http://vwts.info
❑ Removing and installing ⇒ page 76
8 - TCS and ESP button - E256-
❑ Location: in centre of dash panel.

2. Overview of fitting locations 7

 Crafter 2006 ➤
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9 - Steering angle sender - G85-

❑ Only on vehicles having ESP
❑ Location: on steering column between steering wheel and steering column switch
10 - Lateral acceleration sender - G200- , longitudinal acceleration sender - G251- and yaw rate sender - G202-
❑ Only on vehicles having ESP
❑ Combined in one housing.
❑ Location: Under driver's seat.
❑ Removing and installing ⇒ page 33
11 - Diagnostic connection
❑ Fitting location: driver footwell
12 - Front right speed sensor - G45- / front left speed sensor - G47-
❑ Removing and installing ⇒ page 25
13 - Wheel bearing housing with wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing.
14 - Rear right speed sensor - G44- / rear left speed sensor - G46-
❑ Removing and installing ⇒ page 30
15 - Axle beam
16 - Rear axle shaft with wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing.

Fitting location: the diagnostic connection is located on the left A-

pillar in the footwell.

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2.1.2 Components and fitting locations, ABS/TCS/ESP Bosch 8.1, Crafter 5.0 t

1 - ABS hydraulic unit - N55-

❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
2 - ABS control unit - J104-
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
3 - ABS warning lamp - K47-
❑ Fault display ⇒ page 5
4 - ESP and TCS warning lamp
- K155-
❑ Fault display ⇒ page 5
5 - Brake pad warning lamp -
K32-
❑ Fault display ⇒ page 5
6 - Brake system warning lamp
- K118-
❑ Fault display ⇒ page 5
7 - Brake light switch - F-
❑ Removing and installing ⇒ page 76
8 - TCS and ESP button - E256-
❑ Location: in centre of dash panel.
9 - Steering angle sender - G85-
❑ Only on vehicles having ESP
❑ Location: on steering column between steering wheel and steering column switch
10 - Lateral acceleration sender - G200- , longitudinal acceleration sender - G251- and yaw rate sender - G202-
❑ Only on vehicles having ESP
❑ Combined in one housing.
❑ Location: Under driver's seat.
❑ Removing and installing ⇒ page 33
11 - Diagnostic connection
❑ Fitting location: driver footwell
12 - Front right speed sensor - G45- / front left speed sensor - G47-
❑ Removing and installing ⇒ page 25

2. Overview of fitting locations 9

 Crafter 2006 ➤
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13 - Wheel bearing housing with wheel bearing/wheel bearing unit

❑ ABS sensor ring is installed in wheel bearing.
14 - Rear right speed sensor - G44- / rear left speed sensor - G46-
❑ Removing and installing
⇒ “4.2.2 Assembly overview - speed sensor on rear axle, Crafter 5.0 t”, page 28
15 - Axle beam
16 - Rear axle hub with wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in rear axle hub.
17 - Rear axle shaft

Fitting location: the diagnostic connection is located on the left A-

pillar in the footwell.

2.1.3 Components and fitting locations, ABS/TCS/ESP Bosch 9i, Crafter 3.0 t and
3.5 t, 2012 ►

1 - ABS hydraulic unit - N55-

❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
2 - ABS control unit - J104-
❑ With lateral acceleration
sender - G200- , longi‐
tudinal acceleration
sender - G251- and yaw
rate sender - G202- (on‐
ly on vehicles having
ESP)
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
3 - ABS warning lamp - K47-
❑ Fault display ⇒ page 5
4 - ESP and TCS warning lamp
- K155-
❑ Fault display ⇒ page 5

Note

TCS only on Crafter 4MOTION with

Achleitner four-wheel drive.

10 Rep. gr.45 - Anti-lock brake system

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5 - Brake pad warning lamp - K32-

❑ Fault display ⇒ page 5
6 - Brake system warning lamp - K118-
❑ Fault display ⇒ page 5
7 - Brake light switch - F-
❑ Removing and installing ⇒ page 76
8 - ESP button - E256-
❑ Location: in centre of dash panel.
❑ Only on vehicles having ESP

Note

Not on Crafter 4MOTION with

Achleitner four-wheel drive.

9 - Steering angle sender - G85-

❑ Only on vehicles having ESP
❑ Location: on steering column between steering wheel and steering column switch
10 - Diagnostic connection
❑ Fitting location: driver footwell
11 - Front right speed sensor - G45- / front left speed sensor - G47-
❑ Make sure it is installed in correct position:
❑ Removing and installing ⇒ page 25 .
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
12 - Wheel bearing housing with wheel bearing/wheel bearing unit

Note

♦ Allocation ⇒ Electronic Parts

Catalogue “ETKA”
♦ Modified wheel bearing housing
on Crafter 4MOTION with
Achleitner four-wheel drive.
♦ Ensure correct installation posi‐
tion of front speed sensors, be‐
cause malfunction may other‐
wise occur ⇒ page 25 .
❑ ABS sensor ring is installed in wheel bearing.
❑ ⇒ Running gear, axles, steering; Rep. gr. 40
❑ The ABS sensor ring on Crafter 4MOTION with Achleitner four-wheel drive is located on the outer con‐
stant velocity joint.
❑ ⇒ Running gear, axles, steering; Rep. gr. 40
13 - Rear right speed sensor - G44- / rear left speed sensor - G46-
❑ Removing and installing ⇒ page 30
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
14 - Axle beam
15 - Rear axle shaft with wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing.

2. Overview of fitting locations 11

 Crafter 2006 ➤
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2.1.4 Components and fitting locations, ABS/TCS/ESP Bosch 9i, Crafter 5.0 t,
2012 ►

1 - ABS hydraulic unit - N55-

❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
2 - ABS control unit - J104-
❑ With lateral acceleration
sender - G200- , longi‐
tudinal acceleration
sender - G251- and yaw
rate sender - G202- (on‐
ly on vehicles having
ESP)
❑ If the hydraulic control
unit is defective, it can
be replaced only as a
complete unit.
❑ Removing and installing
up to week 27/2012
⇒ page 33
❑ Removing and installing
from week 27/2012
⇒ page 20
3 - ABS warning lamp - K47-
❑ Fault display ⇒ page 5
4 - ESP and TCS warning lamp
- K155-
❑ Fault display ⇒ page 5

Note

TCS only on Crafter 4MOTION with

Achleitner four-wheel drive.

5 - Brake pad warning lamp - K32-

❑ Fault display ⇒ page 5
6 - Brake system warning lamp - K118-
❑ Fault display ⇒ page 5
7 - Brake light switch - F-
❑ Removing and installing ⇒ page 76
8 - ESP button - E256-
❑ Location: in centre of dash panel.
❑ Only on vehicles having ESP

Note

Not on Crafter 4MOTION with

Achleitner four-wheel drive.

12 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 09.2015

9 - Steering angle sender - G85-

❑ Only on vehicles having ESP
❑ Location: on steering column between steering wheel and steering column switch
10 - Diagnostic connection
❑ Fitting location: driver footwell
11 - Front right speed sensor - G45- / front left speed sensor - G47-
❑ Make sure it is installed in correct position:
❑ Removing and installing ⇒ page 28 .
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
12 - Wheel bearing housing with wheel bearing/wheel bearing unit

Note

♦ Allocation ⇒ Electronic Parts

Catalogue “ETKA”
♦ Modified wheel bearing housing
on Crafter 4MOTION with
Achleitner four-wheel drive.
♦ Ensure correct installation posi‐
tion of front speed sensors, be‐
cause malfunction may other‐
wise occur ⇒ page 25 .
❑ ABS sensor ring is installed in wheel bearing.
❑ ⇒ Running gear, axles, steering; Rep. gr. 40
❑ The ABS sensor ring on Crafter 4MOTION with Achleitner four-wheel drive is located on the outer con‐
stant velocity joint.
❑ ⇒ Running gear, axles, steering; Rep. gr. 40
13 - Rear right speed sensor - G44- / rear left speed sensor - G46-
❑ Removing and installing
⇒ “4.2.2 Assembly overview - speed sensor on rear axle, Crafter 5.0 t”, page 28
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”
14 - Axle beam
15 - Rear axle hub with wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in rear axle hub.
16 - Rear axle shaft

2. Overview of fitting locations 13

 Crafter 2006 ➤
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3 Control unit and hydraulic unit

⇒ “3.1 Assembly overview - control unit and hydraulic unit”, page
14
⇒ “3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 ”, page 18
⇒ “3.3 Connecting brake lines to hydraulic unit”, page 24

3.1 Assembly overview - control unit and hy‐

draulic unit
⇒ “3.1.1 Assembly overview - ABS control unit J104 and ABS
hydraulic unit N55 up to week 27/2012”, page 14
⇒ “3.1.2 Assembly overview - ABS control unit J104 and ABS
hydraulic unit N55 , as of week 27/2012”, page 16

3.1.1 Assembly overview - ABS control unit - J104- and ABS hydraulic unit - N55-
up to week 27/2012
Complete brake master cylinders and brake servos can be re‐
newed independently of each other.

1 - Brake servo
❑ Diesel engines are fitted
with a vacuum pump to
generate the necessary
vacuum.
❑ A vacuum reservoir is
additionally installed in
certain vehicle types.
❑ Checking function
❑ With engine switched
off, depress brake pedal
firmly several times (to
deplete vacuum in unit).
❑ Now step on and hold
brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning proper‐
ly, the brake pedal will
be felt to go down as the
servo takes effect.
❑ If faulty renew complete
❑ Checking non-return
valve (in vacuum hose)
⇒ page 80 .
❑ Separating from brake
pedal ⇒ page 64 , Re‐
moving and installing
brake pedal.
❑ Removing and installing
brake servo
⇒ page 77 .
2 - Sealing ring
❑ Renew.

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 Crafter 2006 ➤
Brake systems - Edition 09.2015

3 - Cap
4 - Brake fluid reservoir
5 - Sealing plug
❑ Moisten with brake fluid and press into brake master cylinder.
6 - Bolt
❑ To secure brake fluid reservoir to brake master cylinder.
7 - Nut
❑ Self-locking
❑ 20 Nm
8 - Brake master cylinder
❑ Cannot be repaired, renew complete when faulty.
❑ Removing and installing ⇒ page 78 .
9 - Sealing plug
❑ Connection for vacuum hose.
10 - Connection for brake line
❑ From hydraulic unit to front right brake caliper.
11 - Connection for brake line
❑ From hydraulic unit to rear left brake caliper.
12 - Connection for brake line
❑ From hydraulic unit to rear right brake caliper.
13 - Connection for brake line
❑ From hydraulic unit to front left brake caliper.
14 - Connection for brake line
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
15 - Connection for brake line
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
16 - ABS control unit - J104- and ABS hydraulic unit - N55-
❑ If the hydraulic control unit is defective, it can be replaced only as a complete unit.
❑ Removing and installing ⇒ page 18 .

Note

If the ABS hydraulic unit - N55- with

the ABS control unit - J104- is re‐
newed, it must be recoded in guided
fault finding ⇒ Vehicle diagnostic
tester.

17 - Retaining plate
18 - Bolt
❑ 8 Nm
19 - Bump stop

3. Control unit and hydraulic unit 15

 Crafter 2006 ➤
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3.1.2 Assembly overview - ABS control unit - J104- and ABS hydraulic unit - N55- ,
as of week 27/2012
Complete brake master cylinders and brake servos can be re‐
newed independently of each other.

1 - Brake servo
❑ Diesel engines are fitted
with a vacuum pump to
generate the necessary
vacuum.
❑ A vacuum reservoir is
additionally installed in
certain vehicle types.
❑ Checking function
❑ With engine switched
off, depress brake pedal
firmly several times (to
deplete vacuum in unit).
❑ Now step on and hold
brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning proper‐
ly, the brake pedal will
be felt to go down as the
servo takes effect.
❑ If faulty renew complete
❑ Checking non-return
valve (in vacuum hose)
⇒ page 80 .
❑ Separating from brake
pedal ⇒ page 64 , Re‐
moving and installing
brake pedal.
❑ Removing and installing
brake servo.
2 - Sealing ring
❑ Renew.
3 - Cap
4 - Brake fluid reservoir
5 - Sealing plug
❑ Moisten with brake fluid and press into brake master cylinder.
6 - Bolt
❑ To secure brake fluid reservoir to brake master cylinder.
7 - Nut
❑ Self-locking
❑ 20 Nm
8 - Brake master cylinder
❑ Cannot be repaired, renew complete when faulty.
❑ Removing and installing ⇒ page 78 .
9 - Sealing plug
❑ Connection for vacuum hose.

16 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
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10 - Connection for brake line

❑ From hydraulic unit to front right brake caliper.
❑ 14 Nm
11 - Connection for brake line
❑ From hydraulic unit to rear left brake caliper.
❑ 14 Nm
12 - Connection for brake line
❑ From hydraulic unit to rear right brake caliper.
❑ 14 Nm
13 - Connection for brake line
❑ From hydraulic unit to front left brake caliper.
❑ 14 Nm
14 - Connection for brake line
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
❑ 14 Nm
15 - Connection for brake line
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
❑ 14 Nm
16 - ABS control unit - J104- and ABS hydraulic unit - N55-
❑ If the hydraulic control unit is defective, it can be replaced only as a complete unit.
❑ Removing and installing ⇒ page 20

Note

If the ABS hydraulic unit - N55- with

the ABS control unit - J104- is re‐
newed, it must be recoded in guided
fault finding⇒ Vehicle diagnostic
tester.

17 - Bracket
❑ Removing ⇒ page 23 .
18 - Bump stop
19 - Washer
20 - Nut
❑ 8 Nm
21 - Nut
❑ 8 Nm

3. Control unit and hydraulic unit 17

 Crafter 2006 ➤
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3.2 Removing and installing ABS control

unit - J104- and ABS hydraulic unit -
N55-
⇒ “3.2.1 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 , up to week 27/2012”, page 18
⇒ “3.2.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 , as of week 27/2012”, page 20

3.2.1 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
N55- , up to week 27/2012

Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
♦ Open ring spanner insert,
AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G
1410/7-
♦ Torque wrench - VAS
6854-
♦ Brake pedal depressor -
V.A.G 1869/2-
♦ Assembly tool - V.A.G
1410/8-

18 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

Sealing plugs from repair kit, part number 1 H0 698 311 A

2 - Sealing plug M10
3 - Sealing plug M12
Removing
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
If problems are reported, the hydraulic unit and the control unit
must be renewed together.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Note or request radio code on vehicles with coded radio if

necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Connect bleeder bottle hose to front left brake caliper bleed
valve and open bleed valve.
– Use brake pedal depressor - V.A.G 1869/2- to depress brake
pedal.
– Close front left bleed valve.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.

Note

Ensure no brake fluid gets onto contacts.

– Unscrew brake lines -1- to -4-, -A- and -B- from ABS hydraulic
unit - N55- .
– Seal brake lines and threaded holes using sealing plugs - 1H0
698 311 A- from repair kit.

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 Crafter 2006 ➤
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– Release retainer -1- for connector -2- on control unit in direc‐

tion of -arrow A- and pull connector from control unit in direc‐
tion of -arrow B-.

– Remove ABS hydraulic unit - N55- together with ABS control

unit - J104- -1-.
To do this, first pull ABS hydraulic unit - N55- with ABS control
unit - J104- out of rubber buffers -4- beneath control unit and then
beneath hydraulic unit.
– Remove bolt -3- from retaining plate -2-.
Installing

Note

If the ABS hydraulic unit - N55- with the ABS control unit - J104-
is renewed, it must be recoded in guided fault finding⇒ Vehicle
diagnostic tester.

Install in reverse order. Note the following points:

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be installed.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.

Caution

Brake line nuts must be screwed to end of threads into ABS

hydraulic unit - N55- by hand.
Only then may the nuts be tightened to the specified torque.

– Bleed brake system ⇒ page 88 .

– Carry out a road test.
– Perform road test at more than 40 km/h for at least 80 seconds.
– Read event memory after road test ⇒ Vehicle diagnostic test‐
er.
Specified torques
♦ ⇒ “3.1 Assembly overview - control unit and hydraulic unit”,
page 14

3.2.2 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
N55- , as of week 27/2012

20 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1331-
♦ Open ring spanner insert,
AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G
1410/7-
♦ Torque wrench - VAS
6854-
♦ Brake pedal depressor -
V.A.G 1869/2-
♦ Assembly tool - V.A.G
1410/8-

3. Control unit and hydraulic unit 21

 Crafter 2006 ➤
Brake systems - Edition 09.2015

Sealing plugs from repair kit, part number 1 H0 698 311 A

2 - Sealing plug M10
3 - Sealing plug M12
Removing
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
If problems are reported, the hydraulic unit and the control unit
must be renewed together.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Note or request radio code on vehicles with coded radio if

necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Connect bleeder bottle hose to front left brake caliper bleed
valve and open bleed valve.
– Use brake pedal depressor - V.A.G 1869/2- to depress brake
pedal.
– Close front left bleed valve.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.

Note

Ensure no brake fluid gets onto contacts.

– Unscrew brake lines -1- to -4-, -A- and -B- from ABS hydraulic
unit - N55- .
– Seal brake lines and threaded holes using sealing plugs - 1H0
698 311 A- from repair kit.

22 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Release retainer -1- for connector -2- on control unit in direc‐

tion of -arrow A- and pull connector from control unit in direc‐
tion of -arrow B-.
– Remove nuts -2- and remove rubber buffer with washer

– Pull ABS hydraulic unit - N55- with ABS control unit - J104-
-1- upwards out of bracket.
– Set ABS hydraulic unit - N55- with ABS control unit - J104- on
a clean surface.
Removing bracket

– Remove nuts -1- and remove bracket -1- for ABS hydraulic
unit - N55- with ABS control unit - J104- upwards.
Installing

Note

If the ABS hydraulic unit - N55- with the ABS control unit - J104-
is renewed, it must be recoded in guided fault finding⇒ Vehicle
diagnostic tester.

Install in reverse order. Note the following points:

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be installed.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.

Caution

Brake line nuts must be screwed to end of threads into ABS

hydraulic unit - N55- by hand.
Only then may the nuts be tightened to the specified torque.

Specified torques ⇒ page 16

– Bleed brake system ⇒ page 88 .
– Carry out a road test.
– Perform road test at more than 40 km/h for at least 80 seconds.
– Read event memory after road test ⇒ Vehicle diagnostic test‐
er.

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 Crafter 2006 ➤
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3.3 Connecting brake lines to hydraulic unit

On brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Marked on hydraulic unit with -HZ1-.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Marked on hydraulic unit with -HZ2-.
1 - From hydraulic unit to front left brake caliper.
- Marked on hydraulic unit with -VL-.
2 - From hydraulic unit to front right brake caliper.
- Marked on hydraulic unit with -VR-.
3 - Hydraulic unit, rear left brake caliper.
- Marked on hydraulic unit with -HL-.
4 - Hydraulic unit, rear right brake caliper.
- Marked on hydraulic unit with -HR-.

24 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

4 Sensors
⇒ “4.1 Assembly overview - speed sensor on front axle”,
page 25
⇒ “4.2 Assembly overview - speed sensor on rear axle”,
page 26
⇒ “4.3 Removing and installing speed sensor wire on front axle”,
page 28
⇒ “4.4 Removing and installing speed sensor wire on rear axle,
Crafter 3.0 t and 3.5 t”, page 30
⇒ “4.5 Removing and installing speed sensor wire on rear axle,
Crafter 5.0 t”, page 31
⇒ “4.6 Removing and installing wire for brake pad wear indicator
on front axle”, page 32
⇒ “4.7 Removing and installing wire for brake pad wear indicator
on rear axle”, page 33
⇒ “4.8 Removing and installing yaw rate sender G202 and lateral
acceleration sender G200 ”, page 33
⇒ “4.9 Removing and installing steering angle sender G85 ”, page
34

4.1 Assembly overview - speed sensor on front axle

4. Sensors 25
 Crafter 2006 ➤
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1 - Front right speed sensor -

G45- / front left speed sensor -
G47-
❑ Removing and installing
⇒ page 28 .
2 - Wheel bearing housing with
wheel bearing/wheel bearing
unit
❑ Allocation ⇒ Electronic
Parts Catalogue “ETKA”
❑ ABS sensor ring is in‐
stalled in wheel bearing.
❑ ⇒ Running gear, axles,
steering; Rep. gr. 40 ;
Wheel bearing; Assem‐
bly overview - wheel
bearing
❑ The ABS sensor ring on
Crafter 4MOTION with
Achleitner four-wheel
drive is located on the
outer constant velocity
joint.
❑ ⇒ Running gear, axles,
steering; Rep. gr. 40 ;
Drive shaft; Assembly
overview - drive shaft .

Note

♦ Modified wheel bearing housing

on Crafter 4MOTION with
Achleitner four-wheel drive.
♦ Ensure correct installation posi‐
tion of front speed sensors, be‐
cause malfunction may other‐
wise occur ⇒ page 25 .

3 - Brake disc
4 - Bolt
❑ 22 Nm
5 - Bolt
❑ 8 Nm

4.2 Assembly overview - speed sensor on

rear axle
⇒ “4.2.1 Assembly overview - speed sensor on rear axle,
Crafter 3.0 t and 3.5 t”, page 27
⇒ “4.2.2 Assembly overview - speed sensor on rear axle,
Crafter 5.0 t”, page 28

26 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

4.2.1 Assembly overview - speed sensor on rear axle, Crafter 3.0 t and 3.5 t

1 - Rear right speed sensor -

G44- / rear left speed sensor -
G46-
❑ Removing and installing
⇒ page 30 .
❑ Allocation ⇒ Electronic
Parts Catalogue “ETKA”
2 - Bolt, 8 Nm
3 - Bolt
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42
4 - Axle beam
5 - Splash plate
6 - Rear axle shaft with wheel
bearing/wheel bearing unit
❑ ABS sensor ring is in‐
stalled in wheel bearing.

4. Sensors 27
 Crafter 2006 ➤
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4.2.2 Assembly overview - speed sensor on rear axle, Crafter 5.0 t

1 - Bolt, 8 Nm
2 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Allocation ⇒ Electronic
Parts Catalogue “ETKA”
3 - Axle beam
4 - Splash plate
5 - Rear axle hub
❑ ABS sensor ring is in‐
stalled in rear axle hub.
6 - Rear axle shaft

4.3 Removing and installing speed sensor

wire on front axle
Removing speed sensor wire from control unit to wheel housing
⇒ page 28
Installing speed sensor wire from control unit to wheel housing
⇒ page 29
Removing speed sensor wire from wheel bearing housing to
wheel housing ⇒ page 29
Installing speed sensor wire from wheel bearing housing to wheel
housing ⇒ page 30
Removing speed sensor wire from control unit to wheel housing
Special tools and workshop equipment required

28 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
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♦ Wiring harness repair set - VAS 1978 B-

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery.
– Release retainer -1- for connector -2- on control unit in direc‐
tion of -arrow A- and pull connector from control unit in direc‐
tion of -arrow B-.
– Release cover cap from multi-pin connector using screwdriver,
and remove it.
Contact assignment of 38-pin connector - T38- for wiring harness
on control unit -J104- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Use release tool wiring harness repair set - VAS 1978 B- to
remove relevant contacts.
– Remove front wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .

– In wheel housing, disconnect connector -1- from speed sensor

wire and speed sensor.
♦ Connector colour on left side of vehicle: black
♦ Connector colour on right side of vehicle: colourless
2 - Connector for brake pad wear indicator (blue)
– Remove defective speed sensor wire.
Installing speed sensor wire from control unit to wheel housing
– Install new speed sensor wire.
Removing speed sensor wire from wheel bearing housing to
wheel housing
– Remove front wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .

– In wheel housing, disconnect connector -1- from speed sensor

wire and speed sensor.
♦ Connector colour on left side of vehicle: black
♦ Connector colour on right side of vehicle: colourless
2 - Connector for brake pad wear indicator (blue)

4. Sensors 29
 Crafter 2006 ➤
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– Unclip speed sensor wire -1- from clips -arrows A- on shock

absorber.
Crafter 4MOTION with Achleitner four-wheel drive

Note

♦ Modified wheel bearing housing on Crafter 4MOTION with

Achleitner four-wheel drive.
♦ Ensure correct installation position of front speed sensors,
since otherwise malfunction may occur.

– Unbolt speed sensor wire from frame.

– Separate cable ties.
– Mark installation position of speed sensor.
Continuation for all vehicles

– Unscrew bolt -1- and remove speed sensor -2- from wheel
bearing housing.
Installing speed sensor wire from wheel bearing housing to wheel
housing
Install in reverse order.
Specified torques
♦ ⇒ “4.1 Assembly overview - speed sensor on front axle”, page
25
♦ ⇒ “4.2.1 Assembly overview - speed sensor on rear axle,
Crafter 3.0 t and 3.5 t”, page 27
♦ ⇒ “4.2.2 Assembly overview - speed sensor on rear axle,
Crafter 5.0 t”, page 28

4.4 Removing and installing speed sensor

wire on rear axle, Crafter 3.0 t and 3.5 t
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing speed sensor wire

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

30 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

– On right side of underbody, disconnect connector -1- from

speed sensor wire and speed sensor.
♦ Connector colour on left side of vehicle: black
♦ Connector colour on right side of vehicle: colourless
2 - Connector for brake pad wear indicator (blue)
– Separate all speed sensor wire connections to handbrake ca‐
ble and axle beam.

– Unscrew bolt -1- and remove speed sensor -2- from wheel axle
beam.
Installing speed sensor wire
Install in reverse order.
Specified torques
♦ ⇒ “4.2.1 Assembly overview - speed sensor on rear axle,
Crafter 3.0 t and 3.5 t”, page 27

4.5 Removing and installing speed sensor

wire on rear axle, Crafter 5.0 t
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing speed sensor wire

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .
– On right side of underbody, disconnect connector -1- from
speed sensor wire and speed sensor.
♦ Connector colour on left side of vehicle: black
♦ Connector colour on right side of vehicle: colourless
2 - Connector for brake pad wear indicator (blue)
– Separate all speed sensor wire connections to handbrake ca‐
ble and axle beam.

4. Sensors 31
 Crafter 2006 ➤
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– Unscrew bolt -1- and remove speed sensor -2- from wheel axle
beam.
Installing speed sensor wire
Install in reverse order.
Specified torques
♦ ⇒ “4.2.2 Assembly overview - speed sensor on rear axle,
Crafter 5.0 t”, page 28

4.6 Removing and installing wire for brake

pad wear indicator on front axle
Removing wire for brake pad wear indicator
– Remove front wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .
– In wheel housing, disconnect connector -2-.
♦ Connector colour on left and right sides of vehicle: blue

– Unplug connector -arrow-.

– Unscrew bolt -1- and remove connector -2- from brake caliper.

– Unclip wire -2- from clips -arrows B- on shock absorber.

Installing wire for brake pad wear indicator
Continue installation in reverse order.
Specified torques
Component Specified torque
Connector to brake caliper 8 Nm

32 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

4.7 Removing and installing wire for brake

pad wear indicator on rear axle
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing wire for brake pad wear indicator

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .
– Disconnect connector -2- on right side of underfloor.
♦ Connector colour on left and right sides of vehicle: blue
1 - Connector for speed sensor wire to speed sensor (black or
colourless)
– Separate all wiring connections for brake pad wear indicator
to handbrake cable and axle beam.

– Disconnect connector -arrow-.

– Unscrew bolt -1- and remove connector -2- from brake caliper.
Installing wire for brake pad wear indicator
Install in reverse order.
Specified torques
Component Specified torque
Connector to brake caliper 8 Nm

4.8 Removing and installing yaw rate send‐

er - G202- and lateral acceleration send‐
er - G200-

Note

♦ Not relevant for vehicles equipped with Bosch ESP9i.

♦ The yaw rate sender - G202- and lateral acceleration sender
- G200- are integrated in ABS control unit - J104- .

4. Sensors 33
 Crafter 2006 ➤
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WARNING

Severe shocks (e.g. dropping, impact) may destroy the yaw

rate sender - G202- and the lateral acceleration sender -
G200- .

Removing yaw rate sender - G202- and lateral acceleration send‐

er - G200-
The yaw rate sender - G202- and the lateral acceleration sender
- G200- are combined in one housing. This is installed under the
driver seat.
– Move driver seat to foremost position.
– Pull off connector -1-.
– Remove bolts -arrows-.
– Remove yaw rate sender - G202- and lateral acceleration
sender - G200- -2-.
Installing yaw rate sender - G202- and lateral acceleration sender
- G200-
Install in reverse order.
Specified torques
Component Specified torque
Bolt yaw rate sender - G202- and 6 Nm
lateral acceleration sender -
G200- to base plate.

4.9 Removing and installing steering angle

sender - G85-
The steering angle sender - G85- is located between the steering
wheel and steering column switch.
Removing and installing
Remove steering column combination switch ⇒ Electrical system;
Rep. gr. 94 ; Steering column switch module; Removing and in‐
stalling steering column combination switch .

34 Rep. gr.45 - Anti-lock brake system

 Crafter 2006 ➤
Brake systems - Edition 09.2015

46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brakes”, page 35
⇒ “1.2 Removing and installing brake pads/linings”, page 36
⇒ “1.3 Removing and installing brake caliper”, page 38

1.1 Assembly overview - front brakes

Note

♦ After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that
the brake pads/linings are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).

1 - Protective cap
2 - Bolt
❑ Always renew after re‐
moving.
❑ 35 Nm
3 - Brake hose
❑ Bolted to brake caliper.
❑ 35 Nm
4 - Brake caliper
❑ Removing and installing
⇒ page 38 .
❑ Repairing ⇒ page 66 .
5 - Brake pads
❑ Thickness: 13.5 mm not
including backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let 10.2 .
❑ Always replace on both
sides
❑ Removing and installing
⇒ page 36 .
❑ Pad wear limit: 2 mm
without backplate (re‐
maining pad thickness)
6 - Brake pad wear indicator
❑ Only on outer brake pad
7 - Pad retainer
❑ Always renew when
changing pads.

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1. Front brakes 35
 Crafter 2006 ➤
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8 - Brake carrier
9 - Brake disc
❑ Brake disc, 300 mm in diameter
❑ Internally ventilated.
❑ Thickness: 28 mm
❑ Wear limit: 25 mm.
❑ Always renew on both sides of an axle.
10 - Bolt
❑ 22 Nm
11 - Wheel bearing housing with wheel bearing/wheel bearing unit

Note

♦ Modified wheel bearing housing

on Crafter 4MOTION with
Achleitner four-wheel drive.
♦ Ensure correct installation posi‐
tion of front speed sensors, be‐
cause malfunction may other‐
wise occur ⇒ page 25 .

12 - Bolt
❑ 170 Nm

1.2 Removing and installing brake pads/lin‐

ings
Special tools and workshop equipment required
♦ Piston resetting appliance - T10145-

Removing

Note

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.

36 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Disconnect connector -1- for brake pad wear indicator.

– Remove cover caps -arrows- and unscrew bolts for securing
brake caliper.

– Insert screwdriver into notch -arrow A- on brake carrier.

– Press screwdriver in direction of -arrow B- to pull guide pin out
of brake carrier.
– Remove brake caliper, guiding wire for brake pad wear indi‐
cator through opening in brake caliper.
– Secure brake caliper with wire so that the weight of the brake
caliper does not stress or damage the brake hose.
– Remove brake pads from brake carrier sideways.
– Clean brake caliper housing.

Note

Only use methylated spirits to clean brake caliper housing.

Installing
Before inserting new brake pads, press piston back into cylinder
using piston resetting tool - T10145- . Before pressing piston
back, draw off brake fluid from brake fluid reservoir with bleeder
bottle. Otherwise, fluid can overflow and cause damage, particu‐
larly if reservoir has been topped up.

– Press both pistons back with piston resetting tool - T10145-

-1-.

1. Front brakes 37
 Crafter 2006 ➤
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– Insert brake pads -1-.

Ensure that brake pads -1- are seated correctly in pad retainers
-arrows-.
– Insert brake caliper housing. Make sure that guide pins en‐
gage correctly in brake carrier.
– Tighten new securing bolts to specified torque.

– Insert cover caps -arrows-.

– Connect connector -1- for brake pad wear indicator.
– Fit wheels.
♦ After replacing brake pads/linings, depress brake pedal firmly
several times with vehicle stationary so that the brake pads/
linings are properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.
Specified torques
♦ ⇒ “1.1 Assembly overview - front brakes”, page 35
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Connector for brake pad wear in‐ 8 Nm
dicator to brake caliper

1.3 Removing and installing brake caliper

Special tools and workshop equipment required
♦ Brake pedal depressor - V.A.G 1869/2-

38 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

Removing

Note

This procedure applies only to exchanging the brake caliper or

the following repair work on the brake caliper.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
– Disconnect connector -1- for brake pad wear indicator.
– Remove cover caps -arrows- and unscrew bolts for securing
brake caliper.

– Insert screwdriver into notch -arrow A- on brake carrier.

– Press screwdriver in direction of -arrow B- to push guide pin
out of brake carrier.
– Pull brake caliper from brake carrier.
Installing
• Piston is pressed back.
• The brake pads are seated on the brake carrier.
– Insert brake caliper housing and make sure that guide pins
engage correctly in brake carrier.
– Tighten new securing bolts to specified torque.

1. Front brakes 39
 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Insert cover caps -arrows-.

– Connect connector -1- for brake pad wear indicator.
– Bolt brake hose to brake caliper.
– Remove brake pedal actuator - V.A.G 1869/2- .
– Bleed brake system ⇒ page 88 .
– Fit wheels.

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

Specified torques
♦ ⇒ “1.1 Assembly overview - front brakes”, page 35
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Connector for brake pad wear in‐ 8 Nm
dicator to brake caliper

40 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

2 Rear brakes
⇒ “2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t”,
page 41
⇒ “2.2 Assembly overview - rear brake, Crafter 5.0 t”, page 43
⇒ “2.3 Assembly overview - brake shoes for handbrake,
Crafter 3.0 t and 3.5 t”, page 44
⇒ “2.4 Assembly overview - brake shoes for handbrake,
Crafter 5.0 t”, page 45
⇒ “2.5 Removing and installing brake pads, Crafter 3.0 t and 3.5 t”,
page 45
⇒ “2.6 Removing and installing brake pads, Crafter 5.0 t”,
page 47
⇒ “2.7 Removing and installing brake caliper, Crafter 3.0 t and
3.5 t”, page 50
⇒ “2.8 Removing and installing brake caliper, Crafter 5.0 t”, page
52
⇒ “2.9 Removing and installing brake shoes for handbrake,
Crafter 3.0 t and 3.5 t”, page 54
⇒ “2.10 Removing and installing brake shoes for handbrake,
Crafter 5.0 t”, page 55

2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t

Note

♦ After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that
the brake pads/linings are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
(when doing this, release pressure in system).

2. Rear brakes 41
 Crafter 2006 ➤
Brake systems - Edition 09.2015

1 - Splash plate
2 - Rear axle shaft
3 - Brake disc
❑ Brake disc, 288 mm in
diameter
❑ Thickness: 16 mm
❑ Wear limit: 14 mm.
❑ When worn, renew on
both sides of axle.
❑ Combined with drum for
handbrake (Duo-Ser‐
vo).
4 - Bolt
❑ 22 Nm
5 - Brake carrier
6 - Pad retainer
❑ Always renew when
changing pads.
❑ Always set in place with
angled lug pointing out‐
wards.
7 - Protective cap
❑ Check for damage
8 - Guide pin
9 - Brake pads
❑ Thickness without back‐
plate: 13 mm
❑ Pad wear limit: 2 mm
without backplate (re‐
maining pad thickness)
❑ Checking thickness
⇒ Maintenance ; Booklet 10.2 .
❑ Always replace on both sides
❑ Removing and installing ⇒ page 45 .
10 - Brake pad wear indicator
❑ Only on outer brake pad
11 - Brake caliper
❑ Repairing ⇒ page 69 .
❑ Removing and installing ⇒ page 50 .
12 - Bolt
❑ Renew after removing
❑ 35 Nm
13 - Bolt
❑ Renew after removing
❑ 80 Nm +45°

42 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

2.2 Assembly overview - rear brake,

Crafter 5.0 t

Note

♦ After replacing brake pads/linings, depress brake pedal firmly

several times with vehicle stationary so that the brake pads/
linings are properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor - V.A.G 1869/2- (when doing
this, release pressure in system).

1 - Splash plate
2 - Rear axle shaft
3 - Brake disc
❑ Brake disc, 303 mm in
diameter
❑ Thickness: 28 mm
❑ Wear limit: 25 mm.
❑ When worn, renew on
both sides of axle.
❑ Combined with drum for
handbrake
4 - Flange
5 - Bolt
❑ Renew after removing
❑ 80 Nm +40°
6 - Brake carrier
7 - Pad retainers
❑ Always renew when
changing pads.
❑ Always set in place with
angled lug pointing out‐
wards.
8 - Protective cap
❑ Check for damage
9 - Guide pin
10 - Brake pads
❑ Removing and installing
⇒ page 47 .
❑ Thickness without back‐
plate: 16 mm
❑ Pad wear limit: 2 mm without backplate (remaining pad thickness)
❑ Checking thickness ⇒ Maintenance ; Booklet 10.2 .
❑ Always replace on both sides
11 - Brake pad wear indicator
❑ Only on inner brake pad

2. Rear brakes 43
 Crafter 2006 ➤
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12 - Brake caliper
❑ Removing and installing ⇒ page 52 .
❑ Repairing ⇒ page 70 .
13 - Bolt
❑ Renew after removing
❑ 35 Nm
14 - Bolt
❑ Renew after removing
❑ 260 Nm

2.3 Assembly overview - brake shoes for handbrake, Crafter 3.0 t and 3.5 t

1 - Handbrake cable
2 - Pin
3 - Brake shoes for handbrake
❑ Removing and installing
⇒ page 54 .
4 - Retaining spring
5 - Expander
❑ Check for freedom of
movement.
❑ Before installing brake
shoes, attach to hand‐
brake cable with pin
⇒ Item 2 (page 44) .
6 - Brake disc
❑ When worn, renew on
both sides of axle.
❑ Combined with drum for
handbrake
7 - Bolt
❑ 22 Nm
8 - Rear return spring
9 - Front return spring
10 - Setting pinion for brake
shoes
❑ Check for freedom of
movement.
11 - Brake caliper
12 - Bolt
❑ Always renew after re‐
moving.
❑ 80 Nm +45°

44 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

2.4 Assembly overview - brake shoes for handbrake, Crafter 5.0 t

1 - Upper return spring

2 - Brake shoes for handbrake
❑ Removing and installing
⇒ page 55 .
3 - Retaining spring
4 - Return spring
5 - Return spring
6 - Retaining plate
7 - Brake disc
❑ When worn, renew on
both sides of axle.
❑ Combined with drum for
handbrake
8 - Flange
9 - Bolt
❑ Renew after removing
❑ 80 Nm +40°
10 - Handbrake cable
11 - Expander
❑ Check for freedom of
movement.
❑ Attach to handbrake ca‐
ble ⇒ Item 10 (page 45)
before installing brake
shoes
12 - Brake caliper
❑ Removing and installing
⇒ page 52 .

2.5 Removing and installing brake pads,

Crafter 3.0 t and 3.5 t
Special tools and workshop equipment required
♦ Piston resetting appliance - T10145-

2. Rear brakes 45
 Crafter 2006 ➤
Brake systems - Edition 09.2015

♦ Torque wrench - V.A.G 1331-

Removing

Note

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.
– Disconnect connector -1- for brake pad wear indicator.
– Unscrew securing bolts -arrows- for brake caliper.
– Remove brake caliper, guiding wire for brake pad wear indi‐
cator through opening in brake caliper.
– Secure brake caliper with wire so that the weight of the brake
caliper does not stress or damage the brake hose.
– Remove brake pads from brake carrier sideways.
– Clean brake carrier and brake caliper.

Note

Only use methylated spirits to clean brake caliper housing.

Installing
Install in reverse order of removal, observing the following:
Before inserting new brake pads, press piston back into cylinder
using piston resetting tool - T10145- . Before pressing piston
back, draw off brake fluid from brake fluid reservoir with bleeder
bottle. Otherwise, fluid can overflow and cause damage, particu‐
larly if reservoir has been topped up.

46 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Press pistons back with piston resetting tool - T10145- -1-.

– Insert brake pads -1-.

Ensure that brake pads -1- are seated correctly in pad retainers
-arrows-.
– Insert brake caliper housing.

– Tighten new securing bolts -arrows- to specified torque.

– Connect connector -1- for brake pad wear indicator.
– Fit wheels.
♦ After replacing brake pads/linings, depress brake pedal firmly
several times with vehicle stationary so that the brake pads/
linings are properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.
Specified torques
♦ ⇒ “2.1 Assembly overview - rear brake, Crafter 3.0 t and 3.5 t”,
page 41
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Connector for brake pad wear in‐ 8 Nm
dicator to brake caliper

2.6 Removing and installing brake pads,

Crafter 5.0 t
Special tools and workshop equipment required

2. Rear brakes 47
 Crafter 2006 ➤
Brake systems - Edition 09.2015

♦ Piston resetting appliance - T10145-

♦ Torque wrench - V.A.G 1331-

Removing

Note

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.

48 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Disconnect connector -1- for brake pad wear indicator.

– Unscrew securing bolts -arrows- for brake caliper.
– Remove brake caliper, guiding wire for brake pad wear indi‐
cator through opening in brake caliper.
– Secure brake caliper with wire so that the weight of the brake
caliper does not stress or damage the brake hose.
– Remove brake pads from brake carrier sideways.
– Clean brake carrier and brake caliper.

Note

Only use methylated spirits to clean brake caliper housing.

Installing
Install in reverse order of removal, observing the following:
Before inserting new brake pads, press piston back into cylinder
using piston resetting tool - T10145- . Before pressing piston
back, draw off brake fluid from brake fluid reservoir with bleeder
bottle. Otherwise, fluid can overflow and cause damage, particu‐
larly if reservoir has been topped up.

– Press both pistons back with piston resetting tool - T10145-

-1-.

– Carefully press brake pad wear indicator -2- onto stop in new
brake pad -1-.

2. Rear brakes 49
 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Insert brake pads -1-.

Ensure that brake pads -1- are seated correctly in pad retainers
-arrows-.
– Insert brake caliper housing.

– Tighten new securing bolts -arrows- to specified torque.

– Connect connector -1- for brake pad wear indicator.
– Fit wheels.
♦ After replacing brake pads/linings, depress brake pedal firmly
several times with vehicle stationary so that the brake pads/
linings are properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.
Specified torques
♦ ⇒ “2.2 Assembly overview - rear brake, Crafter 5.0 t”,
page 43
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Connector for brake pad wear in‐ 8 Nm
dicator to brake caliper

2.7 Removing and installing brake caliper,

Crafter 3.0 t and 3.5 t
Special tools and workshop equipment required
♦ Brake pedal depressor - V.A.G 1869/2-

50 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

♦ Torque wrench - V.A.G 1331-

Removing

Note

This procedure applies only to exchanging the brake caliper or

the following repair work on the brake caliper.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
– Disconnect connector -1- for brake pad wear indicator.
– Unscrew securing bolts -arrows- for brake caliper.
– Remove brake caliper, guiding wire for brake pad wear indi‐
cator through opening in brake caliper.
– Pull brake caliper from brake carrier.
Installing
Install in reverse order of removal, observing the following:
• Piston is pressed back.
• The brake pads are seated on the brake carrier.
– Insert brake caliper housing.

2. Rear brakes 51
 Crafter 2006 ➤
Brake systems - Edition 09.2015

– Tighten new securing bolts -arrows- to specified torque.

– Connect connector -1- for brake pad wear indicator.
– Screw brake line to brake caliper.
– Bleed brake system ⇒ page 88 .
– Fit wheels.

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

Specified torques
♦ ⇒ page 41
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Brake hose to brake caliper 35 Nm

2.8 Removing and installing brake caliper,

Crafter 5.0 t
Special tools and workshop equipment required
♦ Piston resetting appliance - T10145-

♦ Torque wrench - V.A.G 1331-

52 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
Brake systems - Edition 09.2015

Removing

Note

This procedure applies only to exchanging or the following repair

work on the brake caliper.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
– Disconnect connector -1- for brake pad wear indicator.
– Unscrew securing bolts -arrows- for brake caliper.
– Remove brake caliper, guiding wire for brake pad wear indi‐
cator through opening in brake caliper.
– Pull brake caliper from brake carrier.
Installing
Install in reverse order of removal, observing the following:
• The pistons are pressed back.
• The brake pads are seated on the brake carrier.
– Insert brake caliper housing.

– Tighten securing bolts -arrows- to specified torque.

– Connect connector -1- for brake pad wear indicator.
– Screw brake line to brake caliper.
– Bleed brake system ⇒ page 88 .
– Fit wheels.

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

Specified torques
♦ ⇒ page 43
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Brake hose to brake caliper 35 Nm

2. Rear brakes 53
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2.9 Removing and installing brake shoes for

handbrake, Crafter 3.0 t and 3.5 t
Special tools and workshop equipment required
♦ Hook - 3438-

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.
Removing

Note

Brake shoes may come apart, fall and be damaged.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.
– Remove brake caliper together with brake carrier and secure
with wire so that weight of brake caliper does not stress or
damage brake hose.
– Reset brake in order to be able to remove brake disc.
– To do this, insert a screwdriver through hole in brake disc and
position it on setting pinion for brake shoes -1-.
– Turn setting pinion for brake shoes -1- by moving screwdriver
in direction of -arrow-.
– Remove brake discs.

– Turn nut -1- to relieve rear handbrake cables.

– Detach handbrake cables -arrows-.

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– Unhook return springs with hook - 3438- .

– Press retaining spring -1- with pliers -2- in direction of

-arrow A- and turn so that hook -3- can be removed through
slot -arrow B- on rear side of cover plate.

Note

Only the lower retaining spring is shown on the illustration. A re‐

taining spring is also installed in the upper section of the brake
shoes; this also has to be removed.

– Pull brake shoes apart as far as necessary and remove for‐

wards (in direction of travel).
Installing
Install in reverse order of removal, observing the following:

– Preassemble brake shoes.

A - Setting pinion
B - Front return spring
C - Brake shoes
F - Direction of travel
– Pull brake shoes apart as far as necessary and insert back‐
wards (opposite direction of travel).
Continue installation in reverse order.
Specified torques
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts

2.10 Removing and installing brake shoes for

handbrake, Crafter 5.0 t
Special tools and workshop equipment required

2. Rear brakes 55
 Crafter 2006 ➤
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♦ Hook - 3438-

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.
Removing

Note

Brake shoes may come apart, fall and be damaged.

– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Remove wheels.
– Remove brake caliper together with brake carrier and secure
with wire so that weight of brake caliper does not stress or
damage brake hose.
Reset brake in order to be able to remove brake disc.
– To reset brake, turn adjuster screw -1- of adjustment jig -2- in
direction of -arrow B- using a commercially available spanner.

Note

The brake shoes are not shown to improve the illustration clarity
of the adjustment jig -2-.

– Remove brake discs.

– Turn nut -1- to relieve rear handbrake cables.

– Detach handbrake cables -arrows-.

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– Unhook return springs with hook - 3438- .

– Press retaining spring -1- with pliers -2- in direction of

-arrow A- and turn so that hook -3- can be removed through
slot -arrow B- on rear side of cover plate.

Note

Only one retaining spring is shown on the illustration. The other

brake shoe is also fitted with a retaining spring that must be re‐
moved as well.

– Pull brake shoes apart as far as necessary and remove for‐

wards (in direction of travel).
Installing
Install in reverse order of removal, observing the following:

– Preassemble brake shoes.

A - Return spring with “longest length”
B - Return spring with “middle length”
C - Return spring with “shortest length”
D - Brake shoes
E - Retaining plate
Pfeil - Direction of travel
– Pull brake shoes apart as far as necessary and insert back‐
wards (opposite direction of travel).
Continue installation in reverse order.
Specified torques
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts

2. Rear brakes 57
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3 Handbrake
⇒ “3.1 Assembly overview - handbrake lever”, page 58
⇒ “3.2 Removing and installing handbrake lever”, page 59
⇒ “3.3 Removing and installing front handbrake cable”,
page 60
⇒ “3.4 Note on adjusting handbrake”, page 60
⇒ “3.5 Adjusting front handbrake cable”, page 60
⇒ “3.6 Adjusting brake shoes for handbrake and rear handbrake
cables, Crafter 3.0 t and 3.5 t”, page 61
⇒ “3.7 Adjusting brake shoes for handbrake and rear handbrake
cables, Crafter 5.0 t”, page 62

3.1 Assembly overview - handbrake lever

1 - Front trim
2 - Rear trim
3 - Bolt
❑ 60 Nm
4 - Bolt
❑ 10 Nm
5 - Handbrake warning switch
- F9-
6 - Handbrake cable, front
❑ Adjusting ⇒ page 60 .
❑ Removing and installing
⇒ page 60 .
7 - Retaining clip
8 - Pin
9 - Handbrake lever
❑ Removing and installing
⇒ page 59 .

58 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
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3.2 Removing and installing handbrake lev‐

er
Removing
– Pull front trim -1- off handbrake lever in -direction of arrow-.
– Remove rear trim -2- from handbrake lever.
• The handbrake lever is in its lowest position, and is not applied.

– Disconnect connector -1- on handbrake warning switch - F9- .

– Remove retaining clip -1- and pull out securing pin for front
handbrake cable out of handbrake lever.
– Press both lugs -arrows- together and slide front handbrake
cable -2- out of handbrake lever -3-.

– Separate connection -1-.

– Unscrew bolts -arrows- and remove handbrake lever -2-.
Installing
Install in reverse order.
– Adjusting front handbrake cable ⇒ page 60 .
Specified torques
♦ ⇒ “3.1 Assembly overview - handbrake lever”, page 58

3. Handbrake 59
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3.3 Removing and installing front hand‐

brake cable
Removing
– Remove rear trim -2- from handbrake lever.
• The handbrake lever is in its lowest position, and is not applied.

– Remove retaining clip -1- and pull out securing pin for front
handbrake cable out of handbrake lever.
– Press both lugs -arrows- together and slide front handbrake
cable -2- out of handbrake lever -3-.
– Push boot of handbrake cable and handbrake cable out
through underbody.
– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

– Detach front handbrake cable from lever -1- -arrow-.

– Pull out front handbrake cable through underbody, in direction
of travel.
Installing
Install in reverse order of removal, observing the following:
– Adjusting front handbrake cable ⇒ page 60 .

3.4 Note on adjusting handbrake

Note

Before adjusting handbrake, first adjust brake shoes for hand‐

brake, then adjust front handbrake cable.

3.5 Adjusting front handbrake cable

– Release handbrake lever.
– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .

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– Unscrew nuts -2- from bracket -3-, and push bracket in direc‐
tion of travel.

– Push bracket backwards until there is 6 mm clearance be‐

tween lever -1- and bracket -3-.

Note

A 6 mm drill may be used as gauge.

– Tighten nuts of bracket.

– Pull handbrake lever on 4 notches.
– Release handbrake lever.
– Check that both wheels turn freely.
Specified torques
Component Specified torque
Nut for bracket to body 40 Nm

3.6 Adjusting brake shoes for handbrake

and rear handbrake cables, Crafter 3.0 t
and 3.5 t
– Unscrew and remove one wheel bolt from each of the rear axle
wheels.
– Release handbrake.
– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .
– Unscrew nuts -2- from bracket -3-, and push bracket in direc‐
tion of travel.

3. Handbrake 61
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– Turn wheel until setting pinion -1- can be seen through hole
for wheel bolt.
– Use screwdriver to turn setting pinion -1- counter to direction
of -arrow- until wheel is fixed.
– Turn back setting pinion by 3 teeth in direction of -arrow-.
– Adjust front handbrake cable ⇒ page 60 .

– Loosen lock nut, and tighten nut -1- until rear handbrake ca‐
bles no longer sag.
– Pull handbrake lever on 4 notches.
– Release handbrake lever.
– Check that both wheels turn freely.
– Lock loosened nuts again.
– Install removed wheel bolts.
Specified torques
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Nut for bracket to body 40 Nm

3.7 Adjusting brake shoes for handbrake

and rear handbrake cables, Crafter 5.0 t
– Release handbrake.
– Raise vehicle ⇒ Maintenance ; Booklet 10.2 .
– Loosen nuts -2- of bracket -3-.
– Push bracket -3- in direction of travel.

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– Turn adjuster screw -1- of adjustment jig -2- in direction of

-arrow A- using a commercially available spanner until wheel
is fixed.

Note

The brake shoes are not shown to improve the illustration clarity
of the adjustment jig.

– Loosen adjustment jig by approx. 3 notches in direction of

-arrow B-.

– Tighten nut -1- until rear handbrake cables no longer sag.

– Tighten lock nut.
– Adjust front handbrake cable ⇒ page 60 .
– Pull handbrake lever on 4 notches.
– Release handbrake lever.
– Check that both wheels turn freely.
Specified torques
♦ Running gear, axles, steering ⇒ Rep. gr. 44 ; Wheels, tyres;
Specified torque for wheel bolts
Component Specified torque
Nut for bracket to body 40 Nm

3. Handbrake 63
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4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 64
⇒ “4.2 Removing and installing brake pedal”, page 64

4.1 Assembly overview - brake pedal

WARNING

The brake pedal travel must not be restricted by additional floor

coverings.

1 - Brake light switch - F-

❑ Removing and installing
⇒ page 76 .
2 - Brake pedal with mounting
bracket
❑ Removing and installing
⇒ page 64 .
3 - Cap
4 - Nut
❑ Always renew after re‐
moving.
❑ 25 Nm

4.2 Removing and installing brake pedal

Removing
– Remove steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Assembly overview -
steering column trim .

64 Rep. gr.46 - Brakes - mechanism

 Crafter 2006 ➤
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– Remove brake light switch - F- from mounting bracket

⇒ page 76 .
– Remove securing spring -arrow- on pin for connecting fork
head to brake pedal.
– Remove pin for connecting fork head to brake pedal.
– Unscrew nuts -1- on both sides of mounting bracket.
– Remove brake pedal together with mounting bracket -2-.
Installing
Install in reverse order.

4. Brake pedal 65
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47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - front brake caliper”, page 66
⇒ “1.2 Removing and installing front brake caliper piston”,
page 67

1.1 Assembly overview - front brake caliper

Note

♦ When carrying out repairs, install all parts supplied in repair kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake cylinder, piston and seal.

1 - Brake caliper housing

2 - Brake hose
❑ Tighten at brake caliper
to 35 Nm.
3 - Bleeder valve
❑ 14 Nm
4 - Dust cap
5 - Protective cap
❑ Take care not to dam‐
age when inserting.
6 - Guide pin

WARNING
Two different types of
guide bushes are instal‐
led. Always ensure that
the guide bush with the
moulded insert is instal‐
led »on top« (on bleeder
valve).

7 - Sealing ring
❑ Removing and installing
⇒ page 67 .
8 - Piston
❑ Removing and installing
⇒ page 67 .
9 - Protective cap
❑ Take care not to dam‐
age when inserting pis‐
ton.
10 - Connector for brake pad wear indicator
11 - Bolt
❑ 8 Nm

66 Rep. gr.47 - Brakes - hydraulics

 Crafter 2006 ➤
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1.2 Removing and installing front brake cal‐

iper piston
Special tools and workshop equipment required
♦ Removal wedge - 3409-

♦ Piston resetting appliance - T10145-

Removing
– Press piston out of brake caliper housing using compressed
air.
Place a piece of wood in the recess to prevent damage to the
piston.

– Remove seal using removal wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
Installing

Note

Only use methylated spirits to clean brake caliper housing.

– Apply thin coat of assembly paste - G 052 150 A2- to piston

and seal before installing.
– Insert oil seal in brake caliper housing.

1. Front brake caliper 67

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– Place protective cap with outer sealing lip on piston.

– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper housing.

– Press piston into brake caliper housing using piston resetting

tool - T10145- -1-.
The outer sealing lip on the protective cap will then slip into the
piston groove.

68 Rep. gr.47 - Brakes - hydraulics

 Crafter 2006 ➤
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2 Rear brake caliper

⇒ “2.1 Assembly overview - rear brake caliper, Crafter 3.0 t and
3.5 t”, page 69
⇒ “2.2 Assembly overview - rear brake caliper, Crafter 5.0 t”, page
70
⇒ “2.3 Removing and installing rear brake caliper piston,
Crafter 3.0 t and 3.5 t”, page 70
⇒ “2.4 Removing and installing rear brake caliper piston,
Crafter 5.0 t”, page 72

2.1 Assembly overview - rear brake caliper, Crafter 3.0 t and 3.5 t

Note

♦ When carrying out repairs, install all parts supplied in repair kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake cylinder, piston and seal.

1 - Protective cap
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread.
❑ 14 Nm
3 - Brake caliper housing
4 - Sealing ring
❑ Removing and installing
⇒ page 70 .
5 - Piston
❑ Removing and installing
⇒ page 70 .
6 - Dust boot for piston
❑ Removing and installing
⇒ page 70 .
7 - Connector for brake pad
wear indicator
8 - Bolt
❑ 8 Nm
9 - Brake hose
❑ Secured to brake cali‐
per.
❑ 35 Nm

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2. Rear brake caliper 69

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2.2 Assembly overview - rear brake caliper,

Crafter 5.0 t

Note

♦ When carrying out repairs, install all parts supplied in repair

kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste - G 052 150 A2- to brake
cylinder, piston and seal.

1 - Dust cap
2 - Bleeder valve
❑ Before screwing in, ap‐
ply thin coat of assembly
paste - G 052 150 A2- to
thread.
❑ 14 Nm
3 - Sealing ring
❑ Removing and installing
⇒ page 72 .
4 - Protective cap
5 - Piston
❑ Removing and installing
⇒ page 72 .
6 - Brake caliper housing
7 - Connector for brake pad
wear indicator
8 - Bolt
❑ 8 Nm
9 - Brake hose
❑ Secured to brake cali‐
per.
❑ 35 Nm

2.3 Removing and installing rear brake cal‐

iper piston, Crafter 3.0 t and 3.5 t
Special tools and workshop equipment required

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 Crafter 2006 ➤
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♦ Removal wedge - 3409-

♦ Piston resetting appliance - T10145-

♦ Assembly tool for protective caps - T10146/3-

Removing
– Press piston out of brake caliper housing using compressed
air.
Place a piece of wood in the recess to prevent damage to the
piston.

2. Rear brake caliper 71

 Crafter 2006 ➤
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– Remove seal using removal wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
Installing

Note

Only use methylated spirits to clean brake caliper housing.

– Apply thin coat of assembly paste - G 052 150 A2- to piston

and seal before installing.
– Insert oil seal in brake caliper housing.

– Place protective cap with outer sealing lip on piston.

Hold piston in front of brake caliper housing.

– Press piston into brake caliper housing using piston resetting

tool - T10145- -1-.
A - Vice clamp

– Using assembly tool for protective caps - T10146/3- -1- and

piston resetting appliance - T10145- , press protective cap into
brake caliper so that cap is fitted correctly all round.
The outer sealing lip on the protective cap will then slip into the
piston groove.

2.4 Removing and installing rear brake cal‐

iper piston, Crafter 5.0 t
Special tools and workshop equipment required

72 Rep. gr.47 - Brakes - hydraulics

 Crafter 2006 ➤
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♦ Removal wedge - 3409-

♦ Piston resetting appliance - T10145-

Removing
– Press piston out of brake caliper housing using compressed
air.
Place a piece of wood in the recess to prevent damage to the
piston.

– Remove seal using removal wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
Installing

Note

Only use methylated spirits to clean brake caliper housing.

– Apply thin coat of assembly paste - G 052 150 A2- to piston

and seal before installing.
– Insert oil seal in brake caliper housing.

2. Rear brake caliper 73

 Crafter 2006 ➤
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– Place protective cap with outer sealing lip on piston.

– Using removal wedge - 3409- , insert inner sealing lip into cyl‐
inder groove.
When doing this, hold piston in front of brake caliper housing.

– Press piston into brake caliper housing using piston resetting

tool - T10145- -1-.
The outer sealing lip on the protective cap will then slip into the
piston groove.

74 Rep. gr.47 - Brakes - hydraulics

 Crafter 2006 ➤
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3 Brake servo and brake master cylin‐

der
⇒ “3.1 Assembly overview - brake servo/brake master cylinder”,
page 75
⇒ “3.3 Removing and installing brake servo”, page 77
⇒ “3.4 Removing and installing brake master cylinder”,
page 78
⇒ “3.2 Removing and installing brake light switch F ”, page 76

3.1 Assembly overview - brake servo/brake master cylinder

1 - Brake servo
❑ Diesel engines are fitted
with a vacuum pump to
generate the necessary
vacuum.
❑ A vacuum reservoir is
additionally installed in
certain vehicle types.
❑ Checking function
❑ With engine switched
off, depress brake pedal
firmly several times (to
deplete vacuum in unit).
❑ Now step on and hold
brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning proper‐
ly, the brake pedal will
be felt to go down as the
servo takes effect.
❑ If faulty, renew as a
complete unit.
❑ Checking non-return
valve (in vacuum hose)
⇒ page 80 .
❑ Separating from brake
pedal ⇒ page 64 , Re‐
moving and installing
brake pedal.
❑ Removing and installing
brake servo
⇒ page 77 .
2 - Sealing ring
3 - Cap
4 - Brake fluid reservoir
❑ With switch for brake fluid level
5 - Sealing plug
❑ Moisten with brake fluid and press into brake master cylinder.
6 - Nut
❑ Renew after removing
❑ 20 Nm

3. Brake servo and brake master cylinder 75

 Crafter 2006 ➤
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7 - Brake line
8 - Bolt
9 - Brake master cylinder
❑ Removing and installing ⇒ page 78 .
❑ Cannot be repaired, renew complete when faulty.
10 - Sealing plug
❑ Connection for vacuum hose.

3.2 Removing and installing brake light

switch - F-
⇒ “3.2.1 Removing and installing brake light switch F ▶ 05.2011”,
page 76
⇒ “3.2.2 Removing and installing brake light switch F 06.2011 ▶”,
page 76

3.2.1 Removing and installing brake light

switch - F- ▶ 05.2011
Removing
– Pull connector -1- off brake light switch - F- -2-.
– Press lever -3- in direction of -arrow A- and turn brake light
switch - F- -2- to stop in direction of -arrow B-.
– Remove brake light switch - F- -2- from recess -arrow-.
Installing
Install in reverse order.

3.2.2 Removing and installing brake light

switch - F- 06.2011 ▶
Removing
– Pull brake light switch - F- -1- out of mounting in direction of
arrow -2-.

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 Crafter 2006 ➤
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– Pull connector -1- off brake light switch - F- -2-.

Installing
• Brake pedal in rest position (not depressed).

– Connect connector -1- to brake light switch - F- -2-.

– Insert brake light switch - F- -1- from behind and through de‐
tents of mounting -2- in -direction of arrow- until switch con‐
tacts brake pedal (in rest position). Other adjustments are not
required.
In the figure the brake pedal is shown depressed for clarity

3.3 Removing and installing brake servo

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Remove brake master cylinder ⇒ page 78 .
– Remove driver footwell cover ⇒ General body repairs, interior;
Rep. gr. 70 .

3. Brake servo and brake master cylinder 77

 Crafter 2006 ➤
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– Remove securing spring -arrow- on pin for connecting fork

head to brake pedal.
– Remove pin for connecting fork head to brake pedal.
– Unscrew nuts -1- on both sides of mounting bracket.
– Remove brake servo.
Installing
Install in reverse order of removal, observing the following:
– Bleed brake system ⇒ page 88 .

3.4 Removing and installing brake master

cylinder
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Pull connector -1- off brake fluid level sender.
– Place sufficient lint-free cloths in area of plenum chamber, en‐
gine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234-
or extraction unit - V.A.G 1869/4- .

– Pull off supply hose for clutch master cylinder -1-.

– Mark and unscrew brake lines -2- and -3- from brake master
cylinder. Seal brake lines using sealing plugs from repair kit -
1H0 698 311 A- .

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 Crafter 2006 ➤
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– Unscrew nuts -arrows- from brake master cylinder -1-.

Note

For ease of illustration, brake master cylinder is shown without

brake fluid reservoir.

– Carefully take brake master cylinder out of brake servo.

Installing
Install in reverse order of removal, observing the following:
– Bleed brake system ⇒ page 88 .
Specified torques
♦ ⇒ “3.1 Assembly overview - brake servo/brake master cylin‐
der”, page 75

3. Brake servo and brake master cylinder 79

 Crafter 2006 ➤
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4 Vacuum system
⇒ “4.1 Assembly overview - vacuum pump for vehicles with 5-
cylinder diesel engine”, page 80
⇒ “4.2 Checking non-return valve”, page 80
⇒ “4.3 Removing and installing vacuum pump”, page 81

4.1 Assembly overview - vacuum pump for vehicles with 5-cylinder diesel en‐
gine

1 - Vacuum pump
❑ Removing and installing
⇒ page 81 .
2 - Vacuum hose
❑ Before connecting, ap‐
ply lubricant (e.g. tyre fit‐
ting lubricant) to con‐
nection on vacuum
pump.
3 - Nut
❑ 20 Nm
4 - Sealing ring
❑ Renew after removing
❑ Check for correct seat
when installing
5 - Plunger

4.2 Checking non-return valve

The non-return valve is installed directly at brake servo vacuum
connection.

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 Crafter 2006 ➤
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– Check non-return valve -A-.

The air must pass through the valve in the direction of -arrow-.
The valve must remain closed in the opposite direction.
Observe correct installation position. Arrow must point in direction
of vacuum pump or engine.

4.3 Removing and installing vacuum pump

Removing
– Pull vacuum hose -A- off vacuum pump.

– Unscrew nuts -arrows- and remove vacuum pump -A-.

Installing
Install in reverse order of removal, observing the following:

– If necessary, continue turning engine until plunger -A- is flush

with cylinder head.
Specified torques
♦ ⇒ “4.1 Assembly overview - vacuum pump for vehicles with 5-
cylinder diesel engine”, page 80

4. Vacuum system 81
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5 Brake lines
⇒ “5.1 Assembly overview - flanging tool”, page 82
⇒ “5.2 Notes for repairs to brake lines”, page 83
⇒ “5.3 Repairing brake lines”, page 84
⇒ “5.4 Additional brake line on Crafter 4MOTION with Achleitner
four-wheel drive”, page 86

5.1 Assembly overview - flanging tool

1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws .
2 - Fastening for handle
❑ Must be unbolted to ac‐
cess securing bolt for
upper part
3 - Securing bolt
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ Centring and holding
flanging jaws .
❑ Hexagon socket head
bolt, 2 mm
5 - Flanging jaws
❑ Various
❑ Assembly instructions
⇒ page 83

82 Rep. gr.47 - Brakes - hydraulics

 Crafter 2006 ➤
Brake systems - Edition 09.2015

Flanging jaw assembly instructions:

♦ -VAS 6056/6- (dark) for black brake lines
♦ -VAS 6056/7- (light) for green brake lines

Note

The arrow on the rounded side of the flanging jaws must point to
the edge of the housing, and the straight side of the flanging jaws
must be installed towards the spindle, or the flange will not be
formed correctly.

5.2 Notes for repairs to brake lines

The flanging tool for brake lines - VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this allows sections of brake lines
to be renewed at less expense.
The use of flanging tool - V.A.G 1356- is not permitted due to the
coating and the diameter of the black brake lines.

Note

♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict the cross-section
of the line to an impermissible degree.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle; merely clean with methylated spirits.

Special tools and workshop equipment required

♦ Flanging tool for brake lines - VAS 6056-

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♦ Brake filling and bleeding equipment - VAS 5234-

List of individual tools:

1 - Flanging tool - VAS 6056/1-

❑ Flanging jaws - VAS
6056/6- are installed in
flanging tool - VAS
6056/1- .
2 - Pipe cutter - VAS 6056/2-
3 - Brake line scraper - VAS
6056/3-
❑ Grub screws (in shaft
and at side) are adjus‐
ted and must not be
readjusted!
4 - Set of grips with plastic jaws
- VAS 6056/4-
5 - Pipe bending tool - VAS
6056/5-
6 - Special wrench, 6 mm
7 - Flanging jaws - VAS
6056/7-

5.3 Repairing brake lines

– Unbolt respective brake line from brake caliper or wheel brake
cylinder. Catch escaping brake fluid and dispose of this as per
regulations.

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Brake systems - Edition 09.2015

– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.

– Clamp brake line in a grip wrench -4- so that approx. 50 mm

project from plastic jaws.
– Clamp scraper -3- into drill and position on brake line.
– At slow drill speed and with gentle pressure on brake line,
scrape coating off brake line.

Note

Length of scraping is determined by stop in scraper.

– Remove scraper from brake line and remove scraping resi‐

dues.

– Remove set of grips and slide union nut -D- onto brake line.

– Slide brake line -B- to stop -A- in flanging tool.

Note

Brake line must be positioned against stop when the hexagon

socket head bolts are tightened, or the flange will not be formed
correctly.

– Pre-tension brake line in flanging tool until brake line can no

longer be moved. Then fold up stop -A- and use angled driver
-C- to tighten hexagon socket head bolts in diagonal se‐
quence.

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– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Release hexagon socket head bolts diagonally.
– Remove brake line from flanging tool. Clean and check brake
line and flange.
Briefly flush the section of brake line remaining in the vehicle:
– Connect brake filling and bleeding equipment - VAS 5234- ,
connect bleeder bottle hose to brake line flange and allow
brake filling and bleeding equipment - VAS 5234- to run briefly
until a little brake fluid has run through.
– Blow out new brake line to be inserted with compressed air.

– Join brake lines using connector -E-.

– Install brake line.
– Bleed brake system ⇒ page 88 .

5.4 Additional brake line on Crafter 4MO‐

TION with Achleitner four-wheel drive
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment - VAS 5234-

Note

♦ Crafter 4MOTION with Achleitner four-wheel drive is equipped

with extended brake line to front brake calipers.
♦ When e.g. removing subframe of Crafter 4MOTION with
Achleitner four-wheel drive, this extended brake line needs to
be removed and reinstalled accordingly.

Note

The connecting piece of the brake line can be found on the right
side, behind the heat shield.

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Brake systems - Edition 09.2015

Removing

Note

Observe safety notes when handling brake fluid ⇒ page 88 .

– Extract brake fluid using brake filling and bleeding equipment

- VAS 5234- .
– Unbolt brake lines -1- from brake hose -arrow-, and seal brake
lines using sealing plugs from repair kit - 1H0 698 311 A- .
– Disconnect brake line -1- from connecting piece -2-.
– Seal brake lines on connecting piece -2- using sealing plugs
from repair kit - 1H0 698 311 A- .
– If necessary, unbolt heat shield on right side.

– Unclip brake line -1- by releasing clips -3- and remove it.

Note

Brake pipes may only be bent up to max. 90°. They otherwise kink
or reveal deformations which impermissibly constrict the pipe
cross-section.

Installing
Install in reverse order. Note the following points:
– Bleed brake system using brake filling and bleeding equip‐
ment - VAS 5234- ⇒ page 88 .
– Carry out a road test.

Note

Perform controlled brake test during road test (pulsations must be

felt at brake pedal).

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6 Hydraulic system
⇒ “6.1 Bleeding hydraulic system following standard procedure”,
page 88
⇒ “6.2 Testing for leaks”, page 89

6.1 Bleeding hydraulic system following

standard procedure

Note

Bleeding the brake system is described for brake filling and bleed‐
ing equipment VAS 5234.

♦ Bleeding brake system on vehicles with ABS is performed in

the same way as on vehicles with a conventional brake sys‐
tem.
♦ While bleeding rear wheel brake, move lever of brake pressure
regulator.
♦ Only use new brake fluid - B 000 700 A- (please specify the
container index for the point).
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment - VAS 5234-

Bleeding brake system on vehicles with ABS is performed in same

way as vehicles with a conventional brake system.
– Connect brake filling and bleeding equipment - VAS 5234- .
– Open bleeder valves in specified order and bleed brake cali‐
pers.
Bleeding sequence
1 - Rear right brake caliper
2 - Rear left brake caliper
3 - Front right brake caliper
4 - Front left brake caliper

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Brake systems - Edition 09.2015

– Leave bleeder valve open with bleeder bottle hose connected

until brake fluid free of air bubbles flows out.
Changing brake fluid ⇒ Maintenance ; Booklet 10.2 ; Work se‐
quences; Changing brake fluid

6.2 Testing for leaks

Special tools and workshop equipment required
♦ Tester for brake pressure regulator - V.A.G 1310 A-

♦ Adapter M10 - V.A.G 1310/6-

Test prerequisites:
• Brake system (hydraulic unit, brake hoses, brake lines and
brake calipers) operating properly and free of leaks.
Checking
– Remove bleeder valve at one of front brake calipers. Connect
tester for brake pressure regulator - V.A.G 1310 A- and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.

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