Design change to R2S turbochargers VW Crafter & MAN TGE - silniki 2.0 TDI
Design change to R2S turbochargers
VW Crafter and MAN TGE – 2.0 TDI engines
In vehicles equipped with 2.0 TDI engines used in the VW Crafter and MAN TGE, a design change has been introduced to the EGR branch in the exhaust manifold (see Fig. 1). The older version of the turbocharger has been discontinued – only the new version of the R2S turbocharger is currently available.
If the new version of the turbocharger is installed in a vehicle where the older version was previously fitted, additional mounting components are required. These components are not included with the turbocharger and must be ordered separately.
Fig. 1. Comparison of system versions (old / new) – the difference in the EGR branch area is marked with a circle.
Engines and turbochargers affected by the change
| Version | Vehicle | Engine Code | Production Date | R2S System BW PNs | R2S System VW PNs | R2S System MAN PNs | HP Stage BW PNs | HP Stage VW PNs | HP Stage MAN PNs |
| Old | VW Crafter/ MAN TGE 130 kW | DAVA | until 14.05.2017 | 10009700227 | 03N145703K | 65.09100-6000 | - | - | - |
| New | VW Crafter/ MAN TGE 130 kW | DAVA | from 15.05.2017 | 10009700225/-0238 10009700277/-0313 10009700358/-0359 10009700377/-0378 10009700381-/0382 10009700384/-0385 | 03N145703L 03N145703R 03N145703T 03N145704 03N145704E 03N145704K | 65.09100-6002 65.09100-6007 65.09100-6008 | 16359710024 16359710054 | 03N198701M 03N145713 | 65.09399-6002 65.09100-6010 |
Required additional mounting components (OEM part numbers)
The part numbers listed below apply to the components required to adapt the new version of the turbocharger to the older manifold/EGR configuration. We recommend verifying the correct selection by VIN (depending on the vehicle version and gearbox).
| Part | Quantity | VW Crafter (manual transmission) | VW Crafter (automatic transmission) | |
| Plate (item 5) | 1 | 03N145811B | 03N145811B | |
| Flanged bolt M6x8 (item 6) | 2 | N10688402 | N10688402 | |
| Gasket (items 9 and 16) | 2 | 03L131547P | 03L131547P | |
| Connecting pipe (item 10) | 1 | 04L131521BF | 04L131521BG | |
| Hex socket screw M8x20 (item 12) | 2 | N91026802 | N91026802 | |
| Hex socket screw M8x22 (item 13) | 2 | N91046101 | N91046101 | |
| Part | Quantity | MAN TGE (automatic transmission) |
| |
| Plate (item 5) | 1 | 65.08120-0001 |
| |
| Flanged bolt M6x8 (item 6) | 2 | 65.90405-0135 |
| |
| Gasket (items 9 and 16) | 2 | 65.08901-0002 |
| |
| Connecting pipe (item 10) | 1 | 65.08153-0013 |
| |
| Hex socket screw M8x20 (item 12) | 2 | 65.90030-0028 |
| |
| Hex socket screw M8x22 (item 13) | 2 | 65.90030-0038 |
| |
Fig. 2. Diagram of the adapter components required for installation (positions: 5, 6, 9, 10, 12, 13, 16).
Recommendations
- Verify the vehicle variant (model and gearbox) before installation.
- Treat part numbers as reference only – we recommend confirming the correct selection by VIN.
- Mounting components must be ordered separately (OE / parts supplier) – they are not included in the turbocharger kit.
Source of drawings and data: BORGWARNER manufacturer technical bulletin (Info No. S02B2023, 22.02.2023)
