“AdBlue system malfunction. Starting disabled in 2400 km.” If you drive a VW Crafter (2017+ SY/SZ generation), you’ve probably seen this warning at least once. VW Crafter AdBlue problems are among the most frustrating in the commercial vehicle world—from the notorious AdBlue injector that blocks every 60,000–100,000 miles, to quality sensors that fail without warning, to the dreaded P20BD fault code that locks you out of your van in 1,500 miles. The Crafter shares its platform and AdBlue system with the MAN TGE, so both vans suffer from identical faults. What makes Crafter AdBlue problems particularly difficult is that VW’s diagnostic system requires dealer-level tools (ODIS or VAS) to properly diagnose and reset the system—generic OBD2 scanners can read the codes but can’t clear the countdown or perform system resets. This comprehensive guide covers the 11 most common VW Crafter AdBlue problems (2017–2025 models), what causes them, how to diagnose which component has failed, the correct reset procedures, quick fixes you can try yourself, and when you need specialist help with ODIS diagnostic tools.
11 most common VW Crafter AdBlue problems (2017–2025)
1. AdBlue injector blockage (P20BD – most common fault)
Symptoms:
- “AdBlue system malfunction” message on dash
- Fault code P20BD (reductant dosing system injector circuit/open)
- Countdown: 2400 km → 1200 km → 400 km → starting disabled
- AdBlue consumption drops to zero (tank level doesn’t go down)
- White smoke from exhaust (unburned AdBlue vapour)
- Most common on vans used for short trips (city deliveries, courier work)
- Typically occurs at 60,000–100,000 miles
What causes it:
- Crystallised AdBlue blocking the injector nozzle (70% of cases) – happens when the injector doesn’t reach full operating temperature (short trips under 15 minutes)
- Contaminated AdBlue (sediment blocks the nozzle)
- Failed injector solenoid (won’t open to spray AdBlue)
- Corroded injector connector or wiring
- Carbon buildup on injector tip from exhaust gases
Quick fix (try this first – 40% success rate):
- Drive the van on a motorway for 40–50 minutes at 60+ mph (100+ km/h)
- High exhaust temperature (450–600°C) can burn off light crystallisation in the injector
- Keep the engine under moderate load (don’t just cruise—accelerate occasionally to raise exhaust temp)
- After the drive, turn off the engine, wait 5 minutes, restart
- If the warning clears or countdown stops reducing, the injector has self-cleaned
If that doesn’t work: Injector needs professional cleaning or replacement.
- Ultrasonic cleaning: Remove injector, clean in ultrasonic bath with AdBlue-safe cleaning solution, blow out with compressed air, test on bench. Cost: £120–£220. Success rate: 60–70%.
- Replacement: VW genuine injector (part 04L131113J or 04L131113M): £450–£750. Aftermarket (Bosch, Pierburg): £300–£550. Fitting: £100–£180 (1.5–2 hours labour). Coding with ODIS: £60–£100.
Prevention tip: If you do mostly short trips (under 15 minutes), schedule a weekly motorway run (30–40 minutes at 60+ mph) to allow the injector to reach full operating temperature and self-clean. This can extend injector life from 60,000 to 120,000+ miles.
2. AdBlue quality sensor fault (P20EE, P204F)
Symptoms:
- “AdBlue quality poor – top up AdBlue” message
- Fault codes P20EE (SCR NOx catalyst efficiency below threshold) or P204F (reductant system performance)
- Dash shows AdBlue level at 0% or “—” even with a full tank
- Warning appeared immediately after filling AdBlue tank
- Countdown: 2400 km to starting disabled
What causes it:
- Failed quality sensor (60% of cases) – VW part 04L907807AC is prone to failure at 70,000–120,000 miles
- White crystals (dried AdBlue) on the sensor probe inside the tank
- Corroded sensor connector (green/white deposits on pins)
- Contaminated AdBlue (water, diesel or wrong concentration)
- Sensor calibration drift (end of lifespan)
Quick fix (try this first):
- Top up the AdBlue tank to completely full (18 litres on SY Crafter, 24 litres on SZ long wheelbase)
- Turn the ignition on and off 3 times (don’t start the engine) to cycle the sensor
- Start the engine and drive for 20–30 minutes on a motorway
- If the countdown stops reducing or warning clears, the sensor was temporarily stuck
If that doesn’t work: Quality sensor needs cleaning or replacement.
- Cleaning: Access via AdBlue filler cap (sensor is inside the filler neck on a long probe). Remove sensor, rinse in warm water, scrub gently with soft brush, dry thoroughly, refit. Success rate: 30–40%.
- Replacement: VW genuine sensor (04L907807AC or updated 04L907807AE): £180–£350. Aftermarket (Bosch, VDO): £100–£220. Fitting: £80–£150 (1–2 hours labour). Coding with ODIS: £60–£100.
3. AdBlue pump failure (P20E8)
Symptoms:
- “AdBlue system malfunction” message
- Fault code P20E8 (reductant pressure too low)
- AdBlue consumption drops to zero (tank level doesn’t go down)
- You can’t hear the AdBlue pump priming when you turn the ignition on (should hear a faint whirring for 10–15 seconds)
- Countdown: 2400 km to starting disabled
What causes it:
- Pump motor failure (brushes worn out—common at 80,000–140,000 miles)
- Blocked pump filter (crystallised AdBlue or contamination)
- Corroded pump connector or wiring
- Running the AdBlue tank completely dry (air damages pump seals)
- Frozen AdBlue (pump can’t prime if AdBlue is frozen solid)
How to test the pump:
- Turn the ignition on (engine off)
- Listen for the pump—it’s under the van, driver’s side, mounted on the AdBlue tank
- You should hear a high-pitched whirring for 10–15 seconds
- If you hear nothing, check the pump fuse (fuse box under driver’s seat—check owner’s manual, usually SC42 or SC43)
- If the fuse is intact and you still hear nothing, the pump has failed
Replacement cost: VW genuine pump (part 04L131113B or 04L131113D): £550–£900. Aftermarket (Bosch, Pierburg): £400–£700. Fitting: £150–£250 (2–3 hours labour). Coding with ODIS: £60–£100.
4. AdBlue heater fault (P13DF – winter only)
Symptoms:
- “AdBlue heater malfunction” message
- Fault code P13DF (reductant heater control circuit)
- Warning appears only in cold weather (below 0°C / 32°F)
- Warning clears when the weather warms up
- Countdown: 2400 km to starting disabled
What causes it:
- Failed heater element in the AdBlue tank or pump (AdBlue freezes at -11°C / 12°F, heater prevents this)
- Blown heater fuse or corroded heater wiring
- Failed heater relay (located in fuse box under driver’s seat)
- Temperature sensor fault (reads -40°C even in summer—triggers heater circuit fault)
Quick fix (temporary):
- Park the van indoors or in a heated garage overnight
- Start the engine and let it idle for 20–30 minutes to warm the AdBlue system
- If the warning clears, the AdBlue was frozen but the heater is working—no repair needed
- If the warning stays on even after warming up, the heater has failed
Replacement cost: Heater element is integrated into the pump assembly on most Crafters, so you need to replace the whole pump (£550–£1,150 including pump, heater and fitting). On some models the heater is separate (£150–£300 + fitting).
5. AdBlue temperature sensor fault (P20E9)
Symptoms:
- “AdBlue system malfunction” message
- Fault code P20E9 (reductant temperature sensor circuit)
- Diagnostic scanner shows AdBlue temperature as -40°C or -48°C even in summer
- Warning often appears in cold weather, then clears when it warms up
What causes it:
- Failed temperature sensor in the AdBlue tank or pump
- Corroded sensor wiring or connector
- Water ingress into the sensor connector (common on vans parked outdoors)
Quick fix (if fault is intermittent):
- Jack up the van (driver’s side) and locate the AdBlue pump/tank under the van
- Inspect the temperature sensor connector (usually integrated into the pump or tank sensor)
- Spray with electrical contact cleaner and dry thoroughly
- Check for green/white corrosion on pins—clean with a small wire brush
- Clear codes with ODIS and test
If that doesn’t work: Temperature sensor needs replacing. On most Crafters, the sensor is integrated into the pump or tank sensor assembly, so you may need to replace the whole pump (£550–£900) or tank sensor (£180–£350).
6. NOx sensor failure (P2201, P2BAD – high mileage)
Symptoms:
- “AdBlue system malfunction” message
- Fault codes P2201 (NOx sensor circuit range/performance) or P2BAD (NOx sensor circuit low)
- Van has 100,000+ miles
- AdBlue consumption is normal (tank level drops as expected)
- All other components test OK (pump, injector, quality sensor)
What causes it:
- NOx sensor degraded (soot, oil or carbon contamination)
- Sensor calibration drifted out of spec (end of lifespan—100,000–150,000 miles)
- Poisoned sensor electrodes (from contaminated AdBlue or poor-quality diesel)
- Failed sensor heater element
Which sensor has failed: Crafters have two NOx sensors:
- Upstream NOx sensor (sensor 1): Before the SCR catalyst. Measures raw NOx from the engine.
- Downstream NOx sensor (sensor 2): After the SCR catalyst. Measures NOx after AdBlue treatment.
Check fault codes to identify which sensor: P2201/P2BAD usually refers to sensor 1 (upstream), P2203/P2BAF refers to sensor 2 (downstream).
Can you clean it? Sometimes—see our NOx sensor cleaning guide. Success rate: 30–40% for external contamination, 0% for internal sensor failure.
Replacement cost: VW genuine NOx sensor (part 04L907807D or 04L907807F): £450–£750 per sensor. Aftermarket (Bosch, Continental): £300–£550 per sensor. Fitting: £80–£150 per sensor. Coding with ODIS: £60–£100. Total per sensor: £440–£1,000.
7. AdBlue tank contamination (P204F)
Symptoms:
- “AdBlue quality poor – top up AdBlue” message
- Fault code P204F (reductant system performance)
- Warning appeared immediately after filling AdBlue tank (not before)
- AdBlue in the tank looks cloudy, yellow-tinged or has sediment
- Multiple fault codes (P20EE, P204F, P20BD all at once)
What causes it:
- Contaminated AdBlue (water, diesel, screenwash or wrong concentration)
- Old or expired AdBlue (over 18 months old, or stored in direct sunlight)
- Using opened or partially-used containers (exposure to air degrades urea concentration)
- Accidentally adding diesel or screenwash to the AdBlue tank
- Using non-ISO 22241 AdBlue (cheap, unknown brands)
Fix:
- Drain the AdBlue tank completely (siphon pump or drop the tank—access under the van, driver’s side)
- Flush with 5 litres of fresh AdBlue, then drain again
- Replace the AdBlue filter (located in the pump assembly or tank)
- Refill with fresh, sealed ISO 22241 AdBlue (15–20 litres)
- Clear fault codes with ODIS and perform AdBlue system reset
- Drive for 30–50 km to allow the SCR system to recalibrate
Cost: £40–£70 for fresh AdBlue + £20–£50 for filter + 2–3 hours labour if you do it yourself. Mobile service or garage: £200–£400 for complete drain, flush, filter replacement and refill.
8. Wiring and connector faults (P207F, intermittent warnings)
Symptoms:
- Intermittent AdBlue warnings (comes and goes, especially over bumps or in wet weather)
- Warning clears after restarting the engine, then returns after 10–100 km
- Multiple fault codes that don’t match the symptoms
- Fault code P207F (reductant level sensor circuit)
What causes it:
- Corroded connectors (green/white deposits on pins—common on vans parked outdoors or driven in winter with road salt)
- Chafed wiring (rubs against chassis or exhaust—common near the AdBlue tank under the van)
- Loose connector (vibration causes intermittent contact)
- Water ingress into connector (poor sealing or cracked connector housing)
Quick fix:
- Jack up the van (driver’s side) and inspect all AdBlue system connectors (tank sensor, pump, temperature sensor, injector)
- Look for green/white corrosion on pins, or white crystals (dried AdBlue)
- Disconnect each connector, spray with electrical contact cleaner, scrub with a small brush, dry thoroughly
- Check wiring for chafing, breaks or exposed copper—repair with solder and heat-shrink tubing
- Apply dielectric grease to connector pins to prevent future corrosion
- Clear codes with ODIS and test
Professional repair cost: £100–£220 for connector cleaning and wiring repair (1–2 hours labour).
9. SCR catalyst efficiency fault (P20EE – high mileage)
Symptoms:
- “AdBlue system malfunction” message
- Fault code P20EE (SCR NOx catalyst efficiency below threshold)
- Van has 120,000+ miles
- AdBlue consumption is normal
- All other components test OK
What causes it:
- SCR catalyst degraded (honeycomb structure coated with soot, ash or oil residue)
- Failed NOx sensor (can’t accurately measure NOx reduction)
- DPF blocked (excess soot contaminates the SCR catalyst)
- Long-term use of contaminated or poor-quality AdBlue (poisons the catalyst)
Fix options:
- Replace NOx sensors first: Often the sensors are reading incorrectly, not the catalyst itself. Cost: £440–£1,000 per sensor.
- Clean the SCR catalyst: Some specialists offer SCR cleaning (chemical flush or bake-out). Cost: £300–£500. Success rate: 40–50%.
- Replace the SCR catalyst: VW genuine: £1,500–£2,800 + £300–£500 fitting. Aftermarket: £1,000–£2,000 + fitting.
- AdBlue delete: Software modification to disable the AdBlue system (illegal for road use, MOT fail). Cost: £400–£700.
10. DPF regeneration triggering false AdBlue faults
Symptoms:
- “AdBlue system malfunction” appears during or immediately after a DPF regeneration
- Warning clears after 20–50 km of driving
- Fault code P20EE (SCR efficiency) but no actual AdBlue system fault
- Common on 2019+ Euro 6d Crafters with close-coupled DPF/SCR
What causes it:
- During DPF regeneration, exhaust temperature spikes to 600–700°C
- This temporarily affects NOx sensor readings (sensors are calibrated for 200–500°C normal exhaust temps)
- ECU sees abnormal NOx readings and triggers a false P20EE fault
- Fault is temporary and self-clears once exhaust temperature normalises
Fix:
- If the warning appears during or after a regen, drive normally for 20–30 km
- The warning should clear automatically once the exhaust cools
- If it doesn’t clear, use ODIS to check if the fault is still “active” or just “stored”
- Clear stored codes with ODIS and test
Prevention: Ensure DPF regenerations complete properly (don’t interrupt regens by turning off the engine). If your van does lots of short trips, schedule a monthly motorway run (30–40 minutes at 60+ mph) to allow a full regen cycle.
11. AdBlue level sensor fault (dash shows wrong level)
Symptoms:
- AdBlue gauge shows empty when tank is full, or full when tank is empty
- AdBlue level jumps erratically (50% → 10% → 80% within minutes)
- “AdBlue system malfunction” message with fault code P207F
- Warning may be intermittent (comes and goes over bumps)
What causes it:
- Failed level sensor float mechanism (stuck or broken float arm)
- Corroded sensor connector (green/white deposits on pins)
- White crystals (dried AdBlue) on the sensor probe
- Wiring fault between sensor and ECU
Quick fix (if fault is intermittent):
- Remove the blue AdBlue filler cap
- The level sensor is inside the filler neck on a long probe
- Pull the sensor out carefully (it’s connected by a wire—don’t pull too hard)
- Rinse in warm water, scrub gently with a soft brush, dry thoroughly
- Clean the connector with contact cleaner spray
- Refit, clear codes with ODIS, test
If that doesn’t work: Level sensor needs replacement. VW part 04L907807AC (combined quality + level sensor): £180–£350. Aftermarket: £100–£220. Fitting: £80–£150.
VW Crafter AdBlue reset procedures (ODIS required)
Critical: VW Crafter AdBlue systems require VW ODIS (Offboard Diagnostic Information System) or VAS (Vehicle Diagnostic System) tools to properly reset the countdown and clear fault codes. Generic OBD2 scanners can read codes but cannot reset the countdown or perform system resets.
Method 1: Clear codes and reset countdown (after fixing the fault)
When to use: After replacing a faulty component (injector, sensor, pump) or fixing a wiring fault.
- Connect ODIS diagnostic tool to the OBD port (under the steering column)
- Turn the ignition on (engine off)
- Navigate to: Engine Control Module → Fault Codes → Read Codes
- Note all stored codes (take a photo for reference)
- Select Clear All Codes
- Navigate to: Engine Control Module → Adaptations → AdBlue System Reset
- Select Reset AdBlue Countdown
- Confirm the reset (countdown should reset to 2400 km or disappear)
- Turn off the ignition, wait 30 seconds, restart the engine
- Check the dash—warning should be gone and countdown reset
Cost: If you have ODIS: free. Mobile service with ODIS: £60–£100. VW dealer: £120–£200.
Method 2: Force AdBlue system re-learn (after contamination or tank drain)
When to use: After draining/flushing the tank, replacing AdBlue with fresh fluid, or fixing contamination issues.
- Connect ODIS diagnostic tool
- Turn the ignition on (engine off)
- Navigate to: Engine Control Module → Adaptations → AdBlue System
- Select Reset AdBlue Quality Sensor
- Select Reset AdBlue Level Sensor
- Select Reset AdBlue Dosing System
- Turn off the ignition, wait 30 seconds
- Turn the ignition on (engine off) and wait 60 seconds (system will cycle all sensors)
- Start the engine and let it idle for 5 minutes
- Drive for 20–30 km to allow the system to recalibrate
Cost: Mobile service with ODIS: £80–£150. VW dealer: £150–£250.
Method 3: Manual injector cleaning cycle (try before replacing injector)
When to use: For P20BD injector faults where you suspect crystallisation (not complete injector failure).
- Connect ODIS diagnostic tool
- Turn the ignition on (engine off)
- Navigate to: Engine Control Module → Basic Settings → AdBlue Dosing Valve
- Select Activate Dosing Valve (this forces the injector to cycle open/closed 10 times)
- Listen for clicking from the injector (under the van, exhaust downpipe area)
- Repeat the activation 3–5 times
- Clear fault codes
- Start the engine and drive for 30–40 minutes on a motorway at 60+ mph
- Check if the fault returns
Success rate: 30–40% for light crystallisation. If the fault returns within 50 km, the injector needs cleaning or replacement.
MAN TGE AdBlue problems (identical to VW Crafter)
The MAN TGE shares the same platform, engine and AdBlue system as the VW Crafter. All faults, diagnostic procedures and fixes in this guide apply equally to the MAN TGE.
Key differences:
- Badging and trim only—mechanically identical
- Uses the same diagnostic software (ODIS or MAN-cats)
- Same part numbers for AdBlue components (pump, sensors, injector)
- Same fault codes and symptoms
If you’re searching for “MAN TGE AdBlue problems,” all the information in this guide applies to your van.
How to diagnose VW Crafter AdBlue faults (step-by-step)
Step 1: Read the fault codes
VW Crafters require ODIS or VAS diagnostic tools for full diagnostics (generic OBD2 scanners will only read basic codes, not VW-specific codes or live data).
Options:
- Basic OBD2 scanner: £20–£50 (Halfords, Amazon). Will read generic codes (P20EE, P20BD) but not VW-specific codes or live data.
- VW ODIS diagnostic: Professional diagnostic system (requires dealer tools—£2,500+). Can read all codes, live data, perform resets and coding.
- Aftermarket professional scanner: Launch, Autel, Snap-on with VW software (£500–£2,000). Can read most VW codes and live data.
- Mobile diagnostic service: We carry VW ODIS and Autotuner—can read all codes, live data and perform resets on-site. Cost: £60–£100 for diagnostics.
Key codes to look for:
- P20BD: Injector circuit fault (most common)
- P20EE / P204F: Quality sensor, contamination, or SCR efficiency
- P20E8: Pump failure or air in system
- P13DF / P20E9: Heater or temperature sensor fault
- P207F: Wiring or level sensor circuit fault
- P2201 / P2BAD: NOx sensor fault (upstream or downstream)
Step 2: Check AdBlue level and quality
Even if the dash says “AdBlue empty,” physically check the tank:
- Locate the blue AdBlue filler cap (usually on the driver’s side, near the diesel filler)
- Remove the cap and use a torch to look inside
- AdBlue should be clear and colourless (not cloudy, yellow or with sediment)
- Top up with at least 10 litres of fresh, sealed ISO 22241 AdBlue
- Restart the engine and check if the warning clears or countdown stops reducing
Step 3: Check live data (if you have ODIS)
With the engine running, check:
- AdBlue level sensor: Should read 30–100% (matches actual tank level)
- AdBlue temperature: Should climb from ambient (20°C) to 60–80°C after 10 minutes of driving
- AdBlue pressure: Should read 4–7 bar when the engine is running
- NOx sensor readings: Upstream 200–800 ppm, downstream 0–100 ppm
- AdBlue dosing rate: Should be 0.5–2% of fuel consumption (varies with load and speed)
- Injector duty cycle: Should show 0–100% (varies with engine load)
If any reading is stuck at 0, maximum, or doesn’t change, that component has failed.
Step 4: Inspect components under the van
Jack up the van (driver’s side) and inspect:
- AdBlue tank: Under the van, driver’s side, behind rear wheel. Check for leaks, cracks, white crystalline deposits.
- AdBlue pump: Mounted on the tank. Check connector, listen for pump priming when ignition is turned on.
- Wiring: Follow the wiring from the tank/pump forward to the engine bay. Check for chafing, breaks, corrosion, white crystals.
- AdBlue injector: Located in the exhaust downpipe (after turbo, before DPF/SCR). Check connector and wiring.
Quick fixes you can try before calling a specialist
Fix 1: Motorway burn-off (for P20BD injector faults)
For: P20BD injector faults where the injector is blocked with crystallised AdBlue.
- Drive on a motorway for 40–50 minutes at 60+ mph (100+ km/h)
- Keep the engine under moderate load (accelerate occasionally to raise exhaust temp to 450–600°C)
- High exhaust temperature can burn off light crystallisation
- After the drive, turn off the engine, wait 5 minutes, restart
- Check if the warning has cleared or countdown has stopped reducing
Success rate: 40–50% for light crystallisation, 0% for complete injector failure.
Fix 2: Top up and cycle (for quality sensor faults)
For: P20EE or P204F faults when AdBlue level is low (under 25%).
- Top up the AdBlue tank to completely full (18–24 litres)
- Turn the ignition on and off 3 times (don’t start the engine) to cycle the sensor
- Start the engine and drive for 20–30 minutes on a motorway
- Turn off the engine, wait 2 minutes, restart
- Check if the countdown has stopped or warning has cleared
Success rate: 30–40% for temporary sensor glitches.
Fix 3: Clean connectors (for intermittent faults)
For: Intermittent warnings (P207F, warnings that come and go).
- Jack up the van (driver’s side) and locate all AdBlue system connectors
- Disconnect each connector and inspect for corrosion (green/white deposits) or white crystals
- Spray with electrical contact cleaner, scrub with a small brush, dry thoroughly
- Apply dielectric grease to pins to prevent future corrosion
- Reconnect, clear codes with ODIS (if available), test
Success rate: 60–70% for wiring/connector faults.
Fix 4: Warm up the system (for winter heater faults)
For: P13DF heater faults in cold weather.
- Park the van indoors or in a heated garage overnight
- Start the engine and let it idle for 20–30 minutes
- If the warning clears, the AdBlue was frozen but heater is working
- If warning stays on even after warming, heater has failed
Success rate: 60–70% for temporary freezing issues, 0% for failed heater element.
When to call a mobile specialist
Call for professional help if:
- You’ve tried the quick fixes above and the warning won’t clear
- The countdown is under 400 km (urgent—starting will be disabled once it hits zero)
- You don’t have ODIS diagnostic tools to read codes, check live data or reset the countdown
- The fault is intermittent and hard to diagnose without live data monitoring
- Multiple fault codes are stored (suggests complex fault or multiple failed components)
- You need parts replaced (injector, pump, sensor) and don’t have tools or access to lift the van
- You need ODIS coding/calibration (required after replacing injector, NOx sensors or pump)
- The countdown won’t reset even after fixing the fault (requires ODIS reset procedure)
Our mobile AdBlue service covers Stoke-on-Trent, Newcastle-under-Lyme, Stafford, Crewe and surrounding areas. We carry VW ODIS and Autotuner diagnostic tools, plus common replacement parts (injectors, sensors, pumps, filters). Same-day service available. Call 07503 134 362.
“Got P20BD on my 2019 Crafter at 68,000 miles—’AdBlue system malfunction, starting disabled in 2400 km,'” Dave the delivery driver told me. “I do city deliveries, 40–50 drops a day, engine never gets properly hot. Tried a 30-minute motorway run like the forums said—countdown kept going down. Called two garages—both said ‘needs a new injector, £650–£800, 3-day wait for parts.’ Called you, you came out same afternoon with ODIS. Checked live data, showed me the injector was trying to dose but pressure was zero—blocked nozzle. Pulled the injector out, took it away for ultrasonic cleaning, brought it back 2 hours later, refitted it, ran the ODIS cleaning cycle, cleared the codes, reset the countdown. Warning gone, AdBlue consumption back to normal. £180 for cleaning and reset instead of £650+ for a new injector. You also told me to do a weekly 20-minute motorway run to keep the injector hot—been doing that for 6 months now, no problems since.”
VW Crafter AdBlue Problems FAQ
What are the most common VW Crafter AdBlue problems?
The most common faults are: AdBlue injector blockage (P20BD—70% of cases, typically at 60,000–100,000 miles), quality sensor failures (P20EE/P204F), pump failures at 80,000–140,000 miles, heater faults in winter (P13DF), NOx sensor failures at high mileage, and wiring/connector corrosion causing intermittent faults.
How do I reset the AdBlue warning on a VW Crafter?
You can’t reset the warning without fixing the root cause first. Once fixed, use VW ODIS diagnostic tools to clear the fault codes and reset the countdown. Generic OBD2 scanners cannot reset the countdown on Crafters. Disconnecting the battery won’t work—the countdown is stored in non-volatile memory.
How much does it cost to fix VW Crafter AdBlue problems?
Injector ultrasonic cleaning: £120–£220
Injector replacement: £550–£930 (injector + fitting + coding)
Quality sensor replacement: £260–£500 (sensor + fitting + coding)
Pump replacement: £700–£1,150 (pump + fitting + coding)
NOx sensor replacement: £440–£1,000 per sensor (sensor + fitting + coding)
Tank drain/flush (contamination): £200–£400
Diagnostics with ODIS: £60–£100
Can I drive my VW Crafter with the AdBlue warning light on?
Yes, but only until the countdown reaches zero. The warning gives you 2400 km (1,500 miles) to get it fixed, then reduces to 1200 km, then 400 km, then starting is disabled. Don’t ignore it—get it diagnosed and fixed before you run out of kilometres.
Why does my VW Crafter AdBlue injector keep blocking?
AdBlue injector blockage (P20BD) is caused by crystallised AdBlue in the nozzle. This happens when the injector doesn’t reach full operating temperature (400°C+), which is common on vans used for short trips (under 15 minutes). Prevention: schedule a weekly motorway run (30–40 minutes at 60+ mph) to allow the injector to reach full temperature and self-clean.
How long does AdBlue last in a VW Crafter?
Depends on engine size, driving style and load. Typical consumption: 1 litre of AdBlue per 600–1,000 km. 2.0 TDI: 800–1,000 km per litre. Heavy loads and motorway driving increase AdBlue consumption. Tank capacity: 18 litres (SY short wheelbase), 24 litres (SZ long wheelbase).
Where is the AdBlue tank on a VW Crafter?
Under the van, driver’s side, behind the rear wheel. Access for sensor cleaning: via the blue AdBlue filler cap (sensor is inside the filler neck). Access for pump replacement: jack up the van and remove plastic undertray.
Are MAN TGE AdBlue problems the same as VW Crafter?
Yes—the MAN TGE and VW Crafter are mechanically identical (same platform, engine, AdBlue system). All faults, diagnostic procedures and fixes are the same. They also share the same parts and diagnostic software (ODIS).
For related VW Crafter and MAN TGE AdBlue guides, see our AdBlue warning light won’t go off troubleshooting, NOx sensor cleaning guide, AdBlue injector cleaning guide, or top AdBlue fault codes explained.
VW Crafter or MAN TGE AdBlue fault won’t clear?
We diagnose and fix all VW Crafter and MAN TGE AdBlue faults on-site across Stoke-on-Trent, Newcastle-under-Lyme, Stafford and Crewe. Injector cleaning, sensor replacement, pump replacement, code clearing and countdown resets using VW ODIS diagnostic tools. Same-day service available.
07503 134 362 | ✉ info@adbluespecialist.co.uk
Hours: Mon–Sun 09:00–20:00 | Average response time: 30–90 minutes
