Workshop Manual Transporter 2016 20-29

Service
Workshop Manual
Transporter 2016 ➤
Auxiliary heater
Edition 02.2019
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
82 - Supplementary heating
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B8056764E

Auxiliary heater - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on vehicles with auxiliary/supplementary heater . . . . . . 2
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Starting conditions for auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.3 Rules for cleanliness s agen working on auxiliary/supplementary
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tcleanliness . . . . . . . . . . . . . . . . . . . . . . . . . e. o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.2 Generalss information . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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3.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.6 Pipe/wire routing and attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1 Overview of fitting locations - auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . 8
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1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 8
2 Auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.1 Overview of fitting locations - auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . 9
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2.2 Assembly overview - auxiliary/supplementary heater, internal . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Assembly overview - auxiliary/supplementary heater attachments . . . . . . . . . . . . . . . . . . 12
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2.4 Removing and installing auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.5 Removing and installing air intake silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2.6 Removing and installing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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2.7 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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2.8 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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2.9 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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2.10 Removing and installing glow plug with flame monitor Q8 . . . . . . . . . . . . . . . . . . . . . . . . 20

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2.11 Removing and installing temperature sensor G18 and overheating sensor G189 . . . . . . . 21
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2.12 Removing and installing auxiliary heater control unit J364 . . . . . . . . . . . . . . . . . . . . . . . . 22
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2.13 Removing and installing combustion air blower V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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2.14 Connector pin assignment for auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . 22
3 Coolant circuit with auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Removing and installing heater coolant shut-off valve N279 . . . . . . . . . . . . . . . . . . . . . . 24
4 Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Checking fuel delivery rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Regulation of auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Switching off auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Removing and installing ambient temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Removing and installing remote control receiver for auxiliary coolant heater R149 . . . . . . 31
6.3 Functional description of remote control for auxiliary/supplementary heater . . . . . . . . . . . . 31
7 Auxiliary air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Contents i
7.1 Assembly overview - Airtronic D3 auxiliary air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.2 Removing and installing auxiliary air heater Airtronic D3 . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Removing and installing air intake silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4 Assembly overview - exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.5 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.6 Removing and dismantling auxiliary air heater bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.7 Removing and installing auxiliary air heater control unit J604 . . . . . . . . . . . . . . . . . . . . . . 44
7.8 Removing and installing heater in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.9 Removing and installing burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.10 Removing and installing glow plug for heater Q9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.11 Removing and installing mantle of Airtronic »D3« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.12 Removing and installing flame monitor G64 and overheating sensor G189 (combination
sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.13 Removing and installing combustion air blower V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.14 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.15 Removing and installing temperature sensor G18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8 Fuel supply to auxiliary air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1 Removing and installing metering pump 2 V386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.2 Checking fuel delivery rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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9 Regulation of auxiliary air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.1 Principle of auxiliary air heater operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.2 Function of auxiliary air heater operating and display unit E407 or roof display unit J702
........................................................................ 65
9.3 Removing and installing auxiliary air heater operating and display unit E407 or roof display
unit J702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.4 Removing and installing operating and display unit for camping equipment E153 . . . . . . 66
10 Other components of auxiliary air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1 Function description of remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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1 Safety information
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⇒ “1.1 Safety precautions during work on fuel system”,
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page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 1
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⇒ “1.3 Safety precautions when using testers and measuring in‐
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struments during a road test”, page 2

⇒ “1.4 Safety precautions when working on the cooling system”,
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⇒ “1.5 Safety precautions when working on vehicles with auxiliary/
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1.1 Safety precautions during work on fuel system
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Danger of fire caused by escaping fuel

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– Disconnect voltage supply to fuel pump before opening the
fuel system.
Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
– Wear protective goggles.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connection
and carefully loosen the connection.
1.2 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
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1.4 Safety precautions when working on the cooling system
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Danger of scalding by hot coolant
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On a warm engine, the cooling system is under high pressure.
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Danger of scalding by steam and hot coolant.
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– Reduce excess pressure by covering cap of coolant expan‐

sion tank with cloths and opening it carefully.
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1.5 Safety precautions when working on vehicles with auxiliary/supplementary

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an explosion. Risk of burns.
– Switch the auxiliary/supplementary heater off in fire and ex‐
plosion-endangered areas.
Danger of poisoning from exhaust fumes

auxiliary/supplementary heaters produce poisonous exhaust
fumes. Risk of poisoning and injuries to respiratory system.
– In closed areas, only switch on the auxiliary/supplementary
heated when it is exclusively connected to an exhaust extrac‐
tor system.
– In closed areas without an exhaust extractor system, switch
off the auxiliary/supplementary heater.
2 Rep. gr.00 - Technical data

Risk of damage when starting the engine

If components of the fuel system or coolant circuit of the auxiliary/
supplementary heater are removed or opened, there is a possi‐
bility of causing damage to the auxiliary/supplementary heater.
– Never attempt to start the engine when components are re‐
moved or opened.
Malfunction caused by air in the fuel supply system

Upon repair work on the fuel tank or the fuel delivery unit, air will
be drawn in by the metering pump and conveyed to the auxiliary/
supplementary heater. Air in the fuel supply system may cause
malfunction of the auxiliary/supplementary heater.
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– Fill fuel take-off pipe with fuel.
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Risk of accidents and risk of injury due to activated timer of aux‐
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If the vehicle’s timer for the auxiliary/supplementary heater is ac‐
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poisoning from exhaust gases, a risk of burns caused by hot aux‐
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iliary/supplementary heater components as well as a risk of fire
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and explosions caused by high temperatures.
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– Deactivate timer for auxiliary/supplementary heater.
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1. Safety information 3
2 General information
⇒ “2.1 Type plates”, page 4
⇒ “2.2 Starting conditions for auxiliary/supplementary heater”,
page 4
⇒ “2.3 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 5
2.1 Type plates

There are different types of type plates.
When the auxiliary heater is renewed, check the type plate and
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Type plate on auxiliary/supplementary
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♦ The date of sfirst
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♦ The year the unit was first put into use must be entered on the
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Genuine part manufacturer's plate.
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Duplicate type plate for auxiliary/supplementary heaters t to the co
♦ In the engine compartment of the vehicle, there is a second

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(duplicate) type plate attached to the right of the lock carrier

(when looking in direction of travel). If there is any doubt con‐
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cerning the type of the auxiliary/supplementary heater, always

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observe the type plate attached directly to the auxiliary/sup‐

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2.2 Starting conditions for auxiliary/supple‐
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mentary heater
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♦ Engine type OK (diesel/petrol)
♦ Terminal 15 (ignition) on
♦ Engine speed > 600 rpm
♦ Coolant temperature < 69 °C
♦ Ambient temperature < 5 °C
♦ Reserve fuel level not reached
♦ Line filling carried out
♦ On-board network manager not active
♦ No crash switch-off
♦ No event memory entries blocking start procedure

2.3 Rules for cleanliness when working on

auxiliary/supplementary heater and fuel
system
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place parts that have been removed on a clean surface (use
sheeting or paper, no cloths containing lint) and cover.
♦ If repair work cannot be performed immediately, carefully cov‐ wagen AG. Volkswagen AG does
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♦ Only install clean parts: horis e
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– Remove replacement parts from their packages s a immedi‐
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– Do not use any parts which have not been stored in their pack‐
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♦ If fuel line has been opened:
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– Do not work with compressed air.
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– Do not move the vehicle.
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– Do not start engine.
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– Do not switch auxiliary heater on.
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2. General information 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 General information”, page 6
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Contact corrosion”, page 7
⇒ “3.4 Contact corrosion”, page 7
⇒ “3.6 Pipe/wire routing and attachment”, page 7
3.1 Rules for cleanliness

Even small amounts of contamination/soiling can lead to defects.
Therefore, observe the following rules for cleanliness when work‐
ing on the air conditioning system:
♦ Seal open pipes and connections immediately with clean
plugs for example from the engine bung set - VAS 6122- .
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♦ Place removed parts on a clean bsurface
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♦ If repair work cannot be sperformed
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♦ Install only clean parts; do not remove new parts from pack‐
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aging until immediately before installing. Do not use parts that
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♦ If system is open, do not work with compressed air.
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spec
♦ Protect disconnected electrical connectors from dirt and water,
es, in part or in w
and only reconnect them in dry condition.

t to the co
3.2 General information
rrectness of i
♦ The engine/motor control unit has a self-diagnosis capability.

Before carrying out repairs and for fault finding, first read event
l purpos
memory.
♦ For trouble-free operation of electrical components, a voltage
nform
ercia
of at least 11.5 volts is necessary.

m
a
com
♦ Do not use sealants containing silicone. Particles of silicone

ion in
drawn into the engine will not be burnt in the engine and dam‐
r
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age the lambda probe.

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♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces

um
fo
the danger of a fire in a crash as the fuel pump is switched off

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via the fuel pump relay.
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♦ The system also improves the starting characteristics of the
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engine. When the driver door is opened, the fuel pump is ac‐ by c lksw
cted agen
tivated for 2 seconds to build up pressure in the fuel system. Prote AG.
3.3 General repair instructions

Never attempt to repair any components of the auxiliary/supple‐
mentary heater. Defective components must be replaced with
Genuine parts.
– Read self-diagnosis of auxiliary/supplementary heater using
⇒ Vehicle diagnostic tester.
– When parts of the fuel system are removed or renewed, en‐
sure that all components for fuel delivery to the auxiliary/
supplementary heater are properly installed.
– Mark coolant hoses before removing to avoid any confusion
when reconnecting.

Following repair work in the vicinity of the auxiliary/supplementary

heater fuel line, check the following points:
♦ that the fuel lines are routed flush with the vehicle underbody
and are protected against mechanical damage.
♦ that the auxiliary/supplementary heater fuel line is protected
from heating which might disturb operation.
♦ The fuel line does not come in contact with parts that become
hot.
3.4 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
installed in the vehicle.
Furthermore, rubber and plastic components as well as adhe‐
sives are made of non-conductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue (ETKA) .
satelettronica
3.5 Nuts and bolts
♦ Specified torques given are for unlubricated nuts and bolts.
♦ Always renew self-locking bolts and nuts.
♦ Always renew nuts and bolts with turning further angle.
AG. Volkswagen AG d
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3.6 Pipe/wire routing and attachment ol not
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Risk of damage to lines utho eo
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Lines may become damaged by moving or hot components.
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– Route lines in their original positions.

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– Make sure there is sufficient clearance between the lines and

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moving as well as hot components.

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3. Repair instructions 7
82 – Supplementary heating
1 Overview of fitting locations - auxili‐
ary/supplementary heater
⇒ “1.1 Overview of fitting locations - components not located in
passenger compartment”, page 8
1.1 Overview of fitting locations - components not located in passenger com‐

partment swa
gen AG
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1 - Fuel tank utho eo
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❑ Removing sa
and sinstalling c
ce
le
⇒ Fuel supply - diesel

un
pt
engines; Rep. gr. 20 ;
an
d
itte
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Fuel tank; Removing
rm
ab
and installing fuel tank .
pe
ility
ot
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, is n
2 - Fuel line
h re
satelettronica
hole
spec
3 - Fuel gauge sender - G-
es, in part or in w
❑ Removing and installing
t to the co
⇒ Rep. gr. 20 ; Fuel de‐
livery unit/fuel gauge
sender; Removing and
rrectness of i
installing fuel delivery
l purpos
unit/fuel gauge sender

4 - Air intake silencer
nform
ercia

⇒ page 15
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tion in
5 - Exhaust system
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thi

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⇒ page 17
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6 - Auxiliary heater
n
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⇒ page 9
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by
7 - Metering pump - V54-
cted agen
Prote AG.
⇒ page 27
❑ Testing quantity of fuel
delivered ⇒ page 26
8 - Circulation pump - V55-
⇒ page 15
9 - Remote control receiver for
auxiliary coolant heater -
R149- or remote control receiver for auxiliary heating - R64-
❑ Removing and installing ⇒ page 31
10 - Shut-off valve for heater coolant - N279-
11 - Ambient temperature sensor - G17-
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Other control components;
Removing and installing ambient temperature sensor G17
8 Rep. gr.82 - Supplementary heating

2 Auxiliary/supplementary heater
⇒ “2.1 Overview of fitting locations - auxiliary/supplementary heat‐
er”, page 9
⇒ “2.2 Assembly overview - auxiliary/supplementary heater, in‐
ternal”, page 11
⇒ “2.3 Assembly overview - auxiliary/supplementary heater at‐
tachments”, page 12
⇒ “2.4 Removing and installing auxiliary/supplementary heater”,
page 13
⇒ “2.5 Removing and installing air intake silencer”, page 15
⇒ “2.6 Removing and installing circulation pump V55 ”,
page 15
⇒ “2.7 Removing and installing exhaust system”, page 17
⇒ “2.8 Removing and installing cover”, page 18
⇒ “2.9 Dismantling and assembling heater unit”, page 19
⇒ “2.10 Removing and installing glow plug with flame monitor Q8
satelettronica
”, page 20
⇒ “2.11 Removing and installing temperature sensor G18 and
overheating sensor G189 .”, page 21
⇒ “2.12 Removing and installing auxiliary heater control unit J364
”, page 22
⇒ “2.14 Connector pin assignment for auxiliary/supplementary
heater”, page 22
2.1 Overview of fitting locations - auxiliary/supplementary heater

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2. Auxiliary/supplementary heater 9
1 - Auxiliary/supplementary
heater
⇒ page 13
❑ Dismantling and assem‐
bling ⇒ page 19
2 - Bracket for auxiliary/supple‐
mentary heater
3 - Bracket
4 - Rubber mounting
5 - Electrical connector
6 - Coolant hose
❑ Removing and installing lkswage es n
⇒ page 15 d byV
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8 - Bracket utho
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❑ For circulation pump - ss
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9 - Exhaust system
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⇒ page 17
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10 - Bracket
hole
spec
❑ For circulation pump -
es, in part or in w
t to the co
V55-
11 - Bolt
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❑ 6 Nm
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12 - Rubber mounting
13 - Bolt
nform
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❑ 20 Nm
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2.2 Assembly overview - auxiliary/supplementary heater, internal
1 - Bolts
❑ Qty. 3
❑ 7 Nm
2 - Heat exchanger n AG. Volkswagen AG do
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⇒ page 19 ised b ran
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3 - Seal au
t or
ac
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❑ Must be renewed each
ce
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un
pt
time after opening
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❑ Observe installation po‐
rm
ab
sition
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4 - Combustion chamber insert
h re
hole
spec
⇒ page 19
es, in part or in w
t to the co
5 - Glow plug with flame moni‐
satelettronica
tor - Q8-
rrectness of i
❑ Ensure it is properly
seated
l purpos

⇒ page 20
nform
ercia
6 - Cover
m
❑ For auxiliary heater con‐ a

com
tion in
trol unit - J364-
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thi

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⇒ page 18
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7 - Cover
n
t.
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8 - Auxiliary heater control unit ht. rig
rig ht
- J364- with combustion air py by
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blower - V6-
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Prote AG.
Note
The auxiliary heater control unit -

J364- and the combustion air blower
- V6- with housing form one compo‐
nent and cannot be dismantled. The
reason is the seal between the aux‐
iliary heater control unit - J364- and
the housing.
9 - Noise insulation
10 - Cover
11 - Coolant connection
❑ Mark installation position before removing
12 - Seals
❑ Renew after removal
13 - Retainer
14 - Bolt
❑ 4 Nm
15 - Coolant connection
❑ Mark installation position before removing
16 - Temperature sensor - G18-
17 - Retaining spring
18 - Bolt
❑ 4 Nm
19 - Overheating sensor - G189-
2.3 Assembly overview - auxiliary/supplementary heater attachments
1 - Bracket
❑ For auxiliary heater
2 - Bolts
satelettronica
❑ Qty. 3 AG. Volkswagen AG d
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❑ 6 Nm d by V gu
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3 - Rubber mounting autho eo
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4 - Air intake silencer
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⇒ page 15
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5 - Exhaust system
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hole
⇒ page 17
spec
es, in part or in w
t to the co
heater
7 - Bracket rrectness of i
❑ For circulation pump -
l purpos
V55- and air intake si‐

lencer
nform
ercia
8 - Bolts
❑ Qty. 2
m
at
om
io
❑ For bracket of circula‐

n
c
in t
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tion pump - V55- and air

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intake silencer
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❑ 6 Nm
um
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9 - Bracket
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❑ For circulation pump - yri
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⇒ page 15
11 - Clip
12 - Coolant hose
13 - Bolt
❑ 8 Nm

14 - Coolant hose
15 - Bolt
❑ 20 Nm
16 - Rubber mounting
2.4 Removing and installing auxiliary/sup‐ n AG. Volkswagen AG

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Special tools and workshop equipment requireds aut ra
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s
♦ Hose hose clamps, up to 25 mm - 3094-
ce
le
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pe
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satelettronica
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♦ Engine bung set - VAS 6122-
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♦ Drip tray for workshop hoist - VAS 6208-
♦ Vehicle diagnostic tester

Removing
– Connect ⇒ Vehicle diagnostic tester and start function “Renew
heater” under “Guided Fault Finding” or “Guided Functions”.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery .
– Remove left underbody cladding ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Underbody cladding; Assembly overview
- underbody cladding .
– Clamp off coolant hoses of auxiliary heater using hose clamps
up to 25 mm - 3094- .
– Open hose clips of coolant hoses.
– Place drip tray for workshop hoist - VAS 6208- underneath.
CAUTION lkswage es n
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On a warm engine, the cooling system is under high pressure. o
ir se tee
Danger of scalding by steam and hot coolant. auth or
ac
ss
Skin and other parts of the body may be scalded.
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– Wear protective goggles. erm
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ility
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spec
– Pull off coolant hoses from auxiliary heater.
es, in part or in w
t to the co
satelettronica
CAUTION
rrectness of i
The fuel system is pressurised.
Danger of injury caused by fuel spray.
l purpos

nform
ercia
– To release pressure, wrap a clean cloth around the connec‐

m
at
om
tion and carefully loosen the connection.
ion
c
in t
or
his
ate
– Pull off fuel line from auxiliary heater to metering pump - V54-
do
riv
and seal with engine bung set - VAS 6122- .

p
cum
for
en
ng
t.
– Secure auxiliary heater with welding wire to prevent it from op
yi Co
falling down.
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– Separate electrical connectors. cop Vo
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– Unscrew bolt -3- from bracket -1-.
Note
Observe the installation position of the rubber disc -2-.

lkswage es n Auxiliary heater - Edition 02.2019
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– Lower auxiliary heater
tho
ris -1- with bracket -2- in direction of eo
-arrow-. au ra
c
ss
ce
le
– Pull out auxiliary heater -1- with bracket -2- from rubber mount‐
un
pt
ings -3-.
an
d
itte
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ab
Installing
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Install in reverse order of removal, observing the following:
is n
h re
ole,
– Bleed coolant circuit ⇒ Rep. gr. 19 ; Cooling system, coolant;
spec
Draining and filling coolant .
t to the co
Specified torques
♦ ⇒ “2.3 Assembly overview - auxiliary/supplementary heater
rrectne
attachments”, page 12
ss
2.5 Removing and installing air intake si‐
o
cial p
f in
lencer
form
mer
atio
Removing
om
n
c
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or
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satelettronica
iv
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en
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– Unscrew bolts -3-.

t.
yi Co
Cop py
.
– Lower auxiliary heater -2- in direction of -arrow A-.
t rig
gh ht
pyri by
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cted agen
Prote AG.
Note
The lines and coolant hoses remain connected.
– Release spreader clip of air intake silencer -1- in direction of

-arrow B-.
– Pull off air intake silencer from auxiliary heater -2-.
Installing
Note
♦ The air intake silencer must not touch the auxiliary/supple‐

mentary heater housing.
♦ Do not kink or crush aluminium pipe.
Specified torques
2.6 Removing and installing circulation

pump - V55-
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - 3094-
satelettronica
Removing
- underbody cladding . agen
AG. Volkswagen AG d
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CAUTION ris
ed ran
tee
tho or
On a warm engine, the under high cooling
au system is pressure. ac
ss
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un
pt

an
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erm
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wit
is n

h re
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spec
t to the co
rrectness o
cial p
f inform
mer
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t. rig
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– Clamp off coolant hoses -1- on circulation pump - V55- -5- us‐
ing hose clamps, up to 25 mm - 3094- .
– Separate electrical connector -3-.
– Loosen hose clips -2- and pull off coolant hoses.
– Pull coolant hoses -1- off circulation pump - V55- -5-.
– Pull off rubber mounting -4- with circulation pump - V55- -5-
from bracket.
Installing
– Bleed cooling system ⇒ Rep. gr. 19 ; Cooling system, coolant;
Draining and filling with coolant .
2.7 Removing and installing exhaust system
satelettronica
Removing
AG. Volkswagen AG d
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– Remove left underbody cladding ⇒ General body repairs, yV
olex‐
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gu
terior; Rep. gr. 66 ; Underbody cladding; Assemblyiseoverview
db ara
nte
- underbody cladding . tho
r eo
au ra
c
ss
CAUTION
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Danger of severe burns from hot exhaust system.
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Burns to hands and other body parts possible.
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– Allow exhaust system to cool.
wit
, is n
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hole
spec
– Unscrew bolt -2-.
es, in part or in w
t to the co
– Pull off exhaust system -1- from heat exchanger in direction of
-arrow-.
rrectness of i
Installing
l purpos
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at
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ate
do
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Risk of damage to lines

Lines may become damaged by moving or hot components.
– Route lines in their original positions.
– Make sure there is sufficient clearance between the lines and
moving as well as hot components.
Specified torques
2.8 Removing and installing cover

nA G. Volkswagen AG d
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⇒ “2.8.1 Removing and installing
ris
ed cover, auxiliary heater control nte
unit J364 ”, page 18 au
tho eo
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⇒ “2.8.2 Removing and installing cover, burner unit”, page 18
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2.8.1 Removing and installing cover, auxiliary

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heater control unit - J364-
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Removing
h re
ole,
spec
– Remove auxiliary heater ⇒ page 13 .
t to the co
– Unclip cover -1- in area -2-.
– Take off cover -1-.
rrectne
satelettronica
Installing
ss o
cial p
f
Install in reverse order of removal.
inform
mer
atio
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n
c
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2.8.2 Removing and installing cover, burner
Co
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unit
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agen
Prote AG.
♦ Torque wrench - V.A.G 1410-

Removing
– Remove auxiliary heater ⇒ page 13 .
– Detach coolant connections together with bracket -4-.
– Unclip cover -1- in area -2-.
Installing

– Check sealing surfaces for soiling and damage.
– Moisten oil seals with coolant before installingecoolant
n AG. Volkcon‐
swagen AG
nections. olks
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– Renew oil seals -3-. rise nte
tho eo
– Insert coolant connections together with bracket -2-. au ra
c
ss
satelettronica
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– Tighten bolt -1-.

nl
pt
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itte
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Specified torques
erm
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ility
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⇒ “2.2 Assembly overview - auxiliary/supplementary heater, in‐
wit
, is n
ternal”, page 11
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.9 Dismantling and assembling heater unit

nform
ercia

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at

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ate
do
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en
ng
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
Dismantling
– Remove cover ⇒ page 18 .
– Separate electrical connectors from temperature sensor -
G18- and overheating sensor - G189- .
– Pull heat exchanger off blower housing.
– Remove seal -1-.

– Separate electrical connector -3-.
– Remove battery unit.
Installing
Assemble in reverse order of dismantling, observing the following:
wage
satelettronica
lks es n
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Note ir se
d b ran
tee
tho
u or
a ac
Make sure that the gasket -1-, the grommet -4- and
ss the fuel con‐
nection -2- are positioned correctly.
ce
e
nl
pt
du
an
itte
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– Clean sealing surfaces.
erm
ab
ility
ot p
– Renew seal -1-.
wit
, is n
h re
Specified torques
hole
spec
es, in part or in w
♦ ⇒ “2.2 Assembly overview - auxiliary/supplementary heater,
t to the co
internal”, page 11
2.10 Removing and installing glow plug with
rrectness of i
flame monitor - Q8-
l purpos
Removing
nf
ercia
– Dismantle heater unit ⇒ page 19 . orm

m
atio
m
– Pull out retaining spring -1- in direction of -arrow-.

o
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– Remove retaining plate -2- in direction of -arrow-.

thi
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– Pull out glow plug with flame monitor - Q8- -3-.

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Installing
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cted agen
Prote AG.
Note
♦ Observe installation position of retaining spring -1- and retain‐

ing plate -2-.
♦ Curvature of retaining spring -1- faces up.

2.11 Removing and installing temperature

sensor - G18- and overheating sensor -
G189- .
lkswage es n
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d ran
ir se tee
tho
u or
a ac
ss
Removing
ce
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pt
du
satelettronica
an
– Remove cover ⇒ page 18 .
itte
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erm
ab
– Unclip wiring harness -1- from retainers -arrows-.
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
o
– Remove retaining spring -1-.
rm
m
atio
m
– Pull out temperature sensor - G18- -4- and overheating sensor

o
n in
c
- G189- -3- using long-nose pliers.

or
thi
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sd
a
Installing
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en
ng
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op
– Coat seals from temperature sensor - G18- and overheating
C py
t. rig
gh
sensor - G189- with coolant for installation.
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Prote AG.
Note
♦ When assembling, ensure proper position of retaining spring

-1-.
♦ Sensors cannot be renewed individually.
Specified torques
♦ ⇒ “2.2 Assembly overview - auxiliary/supplementary heater,
internal”, page 11
2.12 Removing and installing auxiliary heater

control unit - J364-
The auxiliary heater control unit - J364- is an integral part of the
combustion air blower - V6- and cannot be renewed individually
⇒ Electronic parts catalogue (ETKA) .
2.13 Removing and installing combustion air

blower - V6-
Removing
AG. Volkswagen AG d
Dismantling and assembling heater unit ⇒ page 19 . agen oes
olksw not
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by ara
Installing rised
nte
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ut
Install in reverse order of removal. ss a ra
c
ce
e
2.14 Connector pin assignment for auxiliary/supplementary heater

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
1 - 6-pin connector
wit
, is n
❑ Information on pin as‐
h re
satelettronica
hole
signment can be found
spec
in the latest current flow
es, in part or in w
t to the co
diagram ⇒ Current flow
diagrams, Electrical
fault finding and Fitting
locations.
rrectness of i
2 - 2-pin connector
l purpos

nf
ercia
o
rm
m
atio
m
o
n in
c

or
thi
e
locations.
t
sd
iva
o
r
rp
cu
3 - 2-pin connector
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
diagram ⇒ Current flow by c lksw
cted agen
diagrams, Electrical Prote AG.
locations.
4 - 4-pin connector
locations.
5 - 2-pin connector
diagram ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

3 Coolant circuit with auxiliary/supple‐

mentary heater
⇒ “3.1 Connection diagram - coolant hoses”, page 23
⇒ “3.2 Removing and installing heater coolant shut-off valve N279
”, page 24
3.1 Connection diagram - coolant hoses
Note
The -arrows- indicate the direction of coolant flow.
1 - Heat exchanger for heater

in heater and air conditioning
unit
❑ Incorporation in coolant
circuit ⇒ Rep. gr. 19 ; AG. Volkswagen AG d
agen
satelettronica
oes
ksw
Cooling system, cool‐ byV
ol not
gu
ara
ant; Schematic diagram rised
nte
- coolant hoses ut
ho eo
ra
s a c
s
ce
le
un
heater
pt
an
d
itte
y li
rm
ab
⇒ page 13
pe
ility
ot
wit
, is n
h re
hole
❑ The circulation pump -
spec
V55- is integrated in the
es, in part or in w
hose assembly of the
t to the co
auxiliary/supplementary
heater.
rrectness of i
⇒ page 15
l purpos
Note
nform
ercia
♦ For this vehicle, a start/stop sys‐

m
tem is offered as an optional

com
tion in
equipment with certain engines.

r
te o
thi
s
♦ On vehicles equipped with a

iva
do
r
start/stop system, the circulation

rp
cum
fo
pump - V55- of the auxiliary/sup‐

en
ng
t.
yi
plementary heater can be actu‐
Co
op py
ated by the auxiliary heater con‐
. C rig
ht ht
rig
trol unit - J364- while the stop py by
co Vo
function is active. To achieve
by lksw
cted agen
Prote
this, the auxiliary heater control
AG.
unit - J364- is sent a command

via the data bus from the air con‐
ditioning system operating unit,
the Climatronic control unit -
J255- and the air conditioning
system control unit - J301- to
switch on the circulation pump -
V55- (⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode).
3. Coolant circuit with auxiliary/supplementary heater 23

4 - Coolant supply from engine

❑ Connection of auxiliary heater to engine coolant circuit ⇒ Rep. gr. 19 ; Cooling system, coolant; Con‐
nection diagram - coolant hoses .
5 - Coolant return to the engine
❑ Connection of auxiliary heater to engine coolant circuit ⇒ Rep. gr. 19 ; Cooling system, coolant; Con‐
nection diagram - coolant hoses .
3.2 Removing and installing heater coolant

shut-off valve - N279- G. Volkswage nA n AG d
wage oes
Special tools and workshop equipment
yV
required
olks not
gu
b ara
ed
ho
ris nte
eo
t
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
satelettronica
ole,
spec
t to the co
rrectne
♦ Hose clamps up to 25 mm - 3094-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - VAS
6340-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
– Clamp off coolant hoses -3- using hose clamps up to 25 mm
- 3094- .
rrectness of i
– Release spring-type clips -4- with spring-type clip pliers - VAS
5024A- or hose clip pliers - VAS 6340- .
l purpos
CAUTION
satelettronica
nform
ercia

m
a
com
t
ion in
r
– Release pressure by pressing pressure relief valve on cool‐

te o
thi
ing system tester until the gauge shows a pressure of 0.
s
iva
do
r
rp
cum
fo
en
g
– Place drip tray for workshop hoist - VAS 6208- underneath.

n
t.
yi Co
Cop py
– Mark coolant hoses -3-.
t. rig
gh ht
pyri by
Vo
o
– Pull off coolant hoses -3- from heater coolant shut-off valve -
c by lksw
cted agen
N279- -1-.
Prote AG.
– Disconnect connector -5-.

– Remove heater coolant shut-off valve - N279- -1-.
Installing
Note
Ensure proper seating of cooling system hoses.
Specified torques
Component Specified torque

Bolt of heater coolant shut-off valve - N279- 9 Nm
3. Coolant circuit with auxiliary/supplementary heater 25

4 Fuel supply system

⇒ “4.1 Checking fuel delivery rate”, page 26
⇒ “4.2 Removing and installing metering pump V54
gen AG
. Vol”,
kspage 27
wagen AG a does
ksw not
Vol
4.1 Checking fuel delivery rate ed by gu
ara
nte
ris
ho eo
Special tools and workshop aequipment
ut required ra
c
ss
♦ Hand multimeter - V.A.G 1526 E-
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
♦ Auxiliary measuring set - V.A.G 1594C-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Measuring beaker - V.A.G 1602/1- from injection rate tester -

V.A.G 1602-

Conditions for testing
• Resistance of metering pump - V54- = approx. 5 Ω - 5.4 Ω
• Battery voltage: at least 12.5 V
• No fault stored in event memory
• Fuel lines are not damaged or leaking
• Ambient temperature approx. 20°C

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
aut
h
Transporter 2016 ➤ or a
s c
s Auxiliary heater - Edition 02.2019
ce
e
nl
pt
du
an
• Fuel tank sufficiently filled (fuel gauge on dash panel insert not
itte
y li
erm
in red area).
ab
ility
ot p
Check
wit
, is n
h re
hole
spec
CAUTION
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Unclip fuel line -2- from retainer -1-.
at
om
ion
c
in t
– Unclip fuel line -2- from retainer -1-. r
o
his
ate
– Remove clamp -3-.
do
priv
cum
or
– Disconnect fuel line -2-.
f
en
ng t.
yi Co
op
– Guide fuel line -1- into measuring beaker - V.A.G 1602/1- .
C py
ht. rig
satelettronica
rig ht
py by
– Hold measuring beaker - V.A.G 1602/1- at same height as co Vo
by lksw
auxiliary heater.
cted agen
Prote AG.
– Using ⇒ Vehicle diagnostic tester, check fuel delivery rate of

metering pump - V54- .
– Read quantity of diesel in measuring beaker - V.A.G 1602/1- .
Min. quantity of fuel after 60 seconds, ml Max. quantity of fuel after 60 seconds, ml
16.2 17.8
– If fuel delivery rates are not within specifications, renew me‐

tering pump - V54- ⇒ page 27 .
4.2 Removing and installing metering pump

- V54-
♦ Engine bung set - VAS 6122-
4. Fuel supply system 27

Removing
– Loosen lock washers -2-.
satelettronica
CAUTION
– Place drip tray - VAS 6208- under vehicle.

– Pull off fuel hoses -3-.
. Volkswagen AG
gen AG
– Seal fuel hoses -3- with Vaolbung
ksw from engine bung set
a does
n-otVAS
6122- . ed by gu
ara
is nte
or
– Remove metering
au pump - V54- -1- from bracket.
th eo
ra
ss c
Installing
ce
le
un
pt
an
d

itte
y li
rm
ab
– Replace O-type clips with screw-type clips.

pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
28
Prote AG.
Rep. gr.82 - Supplementary heating
5 Regulation of auxiliary/supplementa‐
ry heater
⇒ “5.1 Functional description”, page 29
. Volkswage
⇒ “5.2 Heating mode”, page 29 kswagen AG n AG d
oes
not
Vol gu
y
⇒ “5.3 Switching off auxiliary/supplementary
ise
d b heater”, page 30 ara
n r tee
tho or
5.1 Functional
ss
au description ac
ce
e
nl
The auxiliary heater can be started by means of the remote con‐
pt
du
an
trol, the instant heating button or appropriate programming in the
itte
y li
erm
central monitor. The supplementary heater mode is started auto‐
ab
ility
matically by the vehicle electronics system once all the necessary
ot p
wit
preconditions have been met.
, is n
h re
hole
First, a functional check of the fresh air blower - V2- and the com‐
spec
bined glow plug with flame monitor - Q8- is performed, and then
es, in part or in w
t to the co
the glow plug with flame monitor - Q8- goes through a preheating
phase.
The subsequent starting sequence depends, amongst other
rrectness of i
things, on the coolant temperature; therefore the time required for
satelettronica
l purpos
the starting sequence varies. In addition, fuel is supplied at this

point, the glow plug with flame monitor - Q8- is switched off in
stages and the flame monitor is activated.
nform
ercia
At end of start phase, heater unit burns at full load first and then
m
at
stepless standard operation ensues.
om
ion
c
in t
r
The reference resistance of the glow plug with flame monitoring

o
his
e
- Q8- is automatically re-determined during the starting or run-on

at
do
riv
phase, depending on the unit. This is done to compensate for

p
cum
or
ageing-related changes.
f
en
ng
t.
yi Co
op
As a consequence of this calibrating procedure, processes that C py
t. rig
are affected can also require more time.
gh ht
pyri by
Vo
co lksw
by
After expiry of maximum operating time of 120 minutes or after Prote
cted AG.
agen
manual shutdown by means of remote control or instant heating
button , auxiliary heater is switched off.
The supplementary heater is switched off if at least one of the
defined switch-on criteria is no longer met.
After switch-off, operation of the metering pump - V54- is stopped
immediately.
The combustion air blower - V6- and the glow plug with flame
monitor - Q8- continue to operate for a limited time in order to burn
the remaining fuel in the system and to cool the burner compo‐
nents.
The run-on period of the heater can vary depending on the soft‐
ware version and load level at the time of switch-off.
5.2 Heating mode

Once the coolant temperature has reached a certain level, the
control unit switches to energy-saving mode. If the coolant tem‐
perature continues to rise, the control unit switches to regulated
waiting period. If the coolant temperature does not drop during
the regulated waiting period, however, the heater unit will perform
the usual starting procedure and run in standard mode if coolant
temperature drops below a certain level.
5. Regulation of auxiliary/supplementary heater 29

5.3 Switchingolksoff
wageauxiliary/supplementary
n AG. gen AG Volkswa
does
not
heater y V gu
d b ara
ise r n tee
ho
If the instant heat
sa
ut button is pressed or the preset operating time
or
ac
has expired, combustion stops.
s
ce
le
un
pt
The run-on mode begins.
an
d
itte
y li
erm
ab
The circulation pump - V55- and the combustion air blower - V6- ,
ility
ot p
however, continue to run to cool down the heater (run-on mode)
wit
is n
and are switched off automatically.
h re
ole,
spec
Note
t to the co
The run-on period of the circulation pump - V55- and the com‐
bustion air blower - V6- depends on the operating mode in which
rrectne
the auxiliary heater was switched off.
ss o
Run-on time is up to 4 minutes.
cial p
f inform
Depending on the control unit software version, slight deviations
mer
in the specified run-on values are possible.
atio
m
satelettronica
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6 Other controlling and regulating com‐

ponents
⇒ “6.1 Removing and installing ambient temperature sensor”,
page 31
⇒ “6.2 Removing and installing remote control receiver for auxil‐
iary coolant heater R149 ”, page 31
⇒ “6.3 Functional description of remote control for auxiliary/sup‐
plementary heater”, page 31
6.1 Removing and installing ambient tem‐

perature sensor
Note
The ambient temperature sensor - G17- AisG.used

Volkswfor
agedetermining
n
the outside temperature and as alkswitch-on
swa
gen condition AofG dthe
oes aux‐
not
iliary/supplementary heater.d by Vo gu
ar
e an
satelettronica
ris tee
tho or
– Removing and temperature sensor - G17- installing
au ambient ac
ss
⇒ Heating, air conditioning; Rep. gr. 87 ; Other components
ce
e
nl
for control and regulation; Removing and installing ambient
pt
du
an
temperature sender G17 .
itte
y li
erm
ab
6.2 Removing and installing remote control
ility
ot p
wit
, is n
receiver for auxiliary coolant heater -

h re
hole
R149-
spec
es, in part or in w
Removing t to the co
– Remove cover in left footwell ⇒ General body repairs, interior;

Rep. gr. 68 ; Interior equipment; Removing and installing foot‐
rrectness of i
well cover .
l purpos
– Separate electrical connectors -2-.

– Remove remote receiver -1- from bracket.
nform
ercia
Installing
m
at
om
ion
c

in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6.3 Functional description of remote control

for auxiliary/supplementary heater
6. Other controlling and regulating components 31

♦ Removal wedge - 3409-
Note
♦ The auxiliary heater can be switched on and off from a dis‐

tance of several 100 metres (open space) using the remote
control. This range is restricted in built-up areas or from within
buildings.
satelettronica
♦ The remote control should be held vertically when the buttons
are pressed. The signals are received best by the aerials in
the vehicle in this position and the greatest
agen
AGrange isagachieved.
. Volksw en AG
do w es n
olks ot g
♦ Following disconnection of the
d b vehicle batteries, the auxiliary/
yV ua
ran
supplementary heater remote
ris control does not have to be
e
re- tee
adapted. utho or
a ac
ss
♦ If the remote control does not work properly, check the remote
ce
e
nl
pt
du
control battery.
an
itte
y li
erm
♦ If the remote control is renewed, it must be adapted using

ab
ility
⇒ Vehicle diagnostic tester.

ot p
wit
, is n
♦ If the remote control is renewed, the remote control must be

h re
hole
adapted to the remote control receiver for auxiliary coolant

spec
heater - R149- using ⇒ Vehicle diagnostic tester.

es, in part or in w
t to the co
Vehicles to week 21/2016

rrectness of i
Switching on auxiliary/supplementary heater using remote control

l purpos
– Press button -1-.

• Warning lamp -2- must light up green.
nf
ercia
When the auxiliary/supplementary heater is switched on, its op‐

rm
m
atio
erating time is determined by means of the setting on the multi‐

om
function display.
n in
or c
thi
e
Switching off auxiliary/supplementary heater using remote control

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Press key -3-

• Warning lamp -2- must light up red.
The auxiliary heater switches to run-on mode and then switches
off.
Renewing remote control battery

AG. Volkswagen AG d
agen oes
ksw
Note by Vol not
gu
ara
d
rise nte
o eo
♦ Note installation position of battery.
auth
ra
ss c
♦ Use only the same type of 3-volt battery.
ce
e
nl
pt
du
an
satelettronica
itte
y li
– Turn battery compartment cover -1- in -direction of arrow-.
erm
ab
ility
ot p
– Remove battery.
wit
, is n
h re
– Insert new batteries.
hole
spec
– Close cover again.
es, in part or in w
t to the co
Indicator lamp in remote control
rrectness of i
Once you have pressed a button, the indicator in the remote con‐
trol -2- indicates whether the signal from the remote control has
l purpos
been received by the auxiliary/supplementary heater and whether

the battery in the remote control is low.
nform
ercia
Display -2- Meaning

m
at
om
LED lights up green for 2 sec‐ The auxiliary heater has been ion
c
onds switched on with -1- “ON”.

in t
or
his
te
LED lights up red for 2 seconds The auxiliary heater has been
a
do
riv
switched off with -3- “OFF”.

p
cum
for
en
g
LED slowly flashes green for 2 The signal to switch on was not
n
t.
yi Co
seconds received. Cop py
t. rig
gh ht
LED quickly flashes green for 2 The auxiliary/supplementary yri
p by
o Vo
seconds heater is blocked, e.g. because
c by lksw
cted agen
the fuel tank is nearly empty or
Prote AG.
there is a fault in the auxiliary/

supplementary heater.
LED flashes red for 2 seconds The signal to switch off was not
received.
Lights up orange for 2 seconds, The battery charge is low, but
then green or red the switch on/switch off signal
was received.
Lights up orange for 2 seconds, The battery charge is low and
then flashes green or red the switch on/switch off signal
was not received.
Flashes orange for 5 seconds The battery is dead and the
switch on/switch off signal was
not received.
LED does not light up The battery is dead.
Vehicles from week 22/2016

Switching on auxiliary/supplementary heater using remote control n AG. Volkswagen AG do

lkswage es n
– Press key -3- byV
o ot g
ua
d ran
ir se
• Warning lamp -1- must light up green. utho tee
or
s a ac
When the auxiliary heater is switched on, its operating time is de‐
s
ce
e
termined by means of the setting on the multifunction indicator.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Switching off auxiliary/supplementary heater using remote control
– Press button -2-.
rrectness of i
• Warning lamp -1- must light up red.
l purpos
The auxiliary and supplementary heater switches to run-on mode

and then switches off.
nf
ercia
orm
Renewing remote control battery
m
atio
satelettronica
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Release battery compartment cover -1- using removal wedge C py
t. rig
- 3409- -2-.
gh ht
pyri by
Vo
co lksw
by
– Remove battery. cted agen
Prote AG.
– Insert new battery.

– Close cover again.

Indicator lamp in remote control

Once you have pressed a button, the indicator in the remote con‐
trol -1- indicates whether the signal from the remote control has
been received by the auxiliary heater and whether the battery in
the remote control is low.
Display -1- Meaning
LED lights up green for 2 sec‐ The auxiliary heater has been
onds switched on with button -3-.
LED lights up red for 2 seconds The auxiliary heater has been
switched on with button -2-.
Diode flashes green for 0.5 sec‐ Signal to switch on was not re‐
onds 4 times ceived.
Diode flashes red for 0.5 sec‐ Signal to switch on was not re‐
onds 4 times ceived.
Diode lights up green with fol‐ Auxiliary heater is blocked, e.g.
lowing cycle 3 times: on account of fuel tank being
♦ 0.65 on/0.2 off/0.15 on/0.5 nearly empty or a fault in the
off auxiliary
agen
AG. Vheater.
olkswagen AG
do
ksw es n
Vol ot g
by ua
LED lights up red for 2 secondsiseAuxiliary heater is blocked, e.g.
satelettronica
d ran
tee
ut
hor
on account of fuel tank being or
ss
a nearly empty or a fault in the ac
auxiliary heater.
ce
e
nl
pt
du
Diode lights up orange for 2 Battery charge is low but switch
an
itte
y li
seconds and then green for 2 on/switch off signal was re‐
erm
ab
seconds ceived.
ility
ot p
wit
Diode lights up orange for 2 Battery charge is low but switch
, is n
h re
seconds and then red for 2 sec‐ on/switch off signal was re‐
hole
spec
onds ceived.
es, in part or in w
t to the co
Diode lights up orange for 2 Battery charge is low, switch
seconds and then flashes on/switch off signal was not re‐
green for 0.5 seconds 4 times ceived. rrectness of i
Diode lights up orange for 2 Battery charge is low, switch
seconds and then flashes red on/switch off signal was not re‐
l purpos
for 0.5 seconds 4 times ceived.

Diode lights up with following Auxiliary heater is blocked, e.g.
nf
ercia
cycle 3 times: on account of fuel tank being

orm
♦ 2 seconds orange then 0.65 nearly empty or a fault in the

m
atio
m
on/0.2 off/0.15 on/0.5 off auxiliary heater.

o
n in
c
green
or
thi
te
sd
iva
Diode lights up orange for 2 Auxiliary heater is blocked, e.g.

o
r
rp
cu
seconds and then red for 2 sec‐ on account of fuel tank being
o
m
f
en
ng
onds nearly empty or a fault in the

t.
yi Co
op
auxiliary heater.
C py
t. rig
gh ht
yri
Flashes orange for 0.25 sec‐ Battery is discharged, switch
p by
co Vo
by lksw
onds 12 times on/switch off signal was not re‐ Prote
cted AG.
agen
ceived.
LED does not light up Battery is discharged.

7 Auxiliary air heater

⇒ “7.1 Assembly overview - Airtronic D3 auxiliary air heater”, page
36
⇒ “7.2 Removing and installing auxiliary air heater Airtronic D3”,
page 38
⇒ “7.3 Removing and installing air intake silencer”, page 41
⇒ “7.4 Assembly overview - exhaust system”, page 42
⇒ “7.5 Removing and installing exhaust system”, page 42
⇒ “7.6 Removing and dismantling auxiliary air heater bracket”,
page 43
⇒ “7.7 Removing and installing auxiliary air heater control unit
J604 ”, page 44
⇒ “7.8 Removing and installing heater in housing”, page 46
⇒ “7.9 Removing and installing burner unit”, page 47
⇒ “7.10 Removing and installing glow plug for heater Q9 ”,
page 49
satelettronica
⇒ “7.11 Removing and installing mantle of Airtronic D3 ”,
page 50
⇒ “7.12 Removing and installing flame monitor G64 and over‐
agen
AG. Volkswagen AG d
oes
heating sensor G189 (combination sensor)”, page 52
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⇒ “7.13 Removing and installing combustion airrisblower V6 ”, page tee
54 tho or
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⇒ “7.14 Removing and installing heat exchanger”, page 56
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7.1 Assembly overview - Airtronic D3 auxiliary air heater

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1 - Upper part of outer casing

❑ Made of plastic
⇒ page 46
2 - Flame monitor - G64- and
overheating sensor - G189-
(combination sensor)
❑ Overheating and flame
monitor
❑ Supplied with installa‐
tion tool
⇒ page 52
3 - Glow plug for heater - Q9-
❑ Supplied with special
tool
⇒ page 49
❑ 6 Nm
satelettronica
4 - Front cover
❑ Made of plastic wagen AG. Volkswagen AG does
olks not
❑ Removingd bandy V installing gu
ara
⇒ pageor 46
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5 - Mantle
ss
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❑ Supplied with installa‐

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❑ Removing ⇒ page 50
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6 - Heat exchanger
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⇒ page 56
es, in part or in w
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7 - Combustion chamber
⇒ page 47
rrectness of i
8 - Lower part of outer casing

l purpos
❑ Made of plastic
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9 - Flange seal
m
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❑ Renew if damaged
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10 - Combustion air blower - V6- (combination blower)

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❑ Combustion and heating air blower in one

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11 - Metering pump 2 - V386-
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12 - With auxiliary air heater control unit - J604-
7. Auxiliary air heater 37

Auxiliary heater - Edition
gen AG
02.2019
.Volkswagen AG
d
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7.2 Removing and installing auxiliary air
b ara
ed nte
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heater Airtronic D3
t
au ra
c
ss
ce
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nl
pt
du
an
itte
Note
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ility
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A type plate is fitted on the auxiliary air heater unit. This plate
wit
, is n
provides information about the type of auxiliary air heater installed
h re
in the vehicle ⇒ page 40 .
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The auxiliary air heater Airtronic D3 with bracket should only be
l purpos
removed if the bracket is damaged.
nf
Removing without bracket ⇒ page 40
ercia
orm
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Prote AG.
Removing
– Separate electrical 10-pin connector - T10ba- -1- from auxili‐
ary air heater beneath front right seat.
– Remove right underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
view - underbody cladding .
– Guide wiring harnesses through opening in floor.
CAUTION
– Separate fuel line -arrow- from auxiliary air heater.

– Seal fuel line.
– Detach cable ties on connecting elements -2 and 6-.

– Loosen bolts -1-.
satelettronica
AG. Volkswagen AG d
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du
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es, in part or in w
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Note
Do not remove bolts -1- completely.

– Remove auxiliary air heater -3- from guide -A-.

Type plate
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Date of first use is entered on lower part oforitype plate.
d
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♦ The heat exchanger can be used for 10 ss a years but must be c
replaced once this date has elapsed.
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Removing without bracket
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satelettronica
– Separate electrical 10-pin connector - T10ba- -1- from auxili‐
ary air heater beneath front right seat.
nform
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t
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– Guide wiring harnesses through opening in floor.
do
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CAUTION
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The fuel system is pressurised. ht. rig
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AG.

– Separate fuel line -arrow- from auxiliary air heater.

– Seal fuel line.
– Remove exhaust system ⇒ page 42 .
– Loosen clamp for air intake silencer at auxiliary air heater.
– Detach cable ties at connecting elements -1- of air ducts.

– Push connecting elements in direction of -arrow-.
– Unscrew nuts -3-.

– Remove auxiliary air heater -1- from bracket -2-.
Installing
Specified torques
satelettronica
Bolts securing auxiliary heater to un‐ 8 Nm
derbody
Collar nuts on auxiliary heater 8 Nm
7.3 Removing and installing air intake wagsi‐

en AG . Volkswagen AG
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– Detach clamps or cable ties at connecting elements of air
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ducts -1-.
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– Push air ducts in direction of -arrow- off auxiliary air heater.
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– Unscrew bolts from bracket of auxiliary air heater.
, is n
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– Lower auxiliary air heater.

spec
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– Secure auxiliary air heater to body, e.g. with a welding wire. t to the co

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– Unscrew air intake silencer -1- in direction of arrow.

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– Loosen clamp -5-.

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– Remove air intake silencer -4- from auxiliary air heater.

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Installing
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7.4 Assembly overview - exhaust system
1 - Bracket
❑ Removing ⇒ page 43
2 - Flange nut
❑ 8 Nm
3 - Exhaust system
⇒ page 42
4 - Flange bolt
❑ 8 Nm
5 - Clip
❑ 6 Nm
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7.5 Removing and installing exhaust system

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Removing
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CAUTION
s
Danger of severe burns from hot exhaust system.

s o
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Burns to hands and other body parts possible.

inform
mer
– Allow exhaust system to cool.

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– Loosen clamp -5-.
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– Detach exhaust system -3-.
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Installing cted agen
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Specified torques
♦ ⇒ “7.4 Assembly overview - exhaust system”, page 42
7.6 Removing and dismantling auxiliary air

heater bracket
Remove for renewal only

– Removing auxiliary air heater without bracket ⇒ page 44 .

– Unscrew nuts -3-.
– Remove bracket -2- from auxiliary air heater -1-.
Dismantling bracket
– Remove bracket from auxiliary air heater ⇒ page 43 .
satelettronica
AG. Volkswagen AG d
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The complete bracket consists d by V
of 3 parts, each connected toguaara
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Rubber buffers -1-ss are secured by means of hexagon nuts -2-. c
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♦ Dimension -A- = 10 mm
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♦ Dimension -B- = 16 mm
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During installation, dimension -A- must face upwards.

t to the co
Specified torques
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Nuts securing rubber buffers 8 Nm

Nuts securing auxiliary heater 8 Nm
nform
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ion in
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heater control unit - J604-

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Removing
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– Cut through cable ties -1-. Cop
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– Remove intermediate piece -2-.

– Remove upper part of outer shell -item 1-
⇒ Item 1 (page 37) .

. Volkswagen AG
– Push together retaining clip -2- on opposite
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– Lift out auxiliary air heater control unit - J604- .
– Separate electrical connectors on auxiliary air heater control
unit - J604- -1-.
rrectness of i
– Detach wiring harness with seal -2- from retainer in housing.
l purpos
– Remove auxiliary heater control unit - J364- -1- from heater.

nform
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Installing
m
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ate
Note
do
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♦ When installing auxiliary air heater control unit - J604- -3-, en‐
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sure that wires are clipped into holder on auxiliary air heater C py
t. rig
control unit - J604- and that electrical connectors are connec‐
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♦ Perform a functional check after completing all work on the
heater unit.
Specified torques
Bolt -1- 2 Nm

7.8 Removing and installing heater in hous‐

ing
Removing
Note
Remove housing cover -2- for all repair work on heater units.
AG. Volkswagen AG d
agen oes
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t to the co
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c
in t
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rig ht
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Prote AG.
– Release both locking tabs -1-.

– Lift up housing cover -2- slightly in direction of -arrow A-.
– Remove housing cover -2- forwards in direction of -arrow B-
from plastic housing.
– Release clips -3-.
– Remove side cover -4- in direction of arrow -C- from plastic
housing.
– Remove wiring harness with grommet -5- from fastener in
plastic housing.
– Remove flange seal -6- from heater.

– Pull out heater unit -1- in direction of -arrow- from lower part
of plastic housing.
Installing
– Before installing, check flange seal of heater unit for damage.
Renew if necessary.
wage es n
7.9 Removing and installing burner unit olks ot g
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Removing utho
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ss
ce
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nl
pt
du
– Remove auxiliary air heater from plastic housing ⇒ page 46 .
an
itte
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ab
– Remove auxiliary air heater control unit - J604- ⇒ page 44 .
ility
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satelettronica
wit
– Remove combustion air blower - V6- ⇒ page 54 .
, is n
h re
hole
– Remove glow plug for heater - Q9- ⇒ page 49 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
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t.
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Auxiliary heater - Edition 02.2019 n AG. Volkswagen AG do
lkswage es n
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– Unscrew bolts -1- of burning chamber -3-. ised b ran
or tee
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– Remove burning chamber -3- with seals-2-
au from heat exchang‐
t or
ac
er -4-. s
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Installing
an
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Note ole,
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t to the co
When installing the burning chamber -3-, always renew the seal -2-.
rrectness o
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mer
atio
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Prote AG.
– Fit burning chamber -3- with new seal -2- on heat exchanger
-4-.
– Tighten bolts -1-.
Note
Perform a functional check after completing all work on the heater unit.

Specified torques
Bolts -1- on combustion chamber 4 Nm
7.10 Removing and installing glow plug for

heater - Q9-
Note
♦ Glow plug with flame monitor - Q9- is activated immediately

after activation and switched off again about 1 minute after a
flame has been detected.
♦ The maximum glow period for the Airtronic »D3« is 150 sec‐
onds.
♦ When heater unit is switched off, glow plug with flame monitor
- Q9- is switched back on again during the 4 minute run-on
time to burn off all fuel.
♦ It is essential to check the mantle for carbonised deposits and n AG. Volkswagen AG do
satelettronica
damage if glow plug with flame monitor - Q9- is renewed. lkswage es n
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Removing utho
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Note
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♦ Special tool for removing glow plug with flame monitor - Q9-
ility
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is supplied.
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♦ It is essential to check the mantle for carbonised deposits and
hole
spec
damage if glow plug with flame monitor - Q9- is renewed.
es, in part or in w
t to the co
– Cut through cable ties -1-.
– Remove intermediate piece -2-.
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Prote AG.


– Push together retaining clip -2- on opposite side.
– Lift out auxiliary air heater control unit - J604- .
– Separate electrical connector of glow plug for heater - Q9- on
control unit.
– Remove protective cap of glow plug for heater - Q9- from
heater.
– Remove glow plug for heater - Q9- using special tool supplied
with new part.
Installing
Note
♦ Special tool for installing glow plug with flame monitor - Q9- is
supplied.
♦ It is essential to check the mantle for carbonised deposits and
satelettronica
damage if glow plug with flame monitor - Q9- is renewed.
– Insert glow plug for heater - Q9- in heating unit.

– Tighten glow plug for heater - Q9- using special tool supplied.
– Further assembly is carried out in the reverse order.
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♦ When installing ut glow plug for heater - Q9- , make sure that or a
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wires are clipped into retainer on auxiliary air heater control c
s a
s
unit - J604- and that electrical connectors are connected.
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♦ Perform a functional check after completing all work on the

itte
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ab
heater unit.
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7.11 Removing and installing mantle of Air‐

hole
spec
tronic »D3«
es, in part or in w
t to the co
Removing
– Remove glow plug for heater - Q9- ⇒ page 49 .
rrectness of i
l purpos
Note
nf
ercia
If surface of the mantle is heavily soiled (contaminated) and

rm
m
atio
blocked, it must be renewed.

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or c
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rig ht
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co Vo
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Prote AG.

– Pull out mesh mantle from support using commercially avail‐

able pliers.
– Clean heater unit support.
Installing
Note
A special tool for installing the mantle is supplied.
satelettronica
lkswage es n
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ion
c
in t
or
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ate
do
priv
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for
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ng
t.
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t. rig
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pyri by
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by
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Prote AG.
– Fit mesh mantle -2- on special tool -1- supplied.

Note
The mesh mantle must be located correctly in the locking mechanism -arrow- of the special tool.
– Using special tool -1-, carefully push mesh mantle -2- into
support of heater unit as faraas
genstop.
AG. Volkswagen AG d
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Ensure that the mesh mantle is installed correctly -3- in the heater unit.
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7.12 Removing and installing flame monitor -
erm
ab
ility
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G64- and overheating sensor - G189-
wit
is n
(combination sensor)
h re
ole,
spec
t to the co
Note
satelettronica
♦ Overheating sensor - G189- is installed inside hot air flow.
rrectne
♦ Flame monitor - G64- is installed directly above metal surface
s
of heater unit and has thermal contact with burner housing.
s o
cial p
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Removing
mer
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– Push together retaining clip -2- on opposite side. C py
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– Lift out auxiliary air heater control unit - J604- . cop Vo
by lksw
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Prote
– Separate electrical connectors of combination sensor on aux‐
AG.
iliary air heater control unit - J604- .
– Release retaining bracket -1- in direction of -arrow-.

– Remove combination sensor -2- from heater unit.
Installing

Note
Special tool is supplied with combination sensor.
satelettronica
AG. Volkswagen AG d
agen oes
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ility
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– Push supplied special tool -1- onto combination sensor -2-.

t to the co
– Place combination sensor -2- with special tool -1- on heat ex‐
changer.
rrectness of i
– When doing this, special tool -1- slides onto heat exchanger
l purpos
until combination sensor -2- makes contact with collar (instal‐

lation position of combination sensor).
nf
ercia
– Engage retaining bracket -3-.

orm
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atio
– Pull off special tool -1-.

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or c
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♦ The combination sensor -2- must sit “flat” on the heat exchanger.
t.
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.
♦ Use a tool to check if necessary, e.g. a torch or a mirror.
ht rig
rig ht
py by
co Vo
by lksw
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Prote AG.

– Route wiring harness -4- through bracket -3- up to auxiliary air

heater control unit - J604- .
– Fit electrical connectors again.
– Perform a functional check after completing all work on the
heater unit.
7.13 Removing and installing combustion air

blower - V6-
Removing
Note
Combustion air blower - V6- is referred to as a combination blower because it supplies both the heating and
the combustion air.
satelettronica
AG. Volkswagen AG d
agen oes
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mercia
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tion in
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te o
thi
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t.
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t. rig
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AG. Volkswagen AG d
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– Remove combustion by V air blower - V6- (combinationt gblower)
o
ua
-2- and seal -3-ris from heat exchanger -4-.
ed ran
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Note
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When installing the combustion air blower - V6- , always renew the seal -3-.
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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om
n
c
i
or
satelettronica
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Place combustion air blower - V6- -2- with new seal -3- on heat
exchanger -4-.
– Tighten bolts -1- in diagonal sequence
heater unit.
Specified torques

7.14 Removing and installing heat exchanger

Removing
AG. Volkswagen AG d
agen oes
olksw not
V
satelettronica
by gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Unscrew bolts -1- from combustion air blower - V6- -2-. op Vo
by c lksw
cted agen
Prote
– Remove heat exchanger -4- with seal -3- from combustion air
AG.
blower - V6- -2-.

Installing
Note
♦ Note that seal -3- must always be renewed when heat exchanger -4- is installed.
♦ If heat exchanger is renewed, flame monitor - G64- and overheating sensor - G189- (combination sensor)
must be transferred.

satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– Fit heat exchanger -4- with new seal -3- on combustion air
y li
erm
ab
blower - V6- -2-.

ility
ot p
wit
– Tighten bolts -1- in diagonal sequence

, is n
h re
hole

spec
heater unit.
es, in part or in w
t to the co
Specified torques
rrectness of i

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7.15 Removing and installing temperature

sensor - G18-
Note
Temperature sender - G18- is permanently installed on auxiliary

air heater control unit - J604- -1- and cannot be renewed individ‐
ually.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

8 Fuel supply to auxiliary air heater

⇒ “8.1 Removing and installing metering pump 2 V386 ”,
page 59
⇒ “8.2 Checking fuel delivery rate”, page 60
8.1 Removing andAinstalling metering pump

G. Volkswagen AG d
2 - V386-
yV
olkswagen oes
not
g
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ed ran
Special tools and
ho
risworkshop equipment required tee
t or
au ac
♦ Engine bung
ss set - VAS 6122-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
satelettronica
rrectness
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Fuel supply to auxiliary air heater 59

Transporter 2016 ➤ n AG. Volkswagen AG do
lkswage es n
Auxiliary heater - Edition 02.2019 d byV
o ot g
ua
ran
ir se tee
ho
Removing aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Loosen clamps -3-.
hole
spec
es, in part or in w
CAUTION
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
– Place drip tray - VAS 6208- under vehicle.
n in
or c
thi
e
– Pull off fuel hoses -4-.

t
sd
iva
o
r
rp
cu
satelettronica
– Seal fuel hoses -4- with a bung from engine bung set - VAS
o
m
f
en
ng
6122- .
t.
yi Co
Cop py
– Remove metering pump 2 - V386- -1- from bracket.
t. rig
gh ht
pyri by
Vo
o
Installing
c by lksw
cted agen
Prote AG.
– Replace O-type clips with screw-type clips.
8.2 Checking fuel delivery rate

♦ Fuel hose, length approx. 200 mm
♦ Measuring beaker - V.A.G 1602/1- from injection rate tester -
V.A.G 1602-

Conditions for testing
• Resistance of metering pump 2 - V386- = approx. 10 Ω - 10.5 Ω
• Battery voltage: at least 12.5 V
• No fault stored in event memory
• Fuel lines are not damaged or leaking
• Ambient temperature approx. 20°C
• Fuel tank sufficiently filled (fuel gauge on dash panel insert not
in red area)

n AG. VolkAuxiliary
swagen AGheater - Edition 02.2019
lkswage does
not
o
yV gu
Test sequence ed b ara
nte
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th
au ra
CAUTION ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Disconnect fuel line -1-.
ss o
cial p
f
– Hold measuring beaker - V.A.G 1602/1- at same height as
in
auxiliary air heater.
form
mer
atio
om
n
metering pump 2 - V386- .
c
i
or
n thi
e
satelettronica
t
sd
iva
o
pr
c
Note
um
r
fo
en
ng
t.
yi Co
op
If the fuel is delivered evenly (beginning approx. 60 seconds after C py
t. rig
engine has been started), the fuel line is properly filled and ven‐
gh ht
yri by
ted.
cop Vo
by lksw
cted agen
Prote AG.
– Empty fuel from measuring beaker - V.A.G 1602/1- .

– Hold measuring beaker - V.A.G 1602/1- at height of glow plug
for heater - Q9- .
metering pump 2 - V386- .
– Read quantity of fuel in measuring beaker - V.A.G 1602/1- .
Vehicles with diesel engine

5.0 6.0
Vehicles with petrol engine

6.8 7.6
– If fuel delivery rates are not within specifications, renew me‐

tering pump 2 - V386- ⇒ page 59 .
8. Fuel supply to auxiliary air heater 61

9 Regulation of auxiliary air heater

⇒ “9.1 Principle of auxiliary air heater operation”, page 62
⇒ “9.2 Function of auxiliary air heater operating and display unit
E407 or roof display unit J702 ”, page 65
⇒ “9.3 Removing and installing auxiliary air heater operating and
display unit E407 or roof display unit J702 ”, page 65
⇒ “9.4 Removing and installing operating and display unit for
camping equipment E153 ”, page 66
9.1 Principle of auxiliary air heater operation
Note
♦ Make sure that the auxiliary air heaters are operated only with diesel fuel. Operation with biodiesel can lead
to malfunctions and damage.
♦ The heaters only have one electric motor. The motor pumps the heating and combustion air.
satelettronica
1 - Electrical connection
2 - Fuel supply system
Pfeil A - Cold air in
Pfeil B - Hot air out
Pfeil C - Combustion air in
Pfeil D - Exhaust out
AG. Volkswagen AG d
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aut ra
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.

Switching on
The warning lamp in the control element lights up when the unit
is switched on. The glow plug is switched on and the combustion
air blower runs at slow speed.
Note
♦ If there is still too much residual heat in the heat exchanger

from a previous heating operation, only the combustion air
blower starts up at first (cold blowing).
♦ The »start« takes place once the existing residual heat has
been dissipated.
Airtronic start
Fuel delivery starts after about 60 seconds and the fuel/air mixture
in the combustion chamber ignites. The glow plug is switched off
60 seconds after the combination sensor (flame monitor and
overheating sensor) has detected the flame.
The heater is now in control mode and reaches the “Power” gov‐
satelettronica
ernor state after a short duration.
Temperature selection with control element
The desired interior temperature is preselected using the control
dial. The value to be set can be chosen from a range of between
+10 °C and +30 °C, depending on the version of the heater unit
installed as well as the volume of the space to be heated and the
prevailing ambient temperature.
. Volkswagen AG
gen AG d
The setting to beVol
selected
ksw
a
on the control knob
oes in this case is based
not
on experience.
ed by gu
ara
is nte
or eo
Heater
au regulation
th ra
ss c
The room temperature or temperature of the drawn heated air is
ce
e
nl
pt
continuously measured during heating. Regulation starts if the

du
an
itte
temperature is higher than the temperature selected on the con‐

y li
erm
ab
trol element.
ility
ot p
wit
There are 4 control levels provided in order that the heat flow de‐
, is n
h re
livered by the heater can be finely adjusted to the heat demand.

hole
The blower speed and fuel volume correspond to the particular

spec
es, in part or in w
control level in this case.

t to the co
If the set temperature is still exceeded even at the lowest control

level, then the heater unit enters control level “Off”, and the blower
continues to operate for about 4 minutes to cool down.
rrectness of i
Then, until the restart, the combustion air blower continues to run
l purpos
at minimum speed (recirculated air mode) or is switched off (fresh

air mode).
nform
ercia
Switching off
m
at
om
When the heater unit is switched off, the warning lamp goes out
on
c
in t
and the fuel delivery is switched off. The blower continues oper‐
or
his
e
ating for about 4 minutes to provide cooling.

at
do
priv
cum
For cleaning, the glow plug is switched on for 40 seconds during

for
en
g
the blower run-on.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
co Vo
by lksw
cted agen
Prote AG.
The heater unit is switched off without any run-on time if no fuel
was pumped before the switch-off or if the heater unit is in the
control level “OFF”.
9. Regulation of auxiliary air heater 63

Control and safety devices of auxiliary air heater Airtronic D3

♦ The start is repeated if the heater unit does not ignite within
90 seconds after fuel delivery starts. A malfunction shut-off
occurs if the heater does not ignite after another 90 seconds.
That means that fuel delivery will be ended and blower run-on
will continue for about 4 minutes. The control unit is locked out
after the permitted number of unsuccessful start attempts has
been exceeded.
♦ If the flame goes out by itself during heating operation, a new
start is performed initially. If the heating unit does not ignite
within 90 seconds after fuel delivery restarts or if it ignites but
goes out within 15 minutes, a malfunction shut-off occurs. That
means that fuel delivery will be ended and blower run-on will
continue for about 4 minutes.
Note
♦ The malfunction shut-down can be revoked by briefly switch‐

ing off and back on again.
♦ Do not repeat the switch on/off procedure more than twice.
satelettronica
♦ Overheating causes the combination sensor (flame monitor/
AG. Volkswagen AG d
overheating sensor) to lbe kswtripped,
agen the fuel supplyoeis
s ninterrupted
and a malfunction shut-down
byV
o is performed. Once the ot gcause of
ua
overheating has ir sebeen eliminated, the heater unit can beanre‐
d r
te
o
started by switching
auth off and back on again. The control unite oisr a
locked outssafter the permitted number of unsuccessful start c
attempts has been exceeded.
ce
e
nl
pt
du
an
itte
♦ A malfunction shut-down will occur 20 seconds after the lower

y li
erm
ab
or upper voltage limit has been reached.

ility
ot p
♦ The heater unit will not start if the glow plug or the blower motor
wit
, is n
h re
is defective, or if there is a discontinuity in the electrical cable

hole
to the metering pump.

spec
es, in part or in w
♦ If the combination sensor (flame monitor/overheating sensor)

t to the co
is defective or there is a discontinuity in the electrical cable,

the heater unit starts and the malfunction shut-down occurs
only during the start phase.
rrectness of i
♦ The speed of the blower motor is continuously monitored. A

l purpos
malfunction shut-down will occur after 30 seconds if the blower

motor does not start or if the speed fluctuates by more than
nform
ercia
10%.
m
♦ When the heater unit is switched off, the glow plug is switched
at
om
io
on for 40 seconds during blower run-on (post-glow) to burn off

n
c
in t
r
combustion residues.
o
his
ate
do
riv
Switching off in an emergency

p
cum
for
en
g
If an emergency shut-off (emergency off) is required during op‐

n
t.
yi Co
eration, proceed as follows: t. Cop py
rig
gh ht
yri
• Switch off heater unit via control element, or p by
co Vo
by lksw
cted agen
• Pull out fuse, or Prote AG.
• Isolate heater unit from battery.

9.2 Function of auxiliary air heater operating

and display unit - E407- or roof display
unit - J702-
Control elements
Functions for auxiliary air heater are selected using buttons 1, 3,
4 and 5.
1 - Button for cancelling settings
2 - Display for various values of auxiliary air heater
3 - Button for selecting settings (e.g. extending operation and
heating time, switching child safety on or off, setting date and
starting time)
4 - Button for selecting settings (e.g. extending operation and
heating time, switching child safety on or off, setting date and
starting time)
- Button for confirming settings
satelettronica
heater operating and display unit -
E407- or roof display unit - J702-
Note
If the display of the auxiliary heater operating and display unit -

E407- or roof display unit - J702- flashes, there is a fault in the
system.
wage
Special tools and workshop equipmenty Vrequired
olks es n
ot g
d b ua
ran
♦ Removal wedge - 3409- ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Using removal wedge - 3409- , lever auxiliary heater operating

and display unit - E407- -1- out of headliner.
nform
ercia
– Separate electrical connector.

m
a
com
tion in
Installing
r
te o
thi
s

iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Regulation of auxiliary air heater 65

9.4 Removing and installing operating and

display unit for camping equipment -
E153-
Note
If the display of the operating and display unit for camping equip‐
ment - E153- flashes, there is a fault in the system.

♦ Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
satelettronica
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Removing
spec
es, in part or in w
– Using removal wedge - 3409- , lever operating and display unit

t to the co
for camping equipment - E153- -1- out of headliner.

– Separate electrical connectors.
rrectness of i
Installing
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10 Other components of auxiliary air

heater
⇒ “10.1 Function description of remote control”, page 67
10.1 Function description of remote control
Note
n AG. Volkswagen A
♦ The auxiliary air heater can
olks
wbe
agswitched
e
on and Goffdofrom
es n a dis‐
o
tance of up to 600 metres db
y V (open space) using the remote t gu
ara
control. This range ori is restricted in built-up areas or from within
s e nte
eo
buildings. auth
ra
ss c
♦ The remote control should be held vertically when the buttons
ce
e
nl
pt
are pressed. The signals are received best by the aerials in
du
an
itte
the vehicle in this position and the greatest range is achieved.
y li
erm
ab
ility
♦ Following disconnection of the vehicle battery, the auxiliary air
ot p
wit
heater remote control does not have to be re-adapted.
, is n
h re
hole
♦ A new remote control must be adapted using ⇒ Vehicle diag‐
satelettronica
spec
nostic tester in the “Adaption” mode.
es, in part or in w
t to the co
Switching auxiliary air heater on using remote control
rrectness of i
– Press button -A-. Warning lamp -C- must light up green.
l purpos
The auxiliary air heater runs for approx. 120 minutes.
nf
ercia
Note
orm
m
atio
m
The running time can be interrupted by the on-board network

o
n in
or c
management (low voltage).

thi
te
sd
iva
o
r
rp
cu
Switching auxiliary air heater off using remote control

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Press button -B-. Warning lamp -C- must light up red.
c by lksw
cted agen
Prote AG.
The auxiliary air heater switches to run-on and then off.
Renewing remote control batteries
Note
♦ Note installation position of batteries.

♦ Use only batteries of the same type with a voltage of 12 V.
♦ The allocation of the remote control to the auxiliary air heated
remains the same. It does not require re-adaption.
10. Other components of auxiliary air heater 67

– Take off battery cover -4- and remove batteries. Insert new
batteries and replace cover.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
satelettronica
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8056764E

3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.6 Pipe/wire routing and attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Overview of fitting locations - auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Assembly overview - auxiliary/supplementary heater, internal . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Removing and installing auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.6 Removing and installing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.7 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.8 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.9 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.10 Removing and installing glow plug with flame monitor Q8 . . . . . . . . . . . . . . . . . . . . . . . . 20

7.1 Assembly overview - Airtronic D3 auxiliary air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

struments during a road test”, page 2

⇒ “1.5 Safety precautions when working on vehicles with auxiliary/

supplementary heater”, page 2

1.1 Safety precautions during work on fuel system

Danger of fire caused by escaping fuel

Risk of injury from highly pressurised fuel.

1.2 Safety measures when working on vehicles with a start/stop system

1.4 Safety precautions when working on the cooling system

Danger of scalding by hot coolant

– Reduce excess pressure by covering cap of coolant expan‐

1.5 Safety precautions when working on vehicles with auxiliary/supplementary

Danger of poisoning from exhaust fumes

2 Rep. gr.00 - Technical data

Risk of damage when starting the engine

Malfunction caused by air in the fuel supply system

tive, the heater may switch on unexpectedly. This poses a risk of

iliary/supplementary heater components as well as a risk of fire

and explosions caused by high temperatures.

2.1 Type plates

Duplicate type plate for auxiliary/supplementary heaters t to the co

♦ In the engine compartment of the vehicle, there is a second

(duplicate) type plate attached to the right of the lock carrier

cerning the type of the auxiliary/supplementary heater, always

observe the type plate attached directly to the auxiliary/sup‐

4 Rep. gr.00 - Technical data

2.3 Rules for cleanliness when working on

– Do not work with compressed air.

3.1 Rules for cleanliness

have been stored outside their packaging (e.g. in tool boxes).

♦ If system is open, do not work with compressed air.

and only reconnect them in dry condition.

♦ The engine/motor control unit has a self-diagnosis capability.

of at least 11.5 volts is necessary.

♦ Do not use sealants containing silicone. Particles of silicone

age the lambda probe.

♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces

the danger of a fire in a crash as the fuel pump is switched off

3.3 General repair instructions

6 Rep. gr.00 - Technical data

Following repair work in the vicinity of the auxiliary/supplementary

3.4 Contact corrosion

– Route lines in their original positions.

– Make sure there is sufficient clearance between the lines and

moving as well as hot components.

1.1 Overview of fitting locations - components not located in passenger com‐

⇒ Fuel supply - diesel