VW Touran 2003 Auxiliary Heater Eng

Service
Workshop Manual
Touran 2003 ➤
Auxiliary heater
Edition 08.2013
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
82 - Supplementary heating
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.
Touran 2003 ➤
Auxiliary heater - Edition 08.2013
Contents
82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures for working on vehicles with auxiliary heaters . . . . . . . . . . . . . . . . . . . . 1
2 Notes on general repairs on vehicles with auxiliary heaters . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Starting conditions for auxiliary heating (preheater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Starting conditions for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Rules for cleanliness when working on the auxiliary heater and the fuel system . . . . . . . . 3
4 Repairing auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Manufacturer's nameplate for Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Removing and installing remote control receiver for auxiliary coolant heater R149 . . . . . . 9
5 Removing and installing auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Components of auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Removing and installing auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Dismantling and assembling supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Dismantling and assembling auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5 Inner components of auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.6 Removing and installing glow plug with flame monitoring Q8 . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Removing and installing temperature sensor G18 and overheating sensor G189 . . . . . . 23
5.8 Removing and installing heater coolant shut-off valve N279 for vehicles with petrol engine
........................................................................ 23
5.9 Removing and installing heater coolant shut-off valve N279 for vehicles with diesel engine
........................................................................ 24
6 Connecting auxiliary heater Thermo Top V to coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BAG,
BKG, BLF, BLN, and BLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BGU,
BSE and BSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes AXW,
BLX, BLY, BLR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.4 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes AVQ,
BKC and BLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.5 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code AZV,
BKD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.6 Connection diagram for coolant hoses in vehicles with auxiliary heating (preheater), engine
code BLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.7 Connection diagram for coolant hoses in vehicles with auxiliary heater, engine codes BLG
and BMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.8 Connection diagram for coolant hoses in vehicles with auxiliary heater, engine codes BKP
and BMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.9 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes AXW
and BLX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.10 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes BVX,
BVY and BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.11 Connection diagram for coolant hoses in vehicles with auxiliary heater, engine codes BRU,
BXE, BXF and BXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.12 Connection diagram for coolant hoses in vehicles with auxiliary heater, engine code BMM
........................................................................ 37
6.13 Connection diagram for coolant hoses in vehicles with auxiliary heater, engine code: CAVB,
CAVC, CAVD, CDGA, CFHC, CFJA, CFJB, CLCA, CTHB and CTHC . . . . . . . . . . . . . . . . 38
6.14 Connection diagram for coolant hoses in vehicles with auxiliary heater, engine code CAYB
and CAYC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.15 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine code:
CBZB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Contents i
Touran 2003 ➤
7 Fuel supply for auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Fuel feed to Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4 Testing quantity of fuel delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8 Regulation of auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.1 Functional description of auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2 Functional description of “large” remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Functional description of “small” remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ii Contents
Touran 2003 ➤
82 – Supplementary heating
1 Auxiliary heater Thermo Top V
(VRL005988; Edition 08.2013)
1.1 Safety measures for working on vehi‐

cles with auxiliary heaters
♦ The auxiliary heater must not be in operation or switched on
in areas in which there is a risk of fire or explosion.
♦ The auxiliary heater must not be in operation or switched on
(including via a preset switch-on time) in closed rooms without
an exhaust extraction system.
♦ When working on a fuel system, always observe applicable
safety regulations and rules for cleanliness. ⇒ Rep. gr. 20
♦ If fuel system components (e.g. metering pump, fuel lines, fuel
gauge sender) are removed or opened, the engine must not
be started.
♦ Before beginning repair work on the auxiliary heater:
– Release pressure in cooling system by opening cap on coolant
expansion tank.
♦ After completing repair work on the auxiliary heater or the fuel
system, check the operation of the auxiliary heater.
♦ After carrying out repairs on the auxiliary heater, carry out the
self-diagnosis using vehicle diagnosis, testing and information
system - VAS 5051A- .
1. Auxiliary heater Thermo Top V 1

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2 Notes on general repairs on vehicles

with auxiliary heaters
♦ Read self-diagnosis of auxiliary heater using vehicle diagno‐
sis, testing and information system - VAS 5051A- .
♦ If parts of the fuel system were removed or renewed, ensure
that all components for fuel delivery to the auxiliary heater are
properly installed.
♦ Following repair work in the vicinity of the auxiliary heater fuel
line, check:
that the fuel line is flush with the vehicle underbody and is pro‐
tected against mechanical damage.
that the auxiliary heater fuel line is protected from heating which
might disturb operation.
that the fuel line does not come in contact with vehicle parts which
heat up.
2.1 Starting conditions for auxiliary heating

(preheater)
♦ Engine type OK (diesel/petrol)
♦ Terminal 15 (ignition) on
♦ Engine speed > 300 rpm
♦ Coolant temperature < 69 °C
♦ Depending on vehicle equipment, either ECON button not ac‐
tivated or temperature preselection is set to ≥ 90% using the
temperature selection knob
♦ Ambient temperature < 5 °C
♦ Reserve fuel level not reached
♦ On-board network manager not active
♦ No crash shut-off
♦ No fault entries blocking start procedure
Note
The AC button has no influence on the operation of the preheater.
2.2 Starting conditions for auxiliary heating

♦ Engine type OK (diesel/petrol)
♦ Auxiliary heater coded in Gateway
♦ No undervoltage shutdown
♦ Reserve fuel level not reached
♦ No crash shut-off
♦ No fault entries blocking start procedure
2 Rep. gr.82 - Supplementary heating

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3 Rules for cleanliness when working

on the auxiliary heater and the fuel
system
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface (use
sheeting or paper, but no fluffy cloths) and cover.
♦ Carefully cover opened components or seal if the repair can‐
not be carried out immediately.
♦ Install clean parts only:
– Remove replacement parts from their packages only immedi‐
ately before installing them.
– Do not use any parts which have not been stored in their pack‐
aging (e.g. in a tool box).
♦ If fuel line has been opened:
Do not work with compressed air.
Do not move vehicle.
Do not start engine.
Do not switch auxiliary heater on.
3. Rules for cleanliness when working on the auxiliary heater and the fuel system 3
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4 Repairing auxiliary heater Thermo

Top V
Before beginning repair work on vehicles with the auxiliary heat‐
ing function, perform the following work.
– Disconnect the battery ⇒ Rep. gr. 27 .
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410- (4…20 Nm)
♦ Hose clamps up to 25 mm Ø - 3094-
Note
♦ There is a manufacturer's nameplate on the auxiliary heater

unit. This nameplate indicates which heater version has been
installed in the vehicle: ⇒ page 6
♦ The coolant circuit must be bled after it is opened ⇒ Rep. gr.
19 .

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1 - Fuel gauge sender - G-

❑ Installation location: un‐
der rear bench seat,
right.
❑ Removing and installing
⇒ Rep. gr. 20
2 - Auxiliary heater aerial -
R182-
❑ For vehicles with auxili‐
ary heater and remote
control
3 - Fuse carrier
❑ Location: under dash
panel on left ⇒ Current
flow diagrams, Electri‐
cal fault finding and Fit‐
ting locations
4 - Battery - A-
❑ Location: in engine
compartment on left
5 - Ambient temperature sen‐
sor - G17-
❑ Checking: vehicle diag‐
nosis, testing and infor‐
mation system - VAS
5051A- .
❑ Fitted from week
45/2010 in centre air in‐
take grille
⇒ page 8
6 - Circulation pump - V55-
❑ Located on the auxiliary
heater
❑ Removing and installing ⇒ page 17
7 - Auxiliary heater Thermo Top V
❑ With auxiliary heater control unit - J364- .
❑ Location: below front bumper on right.
8 - Exhaust system
9 - Heater coolant shut-off valve - N279-
Note
The heater coolant shut-off valve -

N279- is fitted only in vehicles with
the auxiliary heating function.
Function: When auxiliary heating mode is selected, it switches to the smaller coolant circuit. When the heater
coolant shut-off valve - N279- has no voltage, the large coolant circuit is opened.
❑ In vehicles with a petrol engine, it is fixed to the bulkhead of the engine compartment.
❑ In vehicles with a diesel engine, it is fixed to the engine.
4. Repairing auxiliary heater Thermo Top V 5

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10 - Metering pump - V54-

❑ Location: on fuel tank.
❑ Check fuel supply to auxiliary heater.
❑ It is possible that the metering pump ticks audibly but still does not deliver fuel because there is air in the
intake. The control unit then switches it off completely. You should therefore read the fault memory using
vehicle diagnosis, testing and information system - VAS 5051A- , Self-diagnosis of Thermo Top V aux‐
iliary heater. Erase fault memory and carry out final control diagnosis of Thermo Top V auxiliary heater.
❑ Testing quantity of fuel delivered ⇒ page 44
Note
♦ As of Week 12/06, the diesel ver‐

sion has a fuel shut-off valve -
N109- ⇒ page 8 located di‐
rectly at the fuel-line connection
of the auxiliary heater, and also
has a new metering pump - V54-
(grey plastic cap). The control
unit for the auxiliary heater -
J364- is also new. The metering
pump - V54- has a bypass for re‐
ducing the fuel pressure be‐
tween the fuel shut-off valve -
N109- and the metering pump -
V54- when the auxiliary heater is
switched off.
♦ Make sure the part number is
correct. Mixed installation is not
permissible because this would
impair operation of the auxiliary
heater.
11 - Remote control receiver for auxiliary coolant heater - R149-

❑ Removing and installing, ⇒ page 9
4.1 Manufacturer's nameplate for Thermo

Top V
4.1.1 Manufacturer's nameplates used for
Thermo Top V
Manufacturer's nameplate for diesel Thermo Top V on heater unit

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Manufacturer's nameplate for petrol-type Thermo Top V on heat‐

er unit
Manufacturer's nameplate for diesel Thermo Top V on heater unit

(supplementary heater, without auxiliary heating function)
Manufacturer's nameplate for diesel-type Thermo Top V (on lock

carrier)
Duplicate manufacturer's nameplate for petrol-type Thermo Top

V (on lock carrier)

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Duplicate manufacturer's nameplate for diesel-type Thermo Top

V supplementary heater, without auxiliary heating function (on
lock carrier)
Note
♦ The most important technical data are shown on upper part of

manufacturer's nameplate.
♦ The date of first use is entered on the lower part of manufac‐
turer's plate.
♦ The year the unit was first put into use must be entered on the
“Genuine part” manufacturer's plate. The heat exchanger of
the coolant heater does not need to be renewed after 10 years.
Legislation in Germany dictates only that air heaters must be
renewed.
Fuel shut-off valve
4.2 Removing and installing ambient tem‐

perature sensor - G17-
Vehicles up to week 44/2010
– Unclip ambient temperature sensor - G17- -1- and separate
connector.
Vehicles from week 45/2010
Note
♦ Ambient temperature sensor - G17- is located behind centre

air intake grille.
♦ Remove through centre air intake grille.
– Unhook retaining lug -arrow A- from bracket using a suitable

tool.
– Pull ambient temperature sensor - G17- downwards off brack‐
et -in direction of arrow-.
– Remove ambient temperature sensor - G17- forwards through
centre air intake grille and disconnect connector.

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4.3 Removing and installing exhaust system
WARNING
Danger of burn injuries.

Exhaust system could be hot.
Before removing exhaust system, let it cool off.
– Remove right wheel housing liner ⇒ Rep. gr. 66 .

– Loosen securing clamp on exhaust pipe -1- and remove bolts
-2- and -3- (6 Nm).
– Remove exhaust system.
Caution
Risk of short circuit in electric cables.

The exhaust system gets very hot when the heater is running.
Install the exhaust system in such a way that it does not touch
the electric cables.
4.4 Removing and installing remote control

receiver for auxiliary coolant heater -
R149-
Removing and installing remote control receiver for auxiliary cool‐
ant heater - R149- , vehicles up to week 21/2009
⇒ “4.4.1 Vehicles to week 21/2009”, page 10
Removing and installing remote control receiver for auxiliary cool‐
ant heater - R149- , vehicles from week 22/2009
⇒ “4.4.2 Vehicles from wee 22/2011”, page 10

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4.4.1 Vehicles to week 21/2009

Removing
– Remove luggage compartment side trim on right ⇒ Rep. gr.
70 .
– Pull off connectors -1- and -2-.
– Use a screwdriver to pry up tab on bracket and pull out remote
control receiver for auxiliary coolant heater - R149- in
-direction of arrow-.
Installing
Note
♦ Ensure that the connectors are properly seated.

♦ The remote control receiver for auxiliary coolant heater -
R149- must engage audibly.
♦ If the remote control receiver for auxiliary coolant heater -
R149- is renewed, the remote control receiver for auxiliary
coolant heater - R149- must be adapted to the auxiliary coolant
heater using the vehicle diagnostic tester in “Guided fault find‐
ing”.
4.4.2 Vehicles from wee 22/2011

Removing
– Remove luggage compartment side trim on right ⇒ Rep. gr.
70 .
– Pull off connectors -1- and -2-.
– Press retaining tab -A- and pull out remote control receiver for
auxiliary coolant heater - R149- in -direction of arrow-.
Installing
Note
♦ Ensure that the connectors are properly seated.

♦ The remote control receiver for auxiliary coolant heater -
R149- must engage audibly.
♦ If the remote control receiver for auxiliary coolant heater -
R149- is renewed, the remote control receiver for auxiliary
coolant heater - R149- must be adapted to the auxiliary coolant
heater using the vehicle diagnostic tester in “Guided fault find‐
ing”.

Touran 2003 ➤
5 Removing and installing auxiliary

heater Thermo Top V
♦ Vehicle diagnosis, testing and information system - VAS

5051A-
Note
♦ There is a manufacturer's nameplate on the auxiliary heater

unit. This nameplate indicates which heater version has been
installed in the vehicle: ⇒ page 6
19 .
♦ Cooling system is under pressure when engine is warm. If
necessary, release pressure before carrying out repairs.
5. Removing and installing auxiliary heater Thermo Top V 11

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5.1 Components of auxiliary heater Thermo Top V
1 - Auxiliary heater Thermo

Top V
❑ With auxiliary heater
control unit - J364- .
⇒ page 12
2 - Fuel line with quick-release
coupling
❑ Routing of fuel line
⇒ page 41 .
3 - Air intake silencer
⇒ page 17
4 - Exhaust system
⇒ page 18
⇒ page 17
5.2 Removing and installing auxiliary heater

Thermo Top V
Removing
Note
If the Thermo Top V is to be renewed, first connect vehicle diag‐

nosis, testing and information system - VAS 5051A- and call up
the “Renew heater” function under Guided functions.

Touran 2003 ➤

5051A-
Note

19 .
♦ After the auxiliary heater has been detached, it must be se‐
cured to the body with welding wire to prevent damage to the
coolant hoses.
– Remove front right wheel housing liner ⇒ Rep. gr. 66 .

– Remove front noise insulation ⇒ Rep. gr. 50 .
– Remove front bumper ⇒ Rep. gr. 63 .
WARNING

Parts of the exhaust system may be hot.
Before removing exhaust system, let it cool off.
– Remove exhaust pipe from silencer on auxiliary heater

⇒ page 9 .

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WARNING
Risk of scalding.
When the engine is warm, the coolant temperature may be
above 100 °C. The cooling system is pressurised.
If necessary, release pressure and reduce temperature before
carrying out repairs.
– Clamp off coolant hoses -2- using hose clamps up to 25 mm

Ø - 3094- and pull coolant hoses off auxiliary heater.
Do not separate coolant hoses that are connected to each other.
– Remove securing bolts -1- (8 ± 0.8 Nm) from washer fluid res‐
ervoir.

Touran 2003 ➤
– Remove securing bolt -1- (8 ± 0.8 Nm) below reservoir for

windscreen washer system.
– Pull windscreen washer reservoir out of guides -1- in direction
of travel and set it aside.
WARNING
Danger of fuel escaping.

Fuel system is under pressure.
Before opening system, wrap a cloth around the connection.
Then release pressure by carefully loosening the connection.
– Disconnect fuel line at quick-release coupling and seal fuel

lines with appropriate plugs.
Caution
Auxiliary heater control unit - J364- could be damaged.

Overvoltage can occur at the connectors.
First disconnect 8-pin connector.
– Unplug the remaining connectors at the auxiliary heater.
Removal for vehicles up to 09.03:

– Remove securing nuts -arrows- (15 ± 1.5 Nm) on right longi‐
tudinal member.
– Remove securing nut -1- (8 ± 0.8 Nm) from auxiliary heater
-2- on right longitudinal member -3-.
– Remove auxiliary heater from longitudinal member.

Removal for vehicles from 10.03:

Touran 2003 ➤
– Remove auxiliary heater from longitudinal member.

Installing
Caution
When carrying out assembly work, particularly in the engine

compartment due to the restricted space, observe the following
points:
Install all sorts of lines (e.g. for fuel, coolant and refrigerant) as
well as electric wiring so that the original routing is restored.
Make sure there is sufficient clearance between the lines and
all moveable and hot components.
Note
If the Thermo Top V is not to be renewed, connect vehicle diag‐

nosis, testing and information system - VAS 5051A- and call up
the “Release heater” function under the guided functions.
Installation is carried out in the reverse order. When installing,

note the following:
– After installing auxiliary heater, bleed coolant circuit ⇒ Rep.
gr. 19 .
– Then start the auxiliary heater.

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5.3 Dismantling and assembling supple‐

mentary heater
5.3.1 Removing and installing air intake si‐

lencer
Removing
– Remove bolt -1- and pull off air intake silencer
-in direction of arrow-.
Installing
– Slide air intake silencer towards auxiliary heater until it lies
against the combustion air blower housing.
– Tighten bolt -1- (6 Nm).
5.3.2 Removing and installing circulation

pump - V55-
Removing
♦ Pliers for spring-type clips - VAS 5024A-
– Remove front noise insulation ⇒ General body repairs, exte‐

rior; Rep. gr. 50 ; Noise insulation .
– Detach front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing front wheel housing liner .

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– Clamp off coolant hoses using hose clamps to Ø 25 mm -

3094- .
– Loosen clip -1-.
WARNING
Risk of scalding.
– Pull coolant hoses off circulation pump - V55- .

– Pull connector off circulation pump - V55- .
– Remove bolt -2- and remove circulation pump - V55- .
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– After installing circulation pump - V55- , bleed coolant circuit
⇒ Rep. gr. 19 .
5.3.3 Removing and installing silencer with

bracket
WARNING

Silencer could be hot.
Before removing silencer, let it cool off.
– Loosen pipe connections from silencer -A-.

– Remove bolt -1- from support -B- and lay exhaust pipe to side.
– Remove bolt -2- from silencer -A-.
– Remove silencer -A-.
– Remove bolts -3- from bracket.
– Separate bracket from centring tabs and remove.
– Install in reverse order.
Note
When installing bracket -3-, observe centring tabs.

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5.3.4 Removing and installing bracket for aux‐

iliary heater
– Remove bolts -2- and remove bracket -1-.
Note
When installing bracket -1-, observe centring tabs.
5.3.5 Removing and installing cover

– Mark fitting position of coolant connections and remove them
(bolt 4 Nm).
– Unclip cover at -arrows- and pull cover over locking lugs -A-.
5.4 Dismantling and assembling auxiliary

heater Thermo Top V

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– Remove auxiliary heater Thermo Top V ⇒ page 12 .

– Loosen securing clamp -E- and remove silencer with bracket
-D- ⇒ page 18 .
– Remove bracket -H- ⇒ page 19 .
– Pull off connectors -A-, -B- and -C-.
WARNING

– Open O-type clip and pull fuel line -F- off connection. Renew
O-type clip with screw-type clip.
– Seal fuel lines using suitable plugs.
– Unclip cover -G- -arrows-.
5.5 Inner components of auxiliary heater
1 - Cover for auxiliary heating

control unit - J364- .
2 - Temperature sensor - G18-
⇒ page 23
3 - Overheating sensor - G189-
⇒ page 23
4 - Burner tube
Note
♦ Figure shows petrol version with

fine filter in fuel line.
N109- ⇒ page 8 located directly
at the fuel-line connection of the
auxiliary heater, and also has a
new metering pump - V54- (grey
plastic cap). The control unit for
the auxiliary heater - J364- is al‐
so new.
heater.
⇒ page 19
5 - Heat exchanger
⇒ page 19

Touran 2003 ➤
6 - 7 Nm
❑ Qty. 3.
7 - Retaining spring
8 - 4 Nm
9 - Seal
❑ Must be renewed after every opening.
10 - Cover
11 - Coolant connection
❑ Mark fitting position.
12 - 4 Nm
13 - Retaining plate
14 - Coolant connection
❑ Mark fitting position.
15 - Retaining clip
16 - Glow plug with flame monitoring - Q8-
❑ Ensure correct seating.
Note
♦ On vehicles with diesel engine, a

fuel pre-heating heater element -
Z66- is permanently installed on
the combustion tube. The wires
are connected to wires of glow
plug with flame monitoring - Q8- .
With this version, the entire com‐
bustion tube must be renewed if
the glow plug with flame moni‐
toring - Q8- is defective.
♦ As of week 12/06, the diesel ver‐
N109- directly at the fuel-line
connection of the auxiliary heat‐
er and also has a new metering
pump - V54- (grey plastic cap).
The control unit for the auxiliary
heater - J364- is also new. With
this version, the entire combus‐
tion tube must be renewed if the
glow plug with flame monitoring -
Q8- is defective.
heater.
17 - Burner
18 - Combustion air blower - V6-
❑ The combustion air blower - V6- and housing are one component and cannot be dismantled.

Touran 2003 ➤
19 - Auxiliary heater control unit - J364-
Note
The auxiliary heater control unit -

J364- and the combustion air blower
- V6- with housing are one compo‐
nent and cannot be dismantled. The
reason is the seal between the aux‐
iliary heater control unit - J364- and
the housing.
As of week 12/06, the diesel version has a new auxiliary heater control unit - J364- . This control unit also
controls the fuel shut-off valve - N109- at the fuel line connection of the auxiliary heater. These control units
cannot be installed with the old types of combustion tube (without fuel shut-off valve - N109- ) or vice versa.
20 - 4 Nm
❑ Qty. 4.
5.6 Removing and installing glow plug with

flame monitoring - Q8-
Note
♦ The illustration shows the diesel version.

♦ With the diesel version, a heating element for preheating fuel
- Z66- (PTC on burner) -A- is permanently installed. The wires
are connected to wires of glow plug with flame monitoring -
Q8- . With this version, the entire combustion tube must be
renewed if the glow plug with flame monitoring - Q8- is defec‐
tive.
♦ As of week 12/2006, the diesel version has a fuel shut-off valve
- N109- ⇒ page 8 directly at the fuel-line connection of the
auxiliary heater. With this version, the entire combustion tube
must also be renewed if one of the three parts is defective.
♦ Make sure the part number is correct. Mixed installation is not
permissible because this would impair operation of the auxili‐
ary heater.
– Dismantling and assembling auxiliary heater Thermo Top V

⇒ page 19 .
– Using an appropriate screwdriver, raise retaining clip -A- on

both sides and remove.
Note
♦ The illustration shows the petrol version.

♦ During assembly, retaining clip must seat in groove.
♦ Ensure proper seating of glow plug with flame monitoring - Q8-
-B-.

Touran 2003 ➤
5.7 Removing and installing temperature

sensor - G18- and overheating sensor -
G189-
– Dismantling and assembling auxiliary heater Thermo Top V
⇒ page 19 .
– Remove bolt -1- and remove retaining spring -2-.
– Pull out temperature sensor - G18- -3-and overheating sensor
- G189- -4- using long nose pliers.
Note
♦ When assembling, ensure that retaining spring is in proper

position -2-.
♦ Sensors cannot be renewed separately.
5.8 Removing and installing heater coolant

shut-off valve - N279- for vehicles with
petrol engine
Function: When auxiliary heating mode is selected, it switches to

the smaller coolant circuit. When the heater coolant shut-off valve
- N279- has no voltage, the large coolant circuit is opened.
Removing
– Remove engine cover ⇒ Rep. gr. 10 .
– Remove the centre bulkhead ⇒ Rep. gr. 50 .
– Disconnect connector on heater coolant shut-off valve -
N279- .
WARNING
Risk of scalding.
– Clamp off coolant hoses using hose clamps up to Ø 25 mm -

3094- .

Touran 2003 ➤
– Disconnect coolant hoses from heater coolant shut-off valve -

N279- .
– Unscrew securing bolt -1- and nuts -3- (8 Nm).
– Remove heater coolant shut-off valve - N279- -2- from bulk‐
head.
Installing
5.9 Removing and installing heater coolant

shut-off valve - N279- for vehicles with
diesel engine
Function: When auxiliary heating mode is selected, it switches to

the smaller coolant circuit. When the heater coolant shut-off valve
- N279- has no voltage, the large coolant circuit is opened.
Removing
– Remove engine cover ⇒ Rep. gr. 10 .
– Remove the centre bulkhead ⇒ Rep. gr. 50 .
– Disconnect connector on heater coolant shut-off valve -
N279- .
WARNING
Risk of scalding.

Touran 2003 ➤
– Clamp off coolant hoses using hose clamps up to Ø 25 mm -

3094- .
– Unscrew securing nuts -1- (8 Nm).
– Remove heater coolant shut-off valve - N279- -2- from bracket
-4-.
– Remove bracket -4- from intake pipe by unscrewing bolts -3-
(9 Nm).
Installing

Touran 2003 ➤
6 Connecting auxiliary heater Thermo

Top V to coolant circuit
WARNING
Risk of scalding.
Note
The coolant circuit must be free of air for the auxiliary heater to
heat properly.
6.1 Connection diagram for coolant hoses in vehicles with auxiliary heating,
engine codes BAG, BKG, BLF, BLN, and BLP
1 - Expansion tank
2 - Non-return valve
3 - Restrictor
4 - Heat exchanger for heater
5 - Heater coolant shut-off
valve - N279-
Note

the auxiliary heating function.
Function: When auxiliary heat‐

ing mode is selected, it
switches to the smaller coolant
circuit. When the heater cool‐
ant shut-off valve - N279- has
no voltage, the large coolant
circuit is opened.
❑ Secured to engine com‐
partment bulkhead
⇒ page 23

Touran 2003 ➤
6 - Exhaust gas recirculation (water cooled)

7 - Intake manifold
8 - Thermostat housing
9 - Radiator
10 - Engine oil cooler
11 - Cylinder head and cylinder block
engine codes BGU, BSE and BSF
1 - Expansion tank
valve - N279-
Note
♦ The heater coolant shut-off valve

- N279- is fitted only in vehicles
with the auxiliary heating func‐
tion.
♦ Function: When auxiliary heating
mode is selected, it switches to
the smaller coolant circuit. When
the heater coolant shut-off valve
- N279- has no voltage, the large
coolant circuit is opened.
partment bulkhead
⇒ page 23
5 - Intake manifold
6 - Cylinder head and cylinder
block
8 - Radiator
9 - Coolant pump
⇒ page 17
6. Connecting auxiliary heater Thermo Top V to coolant circuit 27

Touran 2003 ➤
engine codes AXW, BLX, BLY, BLR
1 - Expansion tank
valve - N279-
Note

tion.
partment bulkhead
⇒ page 23
5 - Intake manifold
7 - Radiator
⇒ page 17
Top V
⇒ page 12

Touran 2003 ➤
engine codes AVQ, BKC and BLS
1 - Expansion tank
valve - N279-
Note

tion.
❑ Secured to engine.
⇒ page 24
block
6 - ATF cooler
❑ Only vehicles with auto‐
matic transmission
8 - Radiator
⇒ page 17
Top V
11 - Coolant pump
12 - Intake manifold

Touran 2003 ➤
engine code AZV, BKD
1 - Expansion tank
valve - N279-
Note

tion.
❑ Secured to engine.
⇒ page 24
5 - Radiator
⇒ page 17
Top V
⇒ page 12
9 - Coolant pump
10 - Exhaust gas recirculation
(water cooled)

Touran 2003 ➤
6.6 Connection diagram for coolant hoses in vehicles with auxiliary heating
(preheater), engine code BLS
1 - Expansion tank
2 - Bypass flap
cooler
block
6 - ATF cooler
matic transmission
7 - Upper coolant hose
8 - Radiator
9 - Lower coolant hose
11 - Coolant pump/thermostat
Top V
⇒ page 12
❑ With circulation pump -
V55-
circulation pump - V55-
⇒ page 17

Touran 2003 ➤
6.7 Connection diagram for coolant hoses in vehicles with auxiliary heater, en‐
gine codes BLG and BMY
1 - Expansion tank
2 - Intake manifold
6 - Radiator
7 - Coolant circulation pump -
V50-
⇒ Rep. gr. 19
8 - Turbocharger
block
⇒ page 17
Top V
⇒ page 12

Touran 2003 ➤
gine codes BKP and BMN
1 - Expansion tank
2 - Bypass flap
3 - Radiator
❑ For exhaust gas recircu‐
lation
5 - ATF cooler
block
9 - Radiator
⇒ page 17
Top V
⇒ page 12

Touran 2003 ➤
engine codes AXW and BLX
1 - Expansion tank
❑ Note fitting position.
❑ Arrow on non-return
valve points in direction
of flow.
valve - N279-
Note

the auxiliary heating function. Func‐
tion: When voltage is applied, it
switches to the smaller coolant cir‐
cuit.
Location: secured to engine

compartment bulkhead
⇒ page 23
5 - Intake manifold
❑ With throttle valve mod‐
ule - J338-
7 - Radiator
⇒ page 17
Top V

Touran 2003 ➤
engine codes BVX, BVY and BVZ
1 - Expansion tank
valve - N279-
Note

the auxiliary heating function. Func‐
tion: When voltage is applied, it
switches to the smaller coolant cir‐
cuit.
Location: secured to engine

compartment bulkhead
⇒ page 23
4 - ATF cooler
matic transmission
6 - Intake manifold
7 - Radiator
⇒ page 17
Top V
⇒ page 12
❑ Not in the case of BVZ engine

Touran 2003 ➤
gine codes BRU, BXE, BXF and BXJ
1 - Expansion tank
2 - Rear coolant pipe
3 - Bypass flap
cooler
block
7 - Connecting piece
8 - Front coolant pipe
9 - ATF cooler
matic transmission
11 - Radiator
15 - Upper coolant pipe
⇒ page 17
Top V
⇒ page 12

Touran 2003 ➤
gine code BMM
1 - Expansion tank
2 - Rear coolant pipe
cooler
4 - Intake manifold
6 - Connecting piece
7 - Upper coolant pipe
8 - Front coolant pipe
11 - Radiator
block
⇒ page 17
Top V
⇒ page 12

Touran 2003 ➤
gine code: CAVB, CAVC, CAVD, CDGA, CFHC, CFJA, CFJB, CLCA, CTHB
and CTHC
1 - Expansion tank
2 - Coolant pump
3 - Intake manifold
block
7 - Radiator
V50-
⇒ Rep. gr. 19
10 - Turbocharger
⇒ page 17
Top V
⇒ page 12

Touran 2003 ➤
gine code CAYB and CAYC
1 - Expansion tank
2 - Radiator
❑ For exhaust gas recircu‐
lation
❑ With quick-release cou‐
pling
block
V178-
pling
8 - Radiator
❑ Renew coolant after re‐
placement.
pling
10 - 4/2-way valve with ther‐
mostat
placement.
Top V with attached circulation
pump - V55-
Thermo Top V
⇒ page 12
❑ Removing and installing circulation pump - V55- ⇒ page 17

Touran 2003 ➤
engine code: CBZB
1 - Expansion tank
V50-
3 - Coolant pump
4 - Intake manifold with charge
air cooler
❑ Available as individual
replacement parts ⇒
Electronic parts cata‐
logue “ETKA”
❑ Located in coolant hose
❑ Determine position by
feel
❑ Replace coolant hose
also, as needed
8 - Restrictor
9 - Radiator
10 - Turbocharger
11 - Low temperature cooler
for charge air system
❑ Radiator and low tem‐
perature cooler for
charge air system are
one component.
block
placement.
❑ Available as individual replacement parts ⇒ Electronic parts catalogue “ETKA”
❑ Located in coolant hose
❑ Determine position by feel
❑ Replace coolant hose also, as needed
15 - Auxiliary heater Thermo Top V with attached circulation pump - V55-
❑ Removing and installing Thermo Top V ⇒ page 12
❑ Removing and installing circulation pump - V55- ⇒ page 17

Touran 2003 ➤
7 Fuel supply for auxiliary heater Ther‐

mo Top V
7.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface and
cover. Do not use fluffy cloths!
♦ Carefully cover or seal opened components if the repair can‐
not be carried out immediately.
♦ Install clean parts only; remove replacement parts from their
packages only immediately before installing them. Do not use
any parts which have not been stored in their packaging (e.g.
in a tool box).
♦ Fuel hoses and pipes may be shortened only with a clean
sharp knife. Cutting points must not be soiled or deformed.
Cutting points and surfaces must be free of burrs.
7.2 Fuel feed to Thermo Top V
Note
♦ Fuel lines are secured with O-type clips. These O-type clips
must always be replaced with screw-type clips.
♦ To start the auxiliary heater, the following conditions are re‐
quired: ambient temperature sensor - G17- is pulled off and
the coolant temperature is below 50 °C.
♦ If the fuel tank was empty, there may be air in the fuel line to
the auxiliary heater. To remove air from the fuel line, start aux‐
iliary heater repeatedly until it does not go out by itself.
♦ Observe the rules for cleanliness when doing all work on the
fuel supply system.
7. Fuel supply for auxiliary heater Thermo Top V 41

Touran 2003 ➤
1 - Quick-release coupling of
fuel line
❑ Rear right.
fuel line
❑ In engine compartment
on right.
fuel line
❑ On auxiliary heater
Thermo Top V
Top V
5 - Metering pump - V54-
❑ Metering pump - V54- is
located on fuel tank.
⇒ page 43
❑ Testing quantity of fuel
delivered ⇒ page 44 .
Note

N109- ⇒ page 8 located directly
at the fuel-line connection of the
auxiliary heater, and also has a
new metering pump - V54- (grey
plastic cap). The control unit for
the auxiliary heater - J364- is al‐
so new. The metering pump -
V54- has a bypass for reducing
the fuel pressure between the
fuel shut-off valve - N109- and
the metering pump - V54- when
the auxiliary heater is switched
off.
heater.
6 - Fuel gauge sender

❑ Fuel gauge sender is located on right side under bench seat.
❑ Removing and installing ⇒ Rep. gr. 20
7.2.1 Fuel feed to Thermo Top V
WARNING


Touran 2003 ➤
Fuel feed to auxiliary heater is achieved via connection on fuel

gauge sender - G- -arrow-. Fuel gauge sender - G- is located on
right side under bench seat.
7.3 Removing and installing metering pump

- V54-
♦ Engine and gearbox lifter - V.A.G 1383 A-
Note
Have a commercially available screw-type clip at hand. Clamping

range ∅ 9.6 to 11.3 mm.
7.3.1 Removing
– Support fuel tank using engine and gearbox lifter - V.A.G 1383
A- .
– Remove front bolts for fuel tank retaining straps ⇒ Rep. gr.
20 .
– Lower front of fuel tank a maximum of 25 centimetres.

Touran 2003 ➤
– Push a screwdriver through hole in bracket. This releases the

retaining tab and the bracket can then be removed together
with metering pump - V54- .
– Pull connector -3- off metering pump - V54- and remove wiring
harness -4- from retainer.
– Open clip -2-.
WARNING

– Pull fuel line -1- off metering pump - V54- and seal.
– Open quick-release coupling of fuel line leading to Thermo
Top V auxiliary heater and seal fuel line.
7.3.2 Installing
– Remove line leading to fuel tank from Genuine replacement
part.
Make sure that bracket of metering pump - V54- is correctly seat‐
ed.
Replace O-type clip with a screw-type clip. Clamping range ∅ 9.6
to 11.3 mm.
Note
♦ As of Week 12/06, the diesel version has a fuel shut-off valve

- N109- ⇒ page 8 located directly at the fuel-line connection of
the auxiliary heater, and also has a new metering pump - V54-
(grey plastic cap). The control unit for the auxiliary heater -
J364- is also new. The metering pump - V54- has a bypass for
reducing the fuel pressure between the fuel shut-off valve -
N109- and the metering pump - V54- when the auxiliary heater
is switched off.
♦ Make sure the part number is correct. Mixed installation is not
permissible because this would impair operation of the auxili‐
ary heater.
7.4 Testing quantity of fuel delivered

5051A- or later model.

Touran 2003 ➤
♦ Hand multimeter - V.A.G 1526/A-
♦ Auxiliary measuring set - V.A.G 1594/C-

♦ Current flow diagram
♦ Commercially available measuring glass (0 to 50 ml)
♦ Fuel hose, length approx. 300 mm
7.4.1 Test prerequisites:

• Resistance of metering pump - V54- 5.2 +/- 5 % Ω
• Voltage at metering pump - V54- 9.5 to 16.5 Volt.
• No fault stored in fault 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).
7.4.2 Checking:
WARNING

– Disconnect fuel line at metering pump - V54- and seal using

suitable means.

Touran 2003 ➤
– Hold measuring glass at same height as auxiliary heater.

– Call up and start Guided function “Check quantity of fuel
delivered” (open fuel line from metering pump - V54- ) using
vehicle diagnosis, testing and information system - VAS
5051A- .
After approx. 30 seconds, the fuel line is filled and bled.
– Seal fuel line.

Touran 2003 ➤
– Empty measuring glass.

– Hold measuring glass at same height as auxiliary heater.
– Call up and start Guided function “Check quantity of fuel
delivered” (open fuel line from metering pump - V54- ) using
vehicle diagnosis, testing and information system - VAS
5051A- .
Fuel delivery finishes after approx. 120 seconds.
– Connect connector to fuel line.
– Read measuring glass. Fuel delivery rate for petrol and diesel:
22 to 28 ml
– If fuel delivery rate is not within specifications, renew metering
pump - V54- .
Note
♦ If the ambient temperature is above 20 °C, fuel vaporisation

may lead to incorrect measurements.
♦ No bubbles are to be delivered.

Touran 2003 ➤
8 Regulation of auxiliary heater Ther‐

mo Top V
The auxiliary heater is intended to heat coolant.
Various operating modes can be set depending on heat required
in heating circuit:
Note
One method of switching off the auxiliary heater is to press the

ECON button. Starting conditions
⇒ “2.1 Starting conditions for auxiliary heating (preheater)”, page
2 or ⇒ “2.2 Starting conditions for auxiliary heating”, page 2
8.1 Functional description of auxiliary heat‐

er Thermo Top V
Temperature at temperature sensor - G18- less than 50 °C.
Temperature at ambient temperature sensor - G17- must be be‐
low approx. +5 °C.
Turning on the switch enables operation of the auxiliary heater.
The glow plug with flame monitor - Q8- , the combustion air blower
- V6- and the circulation pump - V55- begin to operate. After 30
seconds, the metering pump - V54- is switched on and the com‐
bustion air blower - V6- is switched off for 3 seconds. Then the
combustion air blower - V6- runs up in two stages to nearly full
load within 56 seconds. After a stabilisation phase (attaining
steady motor speed) of 15 seconds, the combustion air blower -
V6- is again brought up to nearly full load in a 50-second stage.
After reaching full-load fuel delivery, the glow plug with flame
monitor - Q8- is switched off and the combustion air blower - V6-
is brought up to full speed. During the next 45 seconds as well as
during normal operation, the glow plug with flame monitoring - Q8-
assumes the task of flame monitoring and checks flame devel‐
opment. Then the automatically regulated heating operation
begins. If no flame develops or the flame extinguishes, then the
fuel supply is interrupted and a malfunction shut-down occurs with
the combustion air blower - V6- continuing in run-on mode. If the
flame is extinguished during normal operation, a new start is au‐
tomatically initiated.
8.1.1 Preheating mode

Once the coolant temperature has reached 84 ℃, the control unit
switches to the energy-saving part load mode. If the coolant tem‐
perature continues to rise above 88 °C, the control unit switches
to the controlled waiting period. If the coolant temperature does
not drop below 76 ℃ within 900 seconds during the controlled
waiting period, the heating unit will start with the normal start pro‐
cedure in full-load mode when the coolant temperature does drop
below 76 ℃.

Touran 2003 ➤
8.1.2 Auxiliary heating mode

Switching on auxiliary heating mode in vehicles without an air
conditioning system:
– Press instant heating button -1-.
Switching on auxiliary heating mode in vehicles with Climatic,

Touran 2003 ►:
Switching on auxiliary heater mode in vehicles equipped with Cli‐

matic, Touran from week 22/2012:
Switching on auxiliary heating mode in vehicles equipped with

Climatronic, Touran 2003 ►:
below 65 ℃.
8. Regulation of auxiliary heater Thermo Top V 49

Touran 2003 ➤
Switching on auxiliary heater mode in vehicles equipped with Cli‐

matronic, Touran from week 22/2012:
below 65 ℃.
8.1.3 Switching off

When switched off manually or after a maximum operating time
of 60 minutes or the coolant reaches a temperature of 84° C,
combustion is ended and the run-on mode begins. The circulation
pump - V55- and the combustion air blower - V6- , however, con‐
tinue to run to cool down the auxiliary heater (run-on mode) and
are switched off automatically.
Note
The run-on period of the circulation pump - V55- and the com‐
bustion air blower - V6- depends on the operating mode in which
the auxiliary heater was switched off.
The run-on period is 175 seconds when heater is switched off

during full-load operation and 110 seconds for part-load opera‐
tion.
Depending on the control unit software version, slight deviations
in the specified run-on values are possible.
8.2 Functional description of “large” remote

control
Note
♦ The auxiliary heater can be switched on and off from a dis‐

tance of up to 600 metres (open terrain) using the remote
control. This range is restricted in built-up areas or from within
buildings.
♦ The remote control should be held upright when operating the
buttons (the radio signals can be received optimally by the ve‐
hicle aerial in this way and the greatest transmission range is
achieved).
♦ Following disconnection of the vehicle battery, the auxiliary
heater remote control does not have to be re-adapted.
♦ If the remote control has been renewed, it will have to be
synchronised with the vehicle diagnosis, testing and informa‐
tion system - VAS 5051B- (or later model).
♦ Start guided fault finding or guided functions using vehicle di‐
agnosis, testing and information system - VAS 5051B- (or later
model) and then call up functional check “Adapting Telestart
sender”.

Touran 2003 ➤
8.2.1 Switching auxiliary heater on using re‐

mote control
– Press button -1-: the warning lamp -2- must light up green.
When the auxiliary heater is switched on, its operating time is de‐
termined by the setting on the multifunction indicator.
8.2.2 Switching auxiliary heater off using re‐

mote control
– Press button -3-; the warning lamp -2- must light up red.
The auxiliary heater switches to run-on and then off.
8.2.3 Renewing remote control batteries
Note
♦ Note installation position of batteries.

♦ Use only batteries of the same type with a voltage of 12 volts.
♦ Allocation of the remote control to the auxiliary heater remains
intact. Re-adapting is not necessary.
– Take off battery cover -1- and remove batteries. Insert new
batteries and replace cover.

Touran 2003 ➤
8.3 Functional description of “small” remote

control
Note
♦ The auxiliary heater can be switched on and off from a dis‐

tance of up to 600 metres (open space) using the remote
control. This range is restricted in built-up areas or from build‐
ings.
♦ The remote control should be held upright when operating the
buttons (the radio signals can be received optimally by the ve‐
hicle aerial in this way and the greatest transmission range is
achieved).
♦ Following disconnection of the vehicle battery, the auxiliary
heater remote control does not have to be re-adapted.
♦ If the remote control has been renewed, it will have to be
synchronised with the vehicle diagnosis, testing and informa‐
tion system - VAS 5051B- (or later model).
♦ Start guided fault finding or guided functions using vehicle di‐
agnosis, testing and information system - VAS 5051B- (or later
model) and then call up functional check “Adapting Telestart
sender”.
8.3.1 Switching auxiliary heater on using re‐

mote control
– Press button -1-: the warning lamp -2- must light up green.
When the auxiliary heater is switched on, its operating time is de‐
termined by the setting on the multifunction indicator.
8.3.2 Switching auxiliary heater off using re‐

mote control
– Press button -3-; the warning lamp -2- must light up red.
The auxiliary heater switches to run-on and then off.

Touran 2003 ➤
8.3.3 Renewing remote control battery
Note
♦ Ensure proper installation position of battery.

♦ Only use batteries of the same type with a voltage of 3 volts.
♦ Allocation of the remote control to the auxiliary heater remains
intact. Re-adapting is not necessary.
– Pull off battery cover -1- in direction of -arrow- and remove

battery. Insert new batteries and refit cover.
8.3.4 Warning lamp in remote control

Once you have pressed the button, the warning lamp in the re‐
mote control -2- shows you 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 -2- Meaning
The LED lights up green for twoThe auxiliary heater has been
seconds. switched on with -1- “ON”.
The LED lights up red for two The auxiliary heater has been
seconds. switched off with -3- “OFF”.
The LED flashes green slowly The signal to switch on has not
for two seconds. been received.
The LED flashes green quickly The auxiliary heater is blocked,
for two seconds. e.g. because the fuel tank is
nearly empty or there is a fault
in the auxiliary heater.
The LED flashes red for two The signal to switch off has not
seconds. been received.
Lights up orange for two sec‐ The battery charge is low, but
onds, then green or red. the switch on/switch off signal
was received.
Lights up orange for two sec‐ The battery charge is low and
onds, then green or red. the switch on/switch off signal
was not received.
Flashes orange for five sec‐ The battery is exhausted and
onds. the switch on/switch off signal
was not received.

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Service

Service Department. Technical Information

7 Fuel supply for auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.1 Safety measures for working on vehi‐

1. Auxiliary heater Thermo Top V 1

2 Notes on general repairs on vehicles

2.1 Starting conditions for auxiliary heating

The AC button has no influence on the operation of the preheater.

2.2 Starting conditions for auxiliary heating

2 Rep. gr.82 - Supplementary heating

3 Rules for cleanliness when working

4 Repairing auxiliary heater Thermo

♦ Hose clamps up to 25 mm Ø - 3094-

♦ There is a manufacturer's nameplate on the auxiliary heater

4 Rep. gr.82 - Supplementary heating

1 - Fuel gauge sender - G-

The heater coolant shut-off valve -

4. Repairing auxiliary heater Thermo Top V 5

10 - Metering pump - V54-

♦ As of Week 12/06, the diesel ver‐

11 - Remote control receiver for auxiliary coolant heater - R149-

4.1 Manufacturer's nameplate for Thermo

6 Rep. gr.82 - Supplementary heating

Manufacturer's nameplate for petrol-type Thermo Top V on heat‐

Manufacturer's nameplate for diesel Thermo Top V on heater unit

Manufacturer's nameplate for diesel-type Thermo Top V (on lock

Duplicate manufacturer's nameplate for petrol-type Thermo Top

4. Repairing auxiliary heater Thermo Top V 7

Duplicate manufacturer's nameplate for diesel-type Thermo Top

♦ The most important technical data are shown on upper part of

Fuel shut-off valve

4.2 Removing and installing ambient tem‐

♦ Ambient temperature sensor - G17- is located behind centre

– Unhook retaining lug -arrow A- from bracket using a suitable

8 Rep. gr.82 - Supplementary heating

4.3 Removing and installing exhaust system

Danger of burn injuries.

– Remove right wheel housing liner ⇒ Rep. gr. 66 .

Risk of short circuit in electric cables.

4.4 Removing and installing remote control

4. Repairing auxiliary heater Thermo Top V 9

4.4.1 Vehicles to week 21/2009

♦ Ensure that the connectors are properly seated.

4.4.2 Vehicles from wee 22/2011

♦ Ensure that the connectors are properly seated.

10 Rep. gr.82 - Supplementary heating

5 Removing and installing auxiliary

♦ Hose clamps up to 25 mm Ø - 3094-

♦ Vehicle diagnosis, testing and information system - VAS

♦ There is a manufacturer's nameplate on the auxiliary heater

5. Removing and installing auxiliary heater Thermo Top V 11

5.1 Components of auxiliary heater Thermo Top V

1 - Auxiliary heater Thermo

5.2 Removing and installing auxiliary heater

If the Thermo Top V is to be renewed, first connect vehicle diag‐

Special tools and workshop equipment required

12 Rep. gr.82 - Supplementary heating

♦ Hose clamps up to 25 mm Ø - 3094-