Volkswagen Transporter 2016 Workshop Manual Download Page 61

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7.14

Removing and installing heat exchanger

Removing
– Removing auxiliary air heater without bracket

⇒ page 39

– Remove auxiliary air heater from plastic housing

⇒ page 47

– Remove auxiliary air heater control unit - J604-

⇒ page 45

– Unscrew bolts -1- from combustion air blower - V6- -2-.
– Remove heat exchanger -4- with seal -3- from combustion air

blower - V6- -2-.

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

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.

Transporter 2016 ➤

Auxiliary heater - Edition 04.2020

7. Auxiliary air heater

Summary of Contents for Transporter 2016

Page 1: ...Workshop Manual Transporter 2016 Auxiliary heater Edition 04 2020 Service Service Department Technical Information...

Page 2: ...ecause 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...

Page 3: ...ementary heater attachments 13 2 4 Removing and installing auxiliary supplementary heater 14 2 5 Removing and installing air intake silencer 16 2 6 Removing and installing circulation pump V55 16 2 7...

Page 4: ...overheating sensor G189 combination sensor 53 7 13 Removing and installing combustion air blower V6 55 7 14 Removing and installing heat exchanger 57 7 15 Removing and installing temperature sensor G1...

Page 5: ...ystem Danger of fire caused by escaping fuel When the battery is connected and the driver door opens the door contact switch activates the fuel pump Escaping fuel can ignite and cause a fire Disconnec...

Page 6: ...r protective goggles Reduce excess pressure by covering cap of coolant expan sion tank with cloths and opening it carefully 1 5 Safety precautions for working on vehicles with auxiliary heater Danger...

Page 7: ...ll draw air and supply it to the auxiliary heater The air in the fuel system may cause the auxiliary heater to malfunction Fill fuel take off pipe with fuel Risk of accidents and risk of injury due to...

Page 8: ...tary heaters 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 Duplicate typ...

Page 9: ...per no cloths containing lint and cover If repair work cannot be performed immediately carefully cov er or seal opened components Only install clean parts Remove replacement parts from their packages...

Page 10: ...immediately before installing Do not use parts that have been stored outside their packaging e g in tool boxes If system is open do not work with compressed air Protect disconnected electrical connec...

Page 11: ...hat become hot 3 4 Contact corrosion Contact corrosion can occur if unsuitable fasteners bolts nuts washers etc are used For this reason only fasteners with a special surface coating are installed in...

Page 12: ...import er must be contacted before any work is undertaken Any repair work must be performed in accordance with ap plicable laws and regulations the state of the art technolo gy any relevant accident p...

Page 13: ...nstalling page 16 5 Exhaust system Removing and installing page 18 6 Auxiliary heater Removing and installing page 10 7 Metering pump V54 Removing and installing page 28 Testing quantity of fuel deliv...

Page 14: ...pump V55 page 16 2 7 Removing and installing exhaust system page 18 2 8 Removing and installing cover page 19 2 9 Dismantling and assembling heater unit page 20 2 10 Removing and installing glow plug...

Page 15: ...ubber mounting 5 Electrical connector 6 Coolant hose 7 Circulation pump V55 Removing and installing page 16 8 Bracket For circulation pump V55 9 Exhaust system Removing and installing page 18 10 Brack...

Page 16: ...unit J364 Removing and installing page 19 7 Cover 8 Auxiliary heater control unit J364 with combustion air blower V6 Note The auxiliary heater control unit J364 and the combustion air blower V6 with...

Page 17: ...6 Nm 3 Rubber mounting 4 Air intake silencer Removing and installing page 16 5 Exhaust system Removing and installing page 18 6 Auxiliary supplementary heater 7 Bracket For circulation pump V55 and ai...

Page 18: ...ne bung set VAS 6122 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 Fun...

Page 19: ...covering cap of coolant expan sion tank with cloths and opening it carefully Pull off coolant hoses from auxiliary heater CAUTION The fuel system is pressurised Danger of injury caused by fuel spray...

Page 20: ...overview underbody cladding Unscrew bolts 3 Lower auxiliary heater 2 in direction of arrow A Note The lines and coolant hoses remain connected Release spreader clip of air intake silencer 1 in direct...

Page 21: ...ding CAUTION On a warm engine the cooling system is under high pressure Danger of scalding by steam and hot coolant Skin and other parts of the body may be scalded Wear protective gloves Wear protecti...

Page 22: ...emoving Remove left underbody cladding General body repairs ex terior Rep gr 66 Underbody cladding Assembly overview underbody cladding CAUTION Danger of severe burns from hot exhaust system Burns to...

Page 23: ...burner unit page 19 2 8 1 Removing and installing cover auxiliary heater control unit J364 Removing Remove auxiliary heater page 14 Unclip cover 1 in area 2 Detach cover 1 Detach cover 3 Installing I...

Page 24: ...and damage Moisten oil seals with coolant before installing coolant con nections Renew oil seals 3 Insert coolant connections together with bracket 2 Tighten bolt 1 Specified torques 2 2 Assembly over...

Page 25: ...surfaces Renew seal 1 Specified torques 2 2 Assembly overview auxiliary supplementary heater internal page 12 2 10 Removing and installing glow plug with flame monitor Q8 Removing Dismantle heater un...

Page 26: ...4 and overheating sensor G189 3 using long nose pliers Installing Install in reverse order of removal observing the following Coat seals from temperature sensor G18 and overheating sensor G189 with co...

Page 27: ...finding and Fitting locations 2 2 pin connector Information on pin as signment can be found in the latest current flow diagram Current flow diagrams Electrical fault finding and Fitting locations 3 2...

Page 28: ...of the auxiliary supplementary heater Removing and installing page 16 Note For this vehicle a start stop sys tem is offered as an optional equipment with certain engines On vehicles equipped with a st...

Page 29: ...gine coolant circuit Rep gr 19 Cooling system coolant Con nection diagram coolant hoses 3 2 Removing and installing heater coolant shut off valve N279 Special tools and workshop equipment required Tor...

Page 30: ...d Release pressure by pressing pressure relief valve on cool ing system tester until the gauge shows a pressure of 0 Place drip tray for workshop hoist VAS 6208 underneath Mark coolant hoses 3 Pull of...

Page 31: ...A G 1526 E Auxiliary measuring set V A G 1594C Measuring beaker V A G 1602 1 from injection rate tester V A G 1602 Vehicle diagnostic tester Conditions for testing Resistance of metering pump V54 appr...

Page 32: ...line 1 into measuring beaker V A G 1602 1 Hold measuring beaker V A G 1602 1 at same height as auxiliary heater Using Vehicle diagnostic tester check fuel delivery rate of metering pump V54 Read quant...

Page 33: ...y Wear protective goggles Wear protective gloves To release pressure wrap a clean cloth around the connec tion and carefully loosen the connection Place drip tray VAS 6208 beneath vehicle Pull off fue...

Page 34: ...or run on phase depending on the unit This is done to compensate for ageing related changes As a consequence of this calibrating procedure processes that are affected can also require more time After...

Page 35: ...n the 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 he...

Page 36: ...ling ambient temperature sensor G17 Heating air conditioning Rep gr 87 Other components for control and regulation Removing and installing ambient temperature sender G17 6 2 Removing and installing re...

Page 37: ...does not work properly check the remote control battery If the remote control is renewed it must be adapted using Vehicle diagnostic tester If the remote control is renewed the remote control must be...

Page 38: ...red for 2 seconds The auxiliary heater has been switched off with 3 OFF LED slowly flashes green for 2 seconds The signal to switch on was not received LED quickly flashes green for 2 seconds The auxi...

Page 39: ...Switching off auxiliary supplementary heater using remote control Press button 2 Warning lamp 1 must light up red The auxiliary and supplementary heater switches to run on mode and then switches off R...

Page 40: ...r 2 seconds and then green for 2 seconds Battery charge is low but switch on switch off signal was re ceived Diode lights up orange for 2 seconds and then red for 2 sec onds Battery charge is low but...

Page 41: ...page 45 7 8 Removing and installing heater in housing page 47 7 9 Removing and installing burner unit page 48 7 10 Removing and installing glow plug for heater Q9 page 50 7 11 Removing and installing...

Page 42: ...lining Supplied with installa tion tool Removing page 51 6 Heat exchanger Removing and installing page 57 7 Combustion chamber Removing and installing page 48 8 Lower part of outer casing Made of plas...

Page 43: ...0 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 A...

Page 44: ...l line Detach cable ties on connecting elements 2 and 6 Loosen bolts 1 Note Do not remove bolts 1 completely Unscrew bolts 4 Transporter 2016 Auxiliary heater Edition 04 2020 40 Rep gr 82 Supplementar...

Page 45: ...ody cladding Assembly over view underbody cladding Guide wiring harnesses through opening in floor CAUTION The fuel system is pressurised Danger of injury caused by fuel spray Wear protective goggles...

Page 46: ...Removing Detach clamps or cable ties at connecting elements of air ducts 1 Push air ducts in direction of arrow off auxiliary air heater Unscrew bolts from bracket of auxiliary air heater Lower auxil...

Page 47: ...and installing exhaust system Removing Remove right underbody cladding General body repairs exterior Rep gr 66 Underbody cladding Assembly over view underbody cladding CAUTION Danger of severe burns...

Page 48: ...observing the following Specified torques 7 4 Assembly overview exhaust system page 43 7 6 Removing and dismantling auxiliary air heater bracket Remove for renewal only Special tools and workshop equ...

Page 49: ...ted to a rubber buffer Rubber buffers 1 are secured by means of hexagon nuts 2 Dimension A 10 mm Dimension B 16 mm Note During installation dimension A must face upwards Specified torques Component Sp...

Page 50: ...move auxiliary heater control unit J364 1 from heater Installing Install in reverse order of removal observing the following Note When installing auxiliary air heater control unit J604 3 en sure that...

Page 51: ...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 w...

Page 52: ...r damage Renew if necessary 7 9 Removing and installing burner unit Removing Removing auxiliary air heater without bracket page 39 Remove auxiliary air heater from plastic housing page 47 Remove auxil...

Page 53: ...der of removal observing the following Note When installing the burning chamber 3 always renew the seal 2 Fit combustion chamber 3 with new seal 2 on heat ex changer 4 Tighten bolts 1 Note Perform a f...

Page 54: ...nitor 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 damage if glow plug with flame monitor Q9 is ren...

Page 55: ...amage 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 re...

Page 56: ...heater unit support Installing Install in reverse order of removal observing the following Note A special tool for installing the mantle is supplied Fit mesh mantle 2 on special tool 1 supplied Transp...

Page 57: ...directly above metal surface of heater unit and has thermal contact with burner housing Removing Removing auxiliary air heater without bracket page 39 Remove upper part of outer shell item 1 Item 1 pa...

Page 58: ...ial tool 1 slides onto heat exchanger until combination sensor 2 makes contact with collar instal lation position of combination sensor Engage retaining bracket 3 Pull off special tool 1 Note The comb...

Page 59: ...combustion air blower V6 Removing Removing auxiliary air heater without bracket page 39 Remove auxiliary air heater from plastic housing page 47 Remove auxiliary air heater control unit J604 page 45 N...

Page 60: ...ustion air blower V6 always renew the seal 3 Place combustion air blower V6 2 with new seal 3 on heat exchanger 4 Tighten bolts 1 in diagonal sequence Perform a functional check after completing all w...

Page 61: ...m combustion air blower V6 2 Remove heat exchanger 4 with seal 3 from combustion air blower V6 2 Installing Install in reverse order of removal observing the following Note Note that seal 3 must alway...

Page 62: ...hten bolts 1 in diagonal sequence Perform a functional check after completing all work on the heater unit Specified torques Component Specified torque Bolts 1 on combustion chamber 4 Nm Transporter 20...

Page 63: ...emperature sensor G18 Note Temperature sender G18 is permanently installed on auxiliary air heater control unit J604 1 and cannot be renewed individ ually Transporter 2016 Auxiliary heater Edition 04...

Page 64: ...ge 60 8 2 Checking fuel delivery rate page 61 8 1 Removing and installing metering pump 2 V386 Special tools and workshop equipment required Engine bung set VAS 6122 Drip tray for workshop hoist VAS 6...

Page 65: ...metering pump 2 V386 1 from bracket Installing Install in reverse order of removal observing the following Replace O type clips with screw type clips 8 2 Checking fuel delivery rate Special tools and...

Page 66: ...el is delivered evenly beginning approx 60 seconds after engine has been started the fuel line is properly filled and ven ted Empty fuel from measuring beaker V A G 1602 1 Guide fuel line 1 into measu...

Page 67: ...ng and display unit for camping equipment E153 page 67 9 1 Principle of auxiliary air heater operation Note Make sure that the auxiliary air heaters are operated only with diesel fuel Operation with b...

Page 68: ...ol knob in this case is based on experience Heater regulation The room temperature or temperature of the drawn heated air is continuously measured during heating Regulation starts if the temperature i...

Page 69: ...cause of overheating has been eliminated the heater unit can be re started by switching off and back on again The control unit is locked out after the permitted number of unsuccessful start attempts h...

Page 70: ...e switching child safety on or off setting date and starting time Button for confirming settings 9 3 Removing and installing auxiliary air heater operating and display unit E407 or roof display unit J...

Page 71: ...ere is a fault in the system Special tools and workshop equipment required Removal wedge 3409 Removing Using removal wedge 3409 lever operating and display unit for camping equipment E153 1 out of hea...

Page 72: ...ted A new remote control must be adapted using Vehicle diag nostic tester in the Adaption mode Switching auxiliary air heater on using remote control Press button A Warning lamp C must light up green...

Page 73: ...Take off battery cover 4 and remove batteries Insert new batteries and replace cover Transporter 2016 Auxiliary heater Edition 04 2020 10 Other components of auxiliary air heater 69...

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