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5

Regulation of auxiliary/supplementa‐

ry heater

Additional information:
♦ For a function description, see ⇒ Self-study programme No.

502 ; Supplementary heating systems Thermo Top V and

Thermo Top Fleece - Design and function .

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

5. Regulation of auxiliary/supplementary heater

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Summary of Contents for Transporter 2020

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

Page 2: ...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 Service All rights reserved No reproduction without prior agreement from publisher Copyright 2020 Volkswagen AG Wolfsburg D4B809B4A5A ...

Page 3: ...liary supplementary heater internal 12 2 3 Assembly overview auxiliary supplementary 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 Removing and installing exhaust system 18 2 8 Removing and installing cover 19 2 9 Dismantling and assembling heater unit 20...

Page 4: ... 12 Removing and installing combustion air blower 2 V385 47 7 13 Removing and installing heat exchanger 48 7 14 Removing and installing temperature sensor G18 50 8 Fuel supply to auxiliary air heater 51 8 1 Removing and installing metering pump 2 V386 51 8 2 Checking fuel delivery rate 52 9 Regulation of auxiliary air heater 54 9 1 Principle of auxiliary air heater operation 54 9 2 Function of aux...

Page 5: ...uel system Risk of fire due to 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 Disconnect voltage supply to fuel pump before opening the fuel system Risk of injury from highly pressurised fuel The fuel system is pressurised Risk of injury from fuel spray Before opening the fuel system We...

Page 6: ...es Wear safety goggles To relieve pressure cover the cap of the coolant expansion tank with a cloth and open it carefully 1 5 Safety precautions for working on vehicles with auxiliary heater Danger of fire and explosion from auxiliary heater In fire and explosion endangered areas a spark or the high tem perature of the auxiliary heater can cause a fire or an explosion Risk of burns Switch the auxi...

Page 7: ...ill 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 activated timer of aux iliary heater If the vehicle s timer for the auxiliary heater is active the heater may switch on unexpectedly This poses a risk of poisoning from exhaust gases a risk of burns...

Page 8: ...cessary Type plate on auxiliary supplementary 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 type plate for auxiliary supplementary heaters In the engine compartment of the vehicle there is a second duplicate type plate attached to the right of the lock c...

Page 9: ...mponents or seal them if repairs cannot be carried out immediately Install only clean parts do not remove new parts from pack aging until immediately before installing Do not use parts that have been kept unpackaged for example in toolboxes If the fuel system is open Do not work with compressed air Do not move the vehicle Do not start the engine Do not switch on auxiliary supplementary heater 2 4 ...

Page 10: ...diately 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 connectors from dirt and water and reconnect them only when dry 3 2 General information The engine control unit has a self diagnosis capability Before carrying out repairs and for fault finding first read event ...

Page 11: ...e in contact with parts that 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 used In addition rubber plastic and adhesives are made of non con ductive materials If there is any doubt about the suitability of parts a general rule is to use new parts Electronic parts...

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 prevention regulations in Germa ny including but not limited to the Information of the German Social Accident Insurance DGUV 200 005 Qualification training for work on vehicles with high voltage syste...

Page 13: ...installing 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 29 Testing quantity of fuel delivered page 28 8 Circulation pump V55 Removing and installing page 16 9 Remote control receiver for auxiliary coolant heater R149 or remote control receiver for auxiliary heating R64 Removing and insta...

Page 14: ...n 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 with flame monitor Q8 page 21 2 11 Removing and installing temperature sensor G18 and overheating sensor G189 page 22 2 12 Removing and installing auxiliary heater control unit J364 page 23 2 14 Con...

Page 15: ...Rubber 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 Bracket For circulation pump V55 11 Bolt 6 Nm 12 Rubber mounting 13 Bolt 20 Nm Transporter 2020 Auxiliary heater Edition 04 2020 2 Auxiliary supplementary heater 11 ...

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 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 Removing and installing page 19 1...

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 air intake si lencer 8 Bolts Qty 2 For bracket of circula tion pump V55 and air intake silencer 6 Nm 9 Bracket For circulation pump V55 10 Circulation pump V55 Removing and installing page 16 11 Clamp 1...

Page 18: ...gine 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 Functions Disconnect battery Electrical system Rep gr 27 Battery Disconnecting and connecting battery Transporter 2020 Auxiliary heater Edition 04 2020 14 Rep gr 82 Supplementary heating ...

Page 19: ...ver the cap of the coolant expansion tank with a cloth and open it carefully Pull off coolant hoses from auxiliary heater CAUTION The fuel system is pressurised Risk of injury caused by fuel spray Wear safety goggles Wear protective gloves To release pressure wrap a clean cloth around the connec tion and carefully loosen the connection Pull off fuel line from auxiliary heater to metering pump V54 ...

Page 20: ...y 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 direction of arrow B Pull off air intake silencer from auxiliary heater 2 Installing Install in reverse order of removal observing the following Note The air intake silencer must not touch the auxiliary su...

Page 21: ...cladding CAUTION On a warm engine the cooling system is under high pressure Risk of scalding from steam or hot coolant Skin and other parts of the body may be scalded Wear protective gloves Wear safety goggles To relieve pressure cover the cap of the coolant expansion tank with a cloth and open it carefully Transporter 2020 Auxiliary heater Edition 04 2020 2 Auxiliary supplementary heater 17 ...

Page 22: ...moving 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 Risk of burns to hands and other parts of body Allow exhaust system to cool down Unscrew bolt 2 Pull off exhaust system 1 from heat exchanger in direction of arrow Installing Install in reverse order of removal...

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 Install in reverse order of removal 2 8 2 Removing and installing cover burner unit Special tools and workshop equipment required Torque wrench V A G 1410 Transporter 2020 Auxiliary heater Edition 04 2...

Page 24: ...g 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 Torque settings 2 2 Assembly overview auxiliary supplementary heater in ternal page 12 2 9 Dismantling and assembling heater unit Special tools and workshop equipment required Torque wrench V A G 1410 Transporter 2020 Auxiliary heate...

Page 25: ...ealing surfaces Renew seal 1 Torque settings 2 2 Assembly overview auxiliary supplementary heater internal page 12 2 10 Removing and installing glow plug with flame monitor Q8 Removing Dismantle heater unit page 20 Pull out retaining spring 1 in direction of arrow Remove retaining plate 2 in direction of arrow Pull out glow plug with flame monitor Q8 3 Installing Install in reverse order of remova...

Page 26: ...8 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 coolant for installation Note When assembling ensure proper position of retaining spring 1 Sensors cannot be renewed individually Torque settings 2 2 Assembly overview auxiliary supplementary heater i...

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 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 4 4 pin connector Information on pin ...

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 start stop system the circulation pump V55 of the auxiliary sup plementary heater can be actu ated by the auxiliary heater con trol unit J364 while the stop function is active To achieve this the auxil...

Page 29: ...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 Special tools and workshop equipment required Torque wrench V A G 1410 Hose clamps to 25 mm 3094 Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340 Transporter 2020 Auxiliary heater Edition 04 2020 3 Coolant circuit with auxiliary supp...

Page 30: ...type clip pliers VAS 5024A or hose clip pliers VAS 6340 CAUTION Risk of scalding from steam or hot coolant Skin and other parts of the body may be scalded 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 off coolant hoses 3 from heater coolant shut off ...

Page 31: ...Component Specified torque Bolt of heater coolant shut off valve N279 9 Nm Transporter 2020 Auxiliary heater Edition 04 2020 3 Coolant circuit with auxiliary supplementary heater 27 ...

Page 32: ...6E Auxiliary measuring set V A G 1594D Measuring beaker V A G 1602 1 from injection rate tester V A G 1602 Vehicle diagnostic tester Test requirements 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 Transporter 2020 Auxiliary heater Edition 04 2020 28 Rep gr 82 Sup...

Page 33: ...e fuel 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 quantity of diesel in measuring beaker V A G 1602 1 Min quantity of fuel after 120 seconds ml Max quantity of fuel after 120 seconds ml 22 28 If fuel delivery rates are not within specifications ren...

Page 34: ...Wear safety 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 fuel hoses 3 Seal fuel hoses 3 with a bung from engine bung set VAS 6122 Remove metering pump V54 1 from bracket Installing Install in reverse order of removal observing the following Replace O type clips with...

Page 35: ...al information For a function description see Self study programme No 502 Supplementary heating systems Thermo Top V and Thermo Top Fleece Design and function Transporter 2020 Auxiliary heater Edition 04 2020 5 Regulation of auxiliary supplementary heater 31 ...

Page 36: ...rol components Check ambient temperature sensor G17 Vehicle diag nostic tester in Guided Fault Finding mode 6 2 Removing and installing remote control receiver for auxiliary coolant heater R149 Special tools and workshop equipment required Removal wedge 3409 Note If the remote control receiver for auxiliary coolant heater R149 is renewed the remote control receiver for auxiliary coolant heat er R1...

Page 37: ...inue installation in reverse order of removal Note If the remote control receiver for auxiliary coolant heater R149 is renewed the remote control receiver for auxiliary coolant heat er R149 must be adapted to the auxiliary heater using Vehicle diagnostic tester in Guided Fault Finding mode Specified torque Install cover in left footwell General body repairs interior Rep gr 68 Interior equipment Re...

Page 38: ...y air heater control unit J604 page 42 7 8 Removing and installing heater in housing page 44 7 9 Removing and installing burner unit page 45 7 10 Removing and installing glow plug for heater Q9 page 45 7 11 Removing and installing flame monitor G64 and combi nation sensor page 46 7 12 Removing and installing combustion air blower 2 V385 page 47 7 13 Removing and installing heat exchanger page 48 7...

Page 39: ...w pin lining Supplied with installa tion tool Vehicle specific 6 Heat exchanger Removing and installing page 48 7 Combustion chamber Removing and installing page 45 8 Lower part of outer casing Made of plastic Removing and installing page 44 9 Flange seal Renew if damaged 10 Combustion air blower V6 combination blower Combustion and heating air blower in one Removing and installing page 47 11 Mete...

Page 40: ...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 If fitted unbolt stone deflector strip Guide wiring harnesses through opening in floor CAUTION The fuel system is pressurised Risk of injury caused by fuel spray Wear safety goggles W...

Page 41: ...l fuel line Detach cable ties on connecting elements 2 and 6 Loosen bolts 1 Note Do not remove bolts 1 completely Unscrew bolts 4 Transporter 2020 Auxiliary heater Edition 04 2020 7 Auxiliary air heater 37 ...

Page 42: ...dy cladding Assembly over view underbody cladding Guide wiring harnesses through opening in floor CAUTION The fuel system is pressurised Risk of injury caused by fuel spray Wear safety goggles Wear protective gloves To release pressure wrap a clean cloth around the connec tion and carefully loosen the connection Separate fuel line arrow from auxiliary air heater Seal fuel line Remove exhaust syste...

Page 43: ...fitted unbolt stone deflector strip 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 auxiliary air heater Secure auxiliary air heater to body e g with a welding wire Unscrew bolt 3 Remove clamp 2 Unscrew air intake silencer 1 in direction of arrow Loosen clamp 5 R...

Page 44: ...stem Removing Remove right underbody cladding General body repairs exterior Rep gr 66 Underbody cladding Assembly over view underbody cladding If fitted unbolt stone deflector strip CAUTION Danger of severe burns from hot exhaust system Risk of burns to hands and other parts of body Allow exhaust system to cool down Transporter 2020 Auxiliary heater Edition 04 2020 40 Rep gr 82 Supplementary heati...

Page 45: ...removal observing the following Torque settings 7 4 Assembly overview exhaust system page 40 7 6 Removing and dismantling auxiliary air heater bracket Remove for renewal only Special tools and workshop equipment required Transporter 2020 Auxiliary heater Edition 04 2020 7 Auxiliary air heater 41 ...

Page 46: ...each connected 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 Torque settings Component Specified torque Nuts securing rubber buffers 8 Nm Nuts securing auxiliary heater 8 Nm 7 7 Removing and installing auxiliary air heater control unit J604 Special tools and workshop equipment re...

Page 47: ...l unit J604 1 upwards from heater unit 2 Installing Install in reverse order of removal observing the following Note When installing make sure that the 10 pin connection is located on the glow plug end Screw in bolts 2 loosely Tighten bolts 2 alternately in diagonal sequence to specified torque Specified torques Component Specified torque Bolts 2 1 5 Nm Transporter 2020 Auxiliary heater Edition 04...

Page 48: ...of arrow out of lower casing 1 and remove it Installing Install in reverse order of removal observing the following Note If the lower casing is to be renewed attach a new type plate and transfer the data from the old type plate to the new one Installing Install in reverse order of removal observing the following Before installing check flange seal of heater unit for damage Renew if necessary Trans...

Page 49: ...olts 2 loosely Tighten bolts 2 alternately in diagonal sequence to specified torque Specified torques Component Specified torque Bolts 2 6 5 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 auxiliary air heater i...

Page 50: ... the locking element of the electrical connector for the glow plug for heater Q9 points towards the combustion air blower 2 V385 7 11 Removing and installing flame monitor G64 and combination sensor Note The combination sensor comprises the flame monitor G64 and overheating sensor G189 in one component Removing Remove auxiliary air heater page 36 Release locking tabs 2 Swing cover 1 in direction o...

Page 51: ...earest cooling fin Note Make sure not to damage the wiring harness when inserting the retaining clip 7 12 Removing and installing combustion air blower 2 V385 Special tools and workshop equipment required Torque wrench V A G 1410A Removing Remove auxiliary air heater control unit J604 page 42 Unscrew bolts 2 Detach combustion air blower 2 V385 1 from heat ex changer 3 Transporter 2020 Auxiliary he...

Page 52: ...13 Removing and installing heat exchanger Removing Removing auxiliary air heater without bracket page 36 Remove auxiliary air heater from plastic housing page 44 Remove auxiliary air heater control unit J604 page 42 Unscrew bolts 1 from combustion air blower V6 2 Transporter 2020 Auxiliary heater Edition 04 2020 48 Rep gr 82 Supplementary heating ...

Page 53: ...exchanger 4 is installed If heat exchanger is renewed flame monitor G64 and overheating sensor G189 combination sensor must be transferred Fit heat exchanger 4 with new seal 3 on combustion air blower V6 2 Tighten bolts 1 in diagonal sequence Perform a functional check after completing all work on the heater unit Transporter 2020 Auxiliary heater Edition 04 2020 7 Auxiliary air heater 49 ...

Page 54: ...4 Nm 7 14 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 Transporter 2020 Auxiliary heater Edition 04 2020 50 Rep gr 82 Supplementary heating ...

Page 55: ... 51 8 2 Checking fuel delivery rate page 52 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 6208 Transporter 2020 Auxiliary heater Edition 04 2020 8 Fuel supply to auxiliary air heater 51 ...

Page 56: ...Remove 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 workshop equipment required Fuel hose length approx 200 mm Measuring beaker V A G 1602 1 from injection rate tester V A G 1602 Vehicle diagnostic tester Test requirements Resistance of metering...

Page 57: ...l 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 measuring beaker V A G 1602 1 Hold measuring beaker V A G 1602 1 at height of glow plug for heater Q9 Using Vehicle diagnostic tester check fuel delivery rate of metering pump 2 V386 Read quantity of fuel i...

Page 58: ...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 1 Electrical connection 2 Fuel supply Pfeil A Cold air in Pfeil B Hot air out Pfeil C Combustion air in Pfeil D Exhaust out Switching on The warning lamp in the control element lights up when th...

Page 59: ...elected on the con trol element There are 4 control levels provided in order that the heat flow de livered by the heater can be finely adjusted to the heat demand The blower speed and fuel volume correspond to the particular control level in this case 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 ...

Page 60: ...s been exceeded A malfunction shut down will occur 20 seconds after the lower or upper voltage limit has been reached The heater unit will not start if the glow plug or the blower motor is defective or if there is a discontinuity in the electrical cable to the metering pump If the combination sensor flame monitor overheating sensor is defective or there is a discontinuity in the electrical cable t...

Page 61: ...c mode of the Climatronic for the rear area on or off 8 Button for switching the in stant heating function of the auxiliary supplementary heat er on off Depending on equip ment 9 Adjustment button for lower temperature setting 10 Adjustment button for higher temperature setting 9 3 Removing and installing auxiliary air heater operating and display unit E407 or roof display unit J702 Special tools ...

Page 62: ...erior Rep gr 68 Compartments and covers Re moving and installing storage compartment in headliner Disconnect electrical connectors for rear Climatronic operat ing and display unit E265 1 Detach rear Climatronic operating and display unit E265 1 at retaining tabs arrows and remove it Installing Install in reverse order of removal Transporter 2020 Auxiliary heater Edition 04 2020 58 Rep gr 82 Supple...

Page 63: ...s not work properly check the remote control battery page 60 If the remote control is renewed it must be adapted using Vehicle diagnostic tester Start guided fault finding or guided functions in Vehicle di agnostic tester and then start Adapt remote control Switching on auxiliary supplementary heater using remote control Press button 3 The indicator lamp 1 must light up green When the auxiliary su...

Page 64: ...p red for 2 seconds The auxiliary supplementary heater has been switched off with 2 OFF LED slowly flashes green for 2 seconds The signal to switch on was not received LED quickly flashes green for 2 seconds The auxiliary supplementary heater is blocked e g because the fuel tank is nearly empty or there is a fault in the auxiliary supplementary heater LED flashes red for 2 seconds The signal to sw...

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