Volkswagen Transporter 2016 Workshop Manual
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Volkswagen Transporter 2016 Workshop Manual

Auxiliary heater
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Service
Workshop Manual
Transporter 2016 ➤
Auxiliary heater
Edition 04.2020
Service Department. Technical Information

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  • Page 1 Service Workshop Manual Transporter 2016 ➤ Auxiliary heater Edition 04.2020 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2020 Volkswagen AG, Wolfsburg D4B8056764E...

  • Page 3: Table Of Contents

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Contents 00 - Technical data ........... .
  • Page 4 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Auxiliary air heater ............

  • Page 5: Technical Data

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 00 – Technical data Safety information (VRL014148; Edition 04.2020) WARNING If the vehicle has been converted by ABT e-Line, it is possible that the repair instructions provided below are no longer valid.

  • Page 6: Safety Precautions When Using Testers And Measuring Instruments During A Road Test

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Safety precautions when using testers and measuring instruments during a road test Risk of injury caused by unsecured testing and measuring instru‐ ments When the front passenger airbag is triggered in an accident, in‐...
  • Page 7 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Risk of damage when starting the engine If components of the fuel system or coolant circuit of the auxiliary heater are removed or opened, there is a possibility of causing damage to the auxiliary heater.

  • Page 8: General Information

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 General information WARNING If the vehicle has been converted by ABT e-Line, it is possible that the repair instructions provided below are no longer valid. • In this case, the workshop manual in ELSA Pro under the tab “Superstructures and modifications”...

  • Page 9: Rules For Cleanliness When Working On Auxiliary/Supplementary Heater And Fuel System

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 ♦ On-board network manager not active ♦ No crash switch-off ♦ No event memory entries blocking start procedure Rules for cleanliness when working on auxiliary/supplementary heater and fuel system ♦ Thoroughly clean all connections and adjacent areas before disconnecting.

  • Page 10: Repair Instructions

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Repair instructions WARNING If the vehicle has been converted by ABT e-Line, it is possible that the repair instructions provided below are no longer valid. • In this case, the workshop manual in ELSA Pro under the tab “Superstructures and modifications”...

  • Page 11: Contact Corrosion

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Read self-diagnosis of auxiliary/supplementary heater using ⇒ Vehicle diagnostic tester. – When parts of the fuel system are removed or renewed, en‐ sure that all components for fuel delivery to the auxiliary/ supplementary heater are properly installed.

  • Page 12: Hazard Classification Of High-Voltage System

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Hazard classification of high-voltage system DANGER The vehicle’s high-voltage system and the high-voltage battery are dangerous and can cause burns or other injuries and even lead to a fatal electric shock. – Any work on the high-voltage system, or on systems which could be indirectly affected by it, must only be carried out by properly trained and qualified expert personnel.

  • Page 13: Supplementary Heating

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 82 – Supplementary heating Overview of fitting locations - auxili‐ ary/supplementary heater ⇒ “1.1 Overview of fitting locations - components not located in passenger compartment”, page 9 Overview of fitting locations - components not located in passenger com‐...

  • Page 14: Auxiliary/Supplementary Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Auxiliary/supplementary heater ⇒ “2.1 Overview of fitting locations - auxiliary/supplementary heat‐ er”, page 10 ⇒ “2.2 Assembly overview - auxiliary/supplementary heater, in‐ ternal”, page 12 ⇒ “2.3 Assembly overview - auxiliary/supplementary heater at‐...
  • Page 15 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 1 - Auxiliary/supplementary heater ❑ Removing and installing ⇒ page 14 ❑ Dismantling and assem‐ bling ⇒ page 20 2 - Bracket for auxiliary/supple‐ mentary heater 3 - Bracket 4 - Rubber mounting...

  • Page 16: Assembly Overview - Auxiliary/Supplementary Heater, Internal

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Assembly overview - auxiliary/supplementary heater, internal 1 - Bolts ❑ Qty. 3 ❑ 7 Nm 2 - Heat exchanger ❑ Removing and installing ⇒ page 20 3 - Seal ❑ Must be renewed each time after opening ❑...

  • Page 17: Assembly Overview - Auxiliary/Supplementary Heater Attachments

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 15 - Union ❑ Mark installation position before removing 16 - Temperature sensor - G18- ❑ Removing and installing ⇒ page 22 17 - Retaining spring 18 - Bolt ❑ 4 Nm 19 - Overheating sensor - G189- ❑...

  • Page 18: Removing And Installing Auxiliary/Supplementary Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 14 - Coolant hose 15 - Bolt ❑ 20 Nm 16 - Rubber mounting Removing and installing auxiliary/sup‐ plementary heater Special tools and workshop equipment required ♦ Hose clamps to 25 mm - 3094- ♦...
  • Page 19 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Remove left underbody cladding ⇒ General body repairs, ex‐ terior; Rep. gr. 66 ; Underbody cladding; Assembly overview - underbody cladding . – Clamp off coolant hoses of auxiliary heater using hose clamps up to 25 mm - 3094- .

  • Page 20: Removing And Installing Air Intake Silencer

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Lower auxiliary heater -1- with bracket -2- in direction of -arrow-. – Pull out auxiliary heater -1- with bracket -2- from rubber mount‐ ings -3-. Installing Install in reverse order of removal, observing the following: –...
  • Page 21 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 ♦ Hose clamps up to 25 mm - 3094- ♦ Drip tray for workshop hoist - VAS 6208- Removing – Remove left underbody cladding ⇒ General body repairs, ex‐ terior; Rep. gr. 66 ; Underbody cladding; Assembly overview - underbody cladding .

  • Page 22: Removing And Installing Exhaust System

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Clamp off coolant hoses -1- on circulation pump - V55- -5- us‐ ing hose clamps, up to 25 mm - 3094- . – Separate electrical connector -3-. – Loosen hose clips -2- and pull off coolant hoses.

  • Page 23: Removing And Installing Cover

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Specified torques ♦ ⇒ “2.3 Assembly overview - auxiliary/supplementary heater attachments”, page 13 Removing and installing cover ⇒ “2.8.1 Removing and installing cover, auxiliary heater control unit J364 ”, page 19 ⇒ “2.8.2 Removing and installing cover, burner unit”, page 19 2.8.1...

  • Page 24: Dismantling And Assembling Heater Unit

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Removing – Remove auxiliary heater ⇒ page 14 – Unscrew bolt -3-. – Detach coolant connections together with bracket -4-. – Unclip cover -1- in area -2-. – Detach cover -1-. Installing Install in reverse order of removal, observing the following: –...

  • Page 25: Removing And Installing Glow Plug With Flame Monitor Q8

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Dismantling – Remove cover ⇒ page 19 – Unscrew bolts -1-. – Separate electrical connectors from temperature sensor - G18- and overheating sensor - G189- . – Pull heat exchanger off blower housing.

  • Page 26: Removing And Installing Temperature Sensor G18 And Overheating Sensor G189

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 2.11 Removing and installing temperature sensor - G18- and overheating sensor - G189- Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1410- Removing – Remove cover ⇒ page 19 –...

  • Page 27: Removing And Installing Auxiliary Heater Control Unit J364

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 2.12 Removing and installing auxiliary heater control unit - J364- The auxiliary heater control unit - J364- is an integral part of the combustion air blower - V6- and cannot be renewed individually ⇒...

  • Page 28: Coolant Circuit With Auxiliary/Supplementary Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Coolant circuit with auxiliary/supple‐ mentary heater ⇒ “3.1 Connection diagram - coolant hoses”, page 24 ⇒ “3.2 Removing and installing heater coolant shut-off valve N279 ”, page 25 Connection diagram - coolant hoses Note The -arrows- indicate the direction of coolant flow.

  • Page 29: Removing And Installing Heater Coolant Shut-Off Valve N279

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 4 - Coolant supply from engine ❑ Connection of auxiliary heater to engine coolant circuit ⇒ Rep. gr. 19 ; Cooling system, coolant; Con‐ nection diagram - coolant hoses . 5 - Coolant return to the engine ❑...
  • Page 30 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 ♦ Drip tray for workshop hoist - VAS 6208- Removing Vehicles with 4-cyl. common rail, 150 kW and 146 kW – Release solenoid valve holder ⇒ Rep. gr. 21 ; charge air sys‐...

  • Page 31: Fuel Supply

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Fuel supply ⇒ “4.1 Checking fuel delivery rate”, page 27 ⇒ “4.2 Removing and installing metering pump V54 ”, page 28 Checking fuel delivery rate Special tools and workshop equipment required ♦ Hand-held multimeter - V.A.G 1526 E- ♦...

  • Page 32: Removing And Installing Metering Pump V54

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 • Fuel tank sufficiently filled (fuel gauge on dash panel insert not in red area). Check CAUTION The fuel system is pressurised. Danger of injury caused by fuel spray. – Wear protective goggles.
  • Page 33 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 ♦ Drip tray for workshop hoist - VAS 6208- Removing – Remove left underbody cladding ⇒ General body repairs, ex‐ terior; Rep. gr. 66 ; Underbody cladding; Assembly overview - underbody cladding .

  • Page 34: Regulation Of Auxiliary/Supplementary Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Regulation of auxiliary/supplementa‐ ry heater ⇒ “5.1 Function description”, page 30 ⇒ “5.2 Heating mode”, page 30 ⇒ “5.3 Switching off auxiliary/supplementary heater”, page 31 Function description The auxiliary heater can be started by means of the remote con‐...

  • Page 35: Switching Off Auxiliary/Supplementary Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Switching off auxiliary/supplementary heater If the instant heat button is pressed or the preset operating time has expired, combustion stops. The run-on mode begins. The circulation pump - V55- and the combustion air blower - V6- , however, continue to run to cool down the heater (run-on mode) and are switched off automatically.

  • Page 36: Other Controlling And Regulating Components

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Other controlling and regulating com‐ ponents ⇒ “6.1 Removing and installing ambient temperature sensor”, page 32 ⇒ “6.2 Removing and installing remote control receiver for auxil‐ iary coolant heater R149 ”, page 32 ⇒...
  • Page 37 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 ♦ Removal wedge - 3409- Note The auxiliary heater can be switched on and off from a dis‐ ♦ tance of several 100 metres (open space) using the remote control. This range is restricted in built-up areas or from within buildings.
  • Page 38 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Press button -3-. • Warning lamp -2- must light up red. The auxiliary heater switches to run-on mode and then switches off. Renewing remote control battery Note Note installation position of battery.
  • Page 39 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Switching on auxiliary/supplementary heater using remote control – Press button -3-. • Warning lamp -1- must light up green. When the auxiliary heater is switched on, its operating time is de‐ termined by means of the setting on the multifunction indicator.
  • Page 40 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Indicator lamp in remote control Once you have pressed a button, the indicator in the remote con‐ trol -1- indicates whether the signal from the remote control has been received by the auxiliary heater and whether the battery in the remote control is low.

  • Page 41: Auxiliary Air Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Auxiliary air heater ⇒ “7.1 Assembly overview - Airtronic D3 auxiliary air heater”, page ⇒ “7.2 Removing and installing auxiliary air heater Airtronic D3”, page 39 ⇒ “7.3 Removing and installing air intake silencer”, page 42 ⇒...
  • Page 42 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 1 - Upper part of outer casing ❑ Made of plastic ❑ Removing and installing ⇒ page 47 2 - Flame monitor - G64- and overheating sensor - G189- (combination sensor) ❑ Overheating and flame monitor ❑...

  • Page 43: Removing And Installing Auxiliary Air Heater Airtronic D3

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Removing and installing auxiliary air heater Airtronic D3 Note A type plate is fitted on the auxiliary air heater unit. This plate provides information about the type of auxiliary air heater installed in the vehicle ⇒...
  • Page 44 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Seal fuel line. – Detach cable ties on connecting elements -2 and 6-. – Loosen bolts -1-. Note Do not remove bolts -1- completely. – Unscrew bolts -4-. Rep. gr.82 - Supplementary heating...
  • Page 45 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Remove auxiliary air heater -3- from guide -A-. Type plate Note Date of first use is entered on lower part of type plate. ♦ The heat exchanger can be used for 10 years but must be ♦...

  • Page 46: Removing And Installing Air Intake Silencer

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Push connecting elements in direction of -arrow-. – Unscrew nuts -3-. – Remove auxiliary air heater -1- from bracket -2-. Installing Install in reverse order of removal, observing the following: Specified torques...

  • Page 47: Assembly Overview - Exhaust System

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Assembly overview - exhaust system 1 - Bracket ❑ Removing ⇒ page 44 2 - Collar nut ❑ 8 Nm 3 - Exhaust system ❑ Removing and installing ⇒ page 43 4 - Flange bolt ❑...

  • Page 48: Removing And Dismantling Auxiliary Air Heater Bracket

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Loosen clamp -5-. – Unscrew bolt -4-. – Detach exhaust system -3-. Installing Install in reverse order of removal, observing the following: Specified torques ♦ ⇒ “7.4 Assembly overview - exhaust system”, page 43...

  • Page 49: Removing And Installing Auxiliary Air Heater Control Unit J604

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 ♦ Torque wrench - V.A.G 1410- – Removing auxiliary air heater without bracket ⇒ page 45 – Unscrew nuts -3-. – Remove bracket -2- from auxiliary air heater -1-. Dismantling bracket – Remove bracket from auxiliary air heater ⇒...
  • Page 50 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Remove intermediate piece -2-. – Remove upper part of outer shell -item 1- ⇒ Item 1 (page 38) – Unscrew bolt -1-. – Push together retaining clip -2- on opposite side.

  • Page 51: Removing And Installing Heater In Housing

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Removing and installing heater in hous‐ Removing Note Remove housing cover -2- for all repair work on heater units. – Release both locking tabs -1-. – Lift up housing cover -2- slightly in direction of -arrow A-.

  • Page 52: Removing And Installing Burner Unit

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Pull out heater unit -1- in direction of -arrow- from lower part of plastic housing. Installing Install in reverse order of removal, observing the following: – Before installing, check flange seal of heater unit for damage.
  • Page 53 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Unscrew bolts -1- of combustion chamber -3-. – Remove combustion chamber -3- with seal -2- from heat ex‐ changer -4-. Installing Install in reverse order of removal, observing the following: Note When installing the burning chamber -3-, always renew the seal -2-.

  • Page 54: Removing And Installing Glow Plug For Heater Q9

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Specified torques Component Specified torque Bolts -1- on combustion chamber 4 Nm 7.10 Removing and installing glow plug for heater - Q9- Note Glow plug with flame monitor - Q9- is activated immediately ♦...

  • Page 55: Removing And Installing Mantle Of Airtronic "D3

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Unscrew bolt -1-. – Push together retaining clip -2- on opposite side. – Lift out auxiliary air heater control unit - J604- . – Separate electrical connector of glow plug for heater - Q9- on control unit.
  • Page 56 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Pull out mesh mantle from support using commercially avail‐ able pliers. – Clean heater unit support. Installing Install in reverse order of removal, observing the following: Note A special tool for installing the mantle is supplied.

  • Page 57: Removing And Installing Flame Monitor G64 And Overheating Sensor G189 (Combination Sensor)

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Note The mesh mantle must be located correctly in the locking mechanism -arrow- of the special tool. – Using special tool -1-, carefully push mesh mantle -2- into support of heater unit as far as stop.
  • Page 58 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Note Special tool is supplied with combination sensor. – Push supplied special tool -1- onto combination sensor -2-. – Place combination sensor -2- with special tool -1- on heat ex‐ changer. – When doing this, special tool -1- slides onto heat exchanger until combination sensor -2- makes contact with collar (instal‐...

  • Page 59: Removing And Installing Combustion Air Blower V6

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Route wiring harness -4- through bracket -3- up to auxiliary air heater control unit - J604- . – Fit electrical connectors again. – Perform a functional check after completing all work on the heater unit.
  • Page 60 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Remove combustion air blower - V6- (combination blower) -2- and seal -3- from heat exchanger -4-. Installing Install in reverse order of removal, observing the following: Note When installing the combustion air blower - V6- , always renew the seal -3-.

  • Page 61: Removing And Installing Heat Exchanger

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 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 62 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – 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.

  • Page 63: Removing And Installing Temperature Sensor G18

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 7.15 Removing and installing temperature sensor - G18- Note Temperature sender - G18- is permanently installed on auxiliary air heater control unit - J604- -1- and cannot be renewed individ‐ ually. 7. Auxiliary air heater...

  • Page 64: Fuel Supply To Auxiliary Air Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Fuel supply to auxiliary air heater ⇒ “8.1 Removing and installing metering pump 2 V386 ”, page 60 ⇒ “8.2 Checking fuel delivery rate”, page 61 Removing and installing metering pump 2 - V386- Special tools and workshop equipment required ♦...

  • Page 65: Checking Fuel Delivery Rate

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Removing – Remove left underbody cladding ⇒ General body repairs, ex‐ terior; Rep. gr. 66 ; Underbody cladding; Assembly overview - underbody cladding . – Disconnect connector -2-. – Loosen clamps -3-.
  • Page 66 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Test sequence CAUTION The fuel system is pressurised. Danger of injury caused by fuel spray. – Wear protective goggles. – Wear protective gloves. – To release pressure, wrap a clean cloth around the connec‐...

  • Page 67: Regulation Of Auxiliary Air Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Regulation of auxiliary air heater ⇒ “9.1 Principle of auxiliary air heater operation”, page 63 ⇒ “9.2 Function of auxiliary air heater operating and display unit E407 or roof display unit J702 ”, page 66 ⇒...
  • Page 68 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Switching on The warning lamp in the control element lights up when the unit is switched on. The glow plug is switched on and the combustion air blower runs at slow speed.
  • Page 69 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Control and safety devices of auxiliary air heater Airtronic D3 ♦ The start is repeated if the heater unit does not ignite within 90 seconds after fuel delivery starts. A malfunction shut-off occurs if the heater does not ignite after another 90 seconds.

  • Page 70: Removing And Installing Auxiliary Air Heater Operating And Display Unit E407 Or Roof Display Unit J702

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Function of auxiliary air heater operating and display unit - E407- or roof display unit - J702- Control elements Functions for auxiliary air heater are selected using buttons 1, 3, 4 and 5.

  • Page 71: Removing And Installing Operating And Display Unit For Camping Equipment E153

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Removing and installing operating and display unit for camping equipment - E153- Note If the display of the operating and display unit for camping equip‐ ment - E153- flashes, there is a fault in the system.

  • Page 72: Other Components Of Auxiliary Air Heater

    Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 Other components of auxiliary air heater ⇒ “10.1 Function description of remote control”, page 68 10.1 Function description of remote control Note The auxiliary air heater can be switched on and off from a dis‐...
  • Page 73 Transporter 2016 ➤ Auxiliary heater - Edition 04.2020 – Take off battery cover -4- and remove batteries. Insert new batteries and replace cover. 10. Other components of auxiliary air heater...

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