Volkswagen Transporter 2020 Manual
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Volkswagen Transporter 2020 Manual

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Service
Workshop Manual
Transporter 2020 ➤
Auxiliary heater
Edition 04.2020
Service Department. Technical Information

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Summary of Contents for Volkswagen Transporter 2020

  • Page 1 Service Workshop Manual Transporter 2020 ➤ 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 D4B809B4A5A...

  • Page 3: Table Of Contents

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Contents 00 - Technical data ........... .
  • Page 4 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Removing and installing auxiliary air heater ........

  • Page 5: Technical Data

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 00 – Technical data Safety information (VRL014130; Edition 04.2020) WARNING If the vehicle has been the subject of an ABT e-Line conversion, the repair instructions below may have lost their validity. •...

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

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Safety precautions when using testing and measuring instruments during a road test Risk of injury caused by unsecured testing and measuring instru‐ ments When the front passenger airbag is deployed in an accident, in‐...
  • Page 7 Transporter 2020 ➤ 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 2020 ➤ 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WARNING If the vehicle has been converted by ABT e-Line, it is possible that the repair instructions provided below are no longer valid.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 2020 ➤ Auxiliary heater - Edition 04.2020 ♦ Line filling carried out ♦ On-board network manager not active ♦ No crash shut-off ♦ No event memory entries blocking start procedure ♦ Has been put into service Rules for cleanliness when working on...

  • Page 10: Repair Notes

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Repair notes 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ Auxiliary heater - Edition 04.2020 ♦ Hose clamps 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 2020 ➤ Auxiliary heater - Edition 04.2020 – Clamp off coolant hoses -1- on circulation pump - V55- -5- us‐ ing hose clamps, up to 25 mm - 3094- . – Disconnect electrical connector -3-. – Loosen hose clips -2- and pull off coolant hoses.

  • Page 23: Removing And Installing Cover

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Torque settings ♦ ⇒ “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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ 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 2020 ➤ Auxiliary heater - Edition 04.2020 ♦ Drip tray for workshop hoist - VAS 6208- Removing Note If the vehicle is fitted with an emission control module, the heater coolant shut-off valve - N279- can be actuated by two different relays.
  • Page 31 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Component Specified torque Bolt of heater coolant shut-off valve - N279- 9 Nm 3. Coolant circuit with auxiliary/supplementary heater...

  • Page 32: Fuel Supply

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Fuel supply ⇒ “4.1 Checking fuel delivery rate”, page 28 ⇒ “4.2 Removing and installing metering pump V54 ”, page 29 Checking fuel delivery rate Special tools and workshop equipment required ♦ Hand-held multimeter - V.A.G 1526E- ♦...

  • Page 33: Removing And Installing Metering Pump V54

    Transporter 2020 ➤ 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. Risk of injury caused by fuel spray. – Wear safety goggles.
  • Page 34 Transporter 2020 ➤ 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 35: Regulation Of Auxiliary/Supplementary Heater

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 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 .

  • Page 36: Other Controlling And Regulating Components

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Other controlling and regulating com‐ ponents ⇒ “6.1 Removing and installing ambient temperature sensor G17 ”, page 32 ⇒ “6.2 Removing and installing remote control receiver for auxil‐ iary coolant heater R149 ”, page 32 Removing and installing ambient tem‐...
  • Page 37 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 – Disconnect electrical connectors -2-. – Release locking tab of bracket -3-. – Remove remote control receiver for auxiliary coolant heater - R149- -1- from bracket. Installing – Connect connectors to remote control receiver for auxiliary coolant heater - R149- .

  • Page 38: Auxiliary Air Heater

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Auxiliary air heater ⇒ “7.1 Assembly overview – auxiliary air heater”, page 34 ⇒ “7.2 Removing and installing auxiliary air heater”, page 36 ⇒ “7.3 Removing and installing air intake silencer”, page 39 ⇒...
  • Page 39 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 1 - Upper part of outer casing ❑ Made of plastic ❑ Removing and installing ⇒ page 44 2 - Flame monitor - G64- and overheating sensor - G189- (combination sensor) ❑ Overheating and flame monitor ❑...

  • Page 40: Removing And Installing Auxiliary Air Heater

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Removing and installing auxiliary air heater 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 41 Transporter 2020 ➤ 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-. 7. Auxiliary air heater...
  • Page 42 Transporter 2020 ➤ 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 43: Removing And Installing Air Intake Silencer

    Transporter 2020 ➤ 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: Torque settings...

  • Page 44: Assembly Overview - Exhaust System

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Assembly overview - exhaust system 1 - Bracket ❑ Removing ⇒ page 41 2 - Collar nut ❑ 8 Nm 3 - Exhaust system ❑ Removing and installing ⇒ page 40 4 - Flange bolt ❑...

  • Page 45: Removing And Dismantling Auxiliary Air Heater Bracket

    Transporter 2020 ➤ 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: Torque settings ♦ ⇒ “7.4 Assembly overview - exhaust system”, page 40...

  • Page 46: Removing And Installing Auxiliary Air Heater Control Unit J604

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 ♦ Torque wrench - V.A.G 1410- – Removing auxiliary air heater without bracket ⇒ page 42 – If fitted, unbolt stone deflector strip. – Unscrew nuts -3-. – Remove bracket -2- from auxiliary air heater -1-.
  • Page 47 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 ♦ Torque screwdriver - VAS 6494- Removing – If fitted, unbolt stone deflector strip. – Remove heater unit from housing ⇒ page 44 – Disconnect electrical connectors -1-. – Move wiring harnesses aside.

  • Page 48: Removing And Installing Heater In Housing

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Removing and installing heater in hous‐ Removing – Release locking tabs -2-. – Swing cover -1- in direction of -arrow-, and detach it. – Remove connector grommet -2- from lower casing -1-.

  • Page 49: Removing And Installing Burner Unit

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Removing and installing burner unit Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1410A- Removing – Remove combustion air blower 2 - V385- ⇒ page 47 – Unscrew bolts -2-.

  • Page 50: Removing And Installing Flame Monitor G64 And Combination Sensor

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 – Release locking tabs -1-. – Swing cover -2- in direction of -arrow-, and detach it. – Pull grommet -3- out of lower casing -1-. – Disconnect electrical connector -2-. – Lever out grommet -4- with a screwdriver.

  • Page 51: Removing And Installing Combustion Air Blower 2 V385

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 – Disconnect electrical connector -1-. – Release retaining clip -1- in area marked by -arrows-, and re‐ move it. – Pull combination sensor -2- out of heater unit. Installing Install in reverse order of removal, observing the following: –...

  • Page 52: Removing And Installing Heat Exchanger

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Installing Install in reverse order of removal, observing the following: – Renew seal -1-. Specified torques Component Specified torque Bolts -2- 6.5 Nm 7.13 Removing and installing heat exchanger Removing – Removing auxiliary air heater without bracket ⇒...
  • Page 53 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 – 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 be renewed when heat exchanger -4- is installed.

  • Page 54: Removing And Installing Temperature Sensor G18

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Torque settings Component Specified torque Bolts -1- on combustion chamber 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‐...

  • Page 55: Fuel Supply To Auxiliary Air Heater

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Fuel supply to auxiliary air heater ⇒ “8.1 Removing and installing metering pump 2 V386 ”, page 51 ⇒ “8.2 Checking fuel delivery rate”, page 52 Removing and installing metering pump 2 - V386- Special tools and workshop equipment required ♦...

  • Page 56: Checking Fuel Delivery Rate

    Transporter 2020 ➤ 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 electrical connector -2-. – Loosen clamps -3-.
  • Page 57 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Sequence of operations 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‐...

  • Page 58: Regulation Of Auxiliary Air Heater

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Regulation of auxiliary air heater ⇒ “9.1 Principle of auxiliary air heater operation”, page 54 ⇒ “9.2 Function of auxiliary air heater operating and display unit E407 or roof display unit J702 ”, page 56 ⇒...
  • Page 59 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Note If there is still too much residual heat in the heat exchanger ♦ from a previous heating operation, only the combustion air blower starts up at first (cold blowing). The »start« takes place once the existing residual heat has ♦...
  • Page 60 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 will continue for about 4 minutes. The control unit is locked out after the permitted number of unsuccessful start attempts has been exceeded. ♦ If the flame goes out by itself during heating operation, a new start is performed initially.

  • Page 61: Removing And Installing Auxiliary Air Heater Operating And Display Unit E407 Or Roof Display Unit J702

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 1 - Selected settings (temper‐ ature, blower speed) display 2 - Increase blower output but‐ 3 - Decrease blower output button ❑ Depending on equip‐ ment button for switching rear air conditioning system on/off ❑...
  • Page 62 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Note If the display of the auxiliary heater operating and display unit - E407- or roof display unit - J702- flashes, there is a fault in the system. Removing – Remove storage compartment in headliner ⇒ General body repairs, interior;...

  • Page 63: Other Components Of Auxiliary Air Heater

    Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Other components of auxiliary air heater ⇒ “10.1 Function description of remote control”, page 59 10.1 Function description of remote control Note The auxiliary/supplementary heater can be switched on and ♦ off from a distance of several 100 metres (open space) using the remote control.
  • Page 64 Transporter 2020 ➤ Auxiliary heater - Edition 04.2020 Note Note installation position of battery. ♦ Use only the same type of 3-volt battery. ♦ Allocation of the remote control to the auxiliary/supplementary ♦ heater remains intact. Re-adapting is not necessary.

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