Auxiliary Engine Coolant Heater, Servicing
Auxiliary Engine Coolant Heater, Servicing
Before starting repair work, perform the following points:
CAUTION:
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key
NOTE:
- If auxiliary engine coolant heater is equipped with Programmable Timer E111, the battery must be disconnected.
- After disconnecting and reconnecting battery on vehicles with Programmable Timer E111 for coolant heater, the heater remote control functions must be adapted using Vehicle Diagnostic, Testing and Information System VAS 5051 in operating mode "Guided Fault".
Special tools, testers and auxiliary items required
- Torque wrench VAG 1410 (or 420 Nm equivalent)
- Hose Clamps up to dia 25 mm 3094
NOTE:
- A manufacturers identification plate is fitted on the auxiliary engine coolant heater unit. This plate indicates which heater version is installed in the vehicle: Auxiliary engine coolant heater (only models with V-10 TDI-PD engines)
- The coolant circuit must be bled after it is opened.
1 - Engine Coolant Temperature (ECT) Sensor G62
- Location: in return hose from radiator.
- Checking, use: Vehicle Diagnostic, Testing and Information System VAS 5051
2 - Programmable Timer E111
- Where applicable
- Location: in front headliner
3 - Fuel Level Sensor
- Location: on right under rear seat
4 - Auxiliary Engine Coolant Heating RF Receiver R149
- Where applicable
- Location: Headliner, rear middle
5 - Auxiliary Battery A1
- Location: under luggage compartment floor
6 - Battery A
- Location: under left front seat
7 - Fuse panel
- Location: under instrument panel, left Wiring Diagrams and Component Locations
8 - Metering Pump V54
- Location: under vehicle floor in tunnel
- Fuel supply to auxiliary engine coolant heater, checking.
- It is possible that the metering pump ticks audibly but does not deliver fuel due to air in the intake. The control module will then switch off permanently. In this case, check Diagnostic Trouble Code (DTC) memory using Vehicle Diagnostic, Testing and Information System VAS 5051. Erase DTC memory and perform Output Diagnostic Test Mode of auxiliary engine coolant heater.
- Fuel delivery, checking
9 - Recirculation Pump V55
- Location: on auxiliary engine coolant heater
- Removing and installing
10 - Auxiliary engine coolant heater (only models with V-10 TDI-PD engines)
- with Heater Control Module J162
- Location: under left fender
11 - Exhaust muffler
12 - Engine Coolant (EC) Switch-off Valve (heater) N279
- Location: in left wheel well
13 - Outside Air Temperature Sensor G17
- Location: behind center air intake grille
- Removing
- Checking, use: Vehicle Diagnostic, Testing and Information System VAS 5051
Manufacturers identification plate for Diesel Thermo Top Z/C D
NOTE:
- The relevant technical data are shown on upper part of manufacturers identification plate.
- The date first put into use is on the lower part of manufacturers identification plate.
- Manufacturers identification plate on "original replacement part" must have date first put in use entered. The water heater heat exchanger need not be replaced after 10 years. Current German legislation dictates that only air type heat exchangers be replaced after a certain period. Check local State or Provincial regulations.
- Manufacturers identification plate must be fitted to a clearly visible location.
Outside Air Temperature Sensor G17 removing and installing
- Remove radiator grille.
- Unclip temperature sensor from lock support -1 -.
- Disconnect electrical connection from Ambient Air Temperature Sensor G17.
Exhaust muffler, removing and installing
CAUTION:
- Muffler housing may be hot.
- Contact with a hot exhaust system can cause severe burns.
- Allow muffler housing to cool off before removing.
- Remove left wheel housings.
- Loosen clamp on exhaust pipe - arrow -.
- Remove left floor trim.
- Remove nut for muffler - arrow - and remove muffler.