Removal and Replacement

Auxiliary Engine Coolant Heater, Removing And Installing







1 - Coolant return hose (from heat exchanger)
2 - Coolant supply hose (to heat exchanger)
3 - Air intake muffler
4 - Recirculation Pump V55
5 - Auxiliary engine coolant heater (only models with V-10 TDI-PD engines)
- with Heater Control Module J162

Removing

Special tools, testers and auxiliary items required







- Torque wrench VAG 1410 (or 420 Nm equivalent)







- Hose Clamps up to dia 25 mm 3094

NOTE:
- The coolant circuit must be bled after it is opened.
- The coolant system is under pressure when the engine is warm. If necessary, release pressure prior to repair work.
- Once the auxiliary engine coolant heater unit has been removed, secure to body with welding wire to prevent damage to coolant hoses.

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".

- Remove front left wheel housing liner.
- Clamp coolant hoses using Hose Clamps up to dia 25 mm 3094.

CAUTION:
- Contact with hot engine coolant can cause severe scalding.
- Engine cooling system is under pressure, and may be over 100 degrees C with a warm engine.
- If necessary, reduce coolant pressure and temperature before beginning repairs.







- Loosen coolant hose clamp type clip -1 - and pull coolant hose off coolant pipes.

CAUTION:
- There is a danger of leaking fuel.
- Fuel system is under pressure.
- Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

- Loosen fuel line clamp type clip - 2 -, separate fuel lines and seal ends. Replace opened clamp type clips with screw type clips.







- Loosen coolant hose clamp type clip -1 - and pull coolant hose off coolant pipes.
- Loosen clamp - 2 - and disconnect exhaust system.







Remove bracket for coolant and exhaust pipe.
- Remove nuts - 2 -.
- Remove nuts -1 -.







Remove bracket for auxiliary engine coolant heater.
- Remove nuts -1 -.
- Unhook auxiliary coolant heater by lifting upwards - arrow -
- Remove auxiliary coolant heater with bracket.
- Disconnect electrical connections from auxiliary engine coolant heater.

Installing
Install in reverse order of removal.







NOTE: Rubber mounting -1 - must be centered on mounting - 2 -. (Fender not shown in illustration)

Air intake muffler, removing and installing







Removing
- Remove screw -1 - and clamp - 3 -. Pull intake connecting piece - 2 - from auxiliary engine coolant heater.

Installing
- Slide intake connecting piece - 2 - towards auxiliary coolant heater until it lies against the combustion air blower housing.
- Engage retainer, tighten screw -1 - and clamp - 3 -.

Recirculation Pump V55, removing and installing

NOTE:
- The coolant circuit must be bled after it is opened.
- The coolant system is under pressure when the engine is warm. If necessary, release pressure prior to repair work.

Special tools, testers and auxiliary items required







- Hose Clamps up to dia 25 mm 3094

Removing







- Clamp coolant hoses.
- Loosen clamp -1 -.

CAUTION:
- Contact with hot engine coolant can cause severe scalding.
- Engine cooling system is under pressure, and may be over 100 degrees C with a warm engine.
- If necessary, reduce coolant pressure and temperature before beginning repairs.

- Remove coolant hoses from Recirculation Pump V55.
- Loosen clamp - 2 -.
- Disconnect electrical connection - 3 - from Recirculation Pump V55.
- Remove Recirculation Pump V55.

Installing
- Install in reverse order of removal.