Service

Workshop Manual
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Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList ofAWorkshop Manual
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82 - Supplementary heating

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Technical information should always be available to the foremen and mechanics, 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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg D3E8033AEE6

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

Contents

82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Auxiliary heater Thermo Top Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures for working on vehicles with auxiliary heaters . . . . . . . . . . . . . . . . . . . . 1
2 Notes on general repairs on vehicles with auxiliary heaters . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Starting conditions for auxiliary heating (preheater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Starting conditions for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Rules for cleanliness when working on the auxiliary heater and the fuel system . . . . . . . . 4
4 Repairing auxiliary heater Thermo Top Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Removing and installing auxiliary heater Thermo Top Z . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Components AG. Volkswagen AG d
agen of auxiliary heater oes Thermo Top Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
lksw not
5.2 d
Removing
byV
o
the Thermo Top Z auxiliary
gu heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ara 9
e
5.3ho Installing the Thermo Top Z auxiliary heater
ris nte
eo .................................... 12
ut
s
5.4
s a Removing and installing air intake silencer ra
c. . .................................. 13
5.5 Removing and installing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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pt
5.6 Removing and installing exhaust pipe for auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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5.7 Dismantling and assembling Thermo Top Z auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . 15
erm

ab
ility
5.8 Removing and installing connector strip cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ot p

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is n

5.9 Plug strip assignment for Thermo Top Z auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . 16

h re
ole,

5.10 Pin assignment of connector strip for Thermo Top Z auxiliary heater . . . . . . . . . . . . . . . .
spec 17
urposes, in part or in wh

5.11 Removing and installing combustion air blower V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

t to the co

5.12 Removing and installing combustion chamber with flame tube . . . . . . . . . . . . . . . . . . . . . . 18

5.13 Removing and installing glow plug for heater Q9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.14 Coolant temperature sender, heating G241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
rrectne

6 Connecting Thermo Top Z auxiliary heater to coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . 20

s

6.1 Connection diagram for coolant hoses in vehicles with auxiliary heating, engine codes CDCA
s o

and CDBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
cial p

f inform

7 Fuel supply for Thermo Top Z auxiliary heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

mer

atio

7.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

om

7.2 Fuel feed to Thermo Top Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

c

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or

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7.3 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

t

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7.4 Testing quantity of fuel delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

pr

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8 Regulation of Thermo Top Z auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Co 27
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8.1 Functional description of Thermo Top Z auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Contents i
 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

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ii Contents
 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

82 – Supplementary heating
1 Auxiliary heater Thermo Top Z

1.1 Safety measures for working on vehi‐

cles with auxiliary heaters
♦ Make sure that the auxiliary heater is not operated or switched
on in areas where there is a risk of fire or explosion.
♦ Make sure that the auxiliary heater is not operated or switched
on (including by means of a preset switch-on
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♦ When working on a fuel system,
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safety regulations and rules
s a for cleanliness. ⇒ Rep. gr. 20
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♦ If fuel system components (e.g. metering pump, fuel lines, fuel

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♦ Before beginning repair work on the auxiliary heater:

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WARNING
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Danger of scalding injuries.
The cooling system is pressurised. When the engine is warm,

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the coolant temperature may be above 100 °C.
If necessary, release pressure and reduce temperature before

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carrying out repairs.

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♦ After completing repair work on the auxiliary heater or the fuel

atio
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system, check the operation of the auxiliary heater.

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♦ After completing repairs on the auxiliary heater, carry out self-

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diagnosis using vehicle diagnosis, testing and information

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system -VAS 5051B- or later model.

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1. Auxiliary heater Thermo Top Z 1

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

2 Notes on general repairs on vehicles

with auxiliary heaters

Note

If the ECON button (depending on vehicle equipment) is pressed,

the auxiliary heater will not operate as a supplementary heater.

♦ Read self-diagnosis of auxiliary heater using vehicle diagno‐

sis, testing and information system -VAS 5051B- or later mod‐
el.
♦ If parts of the fuel system were removed or renewed, ensure
that all components for fuel delivery to the auxiliary heater are
properly installed.
Following repair work in the vicinity of the auxiliary heater fuel line,
check:
♦ That the fuel lines are routed flush with the vehicle underbody
and are protected against mechanical damage.
♦ That the auxiliary heater fuel line is protected from heat which
might disturb operation.
♦ That the fuel line does not come in contact with components
which heat up.

2.1 Starting conditions for auxiliary heating

(preheater)
♦ Engine type OK (diesel/petrol)
♦ Terminal 15 (ignition) on
♦ Engine revs > 400 rpm.
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♦ No fault entries blocking start procedure

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2.2 Starting conditions for auxiliary heating

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Every auxiliary heater also has a supplementary heating function

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♦ Engine type OK (diesel/petrol)

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♦ Auxiliary heater coded in Gateway.

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♦ No undervoltage shutdown
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 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

♦ No fault entries blocking start procedure

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2. Notes on general repairs on vehicles with auxiliary heaters 3

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

3 Rules for cleanliness when working

on the auxiliary heater and the fuel
system
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface (use
sheeting or paper, but no fluffy cloths) and cover.
♦ Carefully cover opened components or seal if the repair can‐
not be carried out immediately.
Install clean parts only:
♦ Remove genuine parts from their packages only immediately
before installing them.
♦ Do not use any parts which have not been stored in their pack‐
aging (e.g. in a tool box).
If fuel line has been opened:
♦ do not work with compressed air.
♦ do not move vehicle.
♦ Do not start engine. agen
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4 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

4 Repairing auxiliary heater Thermo

Top Z
Before beginning repair work, perform the following steps:
– Disconnect battery ⇒ Rep. gr. 27 .
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1410- (4…20 Nm)

♦ Hose clamps up to 25 mm Ø -3094-

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♦ There is a manufacturer's nameplate on the auxiliary heater

unit. This type plate provides information about which version
rrectne

is installed in the vehicle: diesel Thermo Top Z ⇒ page 6

♦ The coolant circuit must be bled after it is opened.
ss o
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4. Repairing auxiliary heater Thermo Top Z 5

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

1 - Ambient temperature sen‐

sor -G17-
❑ Checking: Vehicle diag‐
nosis, testing and infor‐
mation system -VAS agen
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❑ Removing and installing rise
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2 - Dash panel insert -K-

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3 - Fuel gauge sender -G-
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❑ Removing and installing

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⇒ Rep. gr. 20

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4 - Metering pump -V54-
ole,

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❑ Fuel supply to auxiliary
urposes, in part or in wh

heater ⇒ page 22 .

t to the co
❑ It is possible that the
metering pump ticks au‐

rrectne
dibly but still does not
deliver fuel because
there is air in the intake

ss
pipe. The control unit

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will then switch itself off

inform
permanently. You
mer

should therefore read

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out the fault memory us‐

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ing vehicle diagnosis,
or

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testing and information

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system -VAS 5051B- or

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later models (self-diag‐

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nosis of the Thermo Top

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Z auxiliary heater). De‐
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and carry out a final con‐
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trol diagnosis of the Prote AG.
Thermo Top Z auxiliary
heater.
❑ Removing and installing
⇒ page 24
❑ Testing quantity of fuel delivered ⇒ page 25
5 - Auxiliary heater Thermo Top Z
❑ With auxiliary heating control unit -J364- .
❑ Located in engine compartment, front left
❑ Removing and installing ⇒ page 8

Manufacturer's plate on heater unit for Thermo Top Z, diesel

Note

♦ The most important technical data are shown on upper part of

manufacturer's plate.
♦ 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. The heat exchanger of
the coolant heater does not need to be renewed after 10 years.
Legislation in Germany dictates only that air heaters must be
renewed.

6 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
n AG. Volkswagen AG do
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Removing and thinstalling
or
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ambient temperature sensor -G17-tee o
u ra
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– Remove scentre vent ⇒ Rep. gr. 63 . c

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– Unclip ambient temperature sensor -G17- -1- and separate
du

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4. Repairing auxiliary heater Thermo Top Z 7

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

5 Removing and installing auxiliary heater Thermo Top Z

Special tools and workshop agen

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♦ Torque wrench -V.A.G horis nte
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1410- (4…20 Nm) s aut ra
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♦ Hose clamps up to 25 mm

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-3094-

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♦ Vehicle diagnosis, testing

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and information system -

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Note

♦ There is a manufacturer's nameplate on the auxiliary heater

unit. This manufacturer's plate provides information about
which version is installed in vehicle, for example, diesel Ther‐
mo Top Z ⇒ page 6 .
♦ The coolant circuit must be bled after it is opened.
♦ Cooling system is pressurised when engine is warm. If nec‐
essary, release pressure before carrying out repairs.

8 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

5.1 Components of auxiliary heater Thermo Top Z

1 - Exhaust system
❑ Removing and installing
⇒ page 14
2 - Circulation pump -V55-
❑ Removing and installing
⇒ page 13
3 - Fuel line
❑ Routing of fuel line
⇒ page 22 .
4 - Air intake silencer
❑ Removing and installing
⇒ page 13
5 - Auxiliary heater Thermo
Top Z AG. Volkswagen AG d
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❑ With auxiliary heating by
Vol not
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control unit -J364- . rised
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❑ Removing ⇒ page 9 aut ra
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5.2 Removing the Thermo Top Z auxiliary

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If the Thermo Top Z is to be renewed, first connect vehicle diag‐
agen
Prote AG.
nosis, testing and information system -VAS 5051B- or later model
and start the „Renew heater“ function under the guided functions.

5. Removing and installing auxiliary heater Thermo Top Z 9

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1410- (4…20 Nm)
♦ Hose clamps up to 25 mm
-3094-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051B- or later model

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Note
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c

♦ The coolant circuit must be bled after it is opened.

or

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a

♦ After the auxiliary heater has been detached, it must be se‐

iv

o
pr

cured to the body with welding wire to prevent damage to the

um
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coolant hoses.
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Danger of burn injuries.

Parts of the exhaust system may be hot.
Before removing exhaust system, let it cool off.

– Remove exhaust pipe for auxiliary heater ⇒ page 14 .

10 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

WARNING

Danger of fuel escaping.

Fuel system is under pressure.
Before opening system, wrap a cloth around the connection.
Then release pressure by carefully loosening the connection.

– Pull fuel line off auxiliary heater and seal with suitable plugs.

WARNING

Danger of scalding injuries.

When the engine is warm, the coolant temperature may be
above 100 °C. The cooling system is pressurised.
If necessary, release pressure and reduce temperature before
carrying out repairs.

– Clamp off coolant hoses using hose clamps up to 25 mm Ø

-3094- and pull coolant hoses off auxiliary heater.
– Remove left headlight ⇒ Lights, bulbs, switches - exterior;
Rep. gr. 94 ; Removing and installing headlights .

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5. Removing and installing auxiliary heater Thermo Top Z 11

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

AG. Volkswagen AG d
agen oes
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du

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erm

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ility
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es, in part or in w

t to the co
rrectness of i
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nform
mercia

– Loosen securing bolt -1- (8 ± 1 Nm).

at
om

ion
c

– Undo and remove securing bolt -2- (8 ± 1 Nm).

in t
or

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ate

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Caution
um
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Auxiliary heater control unit -J364- could be damaged. Cop py
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Overvoltages can occur at the connectors. p by
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First disconnect 8-pin connector. Prote AG.

– Unplug the other connectors at the auxiliary heater.

5.3 Installing the Thermo Top Z auxiliary

heater

Note

If the Thermo Top Z is not to be renewed, connect vehicle diag‐

nosis, testing and information system -VAS 5051B- or later model
and start the „Release heater“ function under the guided func‐
tions.

12 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

Installation is carried out in the reverse order. When installing,

note the following:
– After installing auxiliary heater, bleed coolant circuit.
– Start auxiliary heater.

5.4 Removing and installing air intake si‐

lencer
Removing
– Loosen clamp -arrow A- and pull air intake silencer off
-arrow B-.
Installing
– Push air intake silencer onto the intake pipe until it can be
clipped onto the bracket.
– Fit clamp.
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pt
5.5 Removing and installing circulation

an
d
itte

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pump -V55-
rm

ab
pe

ility
ot

Removing

wit
, is n

h re
hole

Special tools and workshop equipment required

spec
es, in part or in w

♦ Hose clamps up to 25 mm Ø -3094-

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

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s
iva

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en
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– Clamp off coolant hoses using hose clamps to Ø 25 mm

n

t.
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op
-3094- . C py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

5. Removing and installing auxiliary heater Thermo Top Z 13

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

– Pull connector -4- off circulation pump -V55- .

– Loosen clamps -1- and -2- at the circulation pump -V55- .

WARNING

Danger of scalding injuries.

When the engine is warm, the coolant temperature may be
above 100 °C. The cooling system is pressurised.
If necessary, release pressure and reduce temperature before
carrying out repairs. AG. Volkswagen A
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– Pull coolant hoses off circulation
horis pump -V55- . tee
ut or
a ac
– Remove bolt -3- andss remove circulation pump -V55- .

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Installing

an
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Installation is carried out in the reverse order. When installing,
erm

ab
ility
note the following:
ot p

wit
is n

– After installing circulation pump -V55- , bleed coolant circuit.

h re
ole,

spec
urposes, in part or in wh

5.6 Removing and installing exhaust pipe

t to the co
for auxiliary heater

rrectne
Removing

s
WARNING
s o
cial p

f inform

Danger of burn injuries.

mer

atio

Parts of the exhaust system may be hot.

om

n
c

i
or

Before removing exhaust system, let it cool off.

thi
te

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en

– Unscrew bolt -1- (8 ± 1 Nm).

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op py
– Loosen clamp -2- and pull exhaust pipe of auxiliary heater. t. C rig
gh ht
pyri by
Installing
o Vo
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cted agen
Prote AG.
– Install in reverse order.

14 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

5.7 Dismantling and assembling Thermo

Top Z auxiliary heater

Note

Removing and installing Thermo Top Z auxiliary heater

⇒ page 9 .

1 - Glow plug for heater -Q9-

(with flame monitor)
❑ With inner heating ele‐
ment (glow pin).
❑ Removing and installing agen
AG. Volkswagen AG d
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⇒ page 18 yV
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2 - Seal ris tee
u tho or
❑ Alwaysssrenew
a after dis‐ ac
mantling.

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an
d

3 - Rubber grommet
itte

y li
rm

ab
❑ Always renew after dis‐
pe

ility
mantling.
ot

wit
, is n

h re
4 - Combustion air blower -V6-
hole

spec
❑ Removing and installing
es, in part or in w

⇒ page 17
t to the co
5 - Bolt rrectness of i

6 - Retaining clip
❑ For glow plug for heater
l purpos

-Q9- (with flame moni‐

tor).
nform
ercia

Note
m

a
com

tion in
r
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7 - Clip
thi
s
iva

do

❑ Note fitting position.

r
rp

cum
fo

8 - Combustion chamber with

en
ng

t.
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flame tube t. Cop py
rig
❑ Clean inside and out‐
gh ht
pyri by
side with brass wire
co Vo
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cted
brush (spark plug
agen
Prote AG.
brush).
❑ Removing and installing
⇒ page 18
9 - Seal
❑ Always renew after dismantling.
10 - Water jacket
❑ Clean inside and outside with brass wire brush (spark plug brush).
❑ Do not dismantle further
11 - Cover
❑ For connector strip
❑ Removing and installing ⇒ page 16
❑ Connector strip assignment ⇒ page 16 .

5. Removing and installing auxiliary heater Thermo Top Z 15

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

5.8 Removing and installing connector strip

cover

Note

Removing the Thermo Top Z auxiliary heater ⇒ page 12 .

– Remove cover -A- using screwdriver.

5.9 Plug strip assignment for Thermo Top Z

auxiliary wheater
agen
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♦ 6-pin connector
ed
by-A-
V
ara
is nte
or
♦ Connector
au
th -B- for voltage supply , 12 Volt eo
ra
ss c
♦ Connector -C- for glow plug for heater -Q9- (with flame moni‐
ce
le
un

pt

tor)
an
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itte

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♦ Connector -D- for combustion air blower -V6-

erm

ab
ility
ot p

♦ Connector -E- for circulation pump -V55- (only auxiliary cool‐

wit
is n

ant heater)
h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

16 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

5.10 Pin assignment of connector strip for

Thermo Top Z auxiliary heater
6-pin connector, connector housing -A-
1 - Webasto diagnosis cable
2 - CAN bus high (optional)
3 - CAN bus low (optional)
4 - Coolant shut-off valve, heater -N279- (not on vehicles with
auxiliary heater)
5 - Main switch
6 - Metering pump -V54-
2-pin connector, connector housing -B-
1 - Terminal 30
2 - Terminal 31
2-pin connector, connector housing -C-
1 - Glow plug for heater -Q9- (with flame monitor)
2 - Terminal 31
2-pin connector, connector housing -D-
1 - Combustion air blower -V6-
2 - Terminal 31
2-pin connector, connector housing -E-
1 - Circulation pump -V55-
2 - Terminal 31
AG. Volkswagen AG d
agen oes
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5.11 Removing and installing combustion air ol not
V gu
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blower -V6- ris nte
ho eo
aut ra
s c
Removing s
ce
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un

pt

– Removing the Thermo Top Z auxiliary heater ⇒ page 12 .

an
d
itte

y li
erm

ab

– Remove connector strip cover and separate connections to

ility
ot p

connector strip ⇒ page 16 .

wit
is n

h re

– Remove bolts -A-.

ole,

spec
urposes, in part or in wh

– Separate combustion air blower -V6- -B- from auxiliary coolant

t to the co

heater Thermo Top Z/C.

Installing
rrectne

Note
ss o
cial p

♦ Renew gasket between combustion air blower and additional

inform

coolant heater Thermo Top Z/C.

mer

atio
m

♦ Ensure proper seating of fuel line -C- in new grommet -D-.

o

n
c

i
or

n thi
te

Install in reverse order.

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Removing and installing auxiliary heater Thermo Top Z 17

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010 agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
5.12 Removing and installing combustion ed
ris nte
ho eo
ut
chamber with flame tube ss a ra
c

ce
le
un
Removing

pt
an
d
itte

y li
– Remove combustion air blower -V6- ⇒ page 17 .

erm

ab
ility
ot p
– Remove bolts -A-.

wit
is n

h re
– Release connector from glow plug for heater -Q9- . ole,

spec
urposes, in part or in wh

– Pull combustion chamber, together with flame tube -B-, out of

t to the co
Thermo Top Z auxiliary heater -C-.
Installing

rrectne
Note

ss o
cial p

f i
♦ Renew gasket between combustion chamber with flame tube

nform
and auxiliary coolant heater Thermo Top Z/C.
mer

atio
m

♦ If combustion chamber with flame tube is defective, renew also

o

n
c

glow plug for heater -Q9- (with flame monitor). ⇒ page 18

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

5.13 Removing and installing glow plug for

en
ng

t.
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heater -Q9- Cop py
t. rig
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yri by
Removing
op Vo
by c lksw
cted agen
Prote
– Remove combustion air blower -V6- ⇒ page 17 .
AG.

– Unscrew bolts -1- and lift combustion chamber with flame tube
slightly.
– Pull off retaining clip -2-.
– Pull glow plug for heater -Q9- (with flame monitor) -3- out of
combustion chamber with flame tube.
Installing

Note

♦ Install retaining clip and ensure that the glow plug for heater -
Q9- is correctly seated.
♦ Insert wiring in support and route as in figure.

5.14 Coolant temperature sender, heating -

G241-

Caution

The heater control unit -J162- can be damaged by dampness.

There is no replacement seal part for the cover.
Do not remove cover.

18 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

Note

The coolant temperature sender, heating -G241- is permanently

installed on the board and cannot be renewed.
n AG. Volkswagen AG do
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ss

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itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Removing and installing auxiliary heater Thermo Top Z 19

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

n AG. Volkswagen AG do
wage
6 Connecting Thermo Top Z auxiliary
lks es n
o ot g
byV ua
heater to coolant circuit
d ran
ir se tee
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ss

ce
e

WARNING
nl

pt
du

an
itte

y li
Danger of scalding injuries.
erm

ab
ility
ot p

The cooling system is pressurised. When the engine is warm,

wit
, is n

the coolant temperature may be above 100 °C.

h re
hole

spec
If necessary, release pressure and reduce temperature before
es, in part or in w

carrying out repairs.

t to the co
rrectness of i
Note
l purpos

The coolant circuit must be free of air for the auxiliary heater to

nf
ercia

heat properly.

orm
m

atio
m

6.1 Connection diagram for coolant hoses in vehicles with auxiliary heating,
o

n in
or c

engine codes CDCA and CDBA

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

1 - Expansion tank
t.
yi Co
Cop py
.
2 - Heat exchanger for heater
t rig
gh ht
pyri by
Vo
co
3 - Unions on rear cylinder
by lksw
cted agen
Prote
head
AG.

❑ With coolant tempera‐

ture sender -G62-
4 - Cylinder head
5 - Engine oil cooler
6 - 4/2 way valve
❑ With coolant regulator
❑ Can only be replaced as
a complete unit
7 - Circulation pump -V55-
8 - Auxiliary heater
❑ Depending on equip‐
ment
9 - Radiator
❑ Renew coolant after re‐
placement.
10 - Coolant pump
11 - Continued coolant circula‐
tion pump -V51-
12 - Coolant temperature
sender at cooler outlet -G83-
13 - Exhaust gas recirculation
cooler
14 - Thermostat (Y-piece)
15 - Coolant temperature

20 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

sender -G62-

AG. Volkswagen AG d
agen oes
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byV gu
ara
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ris nte
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an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6. Connecting Thermo Top Z auxiliary heater to coolant circuit 21

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

7 Fuel supply for Thermo Top Z auxili‐ AG. Volkswagen AG d

agen
ary heaters
oes
olksw not
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b a
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oris tee
th or
au ac
Note ss

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un

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Observe safety regulations for working on fuel supply system ⇒

an
d
itte

y li
Rep. gr. 20 .

erm

ab
ility
ot p

wit
is n

h re
Before beginning repair work, perform the following steps:

ole,

spec
urposes, in part or in wh
– Disconnect the battery ⇒ Rep. gr. 27 .

t to the co
7.1 Rules for cleanliness
When working on the fuel supply/injection system, carefully follow

rrectne
the „5 rules“ below:

s
♦ Thoroughly clean all connections and adjacent areas before

s o
disconnecting.
cial p

f inform
♦ Place parts that have been removed on a clean surface and
mer

cover. Do not use fluffy cloths!

atio
om

n
c

♦ Carefully cover or seal opened components if the repair can‐

i
or

n thi
e

not be carried out immediately.

t

sd
iva

o
pr

c
♦ Install clean parts only; remove replacement parts from their

um
r
fo

packages only immediately before installing them. Do not use

en
ng

t.
yi Co
any parts which have not been stored in their packaging (e.g. Cop py
in a tool box).
t. rig
gh ht
pyri by
Vo
co
♦ Fuel hoses and pipes may be shortened only with a clean
by lksw
cted agen
sharp knife. Cutting points must not be soiled or deformed.
Prote AG.

Cutting points and surfaces must be free of burrs.

7.2 Fuel feed to Thermo Top Z

Note

♦ Fuel lines are secured with O-type clips. These O-type clips
must always be replaced with screw-type clips.
♦ To start the auxiliary heater, the following conditions are re‐
quired: ambient temperature sensor -G17- is pulled off and the
coolant temperature is below 50 °C.
♦ The auxiliary heater can only be started in basic setting 1 and
stopped with 4 by means of the vehicle diagnosis, testing and
information system -VAS 5051B- .
♦ If the fuel tank was empty, there may be air in the fuel line to
the auxiliary heater. To remove air from the fuel line, start aux‐
iliary heater repeatedly until it does not go out by itself.
♦ Observe the rules for cleanliness when doing all work on the
fuel supply system ⇒ page 22 .

22 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

1 - Metering pump -V54-

❑ Metering pump -V54- is
located on the fuel tank
on the right-hand side.
❑ Removing and installing
⇒ page 24
❑ Testing quantity of fuel
delivered ⇒ page 25 .
2 - Fuel gauge sender -G-
❑ Fuel gauge sender -G-
is located on right side
under bench seat.
❑ Removing and installing
⇒ Rep. gr. 20 AG. Volkswagen AG d
agen oes
olksw not
3 - Fuel line d byV gu
ara
ise nte
r
4 - Auxiliary heater Thermo ut
ho eo
ra
Top Z ss a c

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le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
r

7.2.1 Fuel feed to Thermo Top Z

p

cum
r
fo

en
ng

t.
yi Co
Cop py
WARNING ht. rig
rig ht
py by
co Vo
by lksw
Danger of fuel escaping. cted agen
Prote AG.

Fuel system is under pressure.

Before opening system, wrap a cloth around the connection.
Then release pressure by carefully loosening the connection.

Note

Observe the safety measures when working on the fuel supply

system ⇒ Rep. gr. 20 .

7. Fuel supply for Thermo Top Z auxiliary heaters 23

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

Fuel feed to auxiliary heater is achieved via connection on fuel

gauge sender -G- -1-. The fuel gauge sender -G- is located on
the fuel tank.

7.3 Removing and installing metering pump

-V54-

Note

♦ The metering pump -V54- for diesel engines has a grey plastic
shell and the one for petrol engines has a black plastic shell.
♦ Make sure the part number is correct.

Removing

Note

Observe the safety measures when working on the fuel supply

system ⇒ Rep. gr. 20 .

– Lower fuel tank ⇒ Engine and gearbox unit; Rep. gr. 20 ;

Removing and installing fuel tank
wage.
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WARNINGthoris nte
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ss c
Danger of fuel escaping.
ce
le
un

pt
an
d

Fuel system is under pressure.

itte

y li
erm

ab

Before opening system, wrap a cloth around the connection.

ility
ot p

Then release pressure by carefully loosening the connection.

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Loosen fuel line clamps -1-.

t to the co

– Pull fuel lines off circulation pump -V55- and seal the lines to
prevent fuel escaping.
rrectne

– Pull metering pump -V54- of bracket in direction of -arrow-.

– Detach bracket -2- for metering pump -V54- on fuel tank using
ss

suitable tools.
o
cial p

f inform

– Pull metering pump -V54- out in direction of -arrow-.

mer

atio

– Disconnect connector on metering pump -V54- .

om

n
c

i
or

Installing
thi
te

sd
va

Make sure the part number is correct.

i

o
pr

cum
r
fo

en
ng

Install in reverse order.

t.
yi Co
op py
– Ensure proper installation position of metering pump -V54- .
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

24 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

7.4 Testing quantity of fuel delivered

Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS
5051B- or later model.

♦ Hand multimeter -V.A.G 1526/A-

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nl

pt
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itte

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erm

ab
ility
ot p

♦ Auxiliary measuring set -V.A.G 1594/C-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t

♦ Current flow diagram

or

his
ate

♦ Commercially available measuring glass (0 to 50 ml)

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

25
co Vo
by lksw
cted 7. Fuel supply for Thermo Top Z auxiliary heaters
agen
Prote AG.
 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

7.4.1 Test prerequisites:

• Resistance of metering pump -V54- 5.2 +/- 5 %
• Voltage at metering pump -V54- 9.5 to 16.5 Volt.
• No fault stored in fault memory.
• Fuel lines are not damaged or leaking.
• Ambient temperature approx. 20 °C
• Fuel tank sufficiently filled (fuel gauge on dash panel insert not
in red area).

7.4.2 Checking:

WARNING

Danger of fuel escaping.

Fuel system is under pressure.
Before opening system, wrap a cloth around the connection.
Then release pressure by carefully loosening the connection.

– Loosen clamp -1- on fuel line.

– Detach and seal fuel line.
– Hold measuring glass under fuel line. AG. Volkswagen A
gen G do
swa es
– Using vehicle diagnosis, testing by
Vol and information system -VAS
k not
gu
5051B- (or later models), ris open guided function „Check quan‐
ed ara
nte
tity of fuel delivered“ut(open
ho fuel line from metering pump - eo
ra
V54- ) and start. ss a c
ce
e
nl

After approx. 30 seconds, the fuel line is filled and bled.

pt
du

an
itte

y li

– Seal fuel line.

erm

ab
ility
ot p

– Empty measuring glass.

wit
, is n

h re

– Hold measuring glass under fuel line.

hole

spec

– Using vehicle diagnosis, testing and information system -VAS

es, in part or in w

t to the co

5051B- (or later models), open guided function „Check quan‐

tity of fuel delivered“ (open fuel line from metering pump -
V54- ) and start.
rrectness of i

Fuel delivery finishes after approx. 120 seconds.

l purpos

– Connect fuel line.

Use new clamp.
nf
ercia

orm

– Read measuring glass. Fuel delivery rate for petrol and diesel:
m

atio
m

22 to 28 ml
o

n in
or c

thi

– If fuel delivery rate is not within specifications, renew metering

te

sd
a

pump -V54- .
iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
♦ If the ambient temperature is above 20 °C, fuel vaporisation
co Vo
by lksw
cted
may lead to incorrect measurements.
agen
Prote AG.

♦ No bubbles are to be delivered.

26 Rep. gr.82 - Supplementary heating

 Amarok 2011 ➤
Auxiliary heater - Edition 11.2010

8 Regulation of Thermo Top Z auxiliary

heater
The auxiliary heater is intended to heat coolant.
Various operating modes can be set depending on heat required
in heating circuit:

8.1 Functional description of Thermo Top Z

auxiliary heater
Temperature at ambient temperature sensor -G17- must be be‐
low approx. +5 °C.
Turning on the switch enables operation of the auxiliary heater.
The glow plug with flame monitor -Q8- , the combustion air blower
-V6- and the circulation pump -V55- begin to operate. After 30
seconds, the metering pump -V54- is switched on and the com‐
bustion air blower -V6- is switched off for 3 seconds. Then the
combustion air blower -V6- runs up in two stages to nearly full
load within 56 seconds. After a stabilisation phase (attaining
steady motor speed) of 15 seconds, the combustion air blower -
V6- is again brought up to nearly full load in a 50-second stage.
After reaching full-load fuel delivery, the glow plug with flame
monitor -Q8- is switched off and the combustion air blower -V6-
is brought up to full speed. During the next 45 seconds as well as
during normal operation, the glow plug with flame monitoring -Q8-
assumes the task of flame monitoring and checks flame devel‐
opment. Then the automatically regulated heating operation
begins. If no flame develops or the flame extinguishes, then the
fuel supply is interrupted and a malfunction shut-down occurs with
the combustion air blower -V6- continuing in run-on mode. If the
flame is extinguished during normal operation, a new start is au‐
tomatically initiated.

8.1.1 Preheating mode . Volkswagen AG

gen AG does
swa
Once the coolant temperature has y V reached 84 ℃, the control unit
olk not
g
switches to the energy-saving ed part load mode. If the coolant tem‐ uara
b
ris nte
perature continues to rise ut above 88 °C, the control unit switches
ho eo
ra
to the controlled waiting
ss a period. If the coolant temperature does c
not drop below 76 ℃ within 900 seconds during the controlled
ce
le
un

pt

waiting period, the heating unit will start with the normal start pro‐
an
d
itte

cedure in full-load mode when the coolant temperature does drop

y li
erm

ab

below 76 ℃.
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

8. Regulation of Thermo Top Z auxiliary heater 27