Service: Caddy 2004 Caddy 2011

Service
Workshop Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
82 - Supplementary heating agen
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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 © 2018 Volkswagen AG, Wolfsburg K0050366320

Caddy 2004 ➤ , Caddy 2011 ➤
Auxiliary heater - Edition 03.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when using test and measuring instruments during a road test . . . . . . 2
1.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Safety precautions when working on vehicles with auxiliary/supplementary heater . . . . . . 2
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Starting conditions for auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system . . 6
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Notes on general repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Overview of fitting locations - auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 8
1.2 Overview of fitting locations - components located outside of passenger compartment, Caddy
2011▶ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Overview of fitting locations - auxiliary/supplementary heater, Thermo Top V and Thermo
Top fleece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Assembly overview - auxiliary/supplementary heater, internal . . . . . . . . . . . . . . . . . . . . . .
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Assembly overview - auxiliary/supplementary heateroeattachments
s no .................. 18
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2.4 Removing and installing d b auxiliary/supplementary heater g.ua. r . . . . . . . . . . . . . . . . . . . . . . . .
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18
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2.5 Dismantling and uassembling
tho auxiliary/supplementary heater . e.o.r . . . . . . . . . . . . . . . . . . . 22
a a
2.6 Removing andssinstalling air intake silencer . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . 22
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2.7 Removing and installing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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2.8 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2.9 Removing and installing silencer with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.10 Removing and installing auxiliary/supplementary heater bracket . . . . . . . . . . . . . . . . . . . . 25

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2.11 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.12 Removing and installing auxiliary heater control unit J364 . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.13 Removing and installing glow plug with flame monitor Q8 . . . . . . . . . . . . . . . . . . . . . . . . 27

t to the co
2.14 Removing and installing temperature sensor G18 and overheating sensor G189 . . . . . . . 28
2.15 Dismantling and assembling burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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3 Coolant circuit with auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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3.1 Coolant hose schematic diagram for vehicles with auxiliary heater, BCA . . . . . . . . . . . . . . 31
3.2 Coolant hose schematic diagram for vehicles with auxiliary heater, BGU . . . . . . . . . . . . . . 33
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3.3 Coolant hose schematic diagram for vehicles with auxiliary heater, BJB . . . . . . . . . . . . . . 34
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3.4 Coolant hose schematic diagram for vehicles with auxiliary heater, BDJ . . . . . . . . . . . . . . 35
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3.5 Coolant hose schematic diagram for vehicles with auxiliary heater, CAYD and CAYE . . . .
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36
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3.6 Coolant hose schematic diagram for vehicles with auxiliary heater, CFCH, CFCE, CFCF,
te o
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CLCA, CFHC, CFHE, CFHF and CFJA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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3.7 Coolant hose schematic diagram for vehicles with auxiliary heater, CBZA and CBZB . . . . 38
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3.8 Removing and installing heater coolant shut-off valve N279 . . . . . . . . . . . . . . . . . . . . . . 38

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4 Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4.1 Overview of fitting locations - fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4.2 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3 Checking fuel delivery rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Regulation of auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Functional description of auxiliary heater Thermo Top V . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Functional description of Thermo Top fleece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Contents i
Caddy 2004 ➤ , Caddy 2011 ➤
5.3 Supplementary heater mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.4 Auxiliary heater mode, Caddy ▶2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5 Auxiliary heater mode, Caddy 2011▶ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.6 Switching off auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Removing and installing ambient temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Removing and installing remote control receiver for auxiliary coolant heater R149 . . . . . . 49
6.3 Functional description of remote control for auxiliary/supplementary heater . . . . . . . . . . . . 50
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ii Contents
Caddy 2004 ➤ , Caddy 2011 ➤
00 – Technical data
1 Safety information
(VRL011229; Edition 03.2018)
⇒ “1.1 Safety precautions during work on fuel system”,
page 1
⇒ “1.2 Safety precautions when working on vehicles with start/
stop system”, page 1
⇒ “1.3 Safety precautions when using test and measuring instru‐
ments during a road test”,AG
page
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⇒ “1.4 Safety precautions when working on cooling
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⇒ “1.5 sSafety
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1.1 Safety precautions during work on fuel system

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Danger of fire caused by escaping fuel
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When the battery is connected and the driver door opens, the door
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contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire. spec
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– Disconnect voltage supply to fuel pump before opening the
fuel system.
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Risk of injury from highly pressurised fuel.

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The fuel system is pressurised. Risk of injury from fuel spray.

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Before opening the fuel system:

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– Wear safety goggles.

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– Wear protective gloves.

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1.2 Safety precautions when working on vehicles with start/stop system

Risk of injury due to unexpected engine start
If the vehicle's start/stop system is activated, the engine could
start unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– To deactivate start/stop system: switch off ignition.
1. Safety information 1
Caddy 2004 ➤ , Caddy 2011 ➤
1.3 Safety precautions when using test and measuring instruments during a
road test
Risk of injury caused by unsecured test and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured test and measuring instruments become dan‐
gerous projectiles.
– Secure test and measuring instruments on the rear seat.
Or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1.4 Safety precautions when working on cooling system

Risk of scalding from hot coolant
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On a warm engine, the cooling system is under highy pressure.
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Risk of scalding from steam and hot coolant. ised b ua
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– Wear protective gloves. aut or
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– To relieve pressure, cover the cap of the coolant expansion
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tank with cloths, and open it carefully.
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1.5 Safety precautions when working on vehicles with auxiliary/supplementary
heater
rrectne
Danger of fire and explosion from auxiliary/supplementary heater
In fire and explosion-endangered areas, a spark or the high tem‐ ss
perature of the auxiliary/supplementary heater can cause a fire or
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an explosion. Risk of burns.

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– Switch the auxiliary/supplementary heater off in fire and ex‐

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plosion-endangered areas.
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Danger of poisoning from exhaust fumes
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fumes. Risk of poisoning and injuries to respiratory system.
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– In closed areas, only switch on the auxiliary/supplementary
heated when it is exclusively connected to an exhaust extrac‐
tor system.
– In closed areas without an exhaust extractor system, switch
off the auxiliary/supplementary heater.
2 Rep. gr.00 - Technical data

Caddy 2004 ➤ , Caddy 2011 ➤
Risk of damage when starting the engine

If components of the fuel system or coolant circuit of the auxiliary/
supplementary heater are removed or opened, there is a possi‐
bility of causing damage to the auxiliary/supplementary heater.
– Never attempt to start the engine when components are re‐
moved or opened.
Malfunction caused by air in the fuel supply system

Upon repair work on the fuel tank or the fuel delivery unit, air will
be drawn in by the metering pump and conveyed to the auxiliary/
supplementary heater. Air in the fuel supply system may cause
malfunction of the auxiliary/supplementary heater.
– Fill fuel take-off pipe with fuel.
Risk of accidents and risk of injury due to activated timer of aux‐

iliary/supplementary heater
If the vehicle’s timer for the auxiliary/supplementary heater is ac‐
tive, the heater may switch on unexpectedly. This poses a risk of
poisoning from exhaust gases, a risk of burns caused by hot aux‐
iliary/supplementary heater components as well as a risk of fire
and explosions caused by high temperatures.
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– Deactivate timer for auxiliary/supplementary heater. olksw not
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1. Safety information 3
Caddy 2004 ➤ , Caddy 2011 ➤
2 General information
⇒ “2.1 Type plates”, page 4
⇒ “2.2 Starting conditions for auxiliary/supplementary heater”,
page 5
⇒ “2.3 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 6
2.1 Type plates
Note
♦ The main technical data are shown on the upper part of the
type plate.
♦ There are different types of type plates.
♦ 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 for auxiliary heaters does not have to be
renewed after 10 years.
♦ Legislation in Germany dictates only that air heaters must be
renewed. Since this does not apply for this particular auxiliary swagen AG. Volkswagen AG does
heater, no renewal is required. by
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♦ In the engine compartment of the vehicle, there is a second
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(duplicate) type plate attached to the right of the locks a carrier
u ac
(when looking in direction of travel). If there is any sdoubt con‐
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cerning the type of the auxiliary/supplementary heater, always

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observe the type plate attached directly to the auxiliary/sup‐

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Type plate for diesel Thermo Top V on heater unit
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Type plate for petrol-type Thermo Top V on heater unit
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Caddy 2004 ➤ , Caddy 2011 ➤
Type plate for diesel Thermo Top V on heater unit (supplementary

heater, without auxiliary heater mode)
Type plate (duplicate) for diesel Thermo Top V (on lock carrier)
Type plate (duplicate) for petrol-type Thermo Top V (on lock car‐
rier)
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Type plate (duplicate) for supplementary heater diesel Thermo
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Top V, without auxiliary heater mode (on lock carrier)
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♦ The main technical data are shown on the upper part of the
type plate.
nf
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♦ The date of first use is entered on the lower part of manufac‐

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turer's plate.
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♦ The year the unit was first put into use must be entered on the
or
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“Genuine part” manufacturer's plate. The heat exchanger of

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the coolant heater does not need to be renewed after 10 years.

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Legislation in Germany dictates only that air heaters must be

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renewed.
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2.2 Starting conditions for auxiliary/supple‐
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mentary heater
♦ Engine type OK (diesel/petrol)
2. General information 5
Caddy 2004 ➤ , Caddy 2011 ➤
♦ Terminal 15 (ignition) on
♦ Engine speed > 300 rpm.
♦ Coolant temperature < 69 °C
♦ ECON - button not pressed and temperature setting not on
“cold”
♦ Ambient temperature < 5 °C
♦ Reserve fuel level not reached
♦ On-board network manager not active
♦ No crash switch-off
♦ No event memory entries blocking start procedure
2.3 Rules for cleanliness when working on

auxiliary/supplementary heater and fuel
system
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en AG. V
♦ Thoroughly clean all joints and surrounding ksw areas before dis‐
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♦ Place parts that have been removed
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sheeting or paper, no clothss containing lint) and cover.
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♦ If repair work cannot be performed immediately, carefully cov‐
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♦ Only install clean parts:
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– Remove replacement parts from their packages only immedi‐
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ately before installing them.
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– Do not use any parts which have not been stored in their pack‐
t to the co
aging (e.g. in a tool box).
♦ If fuel line has been opened: rrectness of i
– Do not work with compressed air.

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– Do not move the vehicle.

– Do not start engine.
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– Do not switch auxiliary heater on.

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Caddy 2004 ➤ , Caddy 2011 ➤
3 Repair notes
⇒ “3.1 Notes on general repairs”, page 7
3.1 Notes on general repairs

♦ Read auxiliary heater self-diagnosis using ⇒ Vehicle diagnos‐
tic tester.
♦ If parts of the fuel system were removed or renewed, ensure
that all components for fuel delivery to the auxiliary heater are
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♦ Following repair work in the vicinity of the fuel
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the auxiliary heater, make sure that: ut
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♦ the coolant circuit is free of air in order for
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the auxiliary heater
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to heat properly;
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♦ fuel lines are flush with the vehicle underbody and are protec‐
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♦ auxiliary heater fuel line is protected from heating which might
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♦ fuel line does not come in contact with components that radiate
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3. Repair notes 7
Caddy 2004 ➤ , Caddy 2011 ➤
82 – Supplementary heating
1 Overview of fitting locations - auxili‐
ary/supplementary heater
⇒ “1.1 Overview of fitting locations - components not located in
passenger compartment”, page 8
⇒ “1.2 Overview of fitting locations - components located outside
of passenger compartment, Caddy 2011▶”, page 9
1.1 Overview of fitting locations - compo‐

nents not located in passenger compart‐
ment
Note
There is a type plate on the auxiliary heater. This type plate indi‐
cates which heater version is installed in the vehicle ⇒ page 4 .
1 - Fuel gauge sender - G-

❑ To remove fuel gauge
sender - G- , the fuel
tank must first be re‐
moved.
❑ Removing and installing
⇒ Fuel supply system -
petrol engines; Rep. gr. agen
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fuel gauge sender; Re‐ ised b ara
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moving and installing ut
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fuel gauge sender -G- . ss a ra
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2 - Auxiliary heater aerial -

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❑ For vehicles with auxili‐
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ary heater and remote

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control h re
ole,
3 - Heater coolant shut-off

spec
valve - N279-
t to the co
Note
rrectne
The heater coolant shut-off valve -

N279- is fitted only on vehicles with
s
the auxiliary heater function.

s o
cial p
f in
❑ On vehicles with petrol

form
mer
engine, it is fixed to the

atio
bulkhead in the engine

om
compartment.
c
i
or
n thi
e
❑ On vehicles with diesel

t
sd
va

i
o
pr
cum
r
engine.
fo
en
ng
t.
yi
Co
Cop py
⇒ page 38 ht. rig
rig ht
py by
o Vo
4 - Fresh air blower relay - J13- by c lksw
cted agen
Prote AG.
❑ Fitting location: relay and fuse carrier on left under dash panel
8 Rep. gr.82 - Supplementary heating

Caddy 2004 ➤ , Caddy 2011 ➤
❑ Checking ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
5 - Auxiliary heater operation relay - J485-
6 - Remote control receiver for auxiliary coolant heater - R149-
❑ Removing and installing ⇒ page 49
7 - Ambient temperature sensor - G17-
❑ Checking ⇒ Vehicle diagnostic tester
8 - Circulation pump - V55-
❑ Located on auxiliary heater
9 - Auxiliary heater Thermo Top V
❑ With auxiliary heater control unit - J364- agen
AG. Volkswagen AG d
oes
olksw not
❑ Fitting location: behind front bumper on right
d by V gu
ara
ise nte
❑ Removing and installing ⇒ page 12 tho r eo
au ra
c
10 - Exhaust system ss
ce
le
un
❑ For auxiliary heater
pt
an
d
itte
y li
erm
ab
ility
ot p
11 - Metering pump - V54-
wit
is n
❑ Fitting location: underbody, on right in direction of travel
h re
ole,
spec
❑ Fuel supply for auxiliary heaters Thermo Top V ⇒ page 40
t to the co
❑ Testing quantity of fuel delivered ⇒ page 42
rrectne
ss o
cial p
f inform
1.2 Overview of fitting locations - compo‐
mer
nents located outside of passenger atio

om
n
c
compartment, Caddy 2011▶

i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
t. rig
There is a type plate on the auxiliary heater. This type plate indi‐ yri
gh by
ht
cates which heater version is installed in the vehicle ⇒ page 4 . cop Vo
by lksw
cted agen
Prote AG.
1. Overview of fitting locations - auxiliary/supplementary heater 9

Caddy 2004 ➤ , Caddy 2011 ➤

moved.
⇒ Fuel supply system - petrol
engines; Rep. gr. 20 ; Fuel de‐
livery unit/fuel gauge sender;
Removing and installing fuel
gauge sender -G-
2 - Auxiliary heater aerial -

R182-
❑ For vehicles with auxili‐
ary heater and remote
control
❑ Fitted in front left door
3 - Heater coolant shut-off n AG. Volkswagen AG do
valve - N279- lkswage es n
o ot g
yV ua
❑ On vehicles with petrol ir se
d b ran
engine, it is fixed to the utho tee
or
bulkhead in the engine ss
a ac
compartment.
ce
le
un
pt
❑ On vehicles with diesel
an
d
itte
y li
rm
ab
engine.
pe
ility
ot
wit
, is n
h re
⇒ page 38
hole
spec
4 - Fresh air blower relay - J13-
es, in part or in w
t to the co
❑ Fitting location: relay
and fuse carrier on left
under dash panel
rrectness of i
❑ Checking ⇒ Current flow
l purpos
diagrams, Electrical
fault finding and Fitting
locations nform
ercia
5 - Auxiliary heater operation relay - J485-

m
a
com
ion in
r
te o
thi
s
iva
do

r
rp
cum
fo

en
ng
t.
yi Co
op
7 - Ambient temperature sensor - G17-
C py
t. rig
gh ht
yri
❑ Checking ⇒ Vehicle diagnostic tester p by
co Vo
by lksw
cted
agen
Prote AG.

❑ Located on auxiliary heater
9 - Auxiliary heater Thermo Top V
❑ With auxiliary heater control unit - J364-
❑ Fitting location: behind front bumper on right
10 - Exhaust system
❑ For auxiliary heater

Caddy 2004 ➤ , Caddy 2011 ➤
11 - Metering pump - V54-

❑ Fitting location: underbody, on right in direction of travel
❑ Fuel supply for auxiliary heaters Thermo Top V ⇒ page 40
AG. Volkswagen AG d
❑ Testing quantity of fuel delivered ⇒ page 42 lksw
agen oes
n o ot g
yV ua
12 - Remote control receiver for auxiliary coolantriseheater
db - R149- ran
tee
o
❑ Removing and installing ⇒ page 49 auth or
ac
ss
ce
le
un
pt
an
d
itte
y li
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Overview of fitting locations - auxiliary/supplementary heater 11

Caddy 2004 ➤ , Caddy 2011 ➤
2 Auxiliary/supplementary heater
n AG. Volkswagen A
⇒ “2.1 Overview of fitting locations -oauxiliary/supplementary
lksw
age heat‐
G do
es n
ot g
er, Thermo Top V and Thermod bTop y V fleece”, page 12 ua
r e an
ris tee
⇒ “2.2 Assembly overview th-o auxiliary/supplementary heater, in‐ or
au
ternal”, page 14 ss ac
ce
e
nl
⇒ “2.3 Assembly overview - auxiliary/supplementary heater at‐
pt
du
an
tachments”, page 18
itte
y li
erm
ab
⇒ “2.4 Removing and installing auxiliary/supplementary heater”,
ility
ot p
page 18
wit
, is n
h re
⇒ “2.5 Dismantling and assembling auxiliary/supplementary heat‐
hole
spec
er”, page 22
es, in part or in w
t to the co
⇒ “2.6 Removing and installing air intake silencer”, page 22
⇒ “2.7 Removing and installing circulation pump V55 ”,
rrectness of i
page 23
l purpos
⇒ “2.8 Removing and installing exhaust system”, page 24

⇒ “2.9 Removing and installing silencer with bracket”, page 25
nf
ercia
o
⇒ “2.10 Removing and installing auxiliary/supplementary heater
rm
m
bracket”, page 25
atio
om
n in
c
⇒ “2.11 Removing and installing cover”, page 26

or
thi
te
sd
a
⇒ “2.12 Removing and installing auxiliary heater control unit J364

iv
o
r
rp
”, page 26 cu
o
m
f
en
ng
t.
yi
⇒ “2.13 Removing and installing glow plug with flame monitor Q8
Co
op py
”, page 27
t. C rig
gh ht
pyri by
Vo
⇒ “2.14 Removing and installing temperature sensor G18 and
co lksw
by
cted agen
overheating sensor G189 .”, page 28 Prote AG.
⇒ “2.15 Dismantling and assembling burner unit”, page 29
2.1 Overview of fitting locations - auxiliary/supplementary heater, Thermo Top

V and Thermo Top fleece

Caddy 2004 ➤ , Caddy 2011 ➤
1 - Auxiliary heater Thermo

Top V
❑ With auxiliary heater
control unit - J364-
❑ Removing ⇒ page 18
2 - Fuel line with quick-release
coupling
❑ Routing of fuel line
⇒ page 40
3 - Air intake silencer
⇒ page 22
wage
4 - Exhaust system olks es n
ot g
byV ua
❑ Removing and installing rised ran
tee
⇒ page 24 autho
or
ac
ss
ce
le
un
pt
an
d
itte
y li
⇒ page 23
rm
ab
pe
ility
6 - Tailpipe
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
There are two versions of the tail
pipe. When assembling the long
version, make sure that the conden‐
sation water opening is not covered.
rrectness of i
l purpos
7 - Chafing protection
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Auxiliary/supplementary heater 13
Caddy 2004 ➤ , Caddy 2011 ➤
2.2 Assembly overview - auxiliary/supple‐

mentary heater, internal
⇒ “2.2.1 Assembly overview - auxiliary/supplementary heater,
Thermo Top V”, page 14
⇒ “2.2.2 Assembly overview - auxiliary/supplementary heater (in‐
terior), Thermo Top fleece”, page 16
2.2.1 Assembly overview - auxiliary/supplementary heater, Thermo Top V
1 - Cover for auxiliary heater

control unit - J364- .
2 - Temperature sensor - G18-
⇒ page 28
3 - Overheating sensor - G189-
⇒ page 28
4 - Combustion tube
Note
♦ Illustration shows petrol version AG. Volkswagen AG d

agen
with fine filter in fuel line. Volksw
oes
not
by gu
d ara
♦ As of week 12/06, the diesel ver‐orise nte
sion has a fuel shut-off valve
aut-
h eo
ra
N109- ⇒ page 15 directly sat the
s c
fuel-line connection of the auxili‐
ce
e
nl
pt
du
ary heater and also has a new

an
itte
y li
metering pump - V54- (grey plas‐
erm
tic cap). The auxiliary heater ab

ility
ot p
control unit - J364- is also new. wit

, is n
h re
♦ Observe correct part number.
hole
spec
Mixed installation is not permis‐

es, in part or in w
sible because this would impair

t to the co
operation of the auxiliary heater.

rrectness of i
⇒ page 29
l purpos
5 - Heat exchanger
nform
ercia
⇒ page 22
m
at
6 - Securing bolts
om
ion
c
❑ 7 Nm
in t
or
his
ate
7 - Retaining spring
do
priv
cum
or
8 - Bolt
f
en
ng
t.
yi Co
❑ 4 Nm t. Cop py
rig
gh ht
9 - Seal yri
p by
co Vo
by lksw
❑ Must be renewed each time after opening cted agen
Prote AG.
❑ Observe installation position
10 - Cover
11 - Coolant connection
❑ Mark installation position

Caddy 2004 ➤ , Caddy 2011 ➤
❑ Renew seals
12 - Bolt
❑ 4 Nm
13 - Support plate
❑ Renew seals
15 - Retaining clip
16 - Glow plug with flame monitor - Q8-
❑ Ensure it is properly seated
❑ Removing and installing ⇒ page 27 (only possible with petrol version).
AG. Volkswagen AG d
agen oes
lksw not
Note d by Vo gu
ara
rise nte
o eo
♦ The dieselaut version is equipped
h
ra
with a spermanently installed fuel
s c
ce
le
pre-heating heater element -

un
pt
Z66- (PTC on burner).
an
d
itte
y li
rm
ab
♦ The wires are permanently con‐
pe
ility
nected to wires of glow plug with
ot
wit
, is n
flame monitor - Q8- .
h re
hole
spec
♦ If a defective glow plug with
es, in part or in w
flame monitor - Q8- needs to be
t to the co
renewed on this version, then the
entire combustion tube must be
renewed.
♦ The new combustion tube will rrectness of i
l purpos
automatically contain a new glow

plug with flame monitor - Q8- .
nform
ercia
17 - Burner
m
a
com

ion in
r
te o
18 - Combustion air blower - V6-

thi
s
iva
do
❑ The combustion air blower - V6- and housing are one component and cannot be dismantled.
r
rp
cum
fo

en
ng
t.
yi Co
op
19 - Auxiliary heater control unit - J364- C py
t. rig
gh ht
yri
❑ Removing and installing ⇒ page 26 p by
co Vo
by lksw
cted agen
20 - Bolt Prote AG.
❑ 4 Nm
Fuel shut-off valve
Caddy 2004 ➤ , Caddy 2011 ➤
2.2.2 Assembly overview - auxiliary/supplementary heater (interior), Thermo Top

fleece
1 - Cover for auxiliary heater

control unit - J364- .
2 - Temperature sensor - G18-
⇒ page 28
3 - Overheating sensor - G189-
⇒ page 28
4 - Retaining plate for retaining
spring of glow plug with flame
monitor - Q8-
❑ Ensure it is properly
seated
5 - Glow plug with flame moni‐
tor - Q8- AG. Volkswagen AG d
agen oes
ksw
❑ Ensure it is properly byV
ol not
gu
ara
seated rised
nte
ho eo
❑ Removing and aut installing ra
c
⇒ page 27ss
ce
le
un
pt
6 - Retaining spring for glow

an
d
itte
y li
plug with flame monitor - Q8-

erm
ab
❑ Ensure it is properly
ility
ot p
seated
wit
is n
h re
ole,
7 - Combustion tube with

spec
fleece
t to the co

⇒ page 29
8 - Heat exchanger
rrectne

⇒ page 22
ss o
cial p
9 - Bolt
inform
mer
❑ 7 Nm
atio
m
❑ Qty. 3
o
n
c
i
or
10 - Retaining spring
thi
te
sd
iva
o
r
11 - Bolt
p
cum
r
fo
en
ng
❑ 4 Nm yi
t.
Co
op py
12 - Seal
. C rig
ht ht
rig by
py
❑ Must be renewed each time after opening co Vo
by lksw
cted agen
❑ Observe installation position Prote AG.
13 - Cover
15 - Bolt
❑ 4 Nm

Caddy 2004 ➤ , Caddy 2011 ➤
16 - Support plate
18 - Combustion air blower - V6-
19 - Auxiliary heater control unit - J364-
Note
The auxiliary heater control unit -

J364- and the combustion air blower
- V6- with housing form one compo‐
nent and cannot be dismantled. The
reason is the seal between the aux‐
iliary heater control unit - J364- and
the housing.
20 - Bolt
❑ Qty. 4
❑ 4 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
2.3 Assembly overview - auxiliary/supplementary heater attachments
1 - Auxiliary/supplementary
heater
AG. Volkswagen AG d
❑ Removing and installing ksw
agen oes
not
l
⇒ page 18 byV
o gu
ara
ed
❑ Dismantling and assem‐ horis nte
eo
bling ⇒ page 22 s aut ra
c
s
2 - Clamps
ce
le
un
pt
an
d
❑ Qty. 2
itte
y li
rm
ab
3 - Coolant hose
pe
ility
ot
wit
, is n
4 - Silencer
h re
hole
spec
⇒ page 22
es, in part or in w
t to the co
5 - Bracket
❑ For circulation pump -
rrectness of i
V55- and silencer
l purpos
6 - Bolts
❑ Qty. 2
nform
ercia
❑ 8 Nm
m
a
com
tion in
r
te o
thi
⇒ page 23
s
iva
do
r
rp
c
8 - Exhaust system
um
fo
en
g

n
t.
yi Co
op
⇒ page 24 C py
ht. rig
rig ht
9 - Nut
py by
co Vo
by lksw
cted
❑ For silencer
agen
Prote AG.
❑ 20 Nm
10 - Bolts
❑ Qty. 3
❑ For bracket for auxiliary/
supplementary heater
❑ 8 Nm
11 - Bracket for auxiliary/supplementary heater
2.4 Removing and installing auxiliary/sup‐

plementary heater
Special tools and workshop equipment required

Caddy 2004 ➤ , Caddy 2011 ➤
♦ Hose clamps, up to Ø 25 mm - 3094-
♦ Engine bung set - VAS 6122-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
♦ Drip tray for workshop hoist - VAS 6208-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
♦ ⇒ Vehicle diagnostic tester

um
for
en
ng
t.
yi Co
Cop py
t. rig
Note gh ht
pyri by
Vo
co lksw
by
cted agen
♦ If the auxiliary heater is to be renewed, first connect the ⇒ Ve‐ Prote AG.
hicle diagnostic tester, and start the “Renew heater” function.
♦ There is a type plate on the auxiliary heater. This nameplate
indicates which heater version has been installed in the vehi‐
cle: ⇒ page 4
♦ The coolant circuit must be bled after it is opened ⇒ Rep. gr.
19 .
♦ Cooling system is pressurized when engine is warm. If nec‐
essary, release pressure before carrying out repairs.
♦ After the auxiliary heater has been detached, it must be se‐
cured to the body with welding wire to prevent damage to the
coolant hoses.
Caddy 2004 ➤ , Caddy 2011 ➤
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Exterior equipment; Noise insulation .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumpers .
– Detach exhaust pipe from silencer of auxiliary heater
⇒ page 24 .
CAUTION
On a warm engine, the cooling system is under high pressure.
Risk of scalding from steam and hot coolant.
There is a risk of injury to the skin and parts of the body due to
scalding.
– Clamp off coolant hoses -1- and -2- using hose clamps for ho‐
ses up to 25 mm - 3094- .
– Open hose clips of coolant hoses -1- and -2-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Pull coolant hoses -1- and -2- off auxiliary heater.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
– Unscrew bolt -1- below washer fluid reservoir.ut
hor eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
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
by
20
copy Vo
by lksw
Rep. gr.82 - Supplementary heating cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
– Unscrew bolts -1- from washer fluid reservoir.
– Pull washer fluid reservoir in direction of travel out of guides

-1-, and set it aside.
CAUTION
The fuel system is pressurised.
Danger of injury caused by fuel spray.
tion, and carefully loosen the connection.
– Disconnect fuel line at quick-release coupling, and seal line

with appropriate plugs from engine bung set - VAS 6122- .
– Disconnect all electrical connectors of auxiliary heater.
– Unscrew nut -2-.

– Unscrew bolt -4- from bracket for auxiliary heater -1- on right
longitudinal member -3-.
– Unscrew nut -6-.
olkswagen AG
en AG. V
– Detach clip -5- from longitudinal
olks member.
wag does
not
yV gu
db ara
Installing rise nte
tho eo
Install in reverse order au
ss of removal, observing the following: ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Risk of damage to lines

Lines may become damaged by moving or hot components.
ss o
cial p
– Route lines in their original positions.

inform
mer
– Ensure there is sufficient clearance to moving or hot compo‐

atio
m
nents.
o
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
yri by
21
op Vo
by c lksw
Prote
cted AG.
agen 2. Auxiliary/supplementary heater
Caddy 2004 ➤ , Caddy 2011 ➤
– Bleed coolant circuit ⇒ Rep. gr. 19 ; Cooling system, coolant;

Draining and filling coolant .
Torque settings
Component Specified torque
Nut -2- 8 Nm
Nut -6- 15 Nm
Bolt -4- 8 Nm
2.5 Dismantling and assembling auxiliary/

supplementary heater
Dismantling
– Remove auxiliary heater ⇒ page 18 .
– Remove air intake silencer ⇒ page 22 .
– Remove bracket ⇒ page 25 .
– Disconnect electrical connector -1-.
– Release wire from terminal -2-.
– Unscrew bolts -arrows-.
– Remove heat exchanger from blower housing by pulling it in
axial direction off threaded connection.
– Clean inside and outside of heat exchanger.
– Dismantle burner unit ⇒ page 29 .
Assembling
Install in reverse order of removal, observing the following:
Torque settings
. Volkswag
♦ ⇒ “2.3 Assembly overview - auxiliary/supplementary
ksw
agen
AG heater
en AG
does
attachments”, page 18 by Vol not
gu
a
ed ran
oris tee
h
2.6 Removing and installing air intake si‐
t or
au ac
ss
lencer
ce
e
nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
– Remove front bumper ⇒ General body repairs, exterior; Rep.

wit
, is n
gr. 63 ; Front bumper; Removing and installing bumper cover .

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Unscrew bolt -1-.

– Pull air intake silencer -2- in -direction of arrow- off intake
manifold.
Installing
Torque settings
Bolt -1- 6 Nm
2.7 Removing and installing circulation

pump - V55-
Special tools and workshop equipment Vrequired
olkswag AG. en AG
agen does
♦ Hose clamps, up to Ø y25
Volmm - 3094-
ksw not
gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Drip tray for workshop hoist - VAS 6208-

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.
Caddy 2004 ➤ , Caddy 2011 ➤
Removing
wage es n
– Remove front right wheel housing liner ⇒ yV
oBody; Rep. gr. 66 ;
lks ot g
ua
Wheel housing liners; Removing and edinstalling front wheel
b ran
ris
housing liner . utho tee
or
s a ac
– Clamp off coolant hoses using hose clamps, up to 25 mm -
s
ce
le
3094- .
un
pt
an
d
itte
y li
– Open hose clips -1-.
rm
ab
pe
ility
– Place drip tray for workshop hoist - VAS 6208- underneath.
ot
wit
, is n
h re
hole
CAUTION
spec
es, in part or in w
On a warm engine, the cooling system is under high pressure.
t to the co
Risk of scalding from steam and hot coolant.
scalding.
rrectness of i
l purpos

nform
ercia

m
a
com
tion in
– Pull coolant hoses off circulation pump - V55- .
r
te o
thi
s
iva
– Disconnect electrical connector on circulation pump - V55- .
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Detach circulation pump - V55- . C py
ht. rig
rig ht
Installing
py by
co Vo
by lksw
cted agen
Prote AG.
– Bleed coolant circuit ⇒ Rep. gr. 19 ; Cooling system, coolant;

Draining and filling coolant .
2.8 Removing and installing exhaust system

Removing
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Exterior equipment; Noise insulation .
CAUTION
Danger of severe burns from hot exhaust system.
Burns to hands and other body parts possible.
– Allow exhaust system to cool.
– Loosen screw-type clip on exhaust pipe -1-.

– Unscrew bolts -2- and -3-.
– Remove exhaust system.
Installing

Caddy 2004 ➤ , Caddy 2011 ➤
Note
. Volkswagen AG
gen AG doe
swa
There are two versions of the exhaust bpipe.
yV
olk When assembling the s not gu
long version, make sure that the condensation
ris
ed water opening ara
nte
-arrow- is not covered. ut
ho eo
ra
s a c
s
ce
e
Torque settings nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Bolts -2- and -3-, exhaust pipe 6 Nm
wit
, is n
Screw-type clip -1-, exhaust 6 Nm
h re
hole
pipe
spec
es, in part or in w
t to the co
2.9 Removing and installing silencer with
bracket
rrectness of i
Removing
l purpos
CAUTION
nform
ercia
Danger of severe burns from hot exhaust system.

m
at
om
Burns to hands and other body parts possible.
ion
c
in t
– Allow exhaust system to cool.
or
his
ate
do
priv
c
– Detach pipes from silencer -A-.
um
for
en
ng
t.
yi
Co
Cop py
ht. rig
– Lay bracket -B- to one side.
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
– Detach silencer -A-.

– Unscrew bolts -3-.
– Remove bracket.
Installing
Note
When installing bracket, observe centring tabs.
Torque settings
♦ ⇒ “2.3 Assembly overview - auxiliary/supplementary heater
attachments”, page 18
2.10 Removing and installing auxiliary/sup‐

plementary heater bracket
Removing
– Remove auxiliary heater ⇒ page 18 .
Caddy 2004 ➤ , Caddy 2011 ➤

– Remove bracket -1-.
– Remove bracket -3-.
Installing
Torque settings
♦ ⇒ “2.3 Assembly overview - auxiliary/supplementary heater
attachments”, page 18
2.11 Removing and installing cover ksw

agen
AG. Volkswagen AG d
oes
ol not
V gu
Removing d by ara
ise nte
or eo
h
– Remove auxiliary heater ⇒ page 18 . s aut ra
c
s
– Mark installation position of coolant connections.
ce
le
un
pt
an
d
itte
– Remove coolant connections.
y li
rm
ab
pe
ility
– Unclip cover in area of -arrows-.
ot
wit
, is n
– Pull cover over locking lug -A-.
h re
hole
spec
Installing
es, in part or in w
t to the co
Torque settings
rrectness of i
l purpos
Bolt for coolant connection 7.5 Nm

nform
mercia
a
com
tio
2.12 Removing and installing auxiliary heater

n in
r
te o
control unit - J364-

thi
s
iva
do
r
rp
Removing
um
fo
en
ng
t.
yi
– Remove cover for auxiliary heater control unit - J364-
Co
op py
⇒ page 26 .
t. C rig
gh ht
pyri by
Vo
o
– Dismantling and assembling supplementary heater by c lksw
cted agen
⇒ page 22 . Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
– Disconnect electrical connectors -A- and -C-.

– Unscrew bolts -arrows-.
Installing
Note
♦ When assembling, the wiring harness of electrical connector

-C- must lie in recess -B-.
♦ Make sure that side cover for wiring harness is properly seat‐
ed.
2.13 Removing and installing glow plug with

flame monitor - Q8-
⇒ “2.13.1 Removing and installing glow plug with flame monitor AG. Volkswagen AG d
Q8 , Thermo Top V”, page 27 agen oes
olksw not
V gu
by ara
⇒ “2.13.2 Removing and installing glow plug with flame monitor
orised
nte
Q8 , Thermo Top fleece”, page 28 au
th eo
ra
ss c
2.13.1 Removing and installing glow plug with
ce
le
un
pt
an
flame monitor - Q8- , Thermo Top V
d
itte
y li
rm
ab
pe
ility
Removing
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Removal is possible on petrol versions only.
♦ The diesel version is equipped with a permanently installed
rrectness of i
fuel pre-heating heater element - Z66- (PTC on burner).
l purpos
♦ The wires are permanently connected to wires of glow plug

with flame monitor - Q8- .
nform
ercia
♦ If a defective glow plug with flame monitor - Q8- needs to be

renewed on this version, then the entire combustion tube must
m
a
com
be renewed.
tion in
r
te o
♦ The new combustion tube will automatically contain a new

thi
s
glow plug with flame monitor - Q8- .

iva
do
r
rp
cum
♦ The illustration shows the diesel version with fuel pre-heating

fo
en
ng
heater element - Z66- (PTC on burner) -A-.

t.
yi Co
Cop py
t. rig
gh ht
yri
– Dismantle auxiliary heater Thermo Top V ⇒ page 22 .
p by
o Vo
by c lksw
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
– Using an appropriate screwdriver, raise retaining clip -A- on

both sides, and remove it.
Installing
Note
♦ During assembly, retaining clip must seat in groove.

♦ Ensure proper seating of glow plug with flame monitor - Q8-
-B-.
2.13.2 Removing and installing glow plug with

flame monitor - Q8- , Thermo Top fleece
Removing
– Dismantle auxiliary heater Thermo Top fleece ⇒ page 22 .
– Pull out retaining spring -1- in direction of -arrow-.
– Remove retaining plate -2-.
– Pull out glow plug with flame monitor - Q8- -3-.
Installing
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li
erm
Observe location of retaining spring -1- and retaining plate -2-.

ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.14 Removing and installing temperature

sensor - G18- and overheating sensor -
nform
ercia
G189- .
m
at
om
ion
c
Removing
in t
or
his
ate
– Remove cover ⇒ page 26 .

do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤

– Remove retaining spring -2-.
– Pull out temperature sensor - G18- -3- and overheating sensor
- G189- -4- using long-nose pliers.
Installing
Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
Note rise nte
tho eo
au ra
♦ When assembling, ensure that retaining spring is in proper
ss c
ce
e
position -2-.
nl
pt
du
an
itte
♦ Sensors cannot be renewed separately.
y li
erm
ab
ility
ot p
Torque settings
wit
, is n
h re
hole
spec
es, in part or in w
Bolt -1- 4 Nm
t to the co
2.15 Dismantling and assembling burner unit
rrectness of i
Dismantling
l purpos
– Dismantle auxiliary/supplementary heater ⇒ page 22 .
nf
ercia
– Detach gasket -1- from blower housing.
orm
m
atio
m

o
n in
or c
– Using only a little force, pull grommet -3- out of blower housing
thi
te
sd
onto combustion pipe -4- while at the same time vertically lift‐
iva
o
r
ing off the burner unit.

rp
cu
o
m
f
en
ng
Assembling
t.
yi Co
Cop py
t. rig
Install in the reverse order of removal, observing the following: opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
Caddy 2004 ➤ , Caddy 2011 ➤
Note
. Volkswagen AG
gen AG does
swa
♦ Renew gasket -1- after every opening. Notey Vinstallation posi‐
olk not
gu
tion. ised b ara
nte
or eo
h
♦ Renew grommet -3-. s aut ra
c
s
ce
le
un
pt
– Check sealing surfaces, and clean them if necessary.
an
d
itte
y li
– Make sure gasket -1- is positioned correctly and electrical
rm
ab
pe
ility
connector -2- is engaged firmly.
ot
wit
, is n
Torque settings
h re
hole
spec
♦ ⇒ “2.2 Assembly overview - auxiliary/supplementary heater,
es, in part or in w
internal”, page 14
t to the co
♦ ⇒ “2.2.2 Assembly overview - auxiliary/supplementary heater
(interior), Thermo Top fleece”, page 16
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.

Caddy 2004 ➤ , Caddy 2011 ➤
3 Coolant circuit
agen
with
AG. Volkswaauxiliary/supple‐
gen AG
does
ksw
mentary
ed by Vol
heater not
gu
ara
ris nte
⇒ “3.1 Coolant
au
thohose schematic diagram for vehicles with auxiliary
eo
ra
heater, BCA”,
ss page 31 c
ce
le
un
⇒ “3.2 Coolant hose schematic diagram for vehicles with auxiliary
pt
an
d
itte
heater, BGU”, page 33
y li
erm
ab
ility
ot p
heater, BJB”, page 34
wit
is n
h re
ole,
spec
heater, BDJ”, page 35
t to the co
heater, CAYD and CAYE”, page 36
rrectne
heater, CFCH, CFCE, CFCF, CLCA, CFHC, CFHE, CFHF and
CFJA”, page 37
ss o
cial p
f
inform
heater, CBZA and CBZB”, page 38
mer
atio
⇒ “3.8 Removing and installing heater coolant shut-off valve N279
om
n
”, page 38
c
i
or
n thi
te
sd
a
3.1 Coolant hose schematic diagram for vehicles with auxiliary heater, BCA
iv
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.
3. Coolant circuit with auxiliary/supplementary heater 31

Caddy 2004 ➤ , Caddy 2011 ➤
1 - Coolant expansion tank

2 - Heat exchanger for heater
valve - N279-
Note

❑ Secured to engine com‐
partment bulkhead
AG. Volkswagen AG d
agen oes
4 - Non-return valve olksw not
y V gu
d b ara
5 - Thermostat housing rise nte
tho eo
au ra
6 - Radiator ss c
ce
le
un
pt
7 - Cylinder head/cylinder
an
d
itte
block
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Top V
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
3.2 Coolant hose schematic diagram for vehicles with auxiliary heater, BGU

2 - Non-return valve
valve - N279-
Note

❑ Secured to engine com‐
partment bulkhead
5 - Intake manifold
AG. Volkswagen AG d
agen
6 - Cylinder head/cylinder olksw
oes
not
block byV gu
ara
ed
ris nte
o eo
7 - Engine oil cooler auth ra
ss c
8 - Radiator
ce
e
nl
pt
du
an
9 - Coolant pump
itte
y li
erm
ab
ility
ot p
wit
, is n

h re
Top V
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
3.3 Coolant hose schematic diagram for vehicles with auxiliary heater, BJB

valve - N279-
Note

❑ Secured to engine
block
6 - Gear oil cooler
♦ Only on vehicles with auto‐
matic gearbox
7 - Engine oil cooler
8 - Radiator
Top V/Thermo Top fleece AG. Volkswagen AG d
agen oes
ksw
11 - Coolant pump by Vol not
gu
d ara
ise nte
12 - Intake manifold thor eo
au ra
c
13 - Exhaust gas recirculation ss
ce
e
(water-cooled)
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
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
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
3.4 Coolant hose schematic diagram for vehicles with auxiliary heater, BDJ

valve - N279-
Note n AG. Volkswagen AG do

lk swage es n
o ot g
byV ua
The heater coolantoshut-off
ir se
d
valve - ran
tee
N279- is fitted only
au on vehicles with
th or
ac
the auxiliary heater
ss function.
ce
le
un
pt
❑ Secured to engine
an
d
itte
y li
rm
ab
5 - Radiator
pe
ility
ot
wit
, is n
h re
hole
7 - Coolant pump
spec
es, in part or in w
t to the co
block
rrectness of i
l purpos
Top V/Thermo Top fleece
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2004 ➤ , Caddy 2011 ➤
3.5 Coolant hose schematic diagram for vehicles with auxiliary heater, CAYD
and CAYE olks
wage es n
ot
yV gu
db ara
rise nte
1 - Coolant expansion tank tho eo
au ra
c
ss
2 - Radiator
ce
e
nl
pt
du
an
❑ For exhaust gas recircu‐ itte
y li
lation
erm
ab
ility
ot p
wit
, is n
h re
❑ With quick-release cou‐
hole
pling
spec
es, in part or in w
t to the co
block
rrectness of i
6 - Coolant circulation pump -
l purpos
V178-
7 - Upper coolant hose
nform
ercia

m
at
pling
om
ion
c
in t
8 - Radiator
or
his
ate
❑ Renew coolant after re‐
do
priv
c
placing
um
for
en
ng
t.
9 - Lower coolant hose
yi Co
Cop py
t. rig
gh ht
yri
pling
p by
o Vo
by c lksw
cted agen
10 - Coolant pump/thermostat
Prote AG.

placing
12 - Supplementary heater
Thermo Top V/Thermo Top
fleece

Caddy 2004 ➤ , Caddy 2011 ➤
3.6 Coolant hose schematic diagram for vehicles with auxiliary heater, CFCH,
CFCE, CFCF, CLCA, CFHC, CFHE, CFHF and CFJA
1 - Radiator
placing
2 - Coolant circulation pump 2
- V178- agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
3 - Engine oil cooler ed by ua
ran
ris tee
4 - 4/2-way valveautwith
ho thermo‐ or
ac
stat ss
ce
e
nl
5 - Coolant pump
pt
du
an
itte
y li
6 - Cylinder head and cylinder
erm
ab
block
ility
ot p
wit
, is n
h re
placing
hole
spec
es, in part or in w
t to the co
❑ With cap
8 - Exhaust gas recirculation
rrectness of i
cooler
l purpos

placing
nf
ercia

or
Top V/Thermo Top fleece
m
m
atio
m

o
n in
or c
thi
e

t
sd
iva
o
r

rp
cu
o
placing
f
en
ng
t.
yi Co
op
12 - Gear oil cooler C py
t. rig
gh ht
yri
❑ For dual clutch gearbox p by
co Vo
by lksw
cted agen
Prote AG.
placing

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
agen
3.7 Coolant hose schematic diagram by
Volfor vehicles with auxiliary
ksw
oes
not
gu heater, CBZA
and CBZB d ara
e nte
ris
ho e t or
au ac
ss
ce
le
un
pt
an
d
itte
2 - Coolant circulation pump -
y li
rm
ab
V50-
pe
ility
ot
wit
3 - Coolant pump
, is n
h re
hole
4 - Intake manifold with charge
spec
air cooler
es, in part or in w
t to the co
6 - Thermostat housing
rrectness of i
l purpos
8 - Throttle
nform
ercia
9 - Radiator
m
10 - Turbocharger
a
com
tion in
11 - Low-temperature radiator
r
te o
thi
for charge air system
s
iva
do
r
❑ Radiator and low-tem‐

rp
cum
fo
perature radiator for
en
ng
t.
yi
charge air system are
Co
op py
one component
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
block Prote AG.
❑ If renewed, renew cool‐

ant
16 - Auxiliary heater
❑ Optional equipment
3.8 Removing and installing heater coolant

shut-off valve - N279-
♦ Hose hose clamps, up to 25 mm - 3094-

Caddy 2004 ➤ , Caddy 2011 ➤
Removing
– Remove bulkhead ⇒ General body repairs, exterior; Rep. gr.
50 ; Bulkhead; Removing and installing bulkhead ⇒ General
body repairs, exterior; Rep. gr. 50 .
– Disconnect electrical connector on heater coolant shut-off
valve - N279- . n AG. Volkswagen A
age G do
ksw es n
Vol ot g
CAUTION ed
by ua
ran
oris tee
On a warm engine, au the cooling system is under
th
high pressure. or a
Risk of scaldingssfrom steam and hot coolant. c
ce
e
nl
pt
du
an
scalding.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Vehicles with petrol engine
rrectness of i
3094- .
l purpos
– Loosen hose clips of coolant hoses.

– Pull coolant hoses off heater coolant shut-off valve - N279- .
nf
ercia
orm
m
atio
om
n in
c
– Unscrew nuts -3-.

or
thi
te
sd
– Detach heater coolant shut-off valve - N279- -2- from bulk‐

iva
o
r
head.
rp
cu
o
m
f
en
ng
t.
Vehicles with diesel engine Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3094- .
– Unscrew nuts -1-.
– Detach heater coolant shut-off valve - N279- -2- from bracket
-4-.
– Remove bracket -4- from intake manifold by loosening bolts
-3-.
Installing
Torque settings
Heater coolant shut-off valve - 8 Nm
N279-

Caddy 2004 ➤ , Caddy 2011 ➤
4 Fuel supply system

⇒ “4.1 Overview of fitting locations - fuel supply system”,
page 40
⇒ “4.2 Removing and installing metering pump V54 ”, page 41
⇒ “4.3 Checking fuel delivery rate”, page 42
4.1 Overview of fitting locations - fuel supply

system
Note
♦ Before beginning repair work on vehicles with the auxiliary

heating function, perform the following work:
♦ Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
♦ Fuel lines are secured with O-type clips. These O-type clips
must always be replaced with screw-type clips.
♦ Before starting the auxiliary heater, make sure that the follow‐
ing conditions are fulfilled: Ambient temperature sender - G17-
is pulled off, and coolant temperatureswisagbelow 50°C.
en AG. V
olkswagen AG
does
k not
Vol
♦ If the fuel tank was empty, or the
ed fuel line or metering pump -
by gu
ara
V54- were removed, there thwillor be air in the fuel line leading to
is nte
eo
the auxiliary heater. To remove
sa
u air from the fuel line, start aux‐ ra
c
iliary heater repeatedly suntil it does not switch off autono‐
ce
le
mously anymore.
un
pt
an
d
itte
y li
♦ Observe the rules for cleanliness when doing all work on the
rm
ab
fuel supply system ⇒ page 6 .

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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
Volksw Caddy 2004 n➤
ot g, Caddy 2011 ➤
y ua
rised b
Auxiliary heater - Edition
ran
tee
03.2018
tho
u or
a ac
1 - Metering pump - V54- ss
ce
le
❑ Fitting location: under‐
un
pt
an
d
body, on right in direc‐
itte
y li
tion of travel
erm
ab
ility
ot p
wit
is n
⇒ page 41
h re
ole,
❑ Testing quantity of fuel
spec
delivered ⇒ page 42 .
t to the co
rrectne
moved ⇒ Rep. gr. 20 .
ss o
cial p
3 - Fuel line
f inform
❑ Route fuel lines so that
mer
they are not pinched at
atio
m
any point.
o
n
c
i
or
n thi
e
4 - Heat shield
t
sd
iva
o
pr
c
um
r
fo
Top V
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.2 Removing and installing metering pump

- V54-
Note
♦ The metering pump - V54- is available in 3 different versions:

♦ DP40 for Thermo Top V - petrol version
♦ DP41 for Thermo Top V - diesel version
♦ DP42 for Thermo Top fleece
The metering pump DP40 is installed in petrol versions of the

auxiliary heater Thermo Top V. It is also suitable for diesel ver‐
sions of the auxiliary heater Thermo Top V without fuel shut-off
valve - N109- .
The metering pump DP41 is installed in diesel versions of the
auxiliary heater Thermo Top V with fuel shut-off valve - N109- .
The metering pumps DP40 and DP41 are nearly identical. Exter‐
nally, the metering pumps are distinguished by the different col‐
ours of the plastic caps of their fuel reservoirs: black in the case
of metering pump DP40, and grey in the case of metering pump
DP41.
4. Fuel supply system 41

Caddy 2004 ➤ , Caddy 2011 ➤
The metering pump DP42 is used for auxiliary heaters Thermo

Top fleece. It is designed without fuel reservoir, and is therefore
different from the metering pumps DP40 and DP41.
A metering pump must always be replaced by a metering pump
of the same type.
♦ Engine bung set - VAS 6122-
Removing
– Disconnect electrical connector on metering pump - V54- -1-.
CAUTION
Danger of injury caused by fuel spray.
– Wear safety goggles. lkswage es n
o ot g
byV ua
– Wear protective gloves. ir se
d ran
tee
ho
– To release pressure, wrap a clean cloth around sthe
au connec‐
t or
ac
tion, and carefully loosen the connection. s
ce
le
un
pt
an
d
itte
y li
– Pull fuel hoses off metering pump - V54- -1-.
erm
ab
ility
ot p
– Seal fuel hoses on metering pump - V54- with plugs from en‐
wit
gine bung set - VAS 6122- .
is n
h re
ole,

spec
– Detach bracket -3- for metering pump - V54- . t to the co

Installing
rrectne

s
The installation position of metering pump - V54- must be within

s o
range -a-.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
The -arrow- indicates direction of flow.

t
sd
iva
o
pr
cum
r
fo
Torque settings
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Bolts for metering pump - V54- 5 Nm
co Vo
by lksw
cted agen
Prote AG.
4.3 Checking fuel delivery rate


Caddy 2004 ➤ , Caddy 2011 ➤
♦ ⇒ Vehicle diagnostic tester

♦ Auxiliary measuring set - V.A.G 1594/C-
♦ Hand-held multimeter - V.A.G 1526 E-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Commercially available measuring glass (0 ml to 40 ml)

hole
spec
es, in part or in w
♦ Fuel hose, length approx. 200 mm

t to the co
Test prerequisites:
• Resistance of metering pump - V54- 5.2 +/- 5% Ω
rrectness of i
• Voltage at metering pump - V54- 9.5 to 16.5 V

l purpos
• No fault stored in event memory

nf
ercia
• Ambient temperature approx. 20°C

orm
m
atio
• Fuel tank sufficiently filled (fuel gauge on dash panel insert not
om
n in
in red area).
or c
thi
te
sd
iva
CAUTION
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op
Danger of injury caused by fuel spray. C py
t. rig
gh ht
yri
– Wear safety goggles. p by
o Vo
by c lksw
cted agen
Prote AG.

tion, and carefully loosen the connection.
4. Fuel supply system 43

Caddy 2004 ➤ , Caddy 2011 ➤
Checking
– Detach fuel line from pressure connection of metering pump -
V54- , fit new fuel hose (length approx. 200 mm) to pressure
connection, guide it into measuring glass (capacity approx.
40 ml), and seal.
– Hold measuring glass at same height as auxiliary heater.
– Using ⇒ Vehicle diagnostic tester, select function “Check fuel
delivery rate” (opens fuel line for metering pump - V54- ), and
start.
– After approx. 30 seconds, the fuel line is filled and bled.
– Seal fuel line.
– Empty measuring glass.
– Hold measuring glass at same height as auxiliary heater. AG. Volkswagen AG d

agen oes
lksw not
– Using ⇒ Vehicle diagnostic tester, select function “Check fuel d byV
o gu
ara
delivery rate” (opens fuel line for metering pump - V54-or),is and
e nte
start. aut
h eo
ra
ss c
– Fuel delivery finishes after approx. 120 seconds.
ce
le
un
pt
an
d
– Connect hose connection to fuel line.

itte
y li
erm
ab
– Check measuring glass. Specified fuel delivery rate for petrol
ility
ot p
and diesel: 22 to 28 ml.
wit
is n
h re
ole,
If fuel delivery rate is not within specifications, renew metering
spec
pump - V54- .
t to the co
Note
rrectne
♦ If the ambient temperature is above 20°C, fuel vaporisation
may lead to incorrect measurements.
ss o
cial p
♦ No bubbles are to be delivered.
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.

Caddy 2004 ➤ , Caddy 2011 ➤
5 Regulation of auxiliary/supplementa‐
ry heater
⇒ “5.1 Functional description of auxiliary heater Thermo Top V”,
page 45
⇒ “5.2 Functional description of Thermo Top fleece”, page 45
⇒ “5.3 Supplementary heater mode”, page 46 agen
AG. Volkswagen AG d
oes
olksw not
V
⇒ “5.4 Auxiliary heater mode, Caddy ▶2011”, page 47 ed by gu
ara
ris nte
o
⇒ “5.5 Auxiliary heater mode, Caddy 2011▶”, page 47auth eo
ra
ss c
⇒ “5.6 Switching off auxiliary/supplementary heater”, page 48
ce
e
nl
pt
du
an
5.1 Functional description of auxiliary heat‐
itte
y li
erm
ab
er Thermo Top V
ility
ot p
wit
, is n
The auxiliary heater is intended to heat coolant.
h re
hole
spec
Various operating modes can be set depending on heat required
es, in part or in w
in heating circuit:
t to the co
Note
rrectness of i
l purpos
One method of switching off the auxiliary heater is to press the

ECON button.
nf
ercia
or
Temperature at temperature sensor - G18- less than approx. 50°
m
m
atio
C.
om
n in
or c
Temperature at ambient temperature sensor - G17- less than ap‐
thi
te
prox. +5°C
sd
iva
o
r
rp
cu
When switched on, the auxiliary heater is in ready mode. The glow
o
m
f
en
ng
plug with flame monitor - Q8- , the combustion air blower - V6-
t.
yi Co
op
and the circulation pump - V55- begin to operate. After 30 sec‐ C py
t. rig
onds, the metering pump - V54- is switched on and the
gh ht
pyri by
combustion air blower - V6- is switched off for 3 seconds. Then
o Vo
by c lksw
cted
the combustion air blower - V6- runs up in two stages to nearly
agen
Prote AG.
full load within 56 seconds. After a stabilisation phase (steady
speed) of 15 seconds, the combustion air blower - V6- is again
brought up to nearly full load in over a period of 50 seconds.
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 load. 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 automatically regulated heating operation begins.
If no flame develops or there is a flame failure, then the fuel supply
is interrupted and a malfunction shut-down occurs with the com‐
bustion air blower - V6- continuing in run-on mode. If there is a
flame failure during normal operation, a new start is automatically
initiated.
5.2 Functional description of Thermo Top

fleece
The auxiliary heater can be started by means of the remote con‐
trol, the instant heating button - E537- or appropriate program‐
ming in the dash panel insert. The supplementary heater is
started automatically by the vehicle electronics system once all
the necessary preconditions have been met.
First, the function of the fresh air blower - V2- and the combined
glow plug with flame monitoring - Q8- are tested and then the glow
5. Regulation of auxiliary/supplementary heater 45

Caddy 2004 ➤ , Caddy 2011 ➤
plug with flame monitoring - Q8- goes through a preheating

phase.
The subsequent starting process depends on the coolant tem‐
perature, among other things, and can therefore vary in the
amount of time it takes. The fuel is supplied, the glow plug with
flame monitoring - Q8- is switched off in stages and the flame
monitor is activated.
After completion of the starting phase, the unit operates under full
load, and further load control (sparking mode, full load, partial
load and controlled waiting period) takes place on the basis of the
following coolant temperature thresholds.
Auxiliary heater:
– Change from full load to partial load: approx. 82°C
– Change from partial load to controlled waiting period: approx.
88°C
Supplementary heater: . Volkswagen AG
gen AG does
swa
– Change from full load to partialy Vload: approx. 84°C
olk not
gu
edb ara
nte
– Change from partial loadthoto controlled waiting period: approx.
ris
eo
88°C s au ra
c
s
ce
le
The reference resistance of the glow plug with flame monitoring

un
pt
- Q8- is automatically re-determined during the starting or run-on
an
d
itte
y li
phase, depending on the unit. This is done to compensate for
rm
ab
ageing-related changes.
pe
ility
ot
wit
, is n
As a consequence of this calibrating procedure, processes that
h re
are affected can also require more time.
hole
spec
es, in part or in w
After expiry of the maximum run time of 60 min. or after manual t to the co
shutdown by means of the remote control or the instant heating
button - E537- , the auxiliary heater is switched off.
rrectness of i
The supplementary heater is switched off if at least one of the

defined switch-on criteria is no longer met.
l purpos
After switch-off, operation of the metering pump - V54- is stopped

immediately.
nform
ercia
The combustion air blower - V6- and the glow plug with flame
m
monitoring - Q8- continue to operate for a limited time in order to

com
tio
burn the remaining fuel still in the system and to cool the burner
n in
r
te o
components.
thi
s
iva
do
The run-on period of the heater can vary depending on the soft‐
r
rp
cum
fo
ware version and load level at the time of switch-off.

en
ng
t.
yi Co
op
5.3 Supplementary heater mode
C py
t. rig
gh ht
pyri by
Vo
Once the coolant temperature has reached 84°C, the control unit
o
by c lksw
cted agen
switches to energy-saving part load operation. If the coolant tem‐ Prote AG.
perature continues to rise above 88°C, the control unit switches
to the regulated waiting period. If the coolant temperature does
not drop below 76°C within 900 seconds during the controlled
waiting period, the heater unit will start with the normal start pro‐
cedure in full-load mode when the coolant temperature does drop
below 76°C.

Caddy 2004 ➤ , Caddy 2011 ➤
5.4 Auxiliary heater mode, Caddy ▶2011

Switching on auxiliary heater mode in vehicles without air condi‐
tioning system
– Press instant heating button -1-.
Switching on auxiliary heater mode on vehicles with air condi‐
tioning system with electric/manual controls

switches to energy-saving part load operation. If the coolant tem‐
below 65°C.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
5.5 Auxiliary heater mode, Caddy 2011▶ s
ce
le
un
pt
an
d
Switching on auxiliary heater mode in vehicles without air condi‐

itte
y li
erm
tioning system
ab
ility
ot p
wit
is n
h re
ole,
Switching on auxiliary heater mode on vehicles with air condi‐
spec
tioning system with electric/manual controls
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c

i
or
n thi
te
sd
a
Switching on auxiliary heating mode in vehicles with Climatronic

iv
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. Regulation of auxiliary/supplementary heater 47

Caddy 2004 ➤ , Caddy 2011 ➤

switches to energy-saving part load operation. If the coolant tem‐
below 65°C.
5.6 Switching off auxiliary/supplementary

heater
When switched off manually or after a maximum operating time
of 60 minutes, or when the coolant reaches a temperature of 84°
C, combustion is ended and the run-on mode begins. The circu‐
lation pump - V55- and the combustion air blower - V6- , however,
continue to run in order to cool down the auxiliary heater (run-on
mode) and are switched off automatically.
Note
The run-on period of the circulation pump - V55- and the com‐
bustion air blower - V6- depends on the operating mode in which
the auxiliary heater was switched off.
The run-on period is 175 seconds when heater is switched off

during full-load operation and 110 seconds for part-load opera‐
tion.
Depending on the control unit software version, slight deviations
in the specified run-on values are possible. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
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
48
Prote AG.
Rep. gr.82 - Supplementary heating
Caddy 2004 ➤ , Caddy 2011 ➤
6 Other controlling and regulating com‐

ponents
⇒ “6.1 Removing and installing ambient temperature sensor”,
page 49
⇒ “6.2 Removing and installing remote control receiver for auxil‐
iary coolant heater R149 ”, page 49
⇒ “6.3 Functional description of remote control for auxiliary/sup‐
plementary heater”, page 50
6.1 Removing and installing ambient tem‐

perature sensor
Removing
– Unclip ambient temperature sensor -1-.
Installing
Install in reverse order of removal.
6.2 Removing and installing remote control

receiver for auxiliary coolant heater -
R149-
Removing
olkswagen AG
en AG. V
– Remove centre console ⇒ Rep. ogr. ksw68 .
ag does
not
y V l gu
b ara
– Unscrew bolts -2- throughor-9-
ise from bracket -1- in centre under
d
nte
dash panel. auth eo
ra
ss c
Now that the bolts are unscrewed, the bracket becomes loose and
ce
le
un
pt
can be moved within a certain range, sufficient to allow removal

an
d
itte
or installation of the remote control receiver for auxiliary coolant

y li
erm
ab
heater - R149- .
ility
ot p
wit
is n
h re
ole,
spec
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
o
49
c by lksw
cted agen
Prote AG. 6. Other controlling and regulating components
Caddy 2004 ➤ , Caddy 2011 ➤
– Disconnect electrical connectors -1- and -2-.

. Volkswage n AG n AG d
wage oe
– Pull out remote control receiver
yV
olks for auxiliary coolant heater
s no
t gu -
R149- in -direction of
isearrow-.
db ara
n r tee
ho
Installing aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
Make sure that the electrical connectors are properly seated.
hole
spec
es, in part or in w
t to the co
6.3 Functional description of remote control
for auxiliary/supplementary heater
rrectness of i
l purpos
Note
nform
ercia
♦ The auxiliary heater can be switched on and off from a dis‐

m
a
tance of up to 600 metres (open space) using the remote
com
tio
control. This range is restricted in built-up areas or from within
n in
r
buildings.
te o
thi
s
iva
do
♦ The remote control should be held upright when operating the
r
rp
cum
buttons (the radio signals can be received optimally by the ve‐
fo
en
ng
hicle aerial in this way and the greatest transmission range is

t.
yi Co
op
achieved). C py
ht. rig
rig ht
py by
♦ Following disconnection of the vehicle battery, the auxiliary co Vo
by lksw
heater remote control does not have to be re-adapted. cted agen
Prote AG.
♦ If the remote control is renewed, it must be adapted using

⇒ Vehicle diagnostic tester.
♦ On the ⇒ Vehicle diagnostic tester, select functional check
“Adapt Telestart sender”.
Switching auxiliary heater on using remote control

– Press button -1-: the warning lamp -2- must light up green.
The operating period of the auxiliary heater is determined by the
remote control unit when the heater is switched on (a time com‐
ponent is incorporated in the dash panel insert). This time com‐
ponent is variable and can be changed by means of the guided
menu system of the dash panel insert.
Switching auxiliary heater off using remote control
– Press button -3-; the warning lamp -2- must light up red.

Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
The auxiliary heater switches to run-on and then off. agen oes
olksw not
V gu
by ara
Renewing remote control battery rised
nte
ho eo
aut ra
ss c
ce
Note
le
un
pt
an
d
itte
y li
♦ Note installation position of battery.
erm
ab
ility
ot p
♦ Use only the same type of 3-volt battery.
wit
is n
h re
♦ The remote control remains assigned to the auxiliary heater
ole,
spec
and must not be adapted again.
t to the co
– Pull off battery compartment cover -1- in -direction of arrow-,
rrectne
and remove battery. Insert new batteries and refit cover.
Indicator lamp in remote control
ss 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
Once the button is pressed, the warning lamp in the remote con‐
gh ht
pyri by
trol -2- indicates whether the signal from the remote control has
o Vo
by c lksw
cted agen
been received by the auxiliary heater and whether the battery in Prote AG.
the remote control is low.
Warning lamp -2- Meaning
Lights up green for two seconds The auxiliary heater has been
switched on with -1- “ON”.
Lights up red for two seconds The auxiliary heater has been
switched off with -3- “OFF”.
Green, slow flashing, two sec‐ The signal to switch on was not
onds received.
Red, fast flashing, two seconds The auxiliary heater is blocked,
e.g. because the fuel tank is
nearly empty or there is a fault
in the auxiliary heater.
Flashes red for two seconds The signal to switch off was not
received.
Lights up orange for two sec‐ The battery charge is low, but
onds, then green or red the switch on/switch off signal
was received.
Lights up orange for two sec‐ The battery charge is low and
onds, then flashes green or red the switch on/switch off signal
was not received.
Flashes orange for five sec‐ The battery is discharged and
onds the switch on/switch off signal
was not received.
6. Other controlling and regulating components 51

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Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg K0050366320

2.7 Removing and installing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.8 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.9 Removing and installing silencer with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.10 Removing and installing auxiliary/supplementary heater bracket . . . . . . . . . . . . . . . . . . . . 25

2.11 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.12 Removing and installing auxiliary heater control unit J364 . . . . . . . . . . . . . . . . . . . . . . . . 26

2.13 Removing and installing glow plug with flame monitor Q8 . . . . . . . . . . . . . . . . . . . . . . . . 27

3 Coolant circuit with auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CLCA, CFHC, CFHE, CFHF and CFJA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.8 Removing and installing heater coolant shut-off valve N279 . . . . . . . . . . . . . . . . . . . . . . 38

5.3 Supplementary heater mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.1 Safety precautions during work on fuel system

Risk of injury from highly pressurised fuel.

The fuel system is pressurised. Risk of injury from fuel spray.

Before opening the fuel system:

– Wear safety goggles.

– Wear protective gloves.

1.2 Safety precautions when working on vehicles with start/stop system

1.4 Safety precautions when working on cooling system

– To relieve pressure, cover the cap of the coolant expansion

an explosion. Risk of burns.

– Switch the auxiliary/supplementary heater off in fire and ex‐

2 Rep. gr.00 - Technical data

Risk of damage when starting the engine

Malfunction caused by air in the fuel supply system

Risk of accidents and risk of injury due to activated timer of aux‐

2.1 Type plates

cerning the type of the auxiliary/supplementary heater, always

observe the type plate attached directly to the auxiliary/sup‐

Type plate for diesel Thermo Top V on heater unit

Type plate for petrol-type Thermo Top V on heater unit

4 Rep. gr.00 - Technical data

Type plate for diesel Thermo Top V on heater unit (supplementary

Type plate (duplicate) for supplementary heater diesel Thermo

♦ The date of first use is entered on the lower part of manufac‐

“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

2.3 Rules for cleanliness when working on

– Remove replacement parts from their packages only immedi‐

ately before installing them.

– Do not work with compressed air.

– Do not move the vehicle.

– Do not switch auxiliary heater on.

6 Rep. gr.00 - Technical data

3.1 Notes on general repairs

♦ auxiliary heater fuel line is protected from heating which might

1.1 Overview of fitting locations - compo‐

1 - Fuel gauge sender - G-

2 - Auxiliary heater aerial -

ary heater and remote

3 - Heater coolant shut-off

The heater coolant shut-off valve -

the auxiliary heater function.

❑ On vehicles with petrol

engine, it is fixed to the

bulkhead in the engine

❑ On vehicles with diesel

engine, it is fixed to the