D3E8001E354-Auxiliary Engine Coolant Heater PDF

Service
Repair Manual
Touareg 2003 ➤
Auxiliary Engine Coolant Heater
Edition 03.2008
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
82 - Auxiliary Engine Coolant Heater
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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 © 2008 Volkswagen AG, Wolfsburg D3E8001E354

Touareg 2003 ➤
Auxiliary Engine Coolant Heater - Edition 03.2008
AG. Volkswagen AG d
agen
by
Volksw Contents
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82 - Auxiliary Engine Coolant Heater . . . . . . . . . . . . . . . . . a.c . ................... 1
a r
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le
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
un
pt
an
1.1 d
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
itte
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erm
ab
1.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ility
ot p
1.3 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
wit
is n
h re
1.4 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ole,
spec
1.5 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Auxiliary Engine Coolant Heater, Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
t to the co
1.7 Programmable Timer and/or Remote Control, Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
rrectne
2.1 Auxiliary Engine Coolant Heater, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Auxiliary Engine Coolant Heater, Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ss
2.3 Auxiliary Engine Coolant Heater Connector Strip, Designations . . . . . . . . . . . . . . . . . . . . 8
o
cial p
f in
2.4 Connector Pin Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
form
mer
2.5 Coolant Circuit Layout, Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
atio
m
2.6 Fuel Lines, Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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2.7 Fuel Supply Line, Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.8 Remote Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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3.1 Fuel Delivery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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4.1 Exhaust Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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4.2 Auxiliary Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
17
AG.
4.3 Air Intake Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 Outside Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 Recirculation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Engine Coolant Switch-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.7 Connector Strip Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.8 Fresh Air Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9 Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10 Glow Plug with Flame Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.11 Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.12 Remote Control Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Auxiliary Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Contents i
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ii Contents
Touareg 2003 ➤
82 – Auxiliary Engine Coolant Heater

1 General Information
⇒ “1.1 Safety Precautions”, page 1
⇒ “1.2 General Repair Information”, page 1
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⇒ “1.3 Clean WorkingVConditions”,
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⇒ “1.4 Identification
oris Plate”, page 2
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⇒ “1.5 FuelssSupply”, page 3
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⇒ “1.6 Auxiliary Engine Coolant Heater, Regulation”, page 3

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⇒ “1.7 Programmable Timer and/or Remote Control, Regulation”,
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1.1 Safety Precautions
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The auxiliary engine coolant heater must not be in operation
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or be switched on in areas in which there is a risk of fire or
explosion.
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The auxiliary engine coolant heater must not be in operation

or switched on (including via a preset switch-on time where
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applicable) in enclosed areas without adequate ventilation and

an exhaust extraction system.
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When working on a fuel system, always observe applicable

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safety regulations. ⇒ Engine Mechanical, Fuel Injection and

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Ignition; Rep. Gr. 20 ; General Information or ⇒ Engine Me‐

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chanical, Fuel Injection and Glow Plug; Rep. Gr. 20 ; General

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If parts of the fuel system (e.g. metering pump, fuel lines, fuel
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gauge sender) are removed or opened, the vehicle's engine
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Before beginning repair work on the auxiliary engine coolant
heater:
– Release cooling system pressure by slowly and carefully

opening the coolant expansion tank cap.
♦ After finishing repairs to auxiliary engine coolant heater or fuel
system, check auxiliary engine coolant heater function.
♦ Perform On Board Diagnostic with Vehicle Diagnosis, Testing
and Information System -VAS 5051B- after completing repairs
to auxiliary engine coolant heater.
1.2 General Repair Information

♦ Perform On Board Diagnosis of auxiliary engine coolant heat‐
er with Vehicle Diagnostic, Testing and Information System -
VAS 5051B- .
1. General Information 1
Touareg 2003 ➤
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♦ If parts of fuel system werebyremoved
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or replaced, ensure all ot g
components for fuel delivery d to auxiliary engine coolant heater uara
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are properly installed. utho eo
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♦ To avoid interchanging coolant lines, identify them before re‐
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♦ Auxiliary engine coolant heater does not operate when tank
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flap is open.
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♦ Check following points after repair work in area of fuel lines to
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auxiliary engine coolant heater:
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♦ that the fuel line fits flush with the vehicle underbody and is
t to the co
protected from mechanical damage.
♦ that the fuel line is protected from heat source which might
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disturb operation.
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♦ that the fuel line does not come in contact with vehicle parts
which heat up.
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1.3 Clean Working Conditions

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– Thoroughly clean all unions and adjacent areas before dis‐
ion
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connecting.
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ate
♦ Place parts that have been removed on a clean surface (use
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sheeting, paper or lint-free shop rags) and cover.
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♦ If repair is not carried out immediately, components must be
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covered or sealed.
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♦ Only install clean components: cop Vo
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– Only remove original replacement parts from packaging im‐
mediately before installation.
– Do not use any components that were stored out of their pack‐
aging (e.g in tool boxes).
♦ When fuel system is open, do not:
– work with compressed air.
– move vehicle.
– start engine.
– switch on auxiliary engine coolant heater.
1.4 Identification Plate

Diesel Thermo Top manufacturer's identification plate
Note
♦ The relevant technical data are shown on upper area of man‐

ufacturer's identification plate.
♦ The date first put into use is on the lower part of manufacturers
identification plate.
♦ Manufacturer's identification plate on “original replacement
part” must have date first put in use entered. Engine coolant
heater heat exchanger must not be replaced after 10 years.
Current German legislation dictates that only air-type heat ex‐
changers be replaced after a certain period. Check local State
or Provincial regulations.
♦ Attach manufacturer's identification plate in a clearly visible
location.
2 Rep. Gr.82 - Auxiliary Engine Coolant Heater

Touareg 2003 ➤
1.5 Fuel Supply

Clean Working Conditions
When working on the fuel supply/injection system, pay careful at‐
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♦ Thoroughly clean all unions and adjacent oareas
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before dis‐ tee
connecting. auth or
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♦ Place components that have been removed on a clean surface
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and cover. Only use lint-free shop rags!
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♦ Carefully cover opened components or seal if the repair can‐
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not be carried out immediately. ot p
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♦ Only install clean components: Only unpack replacement
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parts immediately prior to installation. Do not use any parts
spec
that have been kept out of packaging (e.g. in a tool box, etc.).
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♦ Only cut coolant hoses and pipes with a clean, sharp knife.
Cutting points must not be soiled or deformed. Cutting points
and surfaces must be free of burrs.
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1.6 Auxiliary Engine Coolant Heater, Regu‐
ss
lation
o
cial p
f inform
The auxiliary engine coolant heater is intended to heat the engine
mer
coolant and thereby assist the heat output of the engine. Opera‐
atio
m
tion takes place either automatically, with Programmable Timer -

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or
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E111- and/or radio remote control ⇒ page 4 .
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Various operating conditions can be set according to heat re‐

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quired in heater circuit:
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♦ If ECON is in use, auxiliary engine coolant heater does not op‐

erate as a preheater.
♦ Auxiliary engine coolant heater does not run when tank door
is open.
Temperature at Auxiliary Heater Coolant Temperature Sensor -

G241- less than approximately 75 °C.
Temperature at Outside Air Temperature Sensor -G17- less than
approximately +5 °C.
This will set the heater to operational readiness mode. Operation
of the Glow Plug (with flame monitoring) -Q8- , Combustion Air
Blower -V6- and Metering Pump -V55- is initiated. After 30 sec‐
onds the Metering Pump -V54- will be switched on and the
Combustion Air Blower -V6- are switched off for 3 seconds. Then
the Combustion Air Blower -V6- will be switched to almost full
load, in two stages, over a period of 56 seconds. After a stabili‐
zation period (constant speed) of 15 seconds the combustion air
blower will be switched to almost full load in two stages again.
After full load combustion is attained, the Glow Plug (with flame
monitoring) -Q8- is switched off and the Combustion Air Blower -
V6- is regulated upwards to full output. During the next 45 sec‐
onds as well as during normal operation the Glow Plug (with flame
monitoring) -Q8- assumes the roll of flame monitor and continu‐
ously checks the flame build–up. Thereafter the automatically
regulated heater mode begins. If no flame is produced or a flame
extinguishes then the fuel supply is interrupted and a malfunction
shut–down along with emergency running mode of the Combus‐
Touareg 2003 ➤
tion Air Blower -V6- is performed. If the flame extinguishes during

normal running mode then an automatic re–start is initiated.
Heating Mode
Once the temperature has risen to 72 °C the control module
switches to the energy saving part load mode. If the coolant tem‐
perature rises to 76.5 °C the control unit will switch towathe con‐
gen AG. Volkswagen AG d
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trolled pause mode. If the coolant temperature drops yV
olk below 71 ° not
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C but not within 900 seconds, the heater unit risewill
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switch to a reg‐ ara
nte
ular start and heat in full load mode. ut
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Switching Off
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When the engine is switched off or the coolant temperature rea‐
an
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ches 85 °C the combustion process is terminated and run–on
erm
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begins. The Recirculation Pump -V55- and Combustion Air Blow‐
ility
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er -V6- continue to run to cool the heater unit down (run–on
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period), and are switched off automatically.
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Note
The run–on period along with the speed of the Combustion Air
rrectne
Blower -V6- are dependent on the operating mode in which the
heater unit is switched off.
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The run–on period is: 175 seconds when switching off in full load
f in
mode and 110 seconds when switching off in part load mode.
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Deviations from standard times are possible depending on the
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software version of the control module.
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1.7 Programmable Timer and/or Remote
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Control, Regulation
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♦ If ECON is in use, auxiliary engine coolant heater does not op‐
erate as a preheater.
♦ Auxiliary engine coolant heater does not run when tank door
is open.
Various operating conditions can be set according to heat re‐

quired in heater circuit:
Prerequisites for switching on:
Fuel tank is filled sufficiently (fuel gauge on dash panel is not in
red area).
Voltage of auxiliary battery (in luggage compartment) not under
11.5 Volt.
– Switch on auxiliary engine coolant heater.
Operation of the Glow Plug (with flame monitoring) -Q8- , Com‐
bustion Air Blower -V6- and Metering Pump -V55- is initiated. After
30 seconds the Metering Pump -V54- will be switched on and the
Combustion Air Blower -V6- are switched off for 3 seconds.
Thereafter the Combustion Air Blower -V6- is set within 57 sec‐
onds to almost full load. After full load combustion is attained, the
Glow Plug (with flame monitoring) -Q8- is switched off and the
Combustion Air Blower -V6- is regulated upwards to full output.
During the next 40 seconds as well as during normal operation
the Glow Plug (with flame monitoring) -Q8- assumes the roll of
flame monitor and continuously checks the flame build–up. There‐
after the automatically regulated heater mode begins. If no flame

Touareg 2003 ➤
develops or the flame goes out, the starting procedure is induced

automatically. If there is still no flame development, the fuel sup‐
ply is cut-off and the system is shut-down with run-on of Com‐
bustion Air Blower -V6- .
Heating Mode
Once the temperature has risen to 86 °C the Heater Control Mod‐
ule -J162- switches to the energy saving part load mode. Should
the engine coolant temperature decrease due to demand during
part load operation, the Heater Control Module -J162- switches
to full load operation at 56 °C. If the coolant temperature rises to
89 °C the Heater Control Module -J162- switches to the controlled
pause mode. Die Recirculation Pump -V55- , the vehicle's Fresh
Air Blower -V2- and operation display remain active during run-
on.
After the engine coolant temperature decreases to 76 °C, the
auxiliary engine coolant heater starts again.
After the auxiliary engine coolant heater switches off, the Engine
Coolant (EC) Switch-off Valve (heater) -N279- opens to the large
coolant circulation circuit.
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Switch off auxiliary engine coolant heater. d byV gu
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Combustion stops and run-on period ut begins. To cool the auxiliary
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engine coolant heater more quickly,
ss a
Recirculation Pump -V55- c
and Combustion Air Blower -V6- continue running.
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Note
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The run on period of the Recirculation Pump -V55- and Combus‐
h re
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tion Air Blower -V6- is dependent on the operation mode present
spec
at the time the heater was switched off.
es, in part or in w
t to the co
With 23 °C ambient temperature and Programmable Timer -
E111- set to 26 °C interior temperature, the run on period amounts
to: approximately 168 seconds of full load mode and approxi‐ rrectness of i
mately 157 seconds of partial load mode.
l purpos
Deviations from standard times are possible depending on the

software version of the control module.
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Touareg 2003 ➤
2 Description and Operation

⇒ “2.1 Auxiliary Engine Coolant Heater, Servicing”, page 6
⇒ “2.2 Auxiliary Engine Coolant Heater, Components”,
page 8
⇒ “2.3 Auxiliary Engine Coolant Heater Connector Strip, Desig‐
nations”, page 8
⇒ “2.4 Connector Pin Designations”, page 9
⇒ “2.5 Coolant Circuit Layout, Diesel”, page 9
⇒ “2.6 Fuel Lines, Routing”, page 11
⇒ “2.7 Fuel Supply Line, Location”, page 11
⇒ “2.8 Remote Control Operation”, page 13
2.1 Auxiliary Engine Coolant Heater, Serv‐

icing
Before Repairing
– Switch off all electrical components.
– Switch off ignition.
– Remove ignition key.
– Identify coolant lines before removing to prevent interchang‐
ing.
Note
♦ If auxiliary engine coolant heater is also powered by Program‐

mable Timer -E111- or remote control agenoperation, disconnect
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♦ After disconnecting vehicle
au
t
battery, auxiliary engine coolant or
ac
heater remote control
ss operation must be reprogrammed Ve‐
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hicle Diagnosis, Testing and Information System -VAS 5051B-

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“Guided Fault Finding”, then select Adapting Telestart.

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Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1410- (or 4–20 Nm equivalent)

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spec
♦ Hose clamps up to Ø 25 mm -3094-

es, in part or in w
t to the co
Note
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♦ A manufacturer's identification plate is attached to the auxiliary

l purpos
engine coolant heater. This plate indicates which heater ver‐

sion is installed in the vehicle: Auxiliary engine coolant heater
(only models with V-10 TDI-PD engines) ⇒ page 2
nform
ercia
♦ The coolant circuit must be bled after it is opened⇒ Engine

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Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; General

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Information or ⇒ Engine Mechanical, Fuel Injection and Glow

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te o
thi
Plug; Rep. Gr. 19 ; General Information

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
1 - Engine Coolant Tempera‐

ture (ECT) Sensor -G62-
❑ Location: in return hose
from radiator.
❑ Checking: Vehicle Diag‐
nosis, Testing and Infor‐
mation System -VAS
5051B-
2 - Programmable Timer -
E111-
❑ Location: at front of
headliner
3 - Fuel Level Sensor
❑ Location: under right
side of rear seat bench
4 - Auxiliary Engine Coolant
Heating RF Receiver -R149-
❑ Location: Headliner,
rear center
5 - Auxiliary Battery -A1-
❑ Location: under luggage
compartment floor
olkswagen AG
en AG. V
6 - Battery -A- ksw
ag does
not
y Vol gu
❑ Location: ed under front left
b ara
nte
ris
seat
ut
ho eo
ra
sa c
7 - Fuse
s carrier
ce
e
nl
pt
❑ Location: on left side un‐

du
an
itte
der instrument panel

y li
erm
ab
⇒ Wiring diagrams,
ility
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Troubleshooting &
wit
, is n
Component locations
h re
hole
8 - Metering Pump -V54-

spec
es, in part or in w
❑ Location: under vehicle

t to the co
floor in tunnel
❑ Fuel supply to auxiliary engine coolant heater, checking ⇒ page 3
rrectness of i
❑ Metering pump may tick audibly but not deliver any fuel because of air in intake. The control module will
then switch off permanently. Retrieve DTC memory with Vehicle Diagnosis, Testing and Information
l purpos
System -VAS 5051B- , Auxiliary engine coolant heater On Board Diagnostic. Erase DTC memory and
perform Output Diagnostic Test Mode on auxiliary engine coolant heater.
nf
ercia
❑ Removing and installing ⇒ page 23

orm
m
❑ Quantity of fuel delivered, checking ⇒ page 14

atio
om
n in
c
9 - Recirculation Pump -V55-

or
thi
te
sd
❑ Location: on auxiliary engine coolant heater

iva
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r
rp
cu

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f
en
ng
t.
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10 - Auxiliary engine coolant heater
Co
Cop py
t. rig
❑ with Heater Control Module -J162-
gh ht
pyri by
Vo
o
❑ Location: under front left fender
c by lksw
cted agen
Prote AG.
11 - Exhaust muffler
12 - Engine Coolant (EC) Switch-Off Valve (heater) -N279-
❑ Location: in front left wheel housing
❑ only installed on vehicles with parking heater
2. Description and Operation 7

Touareg 2003 ➤
13 - Outside Air Temperature Sensor -G17-
❑ Location: behind center air intake grille
❑ Removing ⇒ page 19
❑ checking with Vehicle Diagnosis, Testing and Information System -VAS 5051B-
2.2 Auxiliary Engine Coolant Heater, Components
1 - Coolant return hose (from

heat exchanger)
2 - Coolant supply hose (to
heat exchanger)
3 - Air intake muffler
❑ Removing and installing
⇒ page 19
⇒ page 19
5 - Auxiliary Engine Coolant
Heater
❑ with Heater Control
Module -J162-
❑ Removing and installing agen
AG. Volkswagen AG d
oes
⇒ page 17 olksw not
y V gu
d b ara
6 - Engine Coolant (EC) rise nte
tho eo
Switch-Off Valve (heater) - s au ra
c
N279- s
ce
le
un
pt
❑ only installed on vehi‐
an
d
itte
cles with parking heater

y li
erm
ab
function
ility
ot p
❑ Removing and installing wit

is n
⇒ page 20 h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
2.3 Auxiliary Engine Coolant Heater Con‐

i
or
n thi
te
sd
a
nector Strip, Designations

iv
o
pr
cum
r
fo
en
– Connector -A- 6-Pin

ng
t.
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op py
– Connector -B- Power supply 12 Volt t. C rig
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cted agen
Prote AG.

Touareg 2003 ➤
– Connector -C- for Glow Plug (with flame monitoring) -Q8-

– Connector -D- for Combustion Air Blower -V6-
– Connector -E- not used
2.4 Connector Pin Designations

6-Pin electrical connector, connector housing -A-
1 - Webasto - Diagnostic lead
AG. Volkswagen AG d
agen
2 - CAN high (optional) Volksw
oes
not
by gu
d ara
3- CAN low (optional) orise nte
eo
th
u ra
4- Engine Coolant
ss a
(EC) Switch-Off Valve (heater) -N279- c
ce
e
nl
5 - Main switch
pt
du
an
itte
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erm
ab
ility
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2-Pin electrical connector, connector housing -B-
wit
, is n
h re
1 - Terminal 30
hole
2 - Terminal 31 spec
es, in part or in w
t to the co
2-pin electrical connector, connector housing -C-

1 - Glow Plug (with flame monitoring) -Q8-
rrectness of i
2 - Terminal 31
l purpos
2-pin electrical connector, connector housing -D-

nform
ercia
1 - Combustion Air Blower -V6-

m
at
om
2 - Terminal 31
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.5 Coolant Circuit Layout, Diesel

The coolant circuits of the various engines are not established as
of the editorial deadline due to technical reasons.
Note
♦ The refrigerant system is under pressure when the engine is

warm. Release pressure before repairs, if necessary.
♦ There must not be any air in the coolant circuit so that the
auxiliary engine coolant heater can heat properly.

Touareg 2003 ➤
1 - Heat exchanger for heater

unit
2 - Auxiliary engine coolant
heater
4 - Fuel cooler
5 - Generator
6 - Cylinder head/cylinder
block
7 - Thermostat housing
8 - Valve body
9 - Radiator
10 - Low temperature cooler
❑ for generator and fuel
cooling
11 - Fuel Cooler Pump -V166-
12 - After-Run Coolant Pump -
V51-
13 - Check valve
❑ Observe installed posi‐
tion
14 - Coolant reservoir
lkswage es n
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tho
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pt
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an
itte
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
2.6 Fuel Lines, Routing
Note
♦ Fuel lines are secured with hose clamps, replace these with screw clamps.
♦ Start vehicle engine if fuel tank was empty. Then start auxiliary engine coolant heater. If auxiliary engine
coolant heater turns off, repeat procedure until auxiliary engine coolant heater does not turn off again.
♦ Observe cleanliness rules when working on fuel supply system ⇒ page 3
♦ The gasoline or diesel auxiliary engine coolant heater metering pumps have different flow rates; observe
part numbers. Note replacement part numbers.

⇒ page 23
❑ Quantity of fuel deliv‐
ered, checking
⇒ page 14
2 - Fuel Level Sensor
❑ Location: under right
side of rear seat bench.
3 - Fuel line agen
AG. Volkswagen AG d
oes
olksw not
V gu
4 - Auxiliary engine coolant d by ara
ise nte
heater thor eo
au 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
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cum
fo
en
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t.
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Cop py
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2.7 Fuel Supply Line, Location
cop Vo
by lksw
cted agen
Prote AG.
– Fold right side of rear seat bench up.

Touareg 2003 ➤
– Remove screws-arrows- and remove rear seat mounting

bracket ⇒ Body Interior; Rep. Gr. 72 ; Removal and Installa‐
tion .
– Cut floor covering with a knife at locations marked and fold up.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Remove nuts -arrows- and remove cover plate.
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
– The -arrow- shows the fuel supply location at fuel level sensor.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
2.8 Remote Control Operation
Note
♦ The remote control operation transmission range is about 600

meters in open space. In built-up areas or around buildings,
this range is restricted.
♦ Hold remote control upright when using. In this way, the radio
signal is received best by the vehicle antenna.
♦ After disconnecting vehicle batteries, auxiliary engine coolant
heater remote control operation must be reprogrammed. Se‐
AG. Volkswagen
lect “Guided Fault Finding” on Vehicle Diagnosis,
lksw
agen Testing andAG does
not
Information System -VAS 5051B- and db
ythen
Vo
Adapting Telestart. gu
ar
e an
ris tee
tho or
Switching On with Remote Control
au ac
ss
ce
e
– Press button -1-, indicator light -2- must light up green.

nl
pt
du
an
itte
The operating period of the auxiliary coolant heater is determined
y li
erm
ab
by the remote control unit when the heater is switched on (a time
ility
ot p
component is included in the switching signal). This time compo‐
wit
, is n
nent is permanently stored in the remote control and cannot be
h re
changed.
hole
spec
es, in part or in w
Switching Off with Remote Control
t to the co
– Press button -3-, indicator light -2- must light up red.
The auxiliary coolant heater switches to run-on and then off.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
3 Diagnosis and Testing

⇒ “3.1 Fuel Delivery, Checking”, page 14
3.1 Fuel Delivery, Checking

♦ Vehicle Diagnosis, Testing and Information System -VAS
5051B-
♦ Multimeter -V.A.G 1526C-
♦ Connector test set -V.A.G 1594/C-
♦ Wiring diagram
♦ Commercially available measuring glass (0 ml to 25 ml)
♦ Fuel hose, length approximately 300 mm
Test Prerequisites:
WARNING
There is a danger of leaking fuel.

Fuel system is under pressure.
Before opening the system place a cloth around the connec‐
tion. Then release pressure by carefully loosening the connec‐
tion.
• Metering pump resistance 5.4Ω

AG. Volkswagen AG d
• Voltage at metering pump, 11 to 13 Volt. agen oes
olksw not
y V gu
b ara
• No Diagnostic Trouble Code (DTC) stored in memory
rise
d
nte
tho eo
• Fuel lines are not damaged or leaking. ss au ra
c
ce
e
• Ambient temperature approximately 20 °C

nl
pt
du
an
itte
y li
• Fuel tank is filled sufficiently (fuel gauge on dash panel is not

erm
ab
in red area).
ility
ot p
wit
, is n
Checking:
h re
hole
– Remove fuel line at Metering Pump -V54- pressure connec‐

spec
tion. Place a fuel hose (length approximately 300 mm) on

es, in part or in w
t to the co
pressure connection and fit into measure glass (capacity ap‐

proximately 25 ml).
– Hold measuring glass at same height as auxiliary engine cool‐
rrectness of i
ant heater.
l purpos
– Select address word “18” auxiliary/parking heater in Vehicle

Diagnosis, Testing and Information System -VAS 5051B- .
nform
ercia
Select function “10” Adaptation, and channel number 1. Enter

value 29 and finally confirm with Q key.
m
at
om
io
– After approximately 60 seconds the fuel line is filled and bled.

n
c
in t
or
his
e
– Empty measuring glass.

at
do
priv
cum
– Hold measuring glass at same height as auxiliary engine cool‐

for
en
g
ant heater.
n
t.
yi Co
Cop py
– Select address word “18” auxiliary/parking heater in Vehicle
t. rig
gh ht
yri
Diagnosis, Testing and Information System -VAS 5051B- .
p by
co Vo
by lksw
Select function “10” Adaptation, and channel number 1. Enter Prote
cted AG.
agen
value 29 and finally confirm with Q key.

Touareg 2003 ➤
– Read measuring glass. Quantity delivered: Diesel: 16.2 ml to

17.8 ml
– If quantity delivered does not correspond to specified values,
replace Metering Pump -V54- .
Note
♦ If ambient temperature is above 20 °C then fuel vaporization

may lead to incorrect measurements being achieved.
♦ Not bubbles are to be delivered.
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.
3. Diagnosis and Testing 15

Touareg 2003 ➤
4 Removal and Installation

⇒ “4.1 Exhaust Muffler”, page 16
⇒ “4.2 Auxiliary Engine Coolant Heater”, page 17
⇒ “4.3 Air Intake Muffler”, page 19
⇒ “4.4 Outside Air Temperature Sensor”, page 19
⇒ “4.5 Recirculation Pump”, page 19
⇒ “4.6 Engine Coolant Switch-Off Valve”, page 20
⇒ “4.7 Connector Strip Cover”, page 21
⇒ “4.8 Fresh Air Blower”, page 22
Volkswagen AG
⇒ “4.9 Combustion Chamber”, page 22
swa
gen AG
.
does
k not
y Vol gu
⇒ “4.10 Glow Plug with FlameseMonitoring”,
db page 23 ara
nte
ori eo
h
⇒ “4.11 Metering Pump”,apage
ut 23 ra
c
ss
⇒ “4.12 Remote Control Batteries”, page 25
ce
le
un
pt
an
d
itte
4.1 Exhaust Muffler
y li
erm
ab
ility
ot p
wit
is n
WARNING
h re
ole,
spec
Contact with a hot exhaust system can cause severe burns.
t to the co
Muffler housing may be hot.
Allow muffler housing to cool before removing.
rrectnes
– Remove left wheel housing liner ⇒ Body Exterior; Rep. Gr.

s o
66 ; Description and Operation .

cial p
f inform
– Loosen pipe clamp at exhaust pipe -arrow-.

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.
– Remove underbody trim ⇒ Body Exterior; Rep. Gr. 50 ; De‐

scription and Operation .
– Remove nut -arrow- and remove exhaust muffler.

Touareg 2003 ➤
4.2 Auxiliary Engine Coolant Heater

Removing
Note
♦ If coolant circuit is opened, it must be bled ⇒ Engine Mechan‐

ical, Fuel Injection and Ignition; Rep. Gr. 19 ; General Infor‐
mation or ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 19 ; General Information .
♦ If drive motor is warm, coolant system is pressurized. Release
pressure before repairs, if necessary.
♦ Auxiliary engine coolant heater must be secured to body with
a welding wire after loosening. This will prevent damage to
coolant lines.
Perform the following work before beginning assembly:

– Switch off all electrical consumers.
Note
n AG. Volkswagen A
♦ If auxiliary engine coolant heater
olks
wagis
e
powered by Programmable
G do
es n
o
Timer -E111- and/or remotedb
y V control operation, disconnectt gbat‐
ua
r
teries ⇒ Electrical oEquipment;
rise
Rep. Gr. 27 ; Removal and antee
Installation . au
th or
a
ss c
ce
le
un
pt

an
d
itte
lect “Guided Fault Finding” on Diagnostic Operation System -

y li
erm
ab
VAS 5051A- and then Adapting Telestart.

ility
ot p
wit
is n
– Remove left front wheel housing liner ⇒ Body Exterior; Rep.

h re
ole,
Gr. 66 ; Description and Operation .

spec
– Clamp coolant hoses using Hose Clamps up to Ø 25 mm

t to the co
-3094- .
rrectne
WARNING
s
Contact with hot engine coolant can cause severe burns.

s o
cial p
f in
Coolant system is under pressure. Coolant temperature can

form
mer
be over 1000 C when engine is warm.

atio
m
Release pressure and temperature before repairs.

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
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Removal and Installation 17

Touareg 2003 ➤
– Loosen hose clamps -1- and remove coolant hoses from cool‐
ant pipes.
WARNING

Place a cloth around the connection before opening fuel sys‐
tem. Then release pressure by carefully loosening the con‐
nection.
– Loosen hose clamps -2- and disconnect and seal off fuel lines.
Replace hose clamps with screw clamps.
– Loosen hose clamps -1- and remove coolant hoses from cool‐
ant pipes.
– Loosen hose clamp -2- and disconnect exhaust system.
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
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Loosen coolant exhaust pipe bracket.
spec
es, in part or in w
– Remove nuts -2- and bolts -1-.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
Loosen auxiliary engine coolant heater bracket.

r
rp
cum
fo
en
g
– Remove screws -1-.

n
t.
yi Co
op py
– Unhook auxiliary engine coolant heater by lifting upwards
t. C rig
gh ht
yri
-arrow- p by
co Vo
by lksw
cted agen
– Remove auxiliary engine coolant heater with bracket. Prote AG.
– Remove electrical connectors at auxiliary engine coolant heat‐

er.
Installing
Install in reverse order of removal.

Touareg 2003 ➤
Note
Rubber mounting -1- must seat on guide pin -2- (fender not shown
in illustration).
4.3 Air Intake Muffler

Removing
– Loosen screw -1- from bracket and hose clamp -3-. Remove
air intake -2- from auxiliary engine coolant heater.
Installing
– Slide air intake -2- towards auxiliary coolant heater until it lies
against the combustion air blower housing.
– Engage retainer and tighten screw -1- and hose clamp -3-.
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
4.4 Outside Air Temperature Sensor
itte
y li
erm
ab
ility
ot p
Outside Air Temperature Sensor -G17- removing and installing
wit
, is n
h re
– Remove radiator grille⇒ Body Exterior; Rep. Gr. 66 ; Removal
hole
and Installation
spec
es, in part or in w
t to the co
– Unclip temperature sensor from lock support -1-.
– Disconnect electrical connector at Ambient Air Temperature
Sensor -G17- .
rrectness of i
l purpos
nform
ercia
4.5 Recirculation Pump

m
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
♦ The coolant circuit must be bled after it is opened⇒ Engine

f
en
ng
t.
Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; General op
yi Co
Information or ⇒ Engine Mechanical, Fuel Injection and Glow
C py
t. rig
gh
Plug; Rep. Gr. 19 ; General Information
ht
pyri by
Vo
co lksw
by
♦ The refrigerant system is under pressure when the engine is
cted agen
Prote AG.
warm. Release pressure before repairs, if necessary.


Touareg 2003 ➤
Removing
– Disconnect coolant hoses.
– Loosen hose clamps -1-.
WARNING

Engine cooling system is under pressure, and may be over
1000C with a warm engine.
Release pressure and temperature before repairs, if necessa‐
ry.
– Remove coolant hoses from Recirculation Pump -V55- .

– Loosen screw clamp -2-. AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove electrical connectoris-3-
e from Recirculation Pump -
d b ara
nte
V55- and remove it. hor eo
aut ra
ss c
Installing
ce
e
nl
pt
du
an
itte
– Install in reverse order of removal.
y li
erm
ab
ility
ot p
4.6 Engine Coolant Switch-Off Valve
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Spring Type Clip Pliers -VAS 5024A-
l purpos
Removing
nform
ercia
Note
m
at
om
io
♦ If coolant circuit is opened, it must be bled ⇒ Engine Mechan‐

n
c
in t
r
ical, Fuel Injection and Ignition; Rep. Gr. 19 ; General Infor‐

o
his
te
mation or ⇒ Engine Mechanical, Fuel Injection and Glow Plug;

a
do
riv
Rep. Gr. 19 ; General Information .

p
cum
for
en
g
♦ If drive motor is warm, coolant system is pressurized. Release

n
t.
yi Co
op
pressure before repairs, if necessary. C py
t. rig
gh ht
yri by
♦ Auxiliary engine coolant heater must be secured to body with
op Vo
by c lksw
a welding wire after loosening. This will prevent damage to cted agen
Prote AG.
coolant lines.
Perform the following work before beginning assembly:

– Switch off all electrical consumers.

Touareg 2003 ➤
Note
♦ If auxiliary engine coolant heater is powered by Programmable

Timer -E111- and/or remote control operation, disconnect bat‐
teries ⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and
Installation .
lect “Guided Fault Finding” on Vehicle Diagnosis, Testing and
Information System -VAS 5051B- and then Adapting Telestart.
– Remove left front wheel housing liner ⇒ Body Exterior; Rep.

Gr. 66 ; Description and Operation .
– Clamp coolant hoses using Hose Clamps up to Ø 25 mm
-3094- .
WARNING

Coolant system is under pressure. Coolant temperature can
be over 1000 C when engine is warm.
Release pressure and temperature before repairs.
– Loosen hose clamps -1- and remove coolant hoses -2- from
Engine Coolant (EC) Switch-Off Valve (heater) -N279- -3-.
– Remove screws -4- and remove Engine CoolantA(EC)
G. VolkSwitch-
swagen AG
Off Valve (heater) -N279- . lksw
agen does
no o t gu
yV
Installing edb ara
ris nte
tho eo
– Install in reverse order of removal.
au ra
c
ss
ce
le
– Filling cooling system ⇒ Engine Mechanical, Fuel Injection

un
pt
and Ignition; Rep. Gr. 19 ; General Information or ⇒ Engine

an
d
itte
y li
Mechanical, Fuel Injection and Glow Plug; Rep. Gr. 19 ; Gen‐

rm
ab
eral Information
pe
ility
ot
wit
, is n
h re
hole
4.7 Connector Strip Cover

spec
es, in part or in w
t to the co
Note
rrectness of i
Auxiliary engine coolant heater, removing and installing

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⇒ page 8
nform
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– Pry off connector strip cover -A- with a screwdriver.

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Touareg 2003 ➤
AG. Volkswagen AG d
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– Auxiliary engine coolant heater, removing and installing ss
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⇒ page 8
un
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– Remove connector strip cover and disconnect electrical con‐
erm
ab
nections to connector strip ⇒ page 21 .
ility
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– Remove bolts -A-.
is n
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– Remove Combustion Air Blower -V6- -B- from auxiliary engine
spec
coolant heater.
t to the co
Installing
rrectne
Note
ss
♦ Replace seal between combustion air blower and auxiliary en‐
o
cial p
f i
gine coolant heater.
nform
mer
♦ Ensure correct seating of fuel line -C- in grommet -D-.
atio
om
n
c
i
or
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Install in reverse order of removal.
thi
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4.9 Combustion Chamber
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– Remove Combustion Air Blower -V6- ⇒ page 22 cop Vo
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– Remove Glow Plug (with flame monitoring) -Q8-
AG.
⇒ page 23
– Remove bolts -A-.
– Remove combustion chamber -B- upward out of auxiliary en‐
gine coolant heater -C-.
Installing
Note
♦ Replace seal between combustion chamber and auxiliary en‐

gine coolant heater.
♦ In the event of a faulty combustion chamber insert, always re‐
place Glow Plug (with flame monitoring) -Q8- . ⇒ page 23 .

Touareg 2003 ➤
4.10 Glow Plug with Flame Monitoring

Removing
– Combustion chamber, removing ⇒ page 22
– Remove retaining clip -A-.
Retaining clip changed as of 02.2003: Note location.
Note
A clip turned 180° will result in heating unit malfunction.
– Remove Glow Plug (with flame monitoring) -Q8- -B- from com‐
bustion chamber insert and remove clip -C- and -D-.
Installing
AG. Volkswagen AG d
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♦ Attach retaining clip -A- and ensureaucorrect
th seating of Glow eo
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Plug (with flame monitoring) -Q8- s.
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♦ Insert wiring in clip -D- and route as in figure.
du
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♦ Ensure correct location of seal -C-.
erm
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4.11 Metering Pump
hole
spec
es, in part or in w
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♦ Socket insert -T10058-
Removing
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Touareg 2003 ut
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Auxiliary Engine
ss Coolant Heater - Edition 03.2008 c
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– Remove electrical connector -5-.

– Loosen hose clamps -2-.
WARNING

Before opening the system place a cloth around the connec‐
tion. Then release pressure by carefully loosening the connec‐
tion.
– Remove fuel hoses -3- from metering pump and seal them.
– Remove screw -4- with socket insert -T10058- and remove
metering pump -1- with bracket.
Installing
– Observe installation position of metering pump.

Touareg 2003 ➤
Note
♦ Fuel lines are secured with hose clamps, replace these with
screw clamps.
♦ Observe cleanliness rules when working on fuel supply sys‐
tem
♦ The gasoline or diesel auxiliary engine coolant heater meter‐
ing pumps have different flow rates; observe part numbers.
Note replacement part numbers.
4.12 Remote Control Batteries

swage es n
Note byV
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o
♦ Note location of batteries. auth or
ac
ss
♦ Insert batteries of the same type with a voltage of 12 Volts.
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♦ Allocation of the remote control to the auxiliary coolant heater

itte
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remains intact. Re-adapting is not necessary.
erm
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– Remove battery cover -1- and remove batteries. Insert new
h re
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batteries and replace cover.
spec
t to the co
rrectness o
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Touareg 2003 ➤
5 Disassembly and Assembly

⇒ “5.1 Auxiliary Engine Coolant Heater”, page 26
5.1 Auxiliary Engine Coolant Heater
Note
Auxiliary engine coolant heater, removing and installing

⇒ page 17 .
1 - Glow Plug (with flame mon‐

itoring) -Q8-
❑ removing and installing
⇒ page 23
2 - Seal
❑ Always replace after re‐
moval.
3 - Rubber grommet
4 - Combustion Air Blower -V6-
❑ removing and installing AG. Volkswagen AG d
⇒ page 22 agen oes
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5 - Screw rised
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as of 02.2003 Observe
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A retaining clip turned 1800
will result in malfunction of
auxiliary engine coolant rrectness of i
heater.
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7 - Retaining clip
❑ for Glow Plug (with
nform
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flame monitoring) -Q8-

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8 - Clip
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❑ Observe installed posi‐

or
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9 - Combustion chamber with

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❑ Clean inside and outside with brass wire brush (spark plug brush)
C py
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❑ removing and installing ⇒ page 22
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10 - Seal
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❑ Always replace after removal

11 - Water jacket
❑ Clean inside and outside with brass wire brush (spark plug brush)
❑ Do not disassemble further.

Touareg 2003 ➤
12 - Connector strip cover n AG. Volkswagen AG do

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❑ removing and installing ⇒ page 21 yV
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❑ Connector strip designations ⇒ page 8 o
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5. Disassembly and Assembly 27

Touareg 2003 ➤
6 Special Tools
♦ Vehicle Diagnosis, Testing and Information System -VAS
5051B-
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♦ Multimeter -V.A.G 1526C-
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♦ Connector test set -V.A.G 1594/C-

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Auxiliary ris Engine Coolant Heater - Edition 03.2008
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♦ Spring Type Clip Pliers -VAS 5024A-
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♦ Socket insert -T10058-
6. Special Tools 29
AG. Volkswagen AG d
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Cautions & Warnings
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
wit
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and repair work. You must answer that you have read and you understand these
hole
spec
WARNINGS and CAUTIONS before you will be allowed to view this information.
es, in part or in w
t to the co
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
rrectness of i
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
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wholly or in part by any of the extensive warranties issued by Volkswagen.
nform
ercia
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
m
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tion in
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
r
te o
thi
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
s
iva
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check with your authorized Volkswagen retailer parts department for the latest information.
r
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i t.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
py Co
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•= cted
Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
agen
Prote AG.
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids
AG. Voaway
lkswagfrom
en AGfire hazards. Wipe up spills at
agen does
once, but do not store the oily rags, which can ignite andy burn
olkswspontaneously. not
V g ua
b
ed ran
oris tee
•= Use pneumatic and electric tools only to loosen threaded
uth parts and fasteners. Never use these tools
or to tighten
a ac
fasteners, especially on light alloy parts. Alwaysss use a torque wrench to tighten fasteners to the tightening torque
ce
le
listed.
un
pt
an
d
itte
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erm
•=
ab
Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ility
ot p
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
wit
is n
h re
ole,
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
spec
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
t to the co
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
rrectne
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
s
automotive chemical refrigerants.
s o
cial p
f inform
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
mer
negative terminal (ground strap) and the ABS control module connector. atio
om
n
c
i
or
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
thi
te
sd
a
system pressure and may cause the system to burst.

iv
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pr
cum
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fo
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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
t.
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Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these C py
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components is not separately fused, disconnect the control module connector(s). rig ht
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•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
AG.
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
AG. Volkswagen AG d
agen oes
ksw
•= Never use a test light to conduct electrical
yV
ol tests of the airbag system.noThe
t g system must only be tested by trained
Volkswagen Service technicians rusing d the VAG 1551 Scan Tool (ST) or uan
b ara
ise napproved
tee equivalent. The airbag unit
o
th while it is not installed in the vehicle.
must never be electrically tested
au or
a
ss c
ce
e
nl
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
pt
du
an
itte
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
y li
erm
ab
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
ility
ot p
tire from the rim before attempting any repair.
wit
, is n
h re
hole
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
spec
es, in part or in w
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
t to the co
I have read and I understand these Cautions and Warnings.
rrectness of i
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nf
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orm
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Page 3 of 3
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Service

Service Department. Technical Information

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Copyright © 2008 Volkswagen AG, Wolfsburg D3E8001E354

1.3 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.6 Auxiliary Engine Coolant Heater, Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.5 Coolant Circuit Layout, Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6 Fuel Lines, Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.8 Remote Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.3 Air Intake Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

82 – Auxiliary Engine Coolant Heater

⇒ “1.6 Auxiliary Engine Coolant Heater, Regulation”, page 3

1.1 Safety Precautions

The auxiliary engine coolant heater must not be in operation

applicable) in enclosed areas without adequate ventilation and

When working on a fuel system, always observe applicable

safety regulations. ⇒ Engine Mechanical, Fuel Injection and

Ignition; Rep. Gr. 20 ; General Information or ⇒ Engine Me‐

chanical, Fuel Injection and Glow Plug; Rep. Gr. 20 ; General

– Release cooling system pressure by slowly and carefully

1.2 General Repair Information

♦ Check following points after repair work in area of fuel lines to

1.3 Clean Working Conditions

– Thoroughly clean all unions and adjacent areas before dis‐

♦ Place parts that have been removed on a clean surface (use

1.4 Identification Plate

♦ The relevant technical data are shown on upper area of man‐

2 Rep. Gr.82 - Auxiliary Engine Coolant Heater

1.5 Fuel Supply

♦ Only install clean components: Only unpack replacement

parts immediately prior to installation. Do not use any parts

tion takes place either automatically, with Programmable Timer -

Various operating conditions can be set according to heat re‐

♦ If ECON is in use, auxiliary engine coolant heater does not op‐

Temperature at Auxiliary Heater Coolant Temperature Sensor -

tion Air Blower -V6- is performed. If the flame extinguishes during

er -V6- continue to run to cool the heater unit down (run–on

period), and are switched off automatically.

software version of the control module.

1.7 Programmable Timer and/or Remote

Various operating conditions can be set according to heat re‐

4 Rep. Gr.82 - Auxiliary Engine Coolant Heater

develops or the flame goes out, the starting procedure is induced

The run on period of the Recirculation Pump -V55- and Combus‐

tion Air Blower -V6- is dependent on the operation mode present

Deviations from standard times are possible depending on the

2 Description and Operation

2.1 Auxiliary Engine Coolant Heater, Serv‐

♦ If auxiliary engine coolant heater is also powered by Program‐

hicle Diagnosis, Testing and Information System -VAS 5051B-

“Guided Fault Finding”, then select Adapting Telestart.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1410- (or 4–20 Nm equivalent)

♦ Hose clamps up to Ø 25 mm -3094-

♦ A manufacturer's identification plate is attached to the auxiliary

engine coolant heater. This plate indicates which heater ver‐

♦ The coolant circuit must be bled after it is opened⇒ Engine

Mechanical, Fuel Injection and Ignition; Rep. Gr. 19 ; General

Information or ⇒ Engine Mechanical, Fuel Injection and Glow

Plug; Rep. Gr. 19 ; General Information

6 Rep. Gr.82 - Auxiliary Engine Coolant Heater

1 - Engine Coolant Tempera‐