Service

Workshop Manual
Touareg 2003 ➤
Supplementary heating
Edition 07.2005

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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
82 - Supplementary heating

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0058960520

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

Contents

82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Auxiliary heater Thermo Top Z/C -B- (petrol) or -D- (diesel) . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures for working on vehicles with auxiliary heaters . . . . . . . . . . . . . . . . . . . . 1
2 Notes on general repairs on vehicles with auxiliary heaters . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Rules for cleanliness when working on the auxiliary heater and the fuel system . . . . . . . . 3
4 Auxiliary heater Thermo Top Z/C -D- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Repairing the auxiliary heater Thermo Top Z/C -D- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Auxiliary heater components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Removing and installing auxiliary heater Thermo Top Z/C -D- . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Removing and installing heater cooler shut-off valve N279 . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Dismantling and assembling auxiliary heater Thermo Top Z/C -D- . . . . . . . . . . . . . . . . . . 15
6.1 Removing and installing connector strip cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Connector strip assignment for auxiliary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Pin assignment of the connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Removing and installing combustion air blower V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.5 Removing and installing combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6 Removing and installing glow plug with flame monitoring Q8 . . . . . . . . . . . . . . . . . . . . . . 18
6.7 Connecting auxiliary heater -Thermo Top Z/C -D- in coolant circuit, 10-cylinder . . . . . . . . 18
6.8 Fuel supply to auxiliary heaters Thermo Top Z/C -D- . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.9 Regulating auxiliary heater -Thermo Top Z/C -D- (preheater) . . . . . . . . . . . . . . . . . . . . . . 25
6.10 Regulation of auxiliary heater Thermo Top Z/C -D- with preselection clock E111 and/or
remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.11 Remote control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Contents i
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1 Auxiliary heater Thermo Top Z/C -B-

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1.1 Safety measures for working on vehi‐

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cles with auxiliary heaters

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♦ The auxiliary heater must not be in operation or switched on
in areas in which there is a risk of fire or explosion.
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♦ The auxiliary heater must not be in operation or switched on

(including via a preset switch-on time) in closed rooms without

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an exhaust extraction system.

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♦ When working on a fuel system, always observe applicable
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safety regulations. ⇒ Rep. Gr. 20
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♦ If fuel system components (e.g. metering pump, fuel lines, fuel

a

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gauge sender) are removed or opened, the engine of the ve‐

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hicle must not be started.

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♦ Before beginning repair work on the auxiliary heater:
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– Release pressure in the cooling system by carefully opening cop Vo
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♦ After completing repair work on the auxiliary heater or the fuel

system, check the operation of the auxiliary heater.
♦ After completing repairs on the auxiliary heater, carry out self-
diagnosis using vehicle diagnosis, testing and information
system -VAS 5051B- .

1. Auxiliary heater Thermo Top Z/C -B- (petrol) or -D- (diesel) 1

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

2 Notes on general repairs on vehicles

with auxiliary heaters
♦ Read self-diagnosis of auxiliary heater using vehicle diagno‐
sis, testing and information system -VAS 5051B- .
♦ If parts of the fuel system were removed or renewed, ensure
that all components for fuel delivery to the auxiliary heater are
properly installed.
♦ Mark the coolant hoses for identification purposes to avoid
confusion after they have been removed.
♦ The auxiliary heater will not function if the tank flap has been
opened.
♦ Following repair work in the vicinity of the auxiliary heater fuel
line, check:
♦ that the fuel line fits flush with nthe .vehicle
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♦ that the auxiliaryriheater
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♦ that the fuel line does not come in contact with vehicle parts ce
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2 Rep. Gr.82 - Supplementary heating

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on the auxiliary heater and the fuel

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– Thoroughly clean all connections and adjacent areas before
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♦ Place parts that have been removed on a clean surface (use
sheeting or paper, but no fluffy cloths) and cover.
♦ If the repair is not carried out immediately, cover or seal the

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components.
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♦ Only install clean components:

– Only remove genuine replacement parts from their packages

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immediately before installing them.

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– Do not use components which have been stored unpacked

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(e.g. in a toolbox).

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♦ If the fuel system is open:

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– Do not work with compressed air.

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– Do not start engine. cop Vo
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– Do not switch on auxiliary heater.
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3. Rules for cleanliness when working on the auxiliary heater and the fuel system 3
 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

4 Auxiliary heater Thermo Top Z/C -D-

4.1 Repairing the auxiliary heater Thermo

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4.1.1 Carry out the following work before start‐ au
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– Switch off all electrical consumers.

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– Switch off ignition.
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– Pull out ignition key.
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– Mark the coolant hoses for identification purposes to avoid

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confusion after they have been removed.
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Note

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♦ If the auxiliary heater is also operated with pre-selection clock
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-E111- and/or remote control, the battery must be disconnec‐

ted ⇒ Rep. Gr. 27 .

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♦ The remote control for the auxiliary heater will have to be

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adapted again after the vehicle batteries have been discon‐

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nected. Vehicle diagnosis, testing and information system -

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VAS 5051B- “Guided functions”, then select Adapt Telestart.
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Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1410- (4...20 Nm)
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♦ Hose clamps up to Ø 25 mm -3094-

4 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

Note

♦ A manufacturer's plate is stuck on the auxiliary heater unit.

This manufacturer's plate provides information about which
version is installed in vehicle: diesel - Thermo Top Z/C -D-
⇒ page 6 .
♦ The coolant circuit must be bled after it is opened ⇒ Rep. Gr.
19 .

1 - Coolant temperature send‐

er -G62-
❑ Location: in return hose
from radiator.
❑ Checking: vehicle diag‐
nosis, testing and infor‐
mation system -VAS
5051B- .
2 - Pre-selection clock -E111-
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rear seat bench.

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4 - Remote control receiver for
erm

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auxiliary coolant heater -R149-

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❑ Location: roof, rear cen‐
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5 - Second battery -A1- spec

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❑ Location: under luggage
compartment floor
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6 - Battery -A-
❑ Location: under the front
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left seat.
7 - Fuse carrier
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❑ Location: on the left-

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hand side, under the

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dash panel ⇒ Current

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flow diagrams, Electri‐

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8 - Metering pump -V54-
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❑ Check fuel supply of auxiliary heater, diesel ⇒ page 19 .
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❑ The metering pump can tick audibly but not deliver fuel because there is air in the intake. The control
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unit will then switch off permanently. Read out fault memory of the self-diagnosis of the auxiliary heater
Thermo Top Z/C -D- using vehicle diagnosis, testing and information system -VAS 5051B- . Delete the
fault memory and carry out a final control diagnosis of the auxiliary heater Thermo Top Z/C -D-.
❑ Removing and installing ⇒ page 21 .
❑ Testing quantity of fuel delivered ⇒ page 23 .
9 - Circulation pump -V55-
❑ Location: on auxiliary heater.
❑ Removing and installing ⇒ page 11 .

4. Auxiliary heater Thermo Top Z/C -D- 5

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

10 - Auxiliary heater Thermo Top Z/C -D-

❑ With heater control unit -J162- .
❑ Location: under the front left wing.
❑ Removing and installing ⇒ page 8 .
11 - Silencer
❑ Removing and installing ⇒ page 6 .
12 - Heater coolant shut-off valve -N279-
❑ Location: in front left wheel arch.
❑ Only fitted in vehicles with auxiliary heating.
❑ Removing and installing ⇒ page 12
13 - Ambient temperature sensor -G17-
❑ Location: behind centre air intake grille.
❑ Removing ⇒ page 6 .
❑ Checking with: vehicle diagnosis, testing and information system -VAS 5051B- .

Manufacturer's plate for diesel Thermo Top Z/C-D

Note

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

manufacturer's plate.
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♦ The year the unit was first put into use must be entered onuth the
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“Genuine spare part” manufacturer's plate. The heat exchang‐
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er for the coolant heaters does not have be renewed after 10

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years. Legislation in Germany dictates only that air heaters

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must be renewed.

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♦ Affix the manufacturer's plate in a clearly visible location.
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Removing and installing ambient temperature sensor -G17-
es, in part or in w

t to the co
– Remove radiator grille ⇒ Rep. Gr. 66 .
– Unclip temperature sensor from lock support -1-.

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– Disconnect electrical connector from ambient temperature
sensor -G17- .
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4.1.2 Removing and installing silencer

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Silencer could be hot.

Let the silencer cool off before removing it.

6 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

– Remove left wheel arch liner ⇒ Rep. Gr. 66 .

– Loosen pipe clamp on exhaust pipe -arrow-.

– Remove left floor cover panel ⇒ Rep. Gr. 50 .

– Unscrew securing nut -arrow- and remove silencer.

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4. Auxiliary heater Thermo Top Z/C -D- 7

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

5 Auxiliary heater components

5.1 Removing and installing auxiliary heater Thermo Top Z/C -D-

1 - Coolant hose, return from

heat exchanger
2 - Coolant hose, supply to
heat exchanger
3 - Air intake silencer
❑ Removing and installing
⇒ page 11 .
4 - Circulation pump -V55-
❑ Removing and installing
⇒ page 11 .
5 - Auxiliary heater Thermo
Top Z/C -D
❑ With heater control unit
-J162- .
❑ Removing and installing
⇒ page 8 .
6 - Heater coolant shut-off AG. Volkswagen AG d
valve -N279- agen oes
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❑ Removing and installing
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⇒ page 12
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5.1.1 Removing
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Special tools and workshop equipment required

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

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8 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

♦ Hose clamps up to Ø 25 mm -3094-

Note

♦ Bleed the coolant circuit if it is opened ⇒ Rep. Gr. 19 .

♦ If the drive motor is warm, then the cooling system is pressur‐
ised. If necessary, release pressure before carrying out re‐
pairs.
♦ Once the auxiliary heater -Thermo Top Z/C -D- has been dis‐
connected, it must be secured to the body with welding wire.
This prevents damage to the coolant hoses.

Carry out the following work before starting assembly:

– Switch off all electrical consumers.
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– Switch off ignition. lkswagen oes
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– Pull out ignition
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♦ If the auxiliary heater is operated with pre-selection clock -

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E111- and/or remote control, the batteries must be discon‐

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nected ⇒ Rep. Gr. 27 .

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♦ Following disconnection of the vehicle batteries, the auxiliary

hole

spec

heater remote control must be re-adapted. Select “Guided

es, in part or in w

functions” and then Adapt Telestart on vehicle diagnosis, test‐

t to the co

ing and information system -VAS 5051A- .

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– Remove front left wheel arch liner ⇒ Rep. Gr. 66 .

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

-3094- .
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WARNING
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Danger of scalding injuries.

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

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the coolant temperature may be above 100 0C.

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Reduce pressure and temperature before carrying out repairs.
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5. Auxiliary heater components 9

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

– Loosen clamps -1- and pull coolant hoses off coolant pipes.
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Fuel system is under pressure.

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Before opening fuel system, wrap a cloth around the connec‐

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ab
tion. Then release pressure by carefully loosening the connec‐

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tion.

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– Loosen clamps -2-, disconnect and seal fuel lines. Replacees, in part or in w

t to the co
clamps with screw-type clamps.

– Loosen clamps -1- and pull coolant hoses off coolant pipes.

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– Loosen clamp -2- and disconnect exhaust system.
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Remove bracket for coolant and exhaust pipes. p by
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– Unscrew securing nuts -2- and securing bolts-1-. Prote AG.

Remove bracket for auxiliary heater.

– Unscrew securing bolts -1-.
– Unhook auxiliary heater bracket by lifting upwards -arrow-.
– Remove auxiliary heater with bracket.
– Unplug electrical connectors at auxiliary heater.

10 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

5.1.2 Installing
Installation is carried out in the reverse sequence.

Note

Rubber mounting -1- must sit on guide pin -2- (shown without
wing).

5.1.3 Removing and installing air intake si‐

lencer
Removing
– Unscrew bolt -1- from bracket and loosen clamp -3-. Pullwair
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– Slide air intake connecting piece -2- towardsss auxiliary heater
until it lies against the combustion air blower housing.

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– Attach retainer and tighten bolt -1- and clamp -3-.

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5.1.4 Removing and installing circulation
pump -V55-

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Note
nform
ercia

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

m

at
om

19 .
ion
c

in t
or

♦ Cooling system is pressurized when engine is warm. If nec‐

his
te

essary, release pressure before carrying out repairs.

a

do
priv

cum
for

en
g

Special tools and workshop equipment required

n

t.
yi Co
Cop py
♦ Hose clamps up to Ø 25 mm -3094-
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Auxiliary heater components 11

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

Removing
– Clamp off the coolant hoses.
– Loosen clamps -1-.

WARNING

Danger of scalding injuries.

The cooling system is pressurised. When the engine is warm,
the coolant temperature may be above 100 0C.
Reduce pressure and temperature before carrying out repairs.

– Pull coolant hoses off circulation pump -V55- .

– Loosen screw-type clamp -2-.
– Unplug electrical connector -3- from circulation pump -V55-
and remove it.

Installing
– Install in reverse order.

5.2 Removing and installing heater cooler

shut-off valve -N279-
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1410- (4...20 Nm)

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

♦ Hose clamps up to 25 mm Ø -3094-

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
yri by

12
op Vo
by c lksw
Rep. Gr.82 - Supplementary heating Prote
cted AG.
agen
 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

♦ Pliers for spring-type clips -VAS 5024A-

Removing

Note

♦ Bleed the coolant circuit if it is opened ⇒ Rep. Gr. 19 .

♦ If the drive motor is warm, then the cooling system is pressur‐
ised. If necessary, release pressure before carrying out re‐
pairs.
olkswagen AG
en AG. V
♦ Once the auxiliary heater -Thermo
Vol
kTop
swa Z/C -D- has been dis‐
g does
not
connected, it must be secured d bto the body with welding wire.
y gu
ara
This prevents damage toththeise
or coolant hoses.
nte
eo
au ra
c
ss
Carry out the following work before starting assembly:
ce
le
un

pt
an
d

– Switch off all electrical consumers.

itte

y li
erm

– Switch off ignition. ab

ility
ot p

wit
is n

– Pull out ignition key. h re

ole,

spec
urposes, in part or in wh

Note
t to the co

♦ If the auxiliary heater is operated with pre-selection clock -

E111- and/or remote control, the batteries must be discon‐
rrectne

nected ⇒ Rep. Gr. 27 .

s

♦ Following disconnection of the vehicle batteries, the auxiliary

s o

heater remote control must be re-adapted. Select “Guided

cial p

f in

functions” and then Adapt Telestart on vehicle diagnosis, test‐

form
mer

ing and information system -VAS 5051B- .

atio
om

n
c

i
or

– Remove front left wheel arch liner ⇒ Rep. Gr. 66 .

thi
te

sd
va

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

i

o
pr

cum

-3094- .
r
fo

en
ng

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

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

the coolant temperature may be above 100 0C.
Reduce pressure and temperature before carrying out repairs.

5. Auxiliary heater components 13

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005 n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Loosen the clamps -1- and pull coolant hoses -2- off heater
ir se
d b ran
coolant shut-off valve -N279- -3-. utho tee
or
s a ac
– Remove screws -4- and remove heater coolant shut-off valve
s

ce
e
-N279- .

nl

pt
du

an
itte

y li
Installing

erm

ab
ility
ot p
– Install in reverse order.

wit
, is n

h re
– Filling cooling system ⇒ Rep. Gr. 19 .

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.

14 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

6 Dismantling and assembling auxiliary

heater Thermo Top Z/C -D-

Note

Removing and installing auxiliary heater ⇒ page 8 .

1 - Glow plug with flame moni‐

AG. Volkswagen AG d
toring -Q8- lksw
agen oes
not
Vo
❑ Removing and installing ed by gu
ara
⇒ page 18 . thoris nte
e or
au ac
2 - Seal ss

ce
e
nl

❑ Always renew after re‐

pt
du

an
moval.
itte

y li
erm

ab
3 - Rubber grommet

ility
ot p

wit
, is n

4 - Combustion air blower -V6-

h re
hole

❑ Removing and installing

spec
⇒ page 17 .
es, in part or in w

t to the co
5 - Bolt
6 - Retaining clip

rrectness of i
❑ for glow plug with flame
l purpos

monitoring -Q8-
❑ Retaining clip changed
as of 02.2003: please

nf
ercia

o
check fitting location.

rm
m

atio
om

Note n in
or c

thi
te

sd
a

The auxiliary heater will not operate

iv

o
r
rp

cu

if the retaining clip has been instal‐

o

m
f

en
ng

led turned through 1800.

t.
yi Co
Cop py
t. rig
gh
7 - Retaining clip
ht
pyri by
Vo
o
by c lksw
❑ for glow plug with flame Prote
cted AG.
agen
monitoring -Q8-
8 - Clip
❑ Note fitting position.
9 - Combustion chamber with
flame tube
❑ Clean inside and outside with brass wire brush (spark plug brush).
❑ Removing and installing ⇒ page 18 .
10 - Seal
❑ Always renew after removal.
11 - Water jacket
❑ Clean inside and outside with brass wire brush (spark plug brush).
❑ Do not dismantle further.
12 - Connector strip cover
❑ Removing and installing ⇒ page 16 .
❑ Connector strip assignment ⇒ page 16 .

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 15

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

6.1 Removing and installing connector strip

cover

Note

Removing and installing auxiliary heater ⇒ page 8 .

– Lever connector strip cover -A- off using a screwdriver.

6.2 Connector strip assignment for auxiliary

heater
AG. Volkswagen AG d
agen oes
– 6-pin connector -A- y Volksw not
gu
d b ara
– Connector -B- for voltage supply , 12 Volt rise nte
tho eo
au ra
– Connector -C- to glow plug with flame monitoring
ss -Q8- c

ce
e
nl

pt
– Connector -D- for combustion air blower -V6-
du

an
itte

y li
– Connector -E- not used
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

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.

16 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

6.3 Pin assignment of the connectors

6-pin electrical connector, connector housing -A-
1 - Webasto diagnosis wire
2 - CAN high (optional)
3 - CAN low (optional)
4 - Heater coolant shut-off valve -N279-
5 - Main switch
6 - Metering pump -V54-
2-pin electrical connector, connector housing -B-
1 - Terminal 30 n AG. Volkswagen AG do
lkswage es n
o ot g
2 - Terminal 31 d byV ua
ran
ir se tee
2-pin electrical connector, connector housing -C- utho
or
a ac
ss
1 - Glow plug with flame monitoring -Q8-

ce
le
un

pt
an
2 - Terminal 31
d
itte

y li
erm

ab
ility
ot p

2-pin electrical connector, connector housing -D-

wit
is n

h re
1 - Combustion air blower -V6-
ole,

spec
urposes, in part or in wh

2 - Terminal 31

t to the co
rrectness o
cial p

f inform
mer

atio
om

6.4 Removing and installing combustion air

n
c

i
or

n thi
e

blower -V6-
t

sd
iva

o
pr

cum
r

Removing
fo

en
ng

t.
yi Co
– Removing and installing auxiliary heater ⇒ page 8 . Cop py
t. rig
gh ht
yri
– Remove connector strip cover and disconnect electrical con‐ p by
co Vo
lksw
nections to connector strip ⇒ page 16 .
by
cted agen
Prote AG.
– Remove bolts -A-.
– Remove combustion air blower -V6- -B- from auxiliary heater.
Installing

Note

♦ Renew the seal between the combustion air blower and the
auxiliary heater.
♦ Ensure proper seating of fuel line -C- in grommet -D-.

Install in reverse order.

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 17

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

6.5 Removing and installing combustion

chamber
Removing
– Remove combustion air blower -V6- ⇒ page 17 .
– Remove glow plug with flame monitoring -Q8- ⇒ page 18
– Remove bolts -A-.
– Pull combustion chamber -B- upwards out of auxiliary heater
-C-.
Installing

Note

♦ Renew the seal between the combustion chamber and the

auxiliary heater.
♦ Also renew glow plug with flame monitoring -Q8- if combustion
chamber is defective ⇒ page 18 .
AG. Volkswagen AG d
agen oes
olksw not
6.6 Removing and installing glow plug with ised byV gu
ara
nte
r
flame monitoring -Q8- aut
ho eo
ra
ss c
Removing

ce
le
un

pt
an
d

– Remove combustion chamber ⇒ page 18 .

itte

y li
erm

ab
– Remove retaining clip -A-.

ility
ot p

wit
is n

Retaining clip changed as of 02.2003: please check fitting loca‐

h re
ole,

tion.

spec
urposes, in part or in wh

t to the co
Note

rrectne
A clip turned 180° out of position will cause a heater unit failure.
s
– Remove glow plug with flame monitor -Q8- -B- from the com‐
s o

bustion chamber and clips -C- and -D-.

cial p

f inform

Installing
mer

atio
om

n
c

i
or

Note
thi
te

sd
iva

o
pr

♦ Install retaining clip -A- and ensure that glow plug with flame
um
r
fo

en

monitoring -Q8- is seated correctly.

ng

t.
yi Co
op py
♦ Insert wiring in clip -D- and route as shown in figure.
. C rig
ht ht
rig by
py
♦ Ensure seal -C- is positioned correctly.
co Vo
by lksw
cted agen
Prote AG.

6.7 Connecting auxiliary heater -Thermo

Top Z/C -D- in coolant circuit, 10-cylin‐
der
The coolant circuits of the different engines were, for technical
reasons, not available at the time of going to print.

18 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
d
rise nte
o eo
Cooling system is pressurized when engine a is warm. If nec‐
h
♦ ut ra
essary, release pressure before carrying out repairs.
ss c

ce
le
un

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

an
d
itte
to heat properly.

y li
rm

ab
pe

ility
ot

wit
, is n

h re
1 - Heat exchanger for heater

hole

spec
2 - Auxiliary heater es, in part or in w

t to the co
3 - Circulation pump -V55-
4 - Fuel cooler

rrectness of i
5 - Alternator
l purpos

6 - Cylinder head and cylinder

block

nform
ercia

7 - Thermostat housing
m

a
com

tio
8 - Valve body

n in
r
te o

thi
9 - Radiator

s
iva

do
r
rp

c
10 - Low temperature cooler

um
fo

en
ng

❑ To cool alternator and

t.
yi Co
op
fuel
C py
t. rig
gh ht
yri by
11 - Fuel cooling pump -V166- cop Vo
by lksw
cted agen
Prote
12 - Continued coolant circula‐
AG.

tion pump -V51-

13 - Non-return valve
❑ Note fitting position.
14 - Coolant expansion tank

6.8 Fuel supply to auxiliary heaters Thermo

Top Z/C -D-

6.8.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place components that have been removed on a clean surface
and cover them. Do not use fluffy cloths!

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 19

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

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

not be carried out immediately.
♦ Install clean parts only; remove replacement parts from their
packages only immediately before installing them. Do not use
any parts which have not been stored in their packaging (e.g.
in a tool box).
♦ Fuel hoses and pipes may be shortened only with a clean,
sharp knife. Cutting points
wage
nmust
AG. Vonot
lkswabe
gensoiled
AG do or deformed.
es n
Cutting points and
y Vosurfaces must be free of burrs.
lks ot g
u b ara
ed
6.8.2 Routing of fuel lines -Thermo Top Z/C or -D-
ris tee n
tho
au ac
ss

ce
e
nl

pt
du

Note

an
itte

y li
erm

ab
♦ Fuel lines are secured with clamps. They must be replaced with screw-type clamps.

ility
ot p

wit
, is n

♦ Start vehicle engine if fuel tank was empty. Then start the auxiliary heater. If the auxiliary heater goes out

h re
again, repeat the procedure until the heater does not go out.
hole

spec
es, in part or in w

♦ Observe the rules for cleanliness when doing all work on the fuel supply system ⇒ page 19 .

t to the co
♦ The metering pumps for auxiliary heaters -Z/C -B- and -Z/C -D- have different flow rates; observe part
numbers.

rrectness of i
l purpos

1 - Metering pump -V54-

❑ Removing and installing
nform
ercia

⇒ page 21 .
m

at

❑ Testing quantity of fuel

om

ion

delivered ⇒ page 23 .
c

in t
or

his
te

2 - Fuel gauge sender

a

do
priv

❑ Location: under the

um
for

en
g

right-hand side of the

n

t.
yi Co
rear seat bench. t. Cop py
rig
gh ht
yri
3 - Fuel line p by
co Vo
by lksw
cted agen
4 - Auxiliary heater Prote AG.

20 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

6.8.3 Fuel feed for auxiliary heater Thermo

Top Z/C -D-
– Flip over the the right-hand side of the rear seat bench.
– Unscrew the bolts (20 Nm) -arrows- and remove the support.

– Cut the floor carpeting at the marked point using a knife and
fold it over.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d
– Undo the securing nuts -arrows- and removeortheise cover plate.
ran
tee
th or
au ac
ss

ce
e
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

– The -arrow- indicates the fuel withdrawal point on the fuel

gauge sender.
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
6.8.4 Removing and installing metering pump
cted agen
Prote AG.

-V54-
Special tools and workshop equipment required

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 21

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

♦ Insert -T10058-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

Removing

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.

– Disconnect electrical connector -5-.

– Loosen clamps -2-.

22 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

WARNING

Danger of fuel escaping.

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

AG. Volkswagen A
– Disconnect the ofuel
lkswhoses -3- from the metering
agen G do
es n pump and seal
ot g
them. d by V ua
r
e an
ris te
– Undo uthetho securing bolt -4- using insert -T10058- ande oremove
ra
the smetering
s a
pump -1- with the bracket. c

ce
e
nl

Installing

pt
du

an
itte

y li
– Ensure proper fitting position of metering pump.
erm

ab
ility
ot p

wit
, is n

h re
Note
hole

spec
es, in part or in w

♦ Fuel lines are secured with clamps. They must be replaced

t to the co
with screw-type clamps.
♦ Observe the rules for cleanliness when doing all work on the

rrectness of i
fuel supply system.
l purpos

♦ The metering pumps for auxiliary heaters -Z/C -B- and -Z/C -
D- have different flow rates; observe part numbers.
nform
ercia

6.8.5 Testing quantity of fuel delivered

m

at
om

io

Special tools and workshop equipment required

n
c

in t
or

his
e

♦ Vehicle diagnosis, testing and information system -VAS

at

do
riv

5051B-
p

cum
for

en
ng

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

♦ Hand multimeter -V.A.G 1526C-

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 23

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
♦ Current flow diagram
ot

wit
, is n
♦ Commercially available measuring glass (0 ml to 25 ml)

h re
hole

spec
♦ Fuel hose, length approx. 300 mm
es, in part or in w

t to the co
Test prerequisites:

rrectness of i
WARNING
l purpos

Danger of fuel escaping.

Fuel system is under pressure.

nform
ercia

Before opening system, wrap a cloth around the connection.

m

a
com

Then release pressure by carefully loosening the connection.

tion in
r
te o

thi
s
iva

do
• Resistance of metering pump Ω 5.4 Ω
r
rp

cum
fo

en
g

• Voltage at metering pump, 11 to 13 Volts

n

t.
yi Co
op py
• No fault stored in fault memory
. C rig
ht ht
rig by
py Vo
• Fuel lines not damaged or leaking
co lksw
by
cted agen
Prote AG.
• Ambient temperature approx. 20°C
• Fuel tank sufficiently filled (fuel gauge on dash panel insert not
in red area).
Checking:
– Disconnect the fuel line at the pressure connection on meter‐
ing pump -V54- . Connect a fuel hose (length approx. 300 mm)
to the pressure connection and run it into a measuring glass
(capacity approx. 25 ml).
– Hold measuring glass at same height as auxiliary heater.
– Using vehicle diagnosis, testing and information system -VAS
5051B- , select address word “18” auxiliary/parking heater.
Select “10” Adaptation and enter channel number 1. Then en‐
ter the value 29 and confirm with the Q key.
– After approx. 60 seconds, the fuel line is filled and bled.
– Empty measuring glass.
– Hold measuring glass at same height as auxiliary heater.
– Using vehicle diagnosis, testing and information system -VAS
5051B- , select address word “18” auxiliary/parking heater.
Select “10” Adaptation and enter channel number 1. Then en‐
ter the value 29 and confirm with the Q key.

24 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

– Check the level in the measuring glass. Delivery quantity, die‐

sel: 16.2 to 17.8 ml.
– If the quantity delivered does not correspond to the specified
values, metering pump -V54- must be renewed.

Note

♦ If the ambient temperature is above 20°C, fuel vapourisation

may lead to incorrect measurements.
♦ No bubbles are to be delivered in the fuel hose.

6.9 Regulating auxiliary heater -Thermo

Top Z/C -D- (preheater)
The auxiliary heater is intended to assist the heat output of the
engine by heating the coolant. It can also be used as an auxiliary
heater with pre-selection clock -E111- and/or remote control
⇒ page 26 .
Various operating modes can be set depending on heat required
in heating circuit:

6.9.1 Functional description of Thermo Top Z/

C -D- (preheater)

Note

♦ If ECON is switched on, the auxiliary heater will not operate as

a supplementary heater.
n AG. Volkswagen AG do
♦ The auxiliary heater will not function if the tank flap
olks
wis
agopen.
e es n
ot g
yV ua
db ran
ise
Temperature at coolant temperature sender tho for heater
r -G241- tee
or
must be below approx. 75°C. ss au ac
ce
e

Temperature at ambient temperature sensor -G17- must be be‐

nl

pt
du

an

low approx. +5°C.

itte

y li
erm

ab

This will set the heater to operational readiness mode. The glow
ility
ot p

plug with flame monitor -Q8- , the combustion air blower -V6- and
wit
, is n

the recirculating pump -V55- begin to operate. After 30 seconds,

h re

the metering pump -V54- is switched on and the combustion air

hole

spec

blower -V6- is switched off for 3 seconds. Then the combustion

es, in part or in w

air blower -V6- runs up in two stages to nearly full load within 56
t to the co

seconds. After a stabilisation period (constant speed) of 15 sec‐

onds the combustion air blower is switched to almost full load
again over a period of 50 seconds.
rrectness of i

After reaching full-load fuel delivery, the glow plug with flame
l purpos

monitoring -Q8- is switched off and the combustion air blower -

V6- is brought up to full load. During the next 45 seconds as well
nform
ercia

as during normal operation, the glow plug with flame monitoring

-Q8- assumes the task of flame monitoring and checks flame de‐
m

at

velopment. Then the automatically regulated heating operation

om

ion

begins. If no flame develops or the flame extinguishes, then the

c

in t
or

fuel supply is interrupted and a malfunction shut-down occurs with

his
ate

the combustion air blower -V6- entering a run-on phase. If the

do
priv

flame is extinguished during normal operation, a new start is au‐

um
for

tomatically initiated.
en
ng

t.
yi Co
op py
6.9.2 Heating mode
t. C rig
gh ht
pyri by
Vo
co
Once the temperature has reached 72°C, the control unit
by lksw
cted agen
Prote
switches to the energy-saving part-load mode. If the coolant tem‐
AG.

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 25

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

perature continues to rise above 76.5°C, the control unit switches

to the controlled waiting period. If the coolant temperature does
not drop below 71°C within 900 seconds, the heater unit switches
to a regular start and heats in full-load mode when the coolant
temperature drops below 71°C.

6.9.3 Switching off

When the vehicle engine is switched off or the coolant reaches a
temperature of 85°C, combustion is ended and the run-on period
begins. The recirculating pump -V55- and the combustion air
blower -V6- , however, continue to run to cool down the heater
(post-operation mode) and are switched off automatically.
AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
d
rise nte
o eo
The run-on period and the speed of the combustion air blower -
th
au ra
V6- are dependent on the operating mode ins which the heater unit
s c

ce
le

is switched off.
un

pt
an
d
itte

y li
erm

ab
The post-operation period is 175 seconds when heater is switch‐

ility
ot p

ed off during full-load operation and 110 seconds for part-load

wit
operation.
is n

h re
ole,

Depending on the control unit software version, slight deviations

spec
urposes, in part or in wh

in the specified post-operation values are possible.

t to the co
6.10 Regulation of auxiliary heater Thermo
Top Z/C -D- with preselection clock -

rrectne
E111- and/or remote control

ss o
cial p

f in
Note

form
mer

atio
m

♦ If ECON is switched on, the auxiliary heater will not operate as

o

n
c

a supplementary heater.
i
or

n thi
te

sd
a

♦ The auxiliary heater will not function if the tank flap is open.
iv

o
pr

cum
r
fo

en
ng

Various operating modes can be set depending on heat required

t.
yi Co
op
in heating circuit: C py
t. rig
gh ht
yri by
Prerequisites for switching on: cop Vo
by lksw
cted agen
Prote
Fuel tank sufficiently filled (fuel gauge on dash panel insert not in
AG.

red area).
Voltage of board network battery in the rear is no lower than 11.5
volts.
– Switch on auxiliary heater.
The glow plug with flame monitor -Q8- , the combustion air blower
-V6- and the recirculating pump -V55- begin to operate. After 30
seconds, the metering pump -V54- is switched on and the com‐
bustion air blower -V6- is switched off for 3 seconds. Thereafter,
the combustion air blower -V6- is regulated up to approx. full load
within 57 seconds. After 90 seconds, the glow plug with flame
monitoring -Q8- is switched off and the combustion air blower -
V6- is brought up to full load.
During the next 40 seconds as well as during normal operation,
the glow plug with flame monitoring -Q8- assumes the task of
flame monitoring and checks flame development. Then the auto‐
matically regulated heating operation begins. A new start is au‐
tomatically initiated if no flame develops or the flame extinguish‐
es. If there is still no flame development, the fuel supply is

26 Rep. Gr.82 - Supplementary heating

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

interrupted and a malfunction shut-down occurs with the com‐

bustion air blower -V6- continuing to run in emergency mode.

6.10.1 Heating mode

Once the temperature has reached 86 C, the heater control unit
-J162- switches to the energy-saving part-load mode. If the tem‐
perature of the coolant drops further (due to use of heater) in part-
load mode, the heater control unit -J162- switches back to full load
at a temperature of 56°C. If the coolant temperature continues
AG. Volksto
wagen AG
rise above 89°C, the heater control unit -J162- oswitchesagen to run- does
lksw not
on. The circulation pump -V55- , the vehicled bfresh air blower -V2-
y V gu
ara
and the operating display will remain in ooperation
ris
e
during the run- nte
eo
on period. au
th
ra
ss c
Once the coolant has cooled down to 76°C, the auxiliary heater

ce
e
nl

pt
starts again.
du

an
itte

y li
erm

When the auxiliary heater is switched off, the heater coolant shut-

ab
ility
off valve -N279- opens to the main circuit.
ot p

wit
, is n

6.10.2 Switching off

h re
hole

spec
es, in part or in w

Switch off auxiliary heater.

t to the co
Combustion stops and the run-on period begins. The circulation
pump -V55- and combustion air blower -V6- continue to run so
that the auxiliary heater cools off quicker.

rrectness of i
l purpos

Note

nf
ercia

o
The run-on period of the circulation pump -V55- and the combus‐

rm
m

atio
tion air blower -V6- depends on the operating mode in which the
om

auxiliary heater was switched off.

n in
or c

thi
te

sd
iva

The run-on period at 23 °C ambient temperature and 26 °C interior

o
r
rp

cu
temperature set on the pre-selection clock -E111- : approx. 168
o

m
f

en
ng

seconds when switching off in full-load operation and approx. 157

t.
yi Co
seconds when switching off in part-load operation. Cop py
t. rig
gh ht
yri
Depending on the control unit software version, slight deviations p by
o Vo
by c lksw
in the specified post-operation values are possible. Prote
cted AG.
agen

6.11 Remote control operation

Note

♦ The remote control has a range of 600 metres in open terrain.

This range is restricted in built-up areas or from buildings.
♦ The remote control should be held upright during operation.
The radio signals can be received optimally by the vehicle
aerial in this way.
♦ Following disconnection of the vehicle batteries, the auxiliary
heater remote control must be re-adapted. Select “Guided
functions” and then Adapt Telestart on vehicle diagnosis, test‐
ing and information system -VAS 5051B- .

6.11.1 Switching auxiliary heater on using re‐

mote control
– Press button -1-, warning lamp -2- must light up green.

6. Dismantling and assembling auxiliary heater Thermo Top Z/C -D- 27

 Touareg 2003 ➤
Supplementary heating - Edition 07.2005

The operating period of the auxiliary heater is determined gen AG by the n AG doe
. Volkswage
swa s no
remote control unit when the heater is switched V on (a time com‐
olk t gu
by
ponent is included in the switching signal).risedThis time component ara
nte
is stored permanently in the remote control
ut
ho and cannot be eo
ra
changed. ss a 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
6.11.2 Switching auxiliary heater off using re‐
mote control

rrectness of i
l purpos

– Press button -3-, warning lamp -2- must light up red.

The auxiliary heater switches to run-on and then off.

nform
ercia

6.11.3 Renewing remote control batteries

m

a
com

tion in
r
te o

thi
Note

s
iva

do
r
rp

cum
fo

♦ Ensure proper installation position of batteries.

en
ng

t.
yi Co
op
♦ Only use batteries of the same type with a voltage of 12 volts.
C py
ht. rig
rig ht
py by
♦ Allocation of the remote control to the auxiliary heater remains co Vo
by lksw
intact. Re-adapting is not necessary.
cted agen
Prote AG.

– Take off battery cover -1- and remove batteries. Insert new
batteries and replace cover.

28 Rep. Gr.82 - Supplementary heating