Get Auxiliary air heater Guide for Volkswagen Transporter Van Sixth generation (2015-2021)

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

7

Auxiliary air heater

⇒ “7.1 Assembly overview – auxiliary air heater”, page 34

⇒ “7.2 Removing and installing auxiliary air heater”, page 36

⇒ “7.3 Removing and installing air intake silencer”, page 39

⇒ “7.4 Assembly overview - exhaust system”, page 40

⇒ “7.5 Removing and installing exhaust system”, page 40

⇒ “7.6 Removing and dismantling auxiliary air heater bracket”,

page 41

⇒ “7.7 Removing and installing auxiliary air heater control unit

J604 ”, page 42

⇒ “7.8 Removing and installing heater in housing”, page 44

⇒ “7.9 Removing and installing burner unit”, page 45

⇒ “7.10 Removing and installing glow plug for heater Q9 ”,

page 45

⇒ “7.11 Removing and installing flame monitor G64 and combi‐

nation sensor”, page 46

⇒ “7.12 Removing and installing combustion air blower 2 V385 ”,

page 47

⇒ “7.13 Removing and installing heat exchanger”, page 48

⇒ “7.14 Removing and installing temperature sensor G18 ”, page

50

7.1

Assembly overview – auxiliary air heater

34

Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

1 - Upper part of outer casing

❑ Made of plastic

❑ Removing and installing

⇒ page 44

2 - Flame monitor - G64- and

overheating sensor - G189-

(combination sensor)

❑ Overheating and flame

monitor

❑ Supplied with installa‐

tion tool

❑ Removing and installing

⇒ page 46

3 - Glow plug for heater - Q9-

❑ Supplied with special

tool

❑ Removing and installing

⇒ page 45

❑ 6 Nm

4 - Front cover

❑ Made of plastic

❑ Removing and installing

⇒ page 44

5 - Glow pin lining

❑ Supplied with installa‐

tion tool

❑ Vehicle-specific

6 - Heat exchanger

❑ Removing and installing

⇒ page 48

7 - Combustion chamber

❑ Removing and installing

⇒ page 45

8 - Lower part of outer casing

❑ Made of plastic

❑ Removing and installing ⇒ page 44

9 - Flange seal

❑ Renew if damaged

10 - Combustion air blower - V6- (combination blower)

❑ Combustion and heating air blower in one

❑ Removing and installing ⇒ page 47

11 - Metering pump 2 - V386-

❑ Removing and installing ⇒ page 51

12 - Auxiliary air heater control unit - J604-

❑ Removing and installing ⇒ page 42

7. Auxiliary air heater

35

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

7.2

Removing and installing auxiliary air

heater

Note

A type plate is fitted on the auxiliary air heater unit. This plate

provides information about the type of auxiliary air heater installed

in the vehicle ⇒ page 38 .

Note

The auxiliary air heater with bracket should only be removed if the

bracket is damaged.

Removing without bracket ⇒ page 38

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1410A-

♦ Engine bung set - VAS 6122-

Removing

– Separate electrical 10-pin connector - T10ba- -1- from auxili‐

ary air heater beneath front right seat.

– Remove right underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐

view - underbody cladding .

– If fitted, unbolt stone deflector strip.

– Guide wiring harnesses through opening in floor.

CAUTION

The fuel system is pressurised.

Risk of injury caused by fuel spray.

– Wear safety goggles.

– Wear protective gloves.

– To release pressure, wrap a clean cloth around the connec‐

tion, and carefully loosen the connection.

– Separate fuel line -arrow- from auxiliary air heater.

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Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Seal fuel line.

– Detach cable ties on connecting elements -2- and -6-.

– Loosen bolts -1-.

Note

Do not remove bolts -1- completely.

– Unscrew bolts -4-.

7. Auxiliary air heater

37

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Remove auxiliary air heater -3- from guide -A-.

Type plate

Note

♦ Date of first use is entered on lower part of type plate.

♦ The heat exchanger can be used for 10 years but must be

replaced once this date has elapsed.

Removing without bracket

– Separate electrical 10-pin connector - T10ba- -1- from auxili‐

ary air heater beneath front right seat.

– Remove right underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐

view - underbody cladding .

– Guide wiring harnesses through opening in floor.

CAUTION

The fuel system is pressurised.

Risk of injury caused by fuel spray.

– Wear safety goggles.

– Wear protective gloves.

– To release pressure, wrap a clean cloth around the connec‐

tion, and carefully loosen the connection.

– Separate fuel line -arrow- from auxiliary air heater.

– Seal fuel line.

– Remove exhaust system ⇒ page 40 .

– Loosen clamp for air intake silencer at auxiliary air heater.

– Detach cable ties at connecting elements -1- of air ducts.

38

Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Push connecting elements in direction of -arrow-.

– Unscrew nuts -3-.

– Remove auxiliary air heater -1- from bracket -2-.

Installing

Install in reverse order of removal, observing the following:

Torque settings

Component

Specified torque

Bolts for securing auxiliary heater to 8 Nm

underbody

Collar nuts on auxiliary heater

8 Nm

7.3

Removing and installing air intake si‐

lencer

Removing

– If fitted, unbolt stone deflector strip.

– Detach clamps or cable ties at connecting elements of air

ducts -1-.

– Push air ducts in direction of -arrow- off auxiliary air heater.

– Unscrew bolts from bracket of auxiliary air heater.

– Lower auxiliary air heater.

– Secure auxiliary air heater to body, e.g. with a welding wire.

– Unscrew bolt -3-.

– Remove clamp -2-.

– Unscrew air intake silencer -1- in direction of arrow.

– Loosen clamp -5-.

– Remove air intake silencer -4- from auxiliary air heater.

Installing

Install in reverse order of removal.

7. Auxiliary air heater

39

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

7.4

Assembly overview - exhaust system

1 - Bracket

❑ Removing ⇒ page 41

2 - Collar nut

❑ 8 Nm

3 - Exhaust system

❑ Removing and installing

⇒ page 40

4 - Flange bolt

❑ 8 Nm

5 - Clip

❑ 6 Nm

7.5

Removing and installing exhaust system

Removing

– Remove right underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐

view - underbody cladding .

– If fitted, unbolt stone deflector strip.

CAUTION

Danger of severe burns from hot exhaust system.

Risk of burns to hands and other parts of body.

– Allow exhaust system to cool down.

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Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Loosen clamp -5-.

– Unscrew bolt -4-.

– Detach exhaust system -3-.

Installing

Install in reverse order of removal, observing the following:

Torque settings

♦ ⇒ “7.4 Assembly overview - exhaust system”, page 40

7.6

Removing and dismantling auxiliary air

heater bracket

Remove for renewal only

Special tools and workshop equipment required

7. Auxiliary air heater

41

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

♦ Torque wrench - V.A.G 1410-

– Removing auxiliary air heater without bracket ⇒ page 42 .

– If fitted, unbolt stone deflector strip.

– Unscrew nuts -3-.

– Remove bracket -2- from auxiliary air heater -1-.

Dismantling bracket

– Remove bracket from auxiliary air heater ⇒ page 41 .

The complete bracket consists of 3 parts, each connected to a

rubber buffer.

Rubber buffers -1- are secured by means of hexagon nuts -2-.

♦ Dimension -A- = 10 mm

♦ Dimension -B- = 16 mm

Note

During installation, dimension -A- must face upwards.

Torque settings

Component

Specified torque

8 Nm

Nuts securing rubber buffers

Nuts securing auxiliary heater

7.7

Removing and installing auxiliary air

heater control unit - J604-

Special tools and workshop equipment required

42

Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

♦ Torque screwdriver - VAS 6494-

Removing

– If fitted, unbolt stone deflector strip.

– Remove heater unit from housing ⇒ page 44 .

– Disconnect electrical connectors -1-.

– Move wiring harnesses aside.

– Unscrew bolts -2-.

– Detach auxiliary air heater control unit - J604- -1- upwards

from heater unit -2-.

Installing

Install in reverse order of removal, observing the following:

Note

When installing, make sure that the 10-pin connection is located

on the glow plug end.

– Screw in bolts -2- loosely.

– Tighten bolts -2- alternately in diagonal sequence to specified

torque.

Specified torques

Component

Bolts -2-

Specified torque

1.5 Nm

7. Auxiliary air heater

43

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

7.8

Removing and installing heater in hous‐

ing

Removing

– Release locking tabs -2-.

– Swing cover -1- in direction of -arrow-, and detach it.

– Remove connector grommet -2- from lower casing -1-.

– Pull air outlet cowling -2- off lower casing -1-.

– Pull off flange seal -3-.

– Swing heater unit -2- in direction of -arrow- out of lower casing

-1-, and remove it.

Installing

Install in reverse order of removal, observing the following:

Note

If the lower casing is to be renewed, attach a new type plate, and

transfer the data from the old type plate to the new one.

Installing

Install in reverse order of removal, observing the following:

– Before installing, check flange seal of heater unit for damage.

Renew if necessary.

44

Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

7.9

Removing and installing burner unit

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1410A-

Removing

– Remove combustion air blower 2 - V385- ⇒ page 47 .

– Unscrew bolts -2-.

Note

Combustion chamber -1- is removed along with glow plug for

heater - Q9- and fuel pipe.

– Pull out combustion chamber -1-.

Installing

Install in reverse order of removal, observing the following:

– Renew seal between combustion chamber -1- and heat ex‐

changer.

Note

When reassembling, use the rubber grommets for the wiring har‐

ness of the glow plug for heater - Q9- and fuel pipe as a guide.

– Insert combustion chamber -1-.

– Screw in bolts -2- loosely.

– Tighten bolts -2- alternately in diagonal sequence to specified

torque.

Specified torques

Component

Bolts -2-

Specified torque

6.5 Nm

7.10

Removing and installing glow plug for

heater - Q9-

Note

♦ Glow plug with flame monitor - Q9- is activated immediately

after activation and switched off again about 1 minute after a

flame has been detected.

♦ The maximum glow period for the auxiliary air heater is 150

seconds.

♦ When heater unit is switched off, glow plug with flame monitor

- Q9- is switched back on again during the 4 minute run-on

time to burn off all fuel.

♦ It is essential to check the mantle for carbonised deposits and

damage if glow plug with flame monitor - Q9- is renewed.

Removing

– Remove auxiliary air heater ⇒ page 36 .

7. Auxiliary air heater

45

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Release locking tabs -1-.

– Swing cover -2- in direction of -arrow-, and detach it.

– Pull grommet -3- out of lower casing -1-.

– Disconnect electrical connector -2-.

– Lever out grommet -4- with a screwdriver.

– Remove glow plug for heater - Q9- .

Installing

Install in reverse order of removal, observing the following:

Note

Make sure that the locking element of the electrical connector for

the glow plug for heater - Q9- points towards the combustion air

blower 2 - V385- .

7.11

Removing and installing flame monitor -

G64- and combination sensor

Note

The combination sensor comprises the flame monitor - G64- and

overheating sensor - G189- in one component.

Removing

– Remove auxiliary air heater ⇒ page 36 .

– Release locking tabs -2-.

– Swing cover -1- in direction of -arrow-, and detach it.

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Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Disconnect electrical connector -1-.

– Release retaining clip -1- in area marked by -arrows-, and re‐

move it.

– Pull combination sensor -2- out of heater unit.

Installing

Install in reverse order of removal, observing the following:

– Rout wiring harness through nearest cooling fin.

Note

Make sure not to damage the wiring harness when inserting the

retaining clip.

7.12

Removing and installing combustion air

blower 2 - V385-

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1410A-

Removing

– Remove auxiliary air heater control unit - J604- ⇒ page 42 .

– Unscrew bolts -2-.

– Detach combustion air blower 2 - V385- -1- from heat ex‐

changer -3-.

7. Auxiliary air heater

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Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

Installing

Install in reverse order of removal, observing the following:

– Renew seal -1-.

Specified torques

Component

Bolts -2-

Specified torque

6.5 Nm

7.13

Removing and installing heat exchanger

Removing

– Removing auxiliary air heater without bracket ⇒ page 36 .

– Remove auxiliary air heater from plastic housing ⇒ page 44 .

– Remove auxiliary air heater control unit - J604- ⇒ page 42 .

– Unscrew bolts -1- from combustion air blower - V6- -2-.

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Rep. gr.82 - Supplementary heating

Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

– Remove heat exchanger -4- with seal -3- from combustion air

blower - V6- -2-.

Installing

Install in reverse order of removal, observing the following:

Note

♦ Note that seal -3- must be renewed when heat exchanger -4- is installed.

♦ If heat exchanger is renewed, flame monitor - G64- and overheating sensor - G189- (combination sensor)

must be transferred.

– Fit heat exchanger -4- with new seal -3- on combustion air

blower - V6- -2-.

– Tighten bolts -1- in diagonal sequence

– Perform a functional check after completing all work on the

heater unit.

7. Auxiliary air heater

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Transporter 2020 ➤

Auxiliary heater - Edition 04.2020

Torque settings

Component

Specified torque

4 Nm

Bolts -1- on combustion chamber

7.14

Removing and installing temperature

sensor - G18-

Note

Temperature sender - G18- is permanently installed on auxiliary

air heater control unit - J604- -1- and cannot be renewed individ‐

ually.

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Rep. gr.82 - Supplementary heating

Auxiliary air heater for Your Volkswagen Transporter Van Sixth generation (2015-2021)

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