Service: Passat 2015 Passat Variant 2015

Service
Workshop Manual
Passat 2015 ➤
Passat Variant 2015 ➤
Auxiliary heater
Edition 05.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
82 - Supplementary heating
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Technical information should always be available to the foremen and mechanics, because their Prote AG.
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 © 2016 Volkswagen AG, Wolfsburg D4B804A2FCF

Passat 2015 ➤ , Passat Variant 2015 ➤
Auxiliary heater - Edition 05.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions for working on vehicles with auxiliary/supplementary heater . . . . . . . . 1
1.2 Safety measures for when working on vehicles with a start/stop system . . . . . . . . . . . . . . 2
1.3 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Safety precautions when using testers and measuring instruments during a road test . . . . 3
1.6 Safety precautions when working on high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Safety precautions when working in vicinity of high-voltage components . . . . . . . . . . . . . . 4
2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Starting conditions for auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Notes for vehicles with a start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Rules for cleanliness for working on the auxilary/supplementary heater and the fuel
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Fittings location overview - auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Fittings location overview - auxiliary/supplementary heater components . . . . . . . . . . . . . . 9
2 Auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Fittings location overview - auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Assembly overview - auxiliary/supplementary heater attachments . . . . . . . . . . . . . . . . . . 14
2.3 Assembly overview - auxiliary/supplementary heater, internal . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Removing and installing auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Dismantling and assembling auxilary/supplementary . Volkswagen AG
heater . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Removing and installing air intake w a gen AG
silencer . . . . . . . .do. e.s.no. . . . . . . . . . . . . . . . . . . . . . . . . 23
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2.7 Removing and installing circulation
d by pump V55 . . . . . . . . . . .ua.ra. n. . . . . . . . . . . . . . . . . . . . . 23
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2.8 Removing and installingut
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ho exhaust system . . . . . . . . . . . . . . . . . . . e.o . . . . . . . . . . . . . . . . . .
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26
a
2.9 Removing and installing
ss auxiliary/supplementary heater bracket . . . .c . . . . . . . . . . . . . . . . 26
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2.10 Removing and installing covers for auxiliary heater control unit J364 . . . . . . . . . . . . . . . . 27
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2.11 Removing and installing glow plug with flame monitoring Q8 . . . . . . . . . . . . . . . . . . . . . . 28

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2.12 Removing and installing temperature sensor G18 and overheating sensor G189 . . . . . . 28
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2.13 Connector pin assignment for supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.14 Dismantling and assembling burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.15 Removing and installing auxiliary heater control unit J364 with combustion air blower V6
spec
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........................................................................ 30
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3 Coolant circuit with auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.1 Schematic diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.2 Bleeding coolant circuit of auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . 39

3.3 Removing and installing coolant pipes for auxiliary/supplementary heater . . . . . . . . . . . . 40
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4 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Fittings location overview - fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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4.2 Testing quantity of fuel delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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4.3 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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4.4 Checking metering pump V54 with end sealing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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4.5 Bleeding fuel line to metering pump V54 (filling with fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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5 Regulation of auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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5.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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5.2 Supplementary heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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5.3 Auxiliary heater mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Contents i
5.4 Switching off auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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6 Other control components . . k.s.w.ag. e.n.A.G. . . . . . . e. n. A.G. d.o.e.s . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.1 Removing and installing ambient
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6.2 Removing and installingtho remote control receiver for auxiliary coolant
ris tee heater R149 . . . . . .
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6.3 Functional description
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a of remote control for auxiliary/supplementary rheater ac ............ 60
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ii Contents
00 – Technical data
1 Safety instructions
(VRL008998; Edition 05.2016)
⇒ “1.1 Safety precautions for working on vehicles with auxiliary/
supplementary heater”, page 1
⇒ “1.2 Safety measures for when working on vehicles with a start/
stop system”, page 2
⇒ “1.3 Safety precautions when working on the fuel system”, page
2
⇒ “1.4 Safety precautions when working on cooling system”, page
3
⇒ “1.5 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “1.6 Safety precautions when working on high-voltage system”,
page 3 Volkswa AG. gen AG
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⇒ “1.7 Safety precautionsolkwhen
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1.1 Safety precautions for working on vehicles with auxiliary/supplementary
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Danger of fire and explosion from auxiliary/supplementary heater

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In fire and explosion-endangered areas a spark or the high tem‐

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an explosion. Burn injuries are also possible.

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– Switch auxiliary/supplementary heater off in fire and explo‐

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Danger of poisoning from exhaust fumes

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Auxiliary/supplementary heaters produce poisonous exhaust

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– In closed rooms, switch on auxiliary/supplementary heated

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only when it is connected to an exhaust extractor system.

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– In closed rooms without an exhaust extractor system, switch

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off auxiliary/supplementary heater.

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Danger of damage when engine is started Prote AG.
If the fuel system components (e.g. metering pump, fuel lines, fuel
gauge sender) are removed or opened, there is a possibility of
causing damage to the auxiliary/supplementary heater.
– Never attempt to start the engine when fuel system compo‐
nents are removed or opened.
1. Safety instructions 1
Malfunctions caused by air in the fuel system

After work has been done on the fuel tank or the fuel delivery
pump the metering pump will draw air and convey
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– Fill fuel take-off pipe with
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Risk of accidents and risk of injury due to activated timer of aux‐
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If the vehicle’s timer for the auxiliary/supplementary heater is ac‐
spec
tive, the heater may switch on unexpectedly. This poses a risk of
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poisoning from exhaust gases, a risk of burns caused by hot aux‐
iliary/supplementary heater components as well as a risk of fire
and explosions caused by high temperatures.
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– Deactivate timer for auxilary/supplementary heater.
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1.2 Safety measures for when working on vehicles with a start/stop system
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Risk of injury due to unexpected engine start
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In vehicles with activated start/stop system, the engine may start

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up unexpectedly. The status of the start/stop system is indicated
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– Deactivate start/stop system by switching off ignition. opyri
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1.3 Safety precautions when working on the fuel system

Danger of fire from leaking fuel.
Opening the door activates the fuel pump when the battery is
connected. Leaking fuel can ignite and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
Danger of injury caused by pressurised fuel

The fuel system is pressurised. Injury through fuel spray is pos‐
sible.
Before opening the fuel system:
– Wear eye protection.
– Wear protective gloves.
– To release pressure, wrap a clean cloth around the connection
and carefully loosen the connection.
2 Rep. gr.00 - Technical data

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♦ When working on a fuel system whose fuel lines have been ot p
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disconnected, always observe the applicable rules for clean‐
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♦ Air in the fuel supply to the auxiliary/supplementary heater can
lead to malfunction when the auxiliary/supplementary heater
is in combustion mode. To stop air from being drawn in by the
rrectne
metering pump - V54- and conveyed to the auxiliary/supple‐
mentary heater when the auxiliary/supplementary heater is
first switched on after performing repairs on the fuel tank or
ss
the fuel delivery unit, the fuel take-off pipe must be filled with
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fuel (bled) after performing repairs in this area.
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1.4 Safety precautions when working on cooling system
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Risk of scalding by hot coolant
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When the engine is warm, the cooling system is under pressure.

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Danger of scalding due to steam and hot coolant.
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– Wear eye protection. cop Vo
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– Proceed as follows to release the pressure: cover the cap of
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the coolant expansion tank with a cloth, and open it carefully.
1.5 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury through unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– A second person must operate the testing and measuring in‐
struments on the rear seat.
1.6 Safety precautions when working on high-voltage system

Danger to life due to high voltage
The high-voltage system is under high voltage. There is a risk of
severe or fatal injury due to electric shock.
– Persons with life-sustaining or other electronic medical devi‐
ces in or on their bodies must not perform any work on the
high-voltage system. Such medical devices include internal
analgesic pumps, implanted defibrillators, pacemakers, insu‐
lin pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified technician.
1. Safety instructions 3
Risk of injury due to unexpected engine start

On electric and hybrid vehicles, it is edifficult
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vehicle is in „ready“ mode. There ag n
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– Switch off ignition.
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– Always store ignition key outside vehicle.
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Risk of damage to high-voltage cables
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Improper handling of high-voltage cables or high-voltage connec‐
es, in part or in w
tors may result in damage to their insulation.
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– Never support yourself on high-voltage cables or high-voltage
connectors.
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– Never support any of your tools on high-voltage cables or high-
l purpos
voltage connectors.
– Never kink or severely bend high-voltage cables.
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– Always connect high-voltage connectors according to coding.
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1.7 Safety precautions when working in vicinity of high-voltage components

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The high-voltage system is under high voltage. Damage to high- cop Vo
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electric shock.
– Visually inspect high-voltage components and high-voltage
cables.
– Never use cutting or forming tools, or any other sharp-edged
tools.
– Never use heat sources such as welding, brazing, soldering,
hot air or thermal bonding equipment.

2 General notes
⇒ “2.1 Starting conditions for auxiliary/supplementary heater”,
page 5
⇒ “2.2 Notes for vehicles with a start/stop system”, page 6
⇒ “2.3 Rules for cleanliness for working on the auxilary/supple‐
mentary heater and the fuel system”, page 6
⇒ “2.4 Identification plates”, page 6
2.1 Starting conditions for auxiliary/supple‐

mentary heater
⇒ “2.1.1 Starting conditions for auxiliary/supplementary heater,
auxiliary heater mode”, page 5
⇒ “2.1.2 Starting conditions for auxiliary/supplementary heater,
supplementary heater mode”, page 5
2.1.1 Starting conditions for auxiliary/supple‐

mentary heater, auxiliary heater mode
♦ Auxiliary/supplementary heater coded in Gateway
♦ Reserve fuel level not reached
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♦ No event entries blocking start procedure d by ara
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♦ Commissioning successful aut ra
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The A/C button has no influence on the auxiliary heater opera‐
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2.1.2 Starting conditions for auxiliary/supple‐
t to the co
mentary heater, supplementary heater
mode
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♦ Terminal 15 (ignition) on
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♦ Engine speed > 600 rpm
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♦ Coolant temperature < 72 ℃ f inform

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♦ Ambient temperature < 5 °C

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♦ Not running on fuel reserve

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♦ On-board network manager not active

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♦ No crash shut-off
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♦ No event entries blocking start procedure
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♦ Commissioning successful
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♦ Supplementary heating function activated in multi-function dis‐
play (MFD)
2. General notes 5
Note
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2.2 Notes for vehicles with a start/stop sys‐ s au
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Observe the safety precautions for vehicles with a start/stop sys‐
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The following abort conditions deactivate the start/stop function:
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♦ The start/stop system has been switched off via the start/stop
hole
spec
mode button.
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♦ The charge status of the battery - A- is insufficient to restart
the engine (starting voltage prediction).
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♦ The defrost function is active.
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♦ The windscreen heater function is active.

♦ The temperature set on the operating and display unit varies
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by more than 8°C from the actual interior temperature.
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♦ The engine speed is greater than 1200 rpm.
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♦ The alternator - C- is defective, i.e. belt broken.

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♦ Coolant temperature is not within specifications of 25 °C–100 °

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♦ Blower speed increased by more than 4 stages.
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Additional information:
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♦ Refer to ⇒ Self-study programme No. 426 ; Start/Stop System cted agen
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2009 for full description.
2.3 Rules for cleanliness for working on the

auxilary/supplementary heater and the
fuel system
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place parts that have been removed on a clean surface and
cover. Do not use fluffy cloths!
♦ Carefully cover or seal opened components 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).
If the fuel system is open:
– Do not work with compressed air.
– Do not move the vehicle.
– Do not start the engine.
– switch on auxiliary/supplementary heater.
2.4 Identification plates

There are different types of identification plates.

When the auxiliary heater is renewed, check the type plate and
the duplicate plate and replace as necessary.
Identification plate on auxiliary/supplementary heater
♦ The date of first use is entered on the lower section of the data
plate.
♦ The year the unit was first brought into operation must be en‐
tered on the “Genuine part” identification plate.
Duplicate identification plate for auxiliary/supplementary heater

♦ In the engine compartment of the vehicle, there is a second
(duplicate) identification plate attached to the right of the lock
carrier (when looking in direction of travel). If there is any doubt
concerning the type of the auxiliary/supplementary heater, al‐
ways observe the identification plate attached directly to the
auxiliary/supplementary heater.
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2. General notes 7
3 Repair notes
⇒ “3.1 General repair instructions”, page 8
3.1 General repair instructions agen

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– Observe d by V gu
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⇒ “1.6 Safety precautions when working rise
on high-voltage sys‐ nte
ho eo
tem”, page 3 . aut ra
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ss
– Read self-diagnosis of auxiliary/supplementary heating using
ce
le
un
pt
⇒ Vehicle diagnostic tester.
an
d
itte
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ab
– When parts of the fuel system are removed or renewed, en‐
pe
ility
sure that all components for fuel delivery to the auxiliary/
ot
wit
supplementary heater are properly installed.
, is n
h re
hole
– Mark coolant hoses before removing to avoid any confusion
spec
when reconnecting.
es, in part or in w
t to the co
Following repair work in the vicinity of the auxiliary/supplementary
heater fuel line, check the following points:
rrectness of i
♦ that the fuel lines are routed flush with the vehicle underbody
and are protected against mechanical damage.
l purpos
♦ that the auxiliary/supplementary heater fuel line is protected

from heating which might disturb operation.
nform
ercia
♦ that the fuel line does not come in contact with parts that be‐
m
a
com
ti
come hot.
on in
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82 – Supplementary heating
1 Fittings location overview - auxiliary/
supplementary heater
⇒ “1.1 Fittings location overview - auxiliary/supplementary heater
components”, page 9
1.1 Fittings location overview - auxiliary/

supplementary heater components
⇒ “1.1.1 Fitting locations overview - auxiliary/supplementary heat‐
er components, saloon”, page 9
⇒ “1.1.2 Fitting locations overview - auxiliary/supplementary heat‐
er components, estate ”, page 10
1.1.1 Fitting locations overview - auxiliary/supplementary heater components,

saloon
1 - Auxiliary heater aerial -

R182-
❑ For vehicles with auxili‐ AG. Volkswagen AG d
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heater and remote con‐ ed byV gu
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❑ Removing and installing ss a ra
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auxiliary heater aerial -
ce
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nl
R182- ⇒ Communica‐
pt
du
an
itte
tion; Rep. gr. 91 ; Aerial
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systems .
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2 - Ambient temperature sen‐
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sor - G17-
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spec
❑ Checking ⇒ Vehicle di‐
es, in part or in w
agnostic tester
t to the co
❑ Removing and installing
⇒ page 57
rrectness of i
3 - Exhaust system of auxiliary/
l purpos

⇒ page 26
nform
ercia
4 - Auxiliary/supplementary
m
at
om
heater
ion
c
in t
r
❑ With auxiliary heater

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control unit - J364- .

at
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❑ Location: behind front

um
for
bumper cover on right

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❑ Removing and installing C py
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⇒ page 16 rig ht
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5 - Circulation pump - V55- cted agen
Prote AG.
❑ Fitting location: on aux‐
iliary/supplementary
heater
⇒ page 23
6 - Fuel delivery unit
❑ With fuel gauge sender - G-
1. Fittings location overview - auxiliary/supplementary heater 9

Passat 2015 ➤ , Passat Variant 2015 ➤ agen
AG. Volkswagen AG d
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Auxiliary heater - Edition 05.2016 y Vol
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❑ Removing and installing ⇒ Rep. gr. 20 utho; Fuel delivery unit/fuel gauge sender; Removingor and installing
fuel delivery unit/fuel gauge sender ss a ac
ce
le
un
7 - Metering pump - V54-
pt
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❑ Location: On fuel tank
rm
ab
pe
❑ Check fuel supply to auxiliary/supplementary heater ⇒ page 43 .
ility
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, is n
❑ The metering pump - V54- might tick audibly but fail to deliver fuel because there is air in the suction
h re
hose. The control unit will then switch off permanently. Read event memory using ⇒ Vehicle diagnostic
hole
spec
tester, auxiliary/supplementary heater self-diagnosis. Erase event memory and perform final control di‐
es, in part or in w
agnosis for auxiliary/supplementary heater.
t to the co
❑ Removing and installing ⇒ page 47
❑ Testing quantity of fuel delivered ⇒ page 46
rrectness of i
8 - Remote control receiver for auxiliary coolant heater - R149-
l purpos
nform
mercia
1.1.2 Fitting locations overview - auxiliary/supplementary heater components,
a
com
tion in
estate
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1 - Auxiliary heater aerial -
fo
en
g
R182-
n
t.
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op py
❑ For vehicles with auxili‐
t. C rig
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ary/supplementary p by
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heater and remote con‐
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AG.

auxiliary heater aerial -
R182- ⇒ Communica‐
tion; Rep. gr. 91 ; Aerial
systems .
2 - Ambient temperature sen‐
sor - G17-
❑ Checking ⇒ Vehicle di‐
agnostic tester
⇒ page 57
3 - Exhaust system of auxiliary/
⇒ page 26
heater
⇒ page 16
5 - Circulation pump - V55-
❑ Fitting location: on aux‐
iliary/supplementary
heater
⇒ page 23
❑ With fuel gauge sender - G-
10 Rep. gr.82 - Supplementary heating

❑ Removing and installing ⇒ Rep. gr. 20 ; Fuel delivery unit/fuel gauge sender; Removing and installing
fuel delivery unit/fuel gauge sender
❑ Location: On fuel tank
❑ Check fuel supply to auxiliary/supplementary heater ⇒ page 43 .
❑ The metering pump - V54- might tick audibly but fail to deliver fuel because there is air in the suction
hose. The control unit will then switch off permanently. Read event
wage
n AG. Vmemory
olkswagenusing
AG do ⇒ Vehicle diagnostic
es n
tester, auxiliary/supplementary heater self-diagnosis.yErase Volks event memory and perform ot g final control di‐
ua
agnosis for auxiliary/supplementary heater. ir se
d b ran
o tee
❑ Removing and installing ⇒ page 47 auth or
ac
ss
❑ Testing quantity of fuel delivered ⇒ page 46
ce
e
nl
pt
du
8 - Remote control receiver for auxiliary coolant heater - R149-
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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1. Fittings location overview - auxiliary/supplementary heater 11

2 Auxiliary/supplementary heater
⇒ “2.1 Fittings location overview - auxiliary/supplementary heat‐
er”, page 12
⇒ “2.2 Assembly overview - auxiliary/supplementary heater at‐
tachments”, page 14
⇒ “2.3 Assembly overview - auxiliary/supplementary heater, in‐
ternal”, page 15
⇒ “2.4 Removing and installing auxiliary/supplementary heater”,
page 16
⇒ “2.5 Dismantling and assembling auxilary/supplementary heat‐
er”, page 21
⇒ “2.6 Removing and installing air intake silencer”, page 23
⇒ “2.7 Removing and installing circulation pump V55 ”,
page 23
⇒ “2.8 Removing and installing exhaust system”, page 26
⇒ “2.9 Removing and installing auxiliary/supplementary heater
bracket”, page 26
⇒ “2.10 Removing and installing covers for auxiliary heater control
unit J364 ”, page 27
⇒ “2.11 Removing and installing glow plug with flame monitoring
Q8 ”, page 28
⇒ “2.12 Removing and installing temperature sensor G18 and
overheating sensor G189 ”, page 28
⇒ “2.13 Connector pin assignmentagefor
n AGsupplementary
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does
page 29 olksw not
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⇒ “2.14 Dismantlingthand
or
is assembling burner unit”, page 29
e or
au ac
⇒ “2.15 Removingss and installing auxiliary heater control unit J364
ce
le
with combustion air blower V6 ”, page 30

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2.1 Fittings location overview - auxiliary/supplementary heater

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❑ With auxiliary heater ed
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❑ Removing ⇒ page 16 ss
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2 - Nut
un
pt
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❑ 20 Nm
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3 - Electrical connectors
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4 - Exhaust system
h re
hole
spec
es, in part or in w
⇒ page 26
t to the co
rrectness of i
⇒ page 23
l purpos
6 - Air intake silencer

nform
ercia
⇒ page 23
m
7 - Fuel line with quick-release
a
com
tio
coupling
n in
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8 - Nut
s
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❑ 20 Nm
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2. Auxiliary/supplementary heater 13
2.2 Assembly overview - auxiliary/supplementary heater attachments
heater
2 - Clamping piece
3 - Coolant hose
4 - Air intake silencer
⇒ page 23
5 - Bracket for circulation pump
- V55- and air intake silencer
6 - Bolts
❑ For bracket for circula‐
tion pump - V55- and air
intake silencer
❑ 8 Nm
⇒ page 23
8 - Exhaust system
⇒ page 26
9 - Nut
❑ For exhaust silencer AG. Volkswagen AG d
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❑ 20 Nm Volksw not
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10 - Bolts rise nte
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❑ 8 Nm ss a ra
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11 - Bracket for auxiliary/sup‐

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d
plementary heater
itte
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ab

pe
ility
⇒ page 26
ot
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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tion in
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2.3 Assembly overview - auxiliary/supplementary heater, internal
1 - Bolts
❑ 7 Nm
2 - Heat exchanger
⇒ page 21 .
3 - Seal
❑ Must be renewed after
every opening.
❑ Note fitting position.
AG. Volkswagen AG d
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4 - Burner tube olksw not
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❑ Removing and installing orise nte
⇒ page 21 . aut
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5 - Glow plug with flame moni‐
ce
e
nl
pt
toring - Q8-
du
an
itte
y li
❑ Ensure correct seating.
erm
ab
ility
ot p
wit
⇒ page 28 .
, is n
h re
hole
6 - Cover for auxiliary heater
spec
es, in part or in w
t to the co
⇒ page 27 .
rrectness of i
7 - Cover
l purpos
8 - Auxiliary heater control unit

- J364- with combustion air
blower - V6-
nform
mercia
Note
at
om
ion
c
in t
r
The auxiliary heater control unit -

o
his
te
J364- and the combustion air blower

a
do
riv
- V6- with housing form one compo‐

p
cum
or
nent and cannot be dismantled. The

f
en
ng
t.
reason is the seal between the aux‐
yi Co
op py
iliary heater control unit - J364- and
. C rig
ht ht
the housing.
rig by
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9 - Noise insulation
10 - Cover
❑ Removing and installing ⇒ page 27 .
11 - Coolant connection
❑ Mark installation position before detaching
12 - O-rings
❑ Renew.
13 - Retaining plate
14 - Bolt
❑ 4 Nm
15 - Coolant connection
❑ Mark installation position before detaching
16 - Temperature sensor - G18-
17 - Retaining spring
18 - Bolt
❑ 4 Nm agen
AG. Volkswagen AG d
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19 - Overheating sensor - G189- byV gu
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❑ Removing and installing ⇒ page 28 . ut
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nl
pt
du
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2.4 Removing and installing auxiliary/sup‐
itte
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erm
ab
plementary heater
ility
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wit
Special tools and workshop equipment required , is n
h re
hole
spec
♦ Torque wrench - V.A.G 1410- (4…20 Nm)
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
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♦ Hose clamps, up to 25 mm - 3094-
o
m
f
en
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t.
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Cop py
ht. rig
rig ht
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♦ Pliers for spring-type clips - VAS 5024A-

♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
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ility
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, is n
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hole
♦ Vehicle diagnostic tester
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ There is an identification plate attached to the auxiliary/sup‐
plementary heater. This identification plate indicates which
l purpos
heater version is installed in the vehicle: ⇒ page 6

♦ Coolant circuit must be bled after it is opened ⇒ Rep. gr. 19 ;
nf
ercia
o
Cooling system, coolant; Draining and filling coolant .
rm
m
atio
m
♦ Cooling system is pressurized when engine is warm. If nec‐

o
n in
c
essary, release pressure and reduce temperature before car‐

or
thi
e
rying out repairs.

t
sd
iva
o
r
rp
cu
♦ After the auxiliary/supplementary heater has been disconnec‐
o
m
f
ted, it must be secured to the vehicle body with welding wire.
en
ng
t.
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This prevents damage to the coolant hoses. t. Cop py
rig
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♦ If the auxiliary/supplementary heater is to be renewed, first pyri by
Vo
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connect the ⇒ Vehicle diagnostic tester and start the “Renew
lksw
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heater” function under "Guided Functions".
AG.
Removing
Before beginning repair work, perform the following steps:
– Connect ⇒ Vehicle diagnostic tester and start function “Renew
heater” under “Guided Fault Finding” or “Guided Functions”.
Note
If possible, certain settings and adaption values for the auxiliary/

supplementary heater that is to be renewed are read out and
stored via this function. The stored values can then be imported
again to be used for the new auxiliary/supplementary heater using
⇒ Vehicle diagnostic tester in “Guided Fault Finding” or “Guided
Functions” mode.
– Switch off electrical consumers.

– Switch off ignition.
– Remove ignition key.
Note
Fit all cable ties and other fasteners for wiring harness at the same
places from which they were detached or cut during removal of
the auxiliary/supplementary heater.
– Remove front noise insulation ⇒ General body repairs, exte‐

rior; Rep. gr. 66 ; Noise insulation; Assembly overview - noise
insulation .
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner .
– For vehicles with LED headlights, remove headlights ⇒ Elec‐
trical system; Rep. gr. 94 ; Headlights; Removing and instal‐
ling headlights .
CAUTION
Danger of severe burns from hot exhaust system.
Burns to hands and other body parts possible.
– Allow exhaust system to cool.
– Remove exhaust system of auxiliary/supplementary heater

⇒ page 26 .
– Place drip tray underneath vehicle.
CAUTION
AG. Volkswagen AG d
Scalding of skin and other body parts possible. lkswagen oes
not
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– Wear protective gloves. ed by ara
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– Wear eye protection. ut
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– Proceed as follows to release the pressure:
ss
cover the cap of
ce
le

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pt
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erm
ab
Further safety precautions for working on the cooling system ⇒
ility
ot p
Rep. gr. 00 ; Safety instructions; Safety precautions when work‐

wit
is n
ing on cooling system .

h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

– Clamp off coolant hoses with hose clamps, up to Ø 25 mm -

3094- , release spring-type clips -1- and pull coolant hoses off
coolant pipes.
– Unfasten fuel line at clip -3-.
Note
Observe safety precautions for working on the fuel supply system

⇒ page 2 and ⇒ Rep. gr. 00 ; Safety instructions; Safety pre‐
cautions when working on fuel supply system .
CAUTION
The fuel system is pressurised.
Danger of injury through fuel spray.
– Wear eye protection. AG. Volkswagen AG d
agen oes
– Wear protective gloves. olksw not
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d by ara
– To release pressure, wrap a clean clothoriaround
se the connec‐ nte
tion and carefully loosen the connection.
au
th eo
ra
ss c
ce
le
un
pt
– Unclip fuel line -4- from auxiliary/supplementary heater and
an
d
itte
disconnect it at quick-release coupling. Seal fuel lines using
y li
rm
ab
suitable plugs.
pe
ility
ot
– Unscrew securing nuts -2- and remove auxiliary/supplemen‐
wit
, is n
h re
tary heater from longitudinal member.
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
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cum
fo
en
ng
t.
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t. rig
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pyri by
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Prote AG.
– Carefully swivel auxilary/supplementary heater towards rear

and release and disconnect connector -1- (6-pin) first, to pre‐
vent stress to connectors.
– Release connector -2- then remove auxiliary heater and set it
down carefully. AG. Volkswagen AG d
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lksw not
Installing byV
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nl
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♦ When carrying out assembly work, particularly in the engine
itte
y li
compartment due to the restricted space, observe the follow‐
erm
ab
ing points:
ility
ot p
wit
, is n
♦ Install all sorts of lines (e.g. for fuel, coolant and refrigerant)
h re
as well as electric wiring so that the original routing is restored.
hole
spec
es, in part or in w
♦ Make sure there is sufficient clearance between the lines and
t to the co
all moveable and hot components.
rrectness of i
Note
l purpos
If the auxiliary/supplementary heater has been renewed, ⇒ Vehi‐
nf
ercia
cle diagnostic tester must be connected before the first use of the
or
new auxiliary/supplementary heater, in order to adjust various
m
m
atio
settings (e.g. “Line filling”) using the “Guided Fault Finding” func‐
om
n in
tion.
or c
thi
te
sd
iva
Installation is carried out in the reverse order. When installing,
o
r
rp
cu
o
note the following:
m
f
en
ng
t.
yi Co
– Install auxiliary/supplementary heater and fit and secure cool‐ Cop py
ht. rig
ant hoses (do »NOT« open hose clamps, up to 25 mm - rig ht
py by
3094- ). co Vo
by lksw
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olkswagen AG
en AG. V
– Open O-type clip -3- and hold hose -4- so that ksitwpoints verti‐
ag does
not
Vol
cally upwards. ed
by gu
ara
ris nte
– Open hose clamp -2- until coolant aemerges
ut
ho from auxiliary/ eo
ra
supplementary heater. ss c
ce
e
nl
– Close hose clamp -2-.
pt
du
an
itte
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– Open hose clamp -1- until coolant emerges from coolant hose
erm
ab
-4-.
ility
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wit
– Close hose clamp -1-. , is n
h re
hole
spec
– Fit hose -4- and remove hose clamps, up to Ø 25 mm - 3094- .
es, in part or in w
t to the co
– Bleed coolant circuit of auxiliary/supplementary heater
⇒ page 39 .
rrectness of i
Note
l purpos
If additional air entered cooling system during assembly, entire
nf
ercia
coolant circuit must be bled ⇒ Rep. gr. 19 ; Cooling system,
or
coolant; Draining and filling coolant .
m
m
atio
om
n in
c
– Read event memory and erase entries ⇒ Vehicle diagnostic

or
thi
e
tester in “Guided Fault Finding” mode.

t
sd
iva
o
r
rp
cu
– Start auxiliary/supplementary heater and run it at full load for
o
m
f
en
ng
at least 10 minutes so that fuel line is bled completely and you

t.
yi Co
can check operation of auxiliary/supplementary heater. Cop py
t. rig
gh ht
yri
– Set dash panel vent to maximum heating power. p by
o Vo
by c lksw
cted agen
Specified torque Prote AG.
♦ ⇒ “2.2 Assembly overview - auxiliary/supplementary heater

attachments”, page 14
♦ Nose insulation; Assembly overview - noise insulation ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation .
♦ Wheel housing liner; Removing and installing wheel housing
liner ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
housing liner; Removing and installing front wheel housing lin‐
er .
2.5 Dismantling and assembling auxilary/

Special tools and workshop equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
ss a ra
c
ce
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un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove auxiliary/supplementary heater ⇒ page 16 .

nform
ercia
– Remove covers ⇒ page 27 .

m
– Remove bracket for circulation pump - V55- and air intake si‐
a
com
tio
lencer ⇒ page 14 .
n 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.

– Release catch and unplug connector -1-.

– Release wire from clamp -2-.
– Unscrew bolts -arrows- and remove heat exchanger from
blower housing by pulling it in axial direction of threaded con‐
nection.
– Clean inside and outside of heat exchanger.
Dismantling and assembling burner unit ⇒ page 29
Assembling
– Install in reverse order. n AG. Volkswagen AG do
lkswage es n
o ot g
Specified torque d byV ua
ran
ir se tee
♦ ⇒ “2.2 Assembly overview - auxiliary/supplementary
utho heater or
attachments”, page 14 ss
a ac
ce
le
un
pt
an
d
2.6 Removing and installing air intake si‐

itte
y li
erm
ab
lencer
ility
ot p
wit
is n
Removing
h re
ole,
spec
t to the co
– Switch off auxiliary/supplementary heater and switch off igni‐
tion.
– Remove front part of front right wheel housing liner ⇒ General
rrectne
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .
ss o
– Squeeze spreader clip -1- together and twist air intake silencer
cial p
f in
-2- out of aluminium pipe. Twist aluminium pipe off connection
form
mer
of auxiliary/supplementary heater.
atio
m
Installing
o
n
c
i
or
n thi
e
– Install in reverse order.

t
sd
iva
o
pr
– Push spreader clip -1- of air intake silencer -2- into bracket
um
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fo
en
ng
until it engages. yi
t.
Co
Cop py
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gh ht
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Note cop Vo
by lksw
cted agen
Prote AG.
♦ The air intake silencer must not touch the auxiliary/supple‐
mentary heater housing.
♦ Do not kink or crush aluminium pipe.
Specified torque
Wheel housing liner; Removing and installing wheel housing liner
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Removing and installing front wheel housing liner
2.7 Removing and installing circulation

pump - V55-
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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pt
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itte
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rm
ab
pe
ility
Removing
ot
wit
, is n
h re

hole
spec
es, in part or in w

t to the co
tion.
– Remove front part of front right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
rrectness of i
moving and installing front wheel housing liner .

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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r
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cum
fo
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t.
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Cop py
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. Volkswagen AG
gen AG does
– Clamp off coolant hoses using hose clamps, Vup
olkto
swaØ 25 mm - not
3094- . ed
by gu
ara
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tho eo
CAUTION ss
au ra
c
ce
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nl
pt
du
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itte
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erm
ab
Scalding of skin and other body parts possible.
ility
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– Wear eye protection. hole
spec
es, in part or in w
t to the co
– Unfasten O-type clips -1- and pull coolant hoses off circulation
rrectness of i
pump - V55- -2-.
l purpos
– Disconnect connector -3- of circulation pump - V55- -2- at

auxiliary/supplementary heater or at circulation pump - V55-
(depending on version).
nform
ercia
– Pull circulation pump - V55- -2- off bracket.

m
at
om
ion
Installing
c
in t
or
his
ate
do
riv
– Slide circulation pump - V55- -2- onto bracket.

p
cum
for
– Connect connector -3- of circulation pump - V55- -2- at auxil‐
en
ng
t.
yi Co
iary/supplementary heater or at circulation pump - V55- (de‐ Cop py
pending on version). Ensure proper engagement.
t. rig
gh ht
pyri by
Vo
co
– Fit lower coolant hose.
by lksw
cted agen
Prote AG.
– Open bottom hose clamps, up to Ø 25 mm - 3094- -arrow- until
coolant is up to top edge of circulation pump - V55- .
– Fit upper coolant hose.
– Ensure cables are routed correctly and connectors remain dry.
Remaining installation steps are performed in reverse order of
removal.
– If circulation pump - V55- is renewed, set operating hours
counter of circulation pump - V55- to zero using Guided func‐
tions of ⇒ Vehicle diagnostic tester.
– Read event memory and erase entries ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode.
– If additional air entered cooling system during assembly, cool‐
ant circuit must be bled ⇒ page 39 .
– Start auxiliary/supplementary heater and run it at full load for
at least 10 minutes so that fuel line is bled completely and you
can check operation of auxiliary/supplementary heater.
Specified torque
Wheel housing liner; Removing and installing wheel housing liner
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liner; Removing and installing front wheel housing liner
. Volkswage
Auxiliary heater - aEdition
ksw
gen AG 05.2016n AG doe
sn
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2.8 Removing and installing exhaust system
e
ris tee
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s au ac
Removing s
ce
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un
pt
an
d
itte
CAUTION
y li
erm
ab
Danger of severe burns from hot exhaust system.
ility
ot p
wit
is n
Burns to hands and other body parts possible.
h re
ole,
– Allow exhaust system to cool.
spec
t to the co
rrectne
tion.
ss
o
cial p
f
insulation .
inform
mer
– Remove charge air hose (depending on engine version) ⇒
atio
m
Rep. gr. 21 ; Charge air system; Exploded view - charge air

o
n
c
system .
i
or
n thi
te
sd
– Unscrew securing nut -1- from exhaust system -2-.
iva
o
pr
cum
r
fo
– Remove exhaust system -2- from stud secured by nut -1- in

en
ng
t.
-direction of arrow A-. Cop
yi Co
py
ht. rig
– Remove exhaust system -2- from heater unit in direction of rig ht
py by
arrow -B-. co Vo
by lksw
cted agen
Prote AG.
Installing
note the following:
Note
♦ The exhaust system gets very hot when the heater is running.
♦ Route exhaust system with sufficient distance to electrical wir‐
ing.
Specified torque
♦ Charge air system; Assembly overview - charge air system ⇒
Rep. gr. 21 ; Charge air system; Assembly overview - charge
air system .
2.9 Removing and installing auxiliary/sup‐

plementary heater bracket
Removing
tion.

– Remove bolts -2- and remove bracket -1-.

Installing
– Install in reverse order. AG. Volkswagen AG d
agen oes
ksw
Specified torque by V ol not
gu
ara
ed
is nte
♦ ⇒ “2.2 Assembly
hor overview - auxiliary/supplementary heater
eo
ut
attachments”,
ss a page 14 ra
c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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2.10 Removing and installing covers for aux‐
hole
spec
iliary heater control unit - J364-
es, in part or in w
t to the co
Removing
rrectness of i
l purpos
tion.
nform
ercia

m
– Dismantle auxiliary/supplementary heater as far as necessary
a
com
tio
to gain access to covers for auxiliary heater control unit - J364-
n in
r
⇒ page 21 .
te o
thi
s
iva
do
– Detach cable cover -1- from blower housing.

r
rp
cum
fo
– Unclip covers for auxiliary heater control unit - J364- -2-

en
ng
t.
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-arrows- to remove. . Cop py
rig
ht ht
– Dismantling heater unit ⇒ page 21 .
rig by
copy Vo
by lksw
cted
– Removing and installing glow plug with flame monitor - Q8-
agen
Prote AG.
⇒ page 28 .
– Remove temperature sensor - G18- and overheating sensor -
G189- .
Installing
– Renew seals.
– Check that seals -arrows- are not damaged and are seated
correctly.
– Check sealing surfaces for dirt and damage.
– Before installing cover, lightly coat seals with coolant.
– Remaining installation steps are performed in reverse order of
removal.
Specified torque
2.11 Removing and installing glow plug with

flame monitoring - Q8-
Removing
– Dismantling and assembling auxiliary/supplementary heater
⇒ page 21 .
– Pull out retaining spring -1- in direction of -arrow-.
AG. Volkswagen AG d
– Remove retaining plate -2-. agen oes
olksw not
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– Pull out glow plug with flame monitoring - Q8- -3-. orise nte
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Installing ss a c
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nl
Install in reverse order.
pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Observe location of retaining spring -1- and retaining plate -2-.
l purpos
Specified torque
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
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2.12 Removing and installing temperature
Co
Cop py
ht. rig
sensor - G18- and overheating sensor -
rig ht
py by
co Vo
lksw
G189-
by
cted agen
Prote AG.
Removing
– Dismantling and assembling auxiliary/supplementary heater
⇒ page 21 .
– Remove bolt -1- (4 Nm) and remove retaining spring -2-.
– Pull out temperature sensor - G18- -3-and overheating sensor
- G189- -4- using long nose pliers.
Installing
– Renew seals.
– Check sealing surfaces and clean if necessary.
– Before inserting sensors, coat seals with coolant.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
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h
aut ra
c Auxiliary heater - Edition 05.2016
ss
ce
le
un
– When assembling, ensure that retaining spring is in proper
pt
an
d
position -2-.
itte
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rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
Sensors cannot be renewed separately.
es, in part or in w
t to the co
Specified torque
rrectness of i
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2.13 Connector pin assignment for supplementary heater
nform
mercia
a
com
tion in
1 - 6-pin connector
r
te o
thi
❑ Information on pin as‐
s
iva
do
signment can be found
r
rp
cum
in the latest current flow
fo
en
ng
diagram ⇒ Current flow

t.
yi Co
op
diagrams, Electrical
C py
t. rig
gh
fault finding and Fitting
ht
pyri by
Vo
locations.
co lksw
by
cted agen
Prote AG.
2 - 2-pin connector
locations.
3 - 2-pin connector
locations.
4 - 4-pin connector
locations.
5 - 2-pin connector
diagram ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
2.14 Dismantling and assembling burner unit

Dismantling
– Dismantle auxiliary/supplementary heater ⇒ page 21 .
– Detach gasket -1- from blower housing.

– Release and detach connector -2-.
– Pull grommet -3- out of blower housing onto combustion pipe
-4-, using only a little force, and at the same time lift burner
unit off vertically upwards.
Assembling
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
Renew gasket -1- and grommet -3-.
spec
es, in part or in w
t to the co
rrectness of i
– Make sure gasket -1- is positioned correctly and connector
-2- is engaged securely.
l purpos
nform
ercia
Note
m
at
om
To prevent a short circuit at wiring connections to glow plug with
ion
c
flame monitor - Q8- make sure that the gasket -1- is positioned
in t
or
correctly and that the connector -2- is engaged correctly.
his
ate
do
priv
cum
or
Specified torque
f
en
ng
t.
yi Co
op
♦ ⇒ “2.2 Assembly overview - auxiliary/supplementary heater C py
t. rig
attachments”, page 14 gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.15 Removing and installing auxiliary heater

control unit - J364- with combustion air
blower - V6-
Removing
– Dismantle burner unit ⇒ page 29 .

Installing
Renew gasket -1- and grommet -3-.
– Make sure gasket -1- is positioned correctly and connector
-2- is engaged securely.
Note
To prevent a short circuit at wiring connections to glow plug with

flame monitor - Q8- make sure that the gasket -1- is positioned
correctly and that the connector -2- is engaged correctly.
Specified torque
lkswage es n
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ir se tee
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a ac
ss ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3 Coolant circuit with auxiliary/supple‐

mentary heater
⇒ “3.1 Schematic diagram - coolant hoses”, page 32
⇒ “3.2 Bleeding coolant circuit of auxiliary/supplementary heater”,
page 39
⇒ “3.3 Removing and installing coolant pipes for auxiliary/sup‐
plementary heater”, page 40
3.1 Schematic diagram - coolant hosesswagen AG. Volkswagen AG does

k not
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⇒ “3.1.1 Schematic diagram - coolant hoses, Passat”,db ara
ise nte
page 32 thor eo
au ra
c
⇒ “3.1.2 Schematic diagram - coolant hoses,ssPassat GTE”, page
ce
le
34
un
pt
an
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itte
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3.1.1 Schematic diagram - coolant hoses,
erm
ab
ility
Passat
ot p
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is n
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ole,
spec
Note
t to the co
♦ The schematic diagram for the entire coolant circuit can be
found in the repair group 19 ⇒ Rep. gr. 19 ; Cooling system,
rrectne
coolant; Schematic diagram - coolant hoses .
♦ Topping up coolant and bleeding coolant circuit ⇒ Rep. gr.
s
19 ; Cooling system/coolant; Draining and filling cooling sys‐
s o
cial p
f
tem and ⇒ page 39
inform
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va
The -arrows- indicate the direction of coolant flow.

i
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.

1 - Heat exchanger for heater

in heater and air conditioning
unit
❑ Incorporation in coolant
circuit ⇒ Rep. gr. 19 ;
Cooling system, cool‐
ant; Schematic diagram
- coolant hoses .
heater
⇒ page 16 .
❑ The circulation pump -
V55- is integrated in the
hose assembly of the
auxiliary/supplementary
heater.
⇒ page 23
Note
♦ For this vehicle, a start/stop sys‐

tem is offered as an optional
equipment with certain engines.
♦ On vehicles equipped with a gen AG
. Volkswagen AG
does
start/stop system, the circulation olks
wa not
yV
pump - V55- of the auxiliary/sup‐ b gu
ara
ed
plementary heater can be actu‐ thoris
nte
eo
ated by the auxiliary/supplemen‐ sa
u ra
c
tary heater control unit - J364-s
ce
e
nl
while the stop function is active.
pt
du
an
To achieve this, the auxiliary
itte
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heater control unit - J364- re‐
erm
ab
ility
ceives a command via the data
ot p
bus from the air conditioning sys‐
wit
, is n
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tem operating unit, the Clima‐
hole
tronic control unit - J255- and the

air conditioning system control spec
es, in part or in w
unit - J301- to switch on the cir‐ t to the co

culation pump - V55- (⇒ Vehicle
diagnostic tester in “Guided
rrectness of i
Fault Finding” mode).

l purpos
4 - Coolant supply from engine

❑ Incorporation of auxiliary/supplementary heater in engine coolant circuit ⇒ Rep. gr. 19 ; Cooling system,
nf
ercia

orm
m
atio
5 - Coolant return to the engine

om
n in
c
❑ Incorporation of auxiliary/supplementary heater in engine coolant circuit ⇒ Rep. gr. 19 ; Cooling system,
or
thi
e

t
sd
iva
o
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cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Coolant circuit with auxiliary/supplementary heater 33

3.1.2 Schematic diagram - coolant hoses,

Passat GTE
Note
♦ Currently, only the auxiliary heater version is available. At the

moment the auxiliary heater is not intended to be operated as
a supplementary heater. In vehicles with a high-voltageAG. Volkswsys‐
agen AG
tem, the high-voltage heater (PTC) - Z115- lksw is used as a
agen does
not
supplementary heater ⇒ Heating, air yconditioning; Rep. gr.
Vo gu
d b ara
87 ; Overview of fitting locationsor-isair conditioning system;
e nte
eo
Overview of fitting locations -acomponents
ut
h
outside of passen‐ ra
ger compartment . ss c
ce
le
un
pt
♦ In vehicles with a high-voltage system, the high-voltage heater
an
d
itte
(PTC) - Z115- can be used for heating the passenger com‐
y li
erm
ab
partment.
ility
ot p
wit
♦ Topping up coolant and bleeding coolant circuit ⇒ Rep. gr.
is n
h re
19 ; Cooling system/coolant; Draining and filling cooling sys‐
ole,
spec
tem and ⇒ page 39
t to the co
♦ Connection of heat exchanger for air conditioning system and
auxiliary heater to coolant circuit of engine ⇒ Engine mechan‐
ics; Rep. gr. 19 ; Cooling system, coolant (coolant hose
rrectne
schematic diagram).
ss o
cial p
f
Note
inform
mer
The -arrows- indicate the direction of coolant flow.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - Heat exchanger for heater

and air conditioning unit
❑ Connection of heat ex‐
changer to engine cool‐
ant circuit ⇒ Engine
mechanics; Rep. gr.
19 ; Cooling system,
coolant (coolant hose
schematic diagram).
2 - Non-return valve
❑ Installed in coolant line
between high-voltage
heater (PTC) - Z115-
and heat exchanger of
heater and air condition‐
ing unit.
❑ Install with correct orien‐
AG. Volkswagen AG d
tation and ensure prop‐ ksw
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er operation by
Vo gu
ara
ed
❑ Removing and installing horis nte
eo
⇒ Engine mechanics; s aut ra
c
Rep. gr. 19 ; Coolant s
ce
le
pump/thermostat
un
pt
an
d
itte
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rm
ab
Note
pe
ility
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♦ Prevents coolant from flowing
h re
back from the auxiliary heater
hole
spec
(via the high-voltage heater
es, in part or in w
(PTC) - Z115- ) to the engine
t to the co
when the auxiliary heater is
switched on (and the engine and/
or the coolant pump for high-
rrectness of i
temperature circuit - V467- are
not running).
l purpos
♦ If there are customer complaints

about poor heat output of the air
nform
ercia
conditioning system in auxiliary

m
heater mode, make sure the

a
com
tio
non-return valve is installed with

n in
r
correct orientation and that it

te o
thi
works properly.
s
iva
do
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cum

fo
en
g

n
t.
yi Co
op
conditioning system when the C py
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auxiliary heater is switched on
gh ht
pyri by
(and the auxiliary heater is being
o Vo
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cted
used instead of the -Z115- to
agen
Prote AG.
heat the coolant), make sure the
non-return valve is installed with
correct orientation and that it
works properly.
3 - High-voltage heater (PTC) - Z115- (with high-voltage heater (PTC) control unit - J848- )
❑ Check; ⇒ Vehicle diagnostic tester in “Guided fault finding” mode (of air conditioning system) and ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit; Removing and installing
high-voltage heater (PTC) - Z115- / high-voltage heater (PTC) control unit - J848- )
4 - Coolant valve for gearbox - N488-
❑ Removing and installing ⇒ Engine mechanics; Rep. gr. 19 ; Coolant pump/thermostat
❑ Check; ⇒ Vehicle diagnostic tester in “Guided fault finding” mode (of engine) and ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations

5 - Coolant supply to gearbox

❑ Connection to coolant circuit of engine (and gearbox) ⇒ Engine mechanics; Rep. gr. 19 ; Cooling system,
coolant (coolant hose schematic diagram).
6 - Coolant supply from engine
❑ Connection to engine coolant circuit ⇒ Engine mechanics; Rep. gr. 19 ; Cooling system, coolant (coolant
hose schematic diagram).
7 - Coolant return to the engine
8 - Coolant changeover valve 2 - N633-
Note
AG. Volkswagen AG d
agen oes
olksw not
♦ The -N633- is activatedd by by the
V gu
ara
respective engine oris control unit
e nte
eo
(e.g. by engine
aut control unit -
h
ra
J623- ), when
s heat output is re‐
s c
ce
e
quired by the air conditioning

nl
pt
du
system and the “auxiliary heater”
an
itte
y li
function is activated. However,
erm
ab
the auxiliary heater itself is not
ility
ot p
activated, but instead the -Z115-
wit
, is n
is used for the auxiliary heater
h re
hole
function or the vehicle is in elec‐

spec
tric drive mode, ⇒ Current flow
es, in part or in w
diagrams, Electrical fault finding t to the co

and Fitting locations and ⇒ Vehi‐
cle diagnostic tester in “Guided
fault finding” mode.
rrectness of i

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conditioning system when the
nf
ercia
auxiliary heater is switched off

or
(with engine running and/or at

m
m
atio
standstill, irrespective of whether

om
n in
-Z115- is activated or not), make

or c
thi
sure the component is installed

te
sd
a
with correct orientation and that

iv
o
r
rp
cu
it works properly ⇒ Current flow

o
m
f
en
diagrams, Electrical fault finding

ng
t.
yi Co
and Fitting locations and ⇒ Vehi‐ Cop py
t. rig
gh ht
yri by
fault finding” mode. op Vo
by c lksw
cted agen
Prote AG.

♦ To ensure that the coolant heat‐

ed by the -Z115- is conveyed
through the heat exchanger of
heater and air conditioning unit,
the coolant pump for high-tem‐
perature circuit - V467- and the
coolant valve for gearbox -
N488- must be activated as well
(by the respective engine control
unit). To ensure that the coolant
flows into the correct direction,
the non-return valves installed in
the coolant circuit must be instal‐
led correctly and they must work
properly. For additional informa‐
tion refer to ⇒ Engine mechan‐
ics; Rep. gr. 19 ; Cooling system,
coolant (coolant hose schematic
diagram); ⇒ Vehicle diagnostic
tester in “Guided fault finding
mode” ⇒ Current flow diagrams,
Electrical fault finding and Fitting
locations.
9 - Coolant pump for high-temperature circuit - V467-

AG. Volkswagen AG d
agen oes
Note Volksw not
gu
d by ara
ise nte
The -V467- is activated ubyt the
r
♦ ho eo
ra
respective engine control
ss a unit c
(e.g. by engine control unit -
ce
le
un
pt
J623- ), if heat output is required
an
d
itte
by the air conditioning system

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rm
⇒ Current flow diagrams, Electri‐ ab

pe
ility
cal fault finding and Fitting loca‐
ot
wit
, is n
tions and ⇒ Vehicle diagnostic h re

tester in “Guided fault finding”
hole
spec
mode.
es, in part or in w
t to the co

rrectness of i

l purpos

-Z115- is activated or not), make
sure the component is installed
nform
ercia
with correct orientation and that

m
it works properly ⇒ Current flow

a
com
tio
diagrams, Electrical fault finding

n in
r
and Fitting locations and ⇒ Vehi‐

te o
thi

s
iva
do
fault finding” mode.

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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.

♦ To ensure that the coolant heat‐

ed by the -Z115- is conveyed
through the heat exchanger of
heater and air conditioning unit,
the coolant changeover valve 2 -
N633- and the coolant valve for
gearbox - N488- must be activa‐
ted as well (by the respective en‐
gine control unit). To ensure that
the coolant flows in the correct
direction, the non-return valves
installed in the coolant circuit
( ⇒ Item 2 (page 35) and
⇒ Item 11 (page 38) ) must be
installed correctly and they must
work properly. For additional in‐ wage
formation refer to ⇒ Engine me‐ y Volks
es n
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chanics; Rep. gr. 19 ; Cooling ise d b ua
ran
system, coolant (coolant hose thor tee
or
schematic diagram); ⇒ Vehicle
ss
au ac
diagnostic tester in “Guided fault
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finding” mode ⇒ Current flow di‐
pt
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and Fitting locations.
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10 - Coolant return from gearbox
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❑ Connection to coolant circuit of engine (and gearbox) ⇒ Engine mechanics; Rep. gr. 19 ; Cooling system,
spec
coolant (coolant hose schematic diagram).
t to the co
❑ Depending on vehicle version, installed in coolant line between heat exchanger of heater and air condi‐
rrectne
tioning unit and circulation pump - V55- (as shown in illustration), or in coolant line between auxiliary
heater and heat exchanger of heater and air conditioning unit ⇒ Item 14 (page 39) .
s
❑ Install with correct orientation and ensure proper operation
s o
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♦ Prevents coolant from flowing

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engine and/or the coolant pump
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♦ If there are customer complaints Prote AG.
-Z115- and the coolant pump for
high-temperature circuit - V467-
are activated or not), make sure
the coolant pump/thermostat is
installed with correct orientation
and that it works properly.


auxiliary heater is switched on
(and the -Z115- instead of the
auxiliary heater is activated for
heating the coolant), make sure agen
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❑ The -V55- is connected to the auxiliary heater's hose assembly.
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In electric drive mode (engine not
es, in part or in w
running) the circulation pump - V55-
t to the co
of the auxiliary heater can be acti‐
vated by the auxiliary heater control
unit - J364- . The auxiliary heater
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control unit - J364- is requested to
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switch on the circulation pump -

V55- via the data bus by the air con‐
ditioner operating unit ( Climatronic
nform
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control unit - J255- ) ⇒ Vehicle diag‐

nostic tester in “Guided Fault Find‐
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ing” mode.
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If the -J255- in a vehicle with a high-
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voltage system has decided that the
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auxiliary heater function is required
to achieve the desired passenger
compartment temperature, the aux‐
iliary heater or the high-voltage
heater (PTC) - Z115- is activated
depending on various conditions.
❑ Alternative fitting location, if not installed at ⇒ Item 11 (page 38)
❑ For additional notes refer to ⇒ Item 11 (page 38)
Note
Installed only if the non-return valve

⇒ Item 11 (page 38) is not fitted
3.2 Bleeding coolant circuit of auxiliary/sup‐

plementary heater
The removal and installation procedures for the auxiliary/supple‐
mentary heater and the circulation pump - V55- described in this
Workshop Manual ensure that only a small quantity of air enters
or remains in the coolant circuit. Therefore it is not necessary to
bleed the coolant circuit completely after removing and installing
the auxiliary/supplementary heater or the circulation pump -V55- .

However, if a large quantity of coolant has escaped due to another

problem, e.g. a leaking hose, or after coolant pipes have been
renewed, the coolant circuit must be bled ⇒ Rep. gr. 19 ; Cooling
system, coolant; Draining and filling coolant .
After bleeding and filling the coolant circuit, additional bleeding of
the auxiliary/supplementary heater and the circulation pump -
V55- must be performed as described below.
Bleeding coolant circuit of auxiliary/supplementary heater
– To prevent running dry, fill circulation pump - V55- with cool‐
ant.
Note
As only a small quantity of coolant escapes from the coolant cir‐

cuit during removal and installation of the auxiliary/supplementary
heater or circulation pump - V55- (described earlier), and only a
small quantity of air remains in the coolant circuit during installa‐
AG. Volkswagen AG d
tion (auxiliary/supplementary kswheater
agen and circulation opump
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are already filled with coolant
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– Fill coolant sexpansion tank with coolant as far as upper mark. ce
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– Activate circulation pump - V55- via final control diagnosis

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function ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
erm
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mode. This will bleed coolant circuit from heat exchanger in

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heater and air conditioning unit to circulation pump - V55- ad‐

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– Start engine and choose the highest available setting for tem‐
es, in part or in w
perature (“HI”) on operating and display unit for heater and air
t to the co
conditioning system. On vehicles equipped with Climatronic,

turn rotary knobs to “HI” position (for driver and front passen‐
ger sides).
rrectness of i
– Run auxiliary/supplementary heater at full load for at least

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2 minutes ( circulation pump - V55- is actuated).

– Run engine at high idling speed (approx. 2000 to 2500 rpm)
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for at least 2 minutes.

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– Switch off engine and auxiliary/supplementary heater.

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– Check coolant level in coolant expansion tank and top up

coolant if necessary ⇒ Rep. gr. 19 ; Cooling system/coolant;
Draining and filling cooling system .
3.3 Removing and installing coolant pipes

for auxiliary/supplementary heater

AG. Volkswagen AG d
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♦ Hose clamps, up to 25 mmss- 3094-
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Note
♦ If the coolant circuit is opened, it must be bled ⇒ Rep. gr. 19 ;

Cooling system/coolants; Draining and replenishing with cool‐
ant .
♦ If the drive motor is warm, then the cooling system is pressur‐
ised. If necessary, release pressure before carrying out re‐
pairs.
Removing
insulation .
– Clamp off coolant hoses using hose clamps to Ø 25 mm -
3094- .
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♦ The illustration shows 2 different thversions:
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♦ -I- Vehicles with petrol engine.ss
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♦ -II- Vehicles with diesel engine.
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♦ The removal and installation procedure is identical for both
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CAUTION
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– Release pressure by pressing pressure relief valve on cool‐ rrectness of i
ing system tester until the gauge shows a pressure of 0.
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– Loosen spring-type clip -3-.

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– If fitted (only on specific vehicles), slide protective grommet

m
-6- to one side.

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– Unclip coolant hoses -4- and pull them off coolant pipes -1-
r
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and -5-.
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– Unscrew nuts -2-.

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– Remove coolant pipes -1- and -5-.
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– Install in reverse order.
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Specified torque
Component to be tightened Specified torque
Collar nut 8 Nm

4 Fuel supply
⇒ “4.1 Fittings location overview - fuel supply”, page 43
⇒ “4.2 Testing quantity of fuel delivered”, page 46
⇒ “4.3 Removing and installing metering pump V54 ”, page 47
⇒ “4.4 Checking metering pump V54 with end sealing valve”, page
51
⇒ “4.5 Bleeding fuel line to metering pump V54 (filling with fuel)”,
page 52
4.1 Fittings location

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⇒ “4.1.1 Fittingsslocation
db overview - fuel supply, Passat
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⇒ “4.1.2 Fittings
ss location overview - fuel supply, Passat estate”,
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⇒ “4.1.3 Fittings location overview - fuel supply, Passat GTE”,
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page 45
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4.1.1 Fittings location overview - fuel supply,
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Passat saloon
spec
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Note
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♦ Fuel lines are secured with O-type clips. These O-type clips
l purpos
must always be renewed every time they are removed.

♦ Start engine if fuel tank was empty. Then start the auxiliary/
nform
ercia
supplementary heater repeatedly until the heater does not

switch off by itself.
m
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com
tio
♦ Observe the rules for cleanliness when doing all work on the
n in
r
fuel supply system ⇒ page 6 .

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♦ Always observe the safety precautions when working on the

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4. Fuel supply 43
1 - Fuel line to metering pump

- V54-
heater
⇒ page 16
3 - Quick-release coupling of
fuel line
❑ At auxiliary/supplemen‐
tary heater
fuel line
❑ At metering pump - V54-
AG. Volkswagen AG d
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5 - Metering pump - V54- Vol
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❑ The metering pump - rise d
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V54- is located on the
au
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fuel tank. ss c
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⇒ page 47
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❑ Testing quantity of fuel
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delivered ⇒ page 46 .
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❑ Fuel delivery unit can be spec

es, in part or in w
found on right under

t to the co
bench seat.
❑ With fuel gauge sender
rrectness of i
- G-
l purpos
⇒ Rep. gr. 20 ; Fuel de‐

livery unit/fuel gauge sender; Removing and installing fuel delivery unit/fuel gauge sender
nform
mercia
a
com
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1 - Fuel line to metering pump

- V54-
heater
⇒ page 16
3 - Quick-release coupling of n AG. Volkswagen AG do
fuel line lkswage es n
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❑ At auxiliary/supplemen‐ ir se
d ran
tee
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fuel line
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❑ The metering pump -
h re
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spec
fuel tank.
es, in part or in w
t to the co
⇒ page 47
rrectness of i
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❑ Fuel delivery unit can be
nf
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orm
bench seat.
m
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❑ With fuel gauge sender

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livery unit/fuel gauge sender; Removing and installing fuel delivery unit/fuel gauge sender
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Passat GTE
Figure for the saloon is similar.
Note
♦ Fuel lines are secured with O-type clips. These O-type clips
4. Fuel supply 45
Passat 2015 ➤ , Passat Variant 2015 ➤ AG. Volkswagen AG d
Auxiliary heater - Edition 05.2016 agen oes
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1 - Fuel delivery unit oris eo
th
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❑ Fuel delivery unit can be ss c
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nl
pt
du
bench seat.
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❑ With fuel gauge sender erm
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livery unit/fuel gauge
es, in part or in w
sender; Removing and
t to the co
installing fuel delivery
unit/fuel gauge sender
rrectness of i
heater
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nf
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o
rm
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n in
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⇒ page 16
thi
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fuel line
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❑ At auxiliary/supplemen‐ Cop py
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rig ht
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fuel line
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❑ The metering pump -
fuel tank.
⇒ page 47
6 - Fuel line to metering pump - V54-
4.2 Testing quantity of fuel delivered
Note
Check fuel delivery rate as described in “Guided Fault Finding”

function ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode.
Conditions for checking fuel delivery rate (in short):

♦ Coolant temperature below 30 ℃
♦ Ambient temperature below 25 °C
♦ Fuel tank sufficiently filled (needle on fuel gauge in dash panel
insert is not in red zone)
♦ Battery - A- (vehicle battery) fully charged
♦ Fuel line (from fuel tank to auxiliary/supplementary heater) in‐
stalled according to specifications and filled completely with
fuel

♦ Auxiliary/supplementry heater installed completely and con‐

nected to vehicle electrical system
♦ All auxiliary/supplementary heater fuses OK (according to cur‐
rent flow diagram) ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
♦ Auxiliary/supplementary heater is switched off
♦ Event memories of all self-diagnosis compatible systems have
been read out; causes of any faults displayed in vehicle sys‐
tems have been eliminated; displayed event memory entries
have been erased using "Guided Fault Finding" mode of ⇒ Ve‐
hicle diagnostic tester.
Note
♦ A higher ambient or coolant temperature can lead to incorrect

measurements of the fuel quantity delivered due to fuel evap‐
oration.
♦ Complete description of conditions for checking fuel delivery
rate ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode
♦ If the quantity of fuel delivered is in the lower tolerance range
and there are starting difficulties with the auxiliary/supplemen‐
tary heater, check the fuel lines to the auxiliary/supplementary
heater ⇒ page 43 . If no fault is found, renew the metering
pump - V54- ⇒ page 47 .
AG. Volkswagen
– Check fuel delivery lrate
ksw of metering pump - V54-
agen AG do
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diagnostic tester
db
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V “Guided Fault Finding” mode.
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4.3 au Removing and installing metering pump
tho or
ac
ss
- V54-
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an
⇒ “4.3.1 Removing and installing metering pump V54 , Passat”,

itte
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page 47
erm
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⇒ “4.3.2 Removing and installing metering pump V54 , Passat

wit
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GTE”, page 49
h re
hole
spec
4.3.1 Removing and installing metering pump

es, in part or in w
t to the co
- V54- , Passat
Removing
rrectness of i
l purpos
Note
nform
ercia
♦ Observe safety precautions for working on fuel supply system

⇒ Rep. gr. 00 ; Safety instructions .
m
at
om
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or

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ate
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or

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♦ Pay attention to correct part number of metering pump - V54- C py
t. rig
(different versions) ⇒ Electronic parts catalogue .
gh ht
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tion.
4. Fuel supply 47
CAUTION
– To release pressure, wrap a clean cloth around the connec‐
– Lower fuel tank until metering pump - V54- is accessible ⇒

Rep. gr. 20 ; Fuel tank; Removing and installing fuel tank .
– Press retaining tabs of bracket -1- in -direction of arrow- to
side, using a suitable tool.
– Push up metering pump - V54- -5- with bracket -1- to remove
upwards from fuel tank.
– Separate connector -2- from metering pump - V54- -5-.
– Take metering pump - V54- -5- out of guides -4-.
– Release quick-release coupling of fuel line -3-. Seal fuel lines.
– Open clip -6- and pull fuel lines off metering pump - V54- -5-.
Seal fuel lines.
Installing
AG. Volkswagen AG d
agen oes
Note Volksw not
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♦ There are different typesuthofo the metering pump - V54- ⇒ Elec‐ eo
ra
tronic parts cataloguess. a c
ce
le
♦ Only metering pump - V54- with end sealing valve is permis‐

un
pt
an
d
sible; observe correct part number ⇒ Electronic Parts Cata‐

itte
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logue .
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spec
es, in part or in w
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note the following:
– Renew bracket if retaining tabs -1- and -5- are damaged or
broken off.
– Renew O-type clip -7-.
– Insert metering pump - V54- -6- into bracket so that O-type
clips -8- are seated in guides -5- and connector -2- does not
make contact with bracket. AG. Volkswagen AG d
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lksw not
– Engage electrical wire -3- in guides -arrows-. byV
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– Install bracket with metering pump - V54- -6- ensuring
ut
h that re‐
or eo
taining tabs -1- engage properly. ss a ra
c
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le
– Check that fuel lines are properly secured in retainers -5-.
un
pt
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Note
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If fuel lines make contact with body, they can transmit sound.
hole
spec
es, in part or in w
t to the co
– Check that fuel lines are correctly seated and routed; fuel lines
must not make contact with body (risk of transmitting sound).
Specified torque
rrectness of i
♦ ⇒ “4.1 Fittings location overview - fuel supply”, page 43
l purpos
♦ Fuel tank; Removing and installing fuel tank ⇒ Rep. gr. 20 ;

Fuel tank; Removing and installing fuel tank .
nform
mercia
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4.3.2 Removing and installing metering pump
com
tion in
- V54- , Passat GTE
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Removing
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♦ Pay attention to correct part number of metering pump - V54- Prote
cted AG.
agen
(different versions) ⇒ Electronic Parts Catalogue .
♦ Checking metering pump - V54- with “end sealing valve”
⇒ page 51 .
– Observe safety precautions for working on fuel supply system

⇒ Rep. gr. 00 ; Safety instructions .
– Observe the rules for cleanliness when doing all work on the
– Always observe the safety precautions when working on the
tion.
4. Fuel supply 49
CAUTION
– To release pressure, wrap a clean cloth around the connec‐
– Press securing lugs of bracket -2- to one side with suitable

tool.
– Push up metering pump - V54- -6- with bracket -2- and lift
pump off fuel tank.
– Disconnect connector -3-.
– Take metering pump - V54- -6- out of guides -5-.
– Separate fuel line -4- at quick release coupling. Seal fuel lines.
– Release O-type clips -1- and pull fuel lines off metering pump
- V54- -6-. Seal fuel lines.
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♦ There are different types of the metering pump - V54- ⇒ Elec‐

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ab
tronic Parts Catalogue .

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♦ Different versions; only metering pump - V54- with end sealing

, is n
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valve permissible; pay attention to correct part number ⇒

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Electronic Parts Catalogue

es, in part or in w
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note the following:
rrectness of i
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Note
Install metering pump - V54- -6- in the correct orientation.

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orm
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– Renew bracket if retaining tabs -1- and -5- are damaged or

broken off.
– Renew O-type clip -7-.
– Insert metering pump - V54- -6- into bracket so that O-type
clips -8- are seated in guides -5- and connector -2- does not
make contact with bracket.
– Engage electrical wire -3- in guides -arrows-.
– Install bracket with metering pump - V54- -6- ensuring that re‐
taining tabs -1- engage properly.
– Check that fuel lines are properly securedwin
ageretainers
n AG. Volks-5-.
wagen AG
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If fuel lines make contact with body, they can transmit sound.
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– Check that fuel lines are correctly seated and routed; fuel lines
rm
ab
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ility
must not make contact with body (risk of transmitting sound).
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Specified torque
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♦ ⇒ “4.1 Fittings location overview - fuel supply”, page 43
es, in part or in w
t to the co
4.4 Checking metering pump - V54- with
end sealing valve
rrectness of i
l purpos
– If you are uncertain whether the metering pump - V54- -C- has
an end sealing valve or not, connect e.g. hand vacuum pump
- VAS 6213- to connection -A-.
nform
ercia
– Use hand-operated vacuum pump to a generate a vacuum of

m
a
approx. 0.8 bar.
com
tion in
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• Connection -B- should be open.

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• Vacuum is maintained on metering pumps - V54- with end

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4. Fuel supply 51
4.5 Bleeding fuel line to metering pump -

V54- (filling with fuel)
Note
♦ Air or fuel vapour in the fuel supply to the auxiliary heater can
lead to malfunction when the auxiliary heater is in combustion
mode. To prevent air or fuel vapour from being drawn in by the
metering pump - V54- and conveyed to the auxiliary heater agen AG. Volkswagen AG do
when the auxiliary heater is first switched on after performing Vol
ksw es n
ot g
repairs on the fuel tank or the fuel delivery unit, the ifuel
sed bytake- ua
ran
off pipe must be filled with fuel (bled) after performing
hor repairs tee
ut or
in this area. ss
a ac
ce
♦ The fuel line must be bled, for example, if the fuel line was e
nl
pt
du
removed and the entire fuel line is filled with air. If, for example,
an
itte
y li
only the fuel delivery unit was removed and there is only a
erm
ab
small amount of air in the fuel line; it is sufficient to switch on
ility
ot p
the auxiliary heater and let it run for some time (at least 10 mi‐
wit
, is n
nutes) in full load mode to check its operation after completing
h re
hole
work on the fuel system.
spec
es, in part or in w
♦ After completing work on the fuel system, switch on the aux‐
t to the co
iliary heater, and let it run for some time (at least 10 minutes)
in full load mode.
rrectness of i
♦ On vehicles with high-voltage system, it may not be possible
to switch on the auxiliary heater via the control panel, depend‐
l purpos
ing on the charge level of the hybrid battery unit - AX1- and
the ambient temperature. If the -J255- gets the information that
nf
ercia
the hybrid battery unit - AX1- is sufficiently charged, that there
o
is sufficient power available to operate the high-voltage heater
rm
m
atio
(PTC) - Z115- and that the ambient temperature is above -10°
om
C, the -J255- activates the -Z115- (the auxiliary heater is not
n in
or c
activated). In this case, the auxiliary heater can be switched
thi
te
sd
a
on using e.g. the “Basic setting” function. For additional infor‐

iv
o
r
mation refer to ⇒ Vehicle diagnostic tester in “Guided fault

rp
cu
o
m
f
finding” mode.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
On vehicles with high-voltage system, the meteringgpump en AG. V- V54-

olkswagen AG
-1- cannot be accessed if the fuel tank is installed. VolkswaTherefore, does
not
bleed fuel line -2- (and corresponding riser ed btube)
y leading to me‐ gu
ara
tering pump - V54- after completing work horis on the fuel system of nte
eo
the auxiliary heater (e.g. following repair
sa
ut
work on the fuel delivery ra
c
unit or the -V54- -1-). s
ce
le
un
pt
an
d
– Disconnect fuel line -4- leading from -V54- -1- to auxiliary itte
y li
erm
ab
heater at connection -5- ⇒ Rep. gr. 20 ; Plug-in connectors
ility
ot p
(Separating plug-in connectors).
wit
is n
h re
ole,
spec
Note
t to the co
Observe safety precautions when working on the fuel supply sys‐
tem ⇒ Rep. gr. 20 ; Safety instructions; Safety precautions when
working on fuel supply system .
rrectne
– Hold a container under the opened connection (e.g. the con‐
ss o
tainer of the diesel extractor - VAS 5226- ).
cial p
f inform
– Activate -V54- -1- e.g. via the function “Line filling” in “Basic
mer
setting” for the auxiliary heater for approx. 30 seconds; ⇒ Ve‐
atio
m
hicle diagnostic tester in “Guided fault finding” mode.

o
n
c
i
or
n thi
– Observe the fuel which escapes at connection -5-.
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
If after 30 seconds fuel escapes continuously from connection
ht
pyri by
Vo
o
-5-, the fuel line is filled completely with fuel.
c by lksw
cted agen
Prote AG.
– Connect fuel line to connection -5-.

– After all removed components have been reinstalled, switch
on the auxiliary heater, and let it run in full load mode for ap‐
prox. 10 minutes.
Note
On vehicles with high-voltage system, it may not be possible to

switch on the auxiliary heater via the control panel, depending on
the charge level of the hybrid battery unit - AX1- and the ambient
temperature. If the -J255- gets the information that the hybrid bat‐
tery unit - AX1- is sufficiently charged, that there is sufficient
power available to operate the high-voltage heater (PTC) - Z115-
and that the ambient temperature is above -10°C, the -J255-
activates the -Z115- (the auxiliary heater is not activated). In this
case, the auxiliary heater can be switched on using e.g. the “Basic
setting” function. For additional information refer to ⇒ Vehicle di‐
agnostic tester in “Guided fault finding” mode.
4. Fuel supply 53
5 Regulation of auxiliary/supplementa‐
yV
olks
wage es n
ot g
ry heater d b ua
ran
ise tee
or h
ut or
⇒ “5.1 Functional description”, pagess54
a ac
ce
e
nl
⇒ “5.2 Supplementary heating mode”, page 55
pt
du
an
itte
y li
⇒ “5.3 Auxiliary heater mode”, page 55 erm
ab
ility
ot p
⇒ “5.4 Switching off auxiliary/supplementary heater”, page 55
wit
, is n
h re
5.1 Functional description
hole
spec
es, in part or in w
The auxiliary/supplementary heater can be started by means of
t to the co
the remote control, the instant heating button or appropriate pro‐
gramming in the central monitor. The supplementary heater mode
is started automatically by the vehicle electronics system once all
rrectness of i
the necessary preconditions have been met ⇒ page 5 .
l purpos
Initially, the fresh air blower - V2- and the combined glow plug with
flame monitoring - Q8- are subjected to a functional test and then
the glow plug with flame monitoring - Q8- goes through a pre‐
nf
ercia
o
heating phase.
rm
m
atio
m
The subsequent starting process depends on the coolant tem‐

o
n in
c
perature, among other things, and can therefore vary in the

or
thi
e
amount of time it takes. The fuel is supplied, the glow plug with
t
sd
iva
flame monitoring - Q8- is switched off in stages and the flame
o
r
rp
cu
monitor is activated.
o
m
f
en
ng
t.
yi Co
After completion of the starting phase, the heater unit operates Cop py
. rig
under full load and further load control (sparking mode, full load,
t
gh ht
yri by
partial load and controlled waiting period) takes place on the basis cop Vo
by lksw
of the following coolant temperature thresholds.
cted agen
Prote AG.
Auxiliary/supplementary heater: auxiliary heater mode

– Standard operating temperature: approx. 82 ℃
– Change to controlled waiting period: approx. 88 °C
Auxiliary/supplementary heater: supplementary heater mode
– Standard operating temperature: approx. 82 ℃
– Change to controlled waiting period: approx. 88 °C
The reference resistance of the glow plug with flame monitoring
- Q8- is automatically re-determined during the starting or run-on
phase, depending on the unit. This is done to compensate for
ageing-related changes.
As a consequence of this calibrating procedure, processes that
are affected can also require more time.
After expiry of the maximum operating time of 60 min or after
manual shutdown by means of the remote control or the instant
heating button , the auxiliary/supplementary heater is switched
off.
The booster heater is switched off if at least one of the defined
switch-on criteria is no longer met ⇒ page 5 .
After switch-off, operation of the metering pump - V54- is stopped
immediately.
The combustion air blower - V6- and the glow plug with flame
monitoring - Q8- continue to operate for a limited time in order to
burn the remaining fuel still in the system and to cool the burner
components.
The run-on period of the heater can vary depending on the soft‐
ware version and load level at the time of switch-off.

5.2 Supplementary heating mode

Once the coolant temperature has reached approx. 84 °C, the
control unit switches to energy-saving control mode.geIfnthe AG. coolant
Volkswagen AG
does
temperature continues to rise above approx.V88 olks°C, the control
wa not
unit switches to the controlled waiting period.ed by If the coolant tem‐ gu
ara
perature does not drop below approx.ho76 °C within 15 minutes
ris nte
eo
during the controlled waiting period,s athe
ut heater unit will initiate the ra
c
start procedure into the standard control
s mode when the coolant
ce
e
temperature does drop below approx. 76 °C.
nl
pt
du
an
itte
y li
5.3 Auxiliary heater mode
erm
ab
ility
ot p
Switching on auxiliary heater mode in vehicles with manual air
wit
, is n
conditioning:
h re
hole
spec
– Press instant heating button -1-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
Switching on auxiliary heater mode in vehicles with Climatronic:
or
his
ate
– Press instant heating button -1-.
do
priv
cum
for
en
ng
t.
yi Co
op
Note C py
ht. rig
rig ht
py by
Vo
Once the coolant temperature has reached approx. 82 ℃, the
co lksw
by
cted agen
control unit switches to energy-saving control mode. If the coolant Prote AG.
temperature continues to rise above approx. 88 °C, the control
unit switches to the controlled waiting period. If the coolant tem‐
perature does not drop below approx. 70 ℃ within 15 minutes
during the controlled waiting period, the heater unit will initiate the
start procedure into the standard control mode when the coolant
temperature does drop below approx. 65 ℃.
5.4 Switching off auxiliary/supplementary

heater
If the instant heat button has been pressed or the preset operating
time has expired, and the coolant has reached a temperature of
88° C, then combustion stops and the run-on mode begins.
The run-on begins.
The circulation pump - V55- and the combustion air blower - V6- ,
however, continue to run to cool down the heater (run-on mode)
and are switched off automatically.
Note
The run-on period of the circulation pump - V55- and the com‐
bustion air blower - V6- depends on the operating mode in which
the auxiliary/supplementary heater was switched off.
The run-on period is approx. 3 minutes.
5. Regulation of auxiliary/supplementary heater 55

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Passat 2015 ed b ➤ , Passat Variant 2015 ➤ ara
nte
ris
Auxiliary
ut
ho heater - Edition 05.2016 eo
ra
s a c
s
Depending on the control unit software version, slight deviations
ce
le
un
pt
in the specified run-on values are possible.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
lksw not
6 Other control components Vo gu
by ara
d
rise nte
ho eo
⇒ “6.1 Removing ands ainstalling ambient temperature sensor G17
ut ra
c
”, page 57 s
ce
le
un
pt
⇒ “6.2 Removing and installing remote control receiver for auxil‐
an
d
itte
y li
iary coolant heater R149 ”, page 57
erm
ab
ility
ot p
⇒ “6.3 Functional description of remote control for auxiliary/sup‐
wit
is n
plementary heater”, page 60
h re
ole,
spec
6.1 Removing and installing ambient tem‐
perature sensor - G17-
t to the co
rrectne
Note
s
The ambient temperature sensor - G17- is used for determining
s o
the outside temperature and as a switch-on condition of the aux‐
cial p
f in
iliary/supplementary heater.
form
mer
atio
m
– Removing and installing ambient temperature sensor - G17-

o
n
c
i
⇒ Heating, air conditioning; Rep. gr. 87 ; Other control
or
n thi
e
components .
t
sd
iva
o
pr
cum
– Checking ambient temperature sensor - G17- ⇒ Vehicle diag‐
r
fo
en
ng
nostic tester in “Guided Fault Finding” mode

t.
yi Co
Cop py
6.2 Removing and installing remote control
t. rig
gh ht
pyri by
receiver for auxiliary coolant heater -

co Vo
by lksw
cted agen
Prote AG.
R149-
⇒ “6.2.1 Removing and installing remote control receiver for aux‐
iliary coolant heater R149 , Passat saloon”, page 57
⇒ “6.2.2 Removing and installing remote control receiver for aux‐
iliary coolant heater R149 , Passat estate”, page 58
6.2.1 Removing and installing remote control

receiver for auxiliary coolant heater -
R149- , Passat saloon
♦ Removal wedge - 3409-
Note
If the remote control receiver for auxiliary coolant heater - R149-

is renewed, it must be adapted to the auxiliary/supplementary
heater using “Guided fault finding” of ⇒ Vehicle diagnostic tester.
6. Other control components 57

Removing
– Remove right luggage compartment trim ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Assembly overview - luggage compartment side trims .
– Press locking mechanism downwards from bracket -2- using
removal wedge - 3409- .
– Pull remote control receiver for auxiliary coolant heater - R149-
-1- off bracket -2-.
– Detach connectors -1- and -2- from remote control receiver for
auxiliary coolant heater - R149- -3-.
Installing
– Connect connectors to remote control receiver for auxiliary
coolant heater - R149- .
– Push remote control receiver for auxiliary coolant heater -
R149- onto bracket and engage.
The remaining steps for installation are carried out in reverse or‐
der.
Note

Specified torque
♦ Assembly overview - Luggage compartment side trim ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compartment n AG. Volkswagen A
trims; Assembly overview - Luggage compartment side otrim lksw
age G do
es n
o
yV t gu
db ara
ise nte
6.2.2 Removing and installing remote control
r
tho eo
au ra
receiver for auxiliary coolant
ss heater - c ce
le
un
R149- , Passat estate

pt
an
d
itte
y li
erm
ab

ility
ot p
wit

is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
Note
pr
cum
r
fo
en
ng
t.
yi
Co
op py
t. C rig
gh ht
yri
heater using “Guided fault finding” of ⇒ Vehicle diagnostic tester. p by
o Vo
by c lksw
cted agen
Prote AG.

Removing
– Remove right luggage compartment trim ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Assembly overview - luggage compartment side trims .
– Press locking mechanism downwards from bracket -2- using
removal wedge - 3409- .
– Pull remote control receiver for auxiliary coolant heater - R149-
-1- off bracket -2-.
– Detach connectors from remote control receiver for auxiliary
coolant heater - R149- -1-.
Installing
– Connect connectors to remote control receiver for auxiliary
coolant heater - R149- .
– Push remote control receiver for auxiliary coolant heater -
R149- onto bracket and engage.
n AG. Volkswagen A
The remaining steps for installation
ksw are carried out in reverse
age G do
es n or‐
der. y Vol ot g
ua
db r e an
ris tee
utho or
a ac
Note ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Specified torque
hole
spec
es, in part or in w
♦ Assembly overview - Luggage compartment side trim ⇒ Gen‐

t to the co
eral body repairs, interior; Rep. gr. 70 ; Luggage compartment
trims; Assembly overview - Luggage compartment side trim
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.

6.3 Functional description of remote control

for auxiliary/supplementary heater
⇒ “6.3.1 Functional description of remote control for auxiliary/
supplementary heater, to week 21/2015”, page 60
supplementary heater, from week 22/2015 to week 21/2016”,
page 62
supplementary heater, from week 22/2016”, page 64
6.3.1 Functional description of remote control

for auxiliary/supplementary heater, to
week 21/2015
Note
♦ The auxiliary/supplementary heater can be switched on and agen

AG. Volkswagen AG d
oes
off from a distance of several 100 metres (open space) using yV
olks
w not
gu
the remote control. This range is restricted in built-up areas
ed b or ara
nte
from within buildings. ris
tho eo
au ra
♦ The remote control should be held upright when soperating the
s c
ce
e
buttons (the radio signals can be received optimally by the ve‐

nl
pt
du
hicle aerial in this way and the greatest transmission range is
an
itte
y li
achieved).
erm
ab
ility
ot p
♦ Following disconnection of the vehicle batteries, the auxiliary/
wit
, is n
supplementary heater remote control does not have to be re-
h re
adapted.
hole
spec
es, in part or in w
♦ If the remote control does not work properly, check the remote
t to the co
control battery ⇒ page 61 .
♦ If the remote control is renewed, it must be adapted with the
rrectness of i
l purpos
♦ Start guided fault finding or guided functions in ⇒ Vehicle di‐

agnostic tester, and then start “Adapt Telestart transmitter”.
nf
ercia
o
Switching on auxiliary/supplementary heater using remote control
rm
m
atio
m
– Press button -1-. The indicator lamp -2- must light up green.
o
n in
or c
thi
When the auxiliary/supplementary heater is switched on, its op‐

te
sd
a
erating time is determined by means of the setting on the multi‐

iv
o
r
rp
cu
function indicator.
o
m
f
en
ng
t.
yi
Switching off auxiliary/supplementary heater using remote control
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
by
Vol Passat 2015 ➤ , Passat not
gu Variant 2015 ➤
d ara
orise Auxiliary heater - Edition
nte 05.2016
h eo
aut ra
c
– Press button -3-. The indicator lamp s-2-
s
must light up red.
ce
le
un
pt
The auxiliary/supplementary heater switches to run-on mode and
an
d
itte
y li
then switches off.
erm
ab
ility
ot p
Renewing remote control battery
wit
is n
h re
ole,
spec
Note
t to the co
♦ Note installation position of battery.
♦ Use only the same type of 3-volt battery.
rrectne
♦ Allocation of the remote control to the auxiliary/supplementary
heater remains intact. Re-adapting is not necessary.
ss o
cial p
f inform
– Pull off battery compartment cover -1- in direction of -arrow-
mer
atio
and remove battery.
om
n
c
i
– Insert new batteries and refit cover.
or
n thi
te
sd
va
Indicator lamp in remote control

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Once you have pressed a button, the warning lamp in the remote
control -2- indicates whether the signal from the remote control
has been received by the auxiliary/supplementary heater and
whether the battery in the remote control is low.
Display -2- Meaning
LED lights up green for 2 sec‐ The auxiliary/supplementary
onds. heater has been switched on
with -1- “ON”.
LED lights up red for 2 seconds. The auxiliary/supplementary
heater has been switched off
with -3- “OFF”.
The LED slowly flashes green The signal to switch on was not
for 2 seconds. received.
The LED quickly flashes green The auxiliary/supplementary
for 2 seconds. heater is blocked, e.g. because
the fuel tank is nearly empty or
there is a fault in the auxiliary/
supplementary heater.
LED flashes red for 2 seconds. The signal to switch off was not
received.
Lights up orange for 2 seconds, The battery charge is low, but
then green or red. the switch on/switch off signal
was received.
Lights up orange for 2 seconds, The battery charge is low and
then flashes green or red. the switch on/switch off signal
was not received.
Flashes orange for 5 seconds. The battery is dead and the
switch on/switch off signal was
not received.
LED does not light up. The battery is dead.


for auxiliary/supplementary heater, from
week 22/2015 to week 21/2016
Note
♦ The auxiliary/supplementary heater can be switched on and

off from a distance of several 100 metres (open space) using
the remote control. This range is restricted in built-up areas or
from within buildings.
G. Volkswagen AG d
♦ The remote control should be held upright when operating
lksw
agen the
A
oes
o not
y V gu
b ara
hicle aerial in this way and the greatest transmission
rise
d
range is nte
achieved). autho eo
ra
ss c
ce
e
nl
pt
du
an
adapted.
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
agnostic tester, and then start “Adapt Telestart transmitter”.
rrectness of i
l purpos
When the auxiliary/supplementary heater is switched on, its op‐
nform
ercia
erating time is determined by means of the setting on the multi‐

m
at
function indicator.
om
ion
c
in t
Switching off auxiliary/supplementary heater using remote control
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.
– Press button -3-. The indicator lamp -2- must light up red.
then switches off.
Note


– Pull off battery compartment cover -1- in direction of -arrow-

and remove battery.
– Insert new batteries and refit cover.
Indicator lamp in remote
wage
n control
AG. Volkswagen AG d
oe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Display -2- Meaning
rrectne
s
with -1- “ON”.
s o
cial p
f
inform
mer
with -3- “OFF”. atio

om
The LED slowly flashes green The signal to switch on was not
c
i
or
for 2 seconds. received.

thi
te
sd
va
The LED quickly flashes green The auxiliary/supplementary

i
o
pr
cum
r

fo
en
ng

t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
LED flashes red for 2 seconds. Prote
cted The signal to switch off was not
AG.
agen
received.
was received.
was not received.
not received.


for auxiliary/supplementary heater, from
week 22/2016
Note
♦ The auxiliary/supplementary heater can be switched on and

off from a distance of several 100 metres (open space) using
the remote control. This range is restricted in built-up areas or
from within buildings.
♦ The remote control should be held upright when operating the
hicle aerial in this way and the greatest transmission range is
achieved).
adapted.
agnostic tester, and then start “Adapt remote control”.

When the auxiliary/supplementary heater is switched on, its op‐ swa
gen AG
. Volkswagen AG
does
erating time is determined by means of the setting on the multi‐ by Volk not
gu
function indicator. ris
ed ara
nt ee
tho or
Switching off auxiliary/supplementary heater using remote scontrol
au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Press button -2-. The indicator lamp -1- must light up red. t to the co

then switches off.
rrectness of i

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

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

Note

– Release battery compartment cover -1- using a removal

wedge - 3409- .
– Remove battery.
– Insert new battery and refit cover.
Indicator lamp in remote control
Display -1- Meaning
with button -3-.
AG. Volkswawith -2-
gen AG
do“OFF”.
sw agen es n
olk o g
The LED slowly flashes d by V
green The signal to switch ton uawas not
ran
for 2 seconds.
horis
e
received. tee
ut or
The LED quickly
ss
a flashes green The auxiliary/supplementaryac
ce
e
nl
pt

du
an
itte

y li
erm
ab
ility
ot p
LED flashes red for 2 seconds. The signal to switch off was not
wit
, is n
received.
h re
hole
spec

es, in part or in w

t to the co
was received.
rrectness of i
was not received.

l purpos

nform
ercia
not received.
m
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
o
by c lksw
cted agen
Prote AG.

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Copyright:

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Service: Passat 2015 Passat Variant 2015

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D4B804A2FCF

2.11 Removing and installing glow plug with flame monitoring Q8 . . . . . . . . . . . . . . . . . . . . . . 28

2.13 Connector pin assignment for supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.14 Dismantling and assembling burner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3 Coolant circuit with auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.2 Bleeding coolant circuit of auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . 39

4.2 Testing quantity of fuel delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.3 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.4 Checking metering pump V54 with end sealing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5 Regulation of auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.4 Switching off auxiliary/supplementary heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Danger of fire and explosion from auxiliary/supplementary heater

In fire and explosion-endangered areas a spark or the high tem‐

perature of the auxiliary/supplementary heater can cause a fire or

an explosion. Burn injuries are also possible.

– Switch auxiliary/supplementary heater off in fire and explo‐

Danger of poisoning from exhaust fumes

Auxiliary/supplementary heaters produce poisonous exhaust

fumes. Injuries to airways and poisoning are possible.

– In closed rooms, switch on auxiliary/supplementary heated

only when it is connected to an exhaust extractor system.

– In closed rooms without an exhaust extractor system, switch

off auxiliary/supplementary heater.

Malfunctions caused by air in the fuel system

If the vehicle’s timer for the auxiliary/supplementary heater is ac‐

Risk of injury due to unexpected engine start

In vehicles with activated start/stop system, the engine may start

by a message in the dash panel insert.

1.3 Safety precautions when working on the fuel system

Danger of injury caused by pressurised fuel

2 Rep. gr.00 - Technical data

When the engine is warm, the cooling system is under pressure.

Danger of scalding due to steam and hot coolant.

the coolant expansion tank with a cloth, and open it carefully.

1.6 Safety precautions when working on high-voltage system

Risk of injury due to unexpected engine start

Risk of damage to high-voltage cables

tors may result in damage to their insulation.

1.7 Safety precautions when working in vicinity of high-voltage components

4 Rep. gr.00 - Technical data

2.1 Starting conditions for auxiliary/supple‐

2.1.1 Starting conditions for auxiliary/supple‐

2.1.2 Starting conditions for auxiliary/supple‐

♦ Coolant temperature < 72 ℃ f inform

♦ Ambient temperature < 5 °C

♦ Not running on fuel reserve

♦ On-board network manager not active

The following abort conditions deactivate the start/stop function:

♦ The windscreen heater function is active.

by more than 8°C from the actual interior temperature.

♦ The engine speed is greater than 1200 rpm.

♦ The alternator - C- is defective, i.e. belt broken.

♦ Coolant temperature is not within specifications of 25 °C–100 °

2.3 Rules for cleanliness for working on the

2.4 Identification plates