Dismantling and Assembling Aux Heater for A3 Mk2
Note
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| 1 - | Intake manifold |
| q | Removing and installing → Chapter |
| 2 - | Seal |
| 3 - | Connector housing |
| q | No wiring with petrol version (dummy plug for sealing connector at control unit) |
| 4 - | Auxiliary heater control unit -J364- and combustion air blower -V6- |
| q | Checking → Guided Fault Finding function of vehicle diagnostic, testing and information system VAS 5051 |
| q | Design → Chapter |
| q | Connector assignment at auxiliary heater control unit -J364- → Chapter |
| q | Different versions → Chapter and → Electronic parts catalogue |
| q | Assembling auxiliary heater control unit -J364- and burner element → Chapter |
Note| t | There are different versions of the auxiliary heater control unit -J364- for vehicles with petrol engine or diesel engine; certain functions are differently matched (e.g. preheating times) or not available at all (e.g. activation of fuel pre-heating heater element -Z66-). |
| t | Depending on the version of the auxiliary heater (with or without fuel shut-off valve -N109-), different versions of the auxiliary heater control unit -J364- and the metering pump -V54- are fitted → Chapter and → Electronic parts catalogue. |
| t | The installation of a fuel shut-off valve -N109- is currently only planned for vehicles with diesel engine (only installed on VW vehicles; introduction for Audi vehicles not yet finalised) → Electronic parts catalogue |
| t | Currently no auxiliary heater with a fuel shut-off valve -N109- is installed in Audi A3 vehicles during production (introduction not yet finalised). However it is possible that individual vehicles have been retro-fitted with an auxiliary heater with a fuel shut-off valve -N109-; therefore it is important to pay attention to the correct version. |
| t | Currently the auxiliary heater control unit -J364- and the combustion air blower -V6- are not available as replacement parts (due to component protection, introduction not yet finalised) → Electronic parts catalogue. |
| 5 - | Cover |
| 6 - | Cover |
| q | Use screwdriver to carefully release from fasteners and detach |
| 7 - | Diesel burner element |
| q | With glow plug with flame monitor -Q8- and fuel pre-heating heater element -Z66- |
| q | Checking installation position of glow plug with flame monitor -Q8- → Chapter |
| q | Different versions for vehicles with petrol or diesel engine → Electronic parts catalogue |
| q | Checking glow plug with flame monitor -Q8- and fuel pre-heating heater element -Z66- → Guided Fault Finding function of vehicle diagnostic, testing and information system VAS 5051 |
| q | Checking fuel shut-off valve -N109- → Chapter |
| q | Assembling auxiliary heater control unit -J364- and burner element → Chapter |
Note| t | Currently glow plug with flame monitor -Q8- and fuel pre-heating heater element -Z66- can only be renewed together with burner element (wires welded in joint grommet). |
| t | Fuel shut-off valve -N109- can only be renewed together with burner element. |
| t | With certain restrictions, diesel version is also designed for operation of auxiliary heater with biodiesel (vegetable-oil or rape-oil methylester fuel) → Chapter |
| t | From model year 2006 onwards, auxiliary heaters with a modified glow plug with flame monitor -Q8- are gradually being introduced (changes to insulation and length of ferrules at glow plug). |
| t | Depending on the version of the auxiliary heater (with or without fuel shut-off valve -N109-), different versions of the auxiliary heater control unit -J364- and the metering pump -V54- are fitted → Chapter and → Electronic parts catalogue. |
| t | The installation of a fuel shut-off valve -N109- is currently only planned for vehicles with diesel engine (only installed on VW vehicles; introduction for Audi vehicles not yet finalised) → Electronic parts catalogue |
| t | Currently no auxiliary heater with a fuel shut-off valve -N109- is installed in Audi A3 vehicles during production (introduction not yet finalised). However it is possible that individual vehicles have been retro-fitted with an auxiliary heater with a fuel shut-off valve -N109-; therefore it is important to pay attention to the correct version. |
| 8 - | Petrol burner element |
| q | With glow plug with flame monitor -Q8- (without fuel pre-heating heater element -Z66-) |
| q | Checking installation position of glow plug with flame monitor -Q8- → Chapter |
| q | Checking glow plug with flame monitor -Q8- → Guided Fault Finding function of vehicle diagnostic, testing and information system VAS 5051 |
| q | Assembling auxiliary heater control unit -J364- and burner element → Chapter |
| q | Different versions for vehicles with petrol or diesel engine → Electronic parts catalogue |
Note| t | Currently glow plug with flame monitor -Q8- can be renewed separately (currently also available as separate replacement part) → Electronic parts catalogue. |
| t | From model year 2006 onwards, auxiliary heaters with a modified glow plug with flame monitor -Q8- are gradually being introduced (changes to insulation and length of ferrules at glow plug). |
| t | An additional fine filter might be fitted at the fuel connection of the burner element of auxiliary heaters for vehicles with petrol engine; this filter prevents dirt particles from clogging the fuel injector tube. If there are problems with the operation of the heater, also check that this filter is not blocked (e.g. by checking fuel delivery volume with auxiliary heater switched on → Chapter). |
| 9 - | Moulded gasket |
| q | Renewing → Electronic parts catalogue |
Note| From model year 2006 onwards, auxiliary heaters with a modified moulded gasket are gradually being introduced (changes to outer contour of gasket). |
| 10 - | O-ring |
| q | Renewing → Electronic parts catalogue |
| q | Coat with lubricant (e.g. coolant) before installing |
| 11 - | Connection |
| q | For coolant hose between auxiliary heater and heat exchanger of air conditioning unit (return) |
| q | Installing connection at auxiliary heater → Chapter |
| 12 - | Bracket for connection |
| q | Installing connection at auxiliary heater → Chapter |
| 13 - | Bolt |
| 14 - | Connection |
| q | For coolant hose between circulation pump -V55- and auxiliary heater |
| q | Installing connection at auxiliary heater → Chapter |
| 15 - | Burner housing and heat exchanger |
| q | Remove combustion residue prior to assembly |
| q | Assembling burner housing with heat exchanger and outer casing → Chapter |
| q | Depending on the auxiliary heater version, the burner housing and heat exchanger (item “15”), the O-ring (item “16”) and the outer casing (item “22”) may be permanently connected and cannot be dismantled → Electronic parts catalogue |
| 16 - | O-ring |
| q | Renewing → Electronic parts catalogue |
| q | Coat with lubricant (e.g. coolant) before installing |
| 17 - | Connection |
| q | For corrugated exhaust pipe |
| 18 - | Bolt |
| 19 - | Bolt |
| 20 - | Clip |
| q | For attaching overheating fuse -S24- / overheating sensor -G189- and temperature sensor -G18- |
| 21 - | Bolt |
| 22 - | Outer casing |
| q | Assembling burner housing with heat exchanger and outer casing → Chapter |
| q | Depending on the auxiliary heater version, the burner housing and heat exchanger (item “15”), the O-ring (item “16”) and the outer casing (item “22”) may be permanently connected and cannot be dismantled → Electronic parts catalogue |
Note| From model year 2006 onwards, auxiliary heaters with a modified outer casing are gradually being introduced (changes to seal at connections and second cable guide). |
| 23 - | O-ring |
| q | Renewing → Electronic parts catalogue |
| q | Coat with lubricant (e.g. coolant) before installing |
| 24 - | Overheating fuse -S24- / overheating sensor -G189- and temperature sensor -G18- with corresponding wiring |
| q | Depending on version of auxiliary heater control unit -J364-, overheating fuse -S24- may also be referred to as overheating sensor -G189-. |
| q | Cannot be renewed separately → Electronic parts catalogue |
| q | Removing and installing overheating fuse -S24- / overheating sensor -G189- and temperature sensor -G18- → Chapter |
| q | Checking overheating fuse -S24- / overheating sensor -G189- and temperature sensor -G18- → Guided Fault Finding function of vehicle diagnostic, testing and information system VAS 5051 |
| 25 - | Cover |
| q | For connector console |
| q | Assignment of connector console → Chapter |
| q | Use screwdriver to carefully release from fasteners and detach |