Grzanie Dodatkowe

Service
Workshop Manual
Sharan 1996 ➤
Supplementary heating
Edition 06.2007
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
01 - Self-diagnosis
82 - Supplementary heating
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.
AG.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg 00056607220

Sharan 1996 ➤
Supplementary heating - Edition 06.2007
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Affects vehicles from 06.2000 onwards: Instead of the “Self-diagnosis”, the “Guided fault
finding” function of the vehicle diagnosis, testing and information system VAS 5051A should
be used for fault finding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
82 - Supplementary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Auxiliary heater -D3W- (supplementary heater), vehicles: ▸ 05.00 . . . . . . . . . . . . . . . . . . 2
1.1 Repairing auxiliary heater -D3W- (supplementary heater) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Removing and installing exhaust system . . . . . . . .ge. n.A.G.. .Vo. l.ks.w.a.ge. n. A.G. d. . . . . . . . . . . . . . . . 4
wa oe
1.3 Removing and installing auxiliary heater -D3W- yV
olks. . . . . . . . . . . . . . . . . . .s n. o.t .gu. . . . . . . . . . 6
b a
1.4 Dismantling and assembling auxiliary heater ris
ed
-D3W- . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . 9
o e
1.5 Removing heater control unit J162 a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . . . 10
s c
1.6 Removing glow plug for heater Q9 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ce
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1.7 Removing flame monitor G64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.8 Connecting auxiliary heater -D3W- to coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
erm
ab
1.9 Coolant hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.10 Coolant hose routing on vehicles with 2nd heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.11 Auxiliary heater -D3W- fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ole,
spec
1.12 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
urposes, in part or in wh
t to the co
1.13 Regulation of auxiliary heater -D3W- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.14 Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Auxiliary heater -D5W- Z (supplementary heater), vehicles 06.2000 ▸ . . . . . . . . . . . . . . . . 19
rrectne
2.1 Repairing auxiliary heater -D5W- Z (supplementary heater) . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Connecting auxiliary heater -D5W- Z to coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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2.4 Regulation of auxiliary heater -D5W- Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
form
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3 Auxiliary heater -B4W/ D4W-, vehicles ▸ 05.2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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3.1 Diagnosis with the diagnostic tester 5019 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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3.2 Bleeding coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3.3 Road test for auxiliary heater in vehicle without Climatronic . . . . . . . . . . . . . . . . . . . . . . . . 31

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3.4 Road test for auxiliary heater in vehicle with Climatronic . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3.5 Repairing auxiliary heater -B4W- / -D4W- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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3.6 Removing and installing heater unit -B4W- / -D4W- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.7 Dismantling and assembling heater unit -B4W- (petrol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3.8 Dismantling and assembling heater unit -D4W- (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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3.9 Removing heater control unit J162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.10 Renewing combustion air blower V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12 Removing overheating sensor G189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.13 Removing coolant temperature sender for heater G241 . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.14 Removing glow plug for heater Q9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.15 Checking flame monitor G64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.16 Checking overheating sensor G189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.17 Checking coolant temperature sender for heater G241 . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.18 Connecting auxiliary heater -B4W- and -D4W- to coolant circuit . . . . . . . . . . . . . . . . . . . . 47
3.19 Fuel supply to auxiliary heaters -B4W- / -D4W- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.21 Regulation of auxiliary heaters -B4W- and -D4W- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Auxiliary heater -B5W- S / -D5W- S, vehicles 06.2000 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1 Repairing auxiliary heater -B5W- S / -D5W- S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2 Removing ambient temperature switch F38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3 Removing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Removing pre-selection clock E111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Contents i
Sharan 1996 ➤
4.5 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.8 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.9 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.10 Removing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Volkswa
4.12 Removing glow plug for heater Q9 . . . . . . . . . . . . . . . s. w. a.g.en. A. G. .. . . . . .g.en. A. G. d. o.e.s . . . . . . . 67
lk no
4.13 Removing heater control unit J162 . . . . . . . . . . .d b. y.V.o. . . . . . . . . . . . . . . . . . . . . . .t g. u.ar. . . 68
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4.14 Renewing combustion air blower V6 . . . . . . .ho.ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. te.e 68
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4.15 Removing overheating sensor G189 . . . .ss.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r a69 c
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4.20 Checking ambient temperature switch F38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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4.21 Connecting auxiliary heaters -B5W- S and -D5W- S to coolant circuit . . . . . . . . . . . . . . . . 72
spec
4.22 Connecting auxiliary heaters -B5W- S, -D5W- S and -D5Z- F to coolant circuit for engine code
es, in part or in w
t to the co
AYL (6 cyl.) from 05.2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.24 Bleeding coolant circuit in vehicles with auxiliary heater -B5W- S, -D5W- S or -D5W- Z . . 76
rrectness of i
4.25 Fuel supply to auxiliary heaters -B5W- S, -D5W- S or -D5W- Z . . . . . . . . . . . . . . . . . . . . . . 76
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4.27 Testing quantity of fuel delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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4.28 Regulation of auxiliary heaters -B5W- S and -D5W- S . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.29 Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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5 Auxiliary heater -D5Z- F, vehicles 05.2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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5.1 Repairing auxiliary heater -D5Z- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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5.7 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Prote AG.

5.10 Removing and installing flame monitor G64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.20 Connecting auxiliary heater -D5Z- F to coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.22 Bleeding coolant circuit in vehicles with auxiliary heater -D5Z- F . . . . . . . . . . . . . . . . . . . . 91
5.23 Fuel supply to auxiliary heater -D5Z- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.26 Regulation of auxiliary heater -D5Z- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.27 Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6 Auxiliary heater -D5S- F / -B5S- F, vehicles 05.2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1 Repairing auxiliary heater -D5S- F / -B5S- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ii Contents
Sharan 1996 ➤

6.4 Removing pre-selection clock E111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.8 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.11 Removing and installing flame monitor G64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.21 Connecting auxiliary heater -D5S- F / -B5S- F to coolant circuit . . . . . . . . . . . . . . . . . . . . 96
6.23 Bleeding coolant circuit in vehicles with auxiliary heater -D5S- F / -B5S- F . . . . . . . . . . . . 96
6.24 Fuel supply to auxiliary heater -D5S- F / -B5S- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.27 Regulation of auxiliary heater -D5S- F / -B5S- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.28 Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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Contents iii
Sharan 1996 ➤
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iv Contents
Sharan 1996 ➤
01 – Self-diagnosis
1 Affects vehicles from 06.2000 on‐
wards: Instead of the “Self-diagno‐
sis”, the “Guided fault finding” func‐
tion of the vehicle diagnosis, testing
and information system -VAS 5051A-
should be used for fault finding.
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1. Affects vehicles from 06.2000 onwards: Instead of the “Self-diagnosis”, the “Guided fault finding” function of the vehicle diagnosis, testing
and information system VAS 5051A should be used for fault finding. 1
Sharan 1996 ➤
82 – Supplementary heating
1 Auxiliary heater -D3W- (supplemen‐
tary heater), vehicles: ▸ 05.00
1.1 Repairing auxiliary heater -D3W- (sup‐

plementary heater)
Note
♦ Before every repair, please read out the fault memory of the
heater control unit -J162- using the diagnostic tester -VAS
5019- ⇒ page 25 .
♦ A manufacturer's plate is fitted on the auxiliary heater unit. This
plate provides information about the type of auxiliary heater
installed in the vehicle ⇒ page 3 .
♦ Removing and installing auxiliary heater components
⇒ page 9 ; Dismantling and assembling auxiliary heater -
D3W-.
♦ Check the coolant circuit after working on the coolant circuit
⇒ Rep. Gr. 19 .
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2 Rep. Gr.82 - Supplementary heating

Sharan 1996 ➤
AG. Volkswagen AG d Supplementary heating - Edition 06.2007
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❑ Fuel ut supply to auxiliary
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⇒ page 14 . c
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2 - Auxiliary heater
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❑ With heater control unit
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❑ Removing and installing
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⇒ page 6
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❑ Dismantling and assem‐
bling ⇒ page 9
t to the co
3 - Exhaust system
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⇒ page 4
❑ Securing front exhaust
ss
pipe to auxiliary heater
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⇒ page 5 .
inform
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❑ Securing rear exhaust
atio
pipe to silencer
om
⇒ page 6
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4 - Coolant hoses
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switch -F38-
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❑ Switch position -On- at

temperatures lower
than 5 °C
❑ Switch position -Off- at
temperatures above 5 °
C
❑ Removing ⇒ page 4
Manufacturer's plate
Note
♦ The most important technical data are shown on upper part of

manufacturer's plate.
♦ Only the 25 1864 01 version for -D3W- is factory-fitted in the
Sharan 1996 ▸.
♦ The date of first use is entered on the lower part of manufac‐
turer's plate.
♦ The year the unit was first put into use must be entered on the
“Genuine part” manufacturer's plate. The heat exchanger for
the auxiliary heaters does not have to be renewed after
10 years. Legislation in Germany dictates that air heaters must
be renewed.
1. Auxiliary heater -D3W- (supplementary heater), vehicles: ▸ 05.00 3

Sharan 1996 ➤
Removing ambient temperature switch -F38-

– Unclip ambient temperature switch -F38- -1- from holder.
Note
In vehicles from model year 10.1998, the wiper motor

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1.2 Removing and installing exhaust system
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Special tools and workshop equipment required
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♦ Torque wrench -V.A.G 1410- (4…20 Nm)
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Danger of burn injuries.
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Silencer could be hot.
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Before removing silencer, let it cool off.

Sharan 1996 ➤
-J162-
bling ⇒ page 9
2 - Clip
3 - Front exhaust pipe
⇒ page 5
4 - Hexagon bolt M6×16
❑ 6 Nm
5 - Rear exhaust pipe
pipe to silencer
⇒ page 6
6 - Silencer
7 - Self-tapping screw 4.8x16
8 - Bracket
9 - Longitudinal member
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
Securing front exhaust pipe to auxiliary heater

itte
y li
erm
ab
– Push exhaust pipe -1- in direction of arrow until it contacts

ility
ot p
combustion air blower housing -2-.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Securing rear exhaust pipe eton Asilencer

G. Volkswagen AG
ag does
ksw n
– Push exhaust pipe Vol
by -1- in direction of arrow until it gcontacts si‐
ot
ua
lencer -2-. rised ran
te
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3 Removing and installing auxiliary heater
-D3W-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hose clamps up to 25 mm Ø -3094-
Note
♦ If coolant is in the system, seal coolant hoses using hose

clamps before disconnecting.
♦ Refill with coolant after installing the auxiliary heater ⇒ Rep.
Gr. 19 .

Sharan 1996 ➤
2 - Blind rivet nut M8
3 - Fuel line
❑ From metering pump -
V54- to auxiliary heater.
Note
♦ Hose connections are secured

with either screw-type or spring-
type clips.
♦ Always replace spring-type clips
with screw-type clips.
4 - Coolant hose, supply

5 - Bracket for heater unit
❑ 10 Nm
7 - Exhaust system
⇒ page 5
pipe to silencer
⇒ page 6
❑ 6 Nm wage
es n
lks ot g
Vo
9 - Hexagon nut M8 ed by ua
ran
ir s tee
❑ 10 Nm utho
or
a ac
ss
10 - Clamping plate
ce
le
un
pt
11 - Bracket
an
d
itte
y li
erm
ab

ility
ot p
wit
13 - Coolant hose, return

is n
h re
ole,
❑ In vehicles with a 2nd heat exchanger: supply to 2nd heat exchanger

spec

t to the co
15 - Intake hose
❑ Securing ⇒ page 9 .
rrectne
s
❑ With heater control unit -J162-

s o
cial p
❑ Dismantling and assembling ⇒ page 9

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
Removing:
WARNING
Danger of scalding inju‐
ries.
When the engine is
warm, the coolant tem‐
perature may be above
100 °C. The cooling sys‐
tem is pressurised.
If necessary, release
pressure and reduce
temperature before car‐
rying out repairs.
lkswage es n
o ot g
yV ua
❑ Open the radiator cap. ir se
d b ran
o tee
❑ Clamp off coolant hoses to auxiliary heater
auth with hose clamps up to Ø 25 mm -3094- and or disconnect
ac
hoses. ss
ce
le
un
pt
an
d
itte
WARNING
y li
rm
ab
pe
Danger of fuel escaping.
ility
ot
wit
, is n
Fuel system is under
h re
hole
pressure.
spec
es, in part or in w
t to the co
Before opening system,
wrap a cloth around the
connection. Then re‐
rrectness of i
lease pressure by care‐
fully loosening the con‐
l purpos
nection.
nform
ercia
❑ Pull fuel line off auxiliary heater and seal it.

m
❑ Disconnect 8-pin connector (T8) from heater control unit.

a
com
tion in
r
te o
thi
WARNING
s
iva
do
r

rp
cum
fo
en
ng
t.
yi
Parts of the exhaust sys‐
Co
op py
tem may be hot.
t. C rig
gh ht
pyri by
Vo
co
Before removing ex‐
by lksw
cted agen
Prote
haust system, let it cool
AG.
off.
❑ Unfasten silencer on bracket.

❑ Unscrew auxiliary heater along with its bracket.
❑ Secure intake hose ⇒ page 9 .
❑ Secure front exhaust pipe to auxiliary heater ⇒ page 5 .
❑ Secure rear exhaust pipe to silencer ⇒ page 6 .

Sharan 1996 ➤
Securing intake hose

3 - Bracket for auxiliary heater
AG. Volkswagen AG d
4 - Screw-type clip agen oes
olksw not
V gu
by ara
5 - Intake hose rised
nte
ho eo
ut
6 - Sealing ring ss a ra
c
ce
le
– Push intake hose -5- in direction of -arrow A- until it makes

un
pt
an
d
contact with auxiliary heater housing -1-.

itte
y li
rm
ab
– Fasten screw-type clip -4-.
pe
ility
ot
wit
, is n
– Push intake hose through sealing ring -6- into bulkhead
h re
-arrow B- up to stop.
hole
spec
es, in part or in w
– Insert intake hose into bow of bracket for auxiliary heater -3-.
t to the co
1.4 Dismantling and assembling auxiliary heater -D3W-
rrectness of i
l purpos
1 - Water jacket cover

2 - Bolt M5×12
nform
ercia
3 - Heat exchanger
m
a
com
t
❑ Clean inside and out‐
ion in
side with brass wire
r
te o
thi
brush (spark plug
s
iva
brush). do
r
rp
cum
fo
❑ Note installation posi‐

en
ng
t.
yi
tion ⇒ page 10 .
Co
Cop py
t. rig
4 - O-ring
gh ht
pyri by
Vo
o
by c
❑ Renew
lksw
cted agen
Prote AG.
❑ Lubricate when instal‐
ling.
5 - Seal
❑ Always renew after dis‐
mantling.
6 - Combustion chamber with
flame tube
brush (spark plug
brush).
7 - Combustion air blower cov‐
er
8 - Bolt M5×22
9 - Bolt M4×10
10 - Socket head screw M5×65
❑ 6 Nm
❑ 6 Nm
12 - Heater control unit -J162-
❑ Checking ⇒ page 25

Sharan 1996 ➤
wage es n
13 - Combustion air blower -V6- Vol
ks ot g
d by ua
❑ Do not dismantleofurther
ris
e ran
tee
th or
❑ Checking ⇒ pagesa
u 25 ac
s
ce
le
14 - Cover
un
pt
an
d
itte
15 - Rubber grommet
y li
rm
ab
pe
ility
16 - Seal
ot
wit
, is n
❑ Always renew after dismantling.
h re
hole
spec
17 - Flame monitor -G64-
es, in part or in w
t to the co
18 - Glow plug for heater -Q9-
rrectness of i
l purpos
❑ Clean glow plug with brass wire brush (spark plug brush).
❑ 6 Nm
nform
ercia
m
a
com
tio
19 - Water jacket
n in
r
te o
thi
❑ Clean inside and outside with brass wire brush (spark plug brush).
s
iva
do
r
20 - Overheating sensor -G189-

rp
cum
fo
en
g
n
t.
yi Co
Cop py
21 - Temperature sensor -G18-
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
22 - Spring
❑ Do not bend further.
❑ Renew if damaged.
23 - Screw M5×16
Heat exchanger installation position

– Insert heat exchanger -2- into water jacket -1- until centering
-arrows- engages.
– Push heat exchanger tightly into seating.
1.5 Removing heater control unit -J162-

Before beginning repair work, perform the following jobs:
– Remove auxiliary heater ⇒ page 6 .

AG. Volkswagen AG d
agen oes
Volksw not
gu
Sharan 1996 ➤
y
rise
d b ara
nte Supplementary heating - Edition 06.2007
tho eo
au r a
– Dismantle
ss and assemble auxiliary heater -D3W- ⇒ pagec 9 .
ce
e
nl
– Pull 8-pin connector (T8) off.
pt
du
an
itte
y li
– Loosen both cross-head screws -2- on combustion air blower
erm
ab
cover.
ility
ot p
wit
, is n
– Remove cross head screws -3- and hexagon socket head
h re
hole
bolts -4- and -5-.
spec
es, in part or in w
– Lift up heater control unit -J162- -1-.
t to the co
– Pull 10-pin connector off.
rrectness of i
l purpos
1.6 Removing glow plug for heater -Q9-
nf
ercia
orm
m
atio
om
n in
or c
– Dismantle and assemble auxiliary heater -D3W- ⇒ page 9 .
thi
te
sd
iva
– Remove cover ⇒ Item 14 (page 10) .
o
r
rp
cu
o
m
f
en
– Unscrew glow plug wiring.
ng
t.
yi Co
op py
– Remove glow plug for heater -Q9- -1- (6 Nm). t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7 Removing flame monitor -G64-

– Dismantle and assemble auxiliary heater -D3W- ⇒ page 9 .
– Remove cover ⇒ Item 14 (page 10) .
– Pull flame monitor wiring out of 10-pin connector -2-.
– Unbolt flame monitor -G64- -1-.

Sharan 1996 ➤
1.8 Connecting auxiliary heater -D3W- to

coolant circuit
WARNING
Danger of scalding injuries.

When the engine is warm, the coolant temperature may be
above 100 °C. The cooling system is pressurised.
If necessary, release pressure and reduce temperature before
carrying out repairs.
Note agen
AG. Volkswagen AG d
oes
olksw not
byV gu
Check coolant circuit after working on it ⇒ rRep.
ised Gr. 19 . ara
nte
ho eo
aut ra
c
The arrows in the illustration show thes coolant flow direction.
s
ce
le
un
pt
1 - Heat exchanger (standard)
an
d
itte
y li
erm
ab
2 - 2nd heat exchanger (extra equipment)
ility
ot p
wit
is n
h re
ole,
4 - Engine
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
1.9 Coolant hose routing

um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
Note
rig ht
py by
co Vo
by lksw
cted agen
Prote
The arrows in the illustration show the coolant flow direction.
AG.

Sharan 1996 ➤

❑ From standard equip‐
ment heater heat ex‐
changer
❑ To standard equipment
heater heat exchanger
❑ From coolant distributor
to auxiliary heater
4 - Coolant pipe, supply
5 - Coolant pipe, return
❑ From auxiliary heater to
coolant pipe
❑ From coolant pipe to
auxiliary heater
8 - Heater unit
9 - Coolant hose
❑ To engine
coolant distributor
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
1.10 Coolant hose routing on vehicles with
ut or
a ac
ss
2nd heat exchanger
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
13
by lksw
cted agen
Prote 1. Auxiliary heater -D3W- (supplementary heater), vehicles: ▸ 05.00
AG.
Sharan 1996 ➤

❑ From standard equip‐
ment heater heat ex‐
changer
❑ To standard equipment
heater heat exchanger
❑ From coolant distributor
to heater unit
6 - Heater unit
❑ From heater unit to cool‐
ant pipe
heater unit
9 - To 2nd heat exchanger
10 - From 2nd heat exchanger
11 - Coolant hose
❑ To engine
AG. Volkswagen AG d
❑ From coolant pipe to ksw
agen oes
not
l
coolant distributor by
Vo gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
1.11 Auxiliary heater -D3W- fuel supply

ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ Hose connections are secured with either screw-type or

spring-type clips.
rrectne
♦ Always replace spring-type clips with screw-type clips.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
1.11.1 Fuel take-off
1 - Fuel line
❑ From fuel tank to meter‐
ing pump -V54-
2 - Fuel return
3 - Clamping piece
4 - T-piece
5 - Fuel gauge sender -G-
6 - Heater unit
7 - Metering pump -V54-
⇒ page 15
❑ Dismantling
⇒ page 16
❑ Checking installation
position ⇒ page 16
8 - Fuel line
❑ From metering pump to
heater unit
9 - Fuel line
❑ From T-piece to meter‐
ing pump gen AG
. Volkswagen AG
d
wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.12 Removing and installing metering pump

-V54-
rrectness of i
l purpos
1 - Bracket
nform
ercia
3 - Clamping piece
m
a
com
4 - Fuel line to heater unit

ion in
r
te o
5 - Fuel line, return from engine to fuel tank

thi
s
iva
do
r
6 - Fuel line, supply from fuel tank to engine fuel pump

rp
cum
fo
en
ng
7 - Fuel line from T-piece connection in supply fuel line, from fuel
t.
yi Co
op
tank to engine fuel pump
C py
t. rig
gh ht
pyri by
Vo
co
1.12.1 Removing
by lksw
cted agen
Prote AG.
– Pull connector off.

Sharan 1996 ➤
WARNING

Fuel system is under pressure.
Before opening system, wrap a cloth around the connection.
Then release pressure by carefully loosening the connection.
– Detach fuel hoses -4- and -7- from metering pump and seal
them.
– Remove metering pump from bracket -1-.
1.12.2 Installing
– Install in reverse order; when doing this observe installation
Dismantling metering pump -V54-
1 - Fuel pump
2 - Strainer
3 - Hose connection
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
Checking installation position of metering pump -V54-

, is n
h re
hole
♦ Positioned 15° to 90°

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
1.13 Regulation of auxiliary heater -D3W-

o
his
ate
do
priv
The auxiliary heater -D3W- is intended to heat the coolant and

um
for
thereby assist the heating output of the engine.

en
ng
t.
yi Co
op
Various operating modes can be set depending on heat required
C py
t. rig
gh
in heating circuit:
ht
pyri by
Vo
o
by c lksw
cted
After the engine is started at an ambient temperature of below 5 °
agen
Prote AG.
C and if the coolant temperature is below 75 °C, the heater unit
switches on.
If the heat required is 3000 watts (100% of heating output), then
the heater unit operates in full load mode. The coolant tempera‐
ture increases up to 85 °C (maximum).

Sharan 1996 ➤
If the coolant temperature reaches approx. 85 °C, then the heater

unit operates in part load mode.
If the heat requirement is larger than 1500 watts (50% of heating
output) then the coolant temperature will decrease. When the
temperature reaches approx. 78 °C, the heater unit operates in
full load mode again.
If, because of the low heat requirement, the coolant temperature
increases further, at approx. 88 °C the heater unit goes into the
run-on phase and is switched off after approx. 100 seconds.
1.14 Start sequence

1.14.1 Pin assignment for 8-pin connector -T8-
on heater unit (harness end)
1 - Terminal 30
2 - Terminal 31
6 - Ambient temperature switch -F38-
7 - D+ from alternator
1.14.2 Start signals AG. Volkswagen AG d

agen oes
lksw not
♦ Terminal 30 from fuse box d by
Vo gu
ara
ise nte
r
♦ D+ from alternator; -engine running- ut
ho eo
ra
s a c
♦ Temperature at temperature sensor -G18- less than 75 °C s
ce
le
un
pt
♦ Temperature at ambient temperature switch -F38- less than
an
d
itte
y li
5 °C
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
If the temperature at flame monitor -G64- is greater than 70 °C it
t to the co
will be cooled for 4 minutes at a higher blower speed. Then the
unit will start.
rrectne
1.14.3 Start procedure
ss
After each engine start the flame monitor -G64- must inform the
o
cial p
control unit within 130 seconds after the heating has switched on,
inform
that the flame is burning normally. If this not the case, then the
mer
heater unit automatically attempts a second start. If, after the

atio
m
second start, the flame still does not burn normally, the heater will
o
n
c
remain switched off until the engine is started again.

i
or
n thi
te
sd
a
In part load mode the combustion air blower -V6- operates at re‐
iv
o
pr
duced rpm and the metering pump -V54- delivers only approx.
um
r
fo
en
ng
50% of fuel (reduced pulse frequency). yi

t.
Co
op py
Abortion of start procedure t. C rig
gh ht
pyri by
Vo
The start procedure is aborted if:
o
by c lksw
cted agen
Prote AG.
♦ The flame monitor registers that the flame is not burning nor‐
mally within 130 seconds.
♦ The temperature or overheating sensor detects a temperature
greater than approx. 125 °C.
♦ The temperature difference between the temperature and
overheating sensors exceeds 15 °C.

Sharan 1996 ➤
♦ The control unit detects a fault ⇒ page 25 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
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
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.

Sharan 1996 ➤
2 Auxiliary heater -D5W- Z (supple‐ . Volkswagen AG

gen AG
mentary heater), vehicles k06.2000 ▸
swa does
ol not
y V gu
b a
ed ran
oris tee
th or
au ac
2.1 Repairing auxiliary heater -D5W- Z ss
ce
le
un
pt
(supplementary heater)
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
♦ Before starting electrical welding work on the vehicle, discon‐
nect the positive pole from the battery and connect it to earth
t to the co
in order to protect the heater control unit -J162- .
♦ A manufacturer's plate is attached to the heater unit. This plate
rrectne
provides information about the type of heater unit installed in
the vehicle ⇒ page 20 .
s
♦ The heater unit of the -D5W- Z has the same structure as the
s o
cial p
heater unit of the -D5W- S ⇒ page 53 .
f inform
mer
atio
control unit vehicle diagnostic, testing and information system
om
-VAS 5051A- .
n
c
i
or
n thi
e
♦ Check the coolant circuit after working on it.

t
sd
iva
o
pr
cum
♦ Components identified with * are checked by the self-diagnosis
r
fo
en
ng
function.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Auxiliary heater -D5W- Z (supplementary heater), vehicles 06.2000 ▸ 19

Sharan 1996 ➤
1 - Metering pump -V54- *

❑ Installation position: in
front of fuel tank on the
right
⇒ page 78
❑ Fuel supply to auxiliary AG. Volkswagen AG d
heater ⇒ page 76 . lksw
agen oes
not
o
byV gu
2 - Heater unit * d ara
ise nte
or eo
h
❑ With heater ut
controls aunit ra
c
-J162- s
ce
e
nl
pt
du
an
itte
⇒ page 61
y li
erm
ab
ility
ot p
bling ⇒ page 64
wit
, is n
h re
3 - Exhaust system
hole
spec
es, in part or in w
t to the co
⇒ page 56
❑ Securing silencer to
heater unit ⇒ page 58
rrectness of i
4 - Coolant hoses
l purpos
❑ Coolant hose routing;

connecting auxiliary
nf
ercia
heater to coolant circuit
or
⇒ page 21 .
m
m
atio
m
5 - Ambient temperature
o
n in
or c
switch -F38-
thi
te
sd
a
❑ Switch position -On- at

iv
o
r
rp
cu
temperatures lower
o
m
f
en
ng
than approx. 10 °C.

t.
yi Co
op
❑ Check switch positions
C py
ht. rig
with vehicle diagnostic, rig ht
py by
Vo
testing and information
co lksw
by
cted agen
system -VAS 5051A- in Prote AG.
“Guided fault finding” function
Note

♦ Only the 25 2163 version for -D5W- Z is factory-fitted in the
Sharan 06.2000 ▸.
♦ The heat exchanger for the auxiliary heaters does not have to
be renewed after 10 years. Legislation in Germany dictates
only that air heaters must be renewed.

n AG. Volkswagen AG do Sharan 1996 ➤
lkswage es n
d byV
o
Supplementary ot g
uheating
ara - Edition 06.2007
ir se nte
tho eo
Removing ambient temperature switch
au -F38- ra
c
ss
– Unclip ambient temperature switch -F38- -1- from holder on
ce
e
nl
pt
du
left in plenum chamber.
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
In vehicles from model year 10.1998, the wiper motor must also
spec
be replaced ⇒ Rep. Gr. 92 .
es, in part or in w
t to the co
– Check ambient temperature switch -F38- ⇒ page 70 .
rrectness of i
l purpos
2.2 Connecting auxiliary heater -D5W- Z to

coolant circuit
nf
ercia
orm
m
atio
WARNING
om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
If necessary, release pressure and reduce temperature before t. C rig
gh ht
carrying out repairs. pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Bleed coolant circuit every time after opening it!

♦ Complete hose routing ⇒ Rep. Gr. 19
♦ The arrows in the illustration show the coolant flow direction.

Sharan 1996 ➤
1 - Heat exchanger for heater

2 - Heater unit
3 - Auxiliary heat exchanger
4 - Expansion tank
5 - Coolant circulation pump -
V50-
6 - Switch-off valve for supple‐
mentary heater
7 - ATF cooler
8 - Radiator
❑ a = Bottom
❑ b = Top
9 - Oil cooler
10 - Thermostat
11 - Coolant pump
12 - Cylinder head
13 - Throttle valve preheater
❑ Only 2.0 l and 2.8 l en‐ AG. Volkswagen AG d
gines agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2nd heat exchanger
l purpos
nf
Note
ercia
orm
m
atio

om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤

3 - Heater unit
❑ From heater unit to cool‐
ant pipe n AG. Volkswagen A ge G do
swa es n
by
Vol
k ot g
ua
d ran
❑ From coolant ise pipe to tee
or
thunit
heaterau or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4 Regulation of auxiliary heater -D5W- Z

The auxiliary heater -D5W- Z is intended to assist the heating
output of the engine by heating the coolant.
in heating circuit:
After the engine is started at an ambient temperature of below
approx. 10 °C and if the coolant temperature is below 75 °C, the
heater unit switches on.
If the coolant temperature reaches approx. 85 °C, then the heater
unit operates in part load mode.
If the heat requirement is larger than 2200 watts then the coolant
temperature will decrease. When the temperature reaches ap‐
prox. 78 °C, the heater unit operates in full load mode again.
If, because of the low heat requirement, the coolant temperature
increases further, at approx. 88 °C the heater unit goes into the
run-on phase and is switched off after approx. 100 seconds.

Sharan 1996 ➤
2.4.1 Start sequence

2.4.2 Pin assignment for 8-pin connector -T8-
on heater unit (harness end)
1 - Terminal 30
2 - Terminal 31
7 - Terminal L from alternator
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
2.4.3 Start signals ss a c
ce
e
nl
pt
♦ Terminal 30 from fuse box
du
an
itte
y li
erm
♦ Terminal L from alternator; -engine running-
ab
ility
ot p
♦ Temperature at temperature sensor -G18- less than 75 °C
wit
, is n
h re
♦ Temperature at ambient temperature switch -F38- less than
hole
spec
approx. 10 °C
es, in part or in w
t to the co
Note
rrectness of i
If the temperature at flame monitor -G64- is greater than 70 °C it
l purpos
will be cooled for 4 minutes at a higher blower speed. Then the

unit will start.
nform
ercia

m
at
om
ion
c
in t
or
control unit within 130 seconds after the heating has switched on,
his
ate
do
that the flame is burning normally. If this not the case, then the
priv
heater unit automatically attempts a second start. If, after the

um
for
en
g
second start, the flame still does not burn normally, the heater will
n
t.
yi Co
remain switched off until the engine is started again. Cop py
ht. rig
rig ht
In part load mode the combustion air blower -V6- operates at re‐ py by
co Vo
lksw
duced rpm and the metering pump -V54- delivers only part of the
by
cted agen
Prote
fuel (reduced pulse frequency).
AG.
Abortion of start procedure

♦ The flame monitor -G64- registers that the flame is not burning
normally within 130 seconds.
♦ The temperature or overheating sensor detects a temperature
greater than 125 °C.
♦ The temperature difference between the temperature sensor
-G18- and the overheating sensor -G189- exceeds 15 °C.
♦ The control unit detects a fault vehicle diagnostic, testing and
information system -VAS 5051A-

Sharan 1996 ➤
3 Auxiliary heater -B4W/ D4W-, vehi‐

cles ▸ 05.2000
3.1 Diagnosis with the diagnostic tester

-5019-
♦ Diagnostic tester -5019-
The heater control unit -J162- in the -B4W-/ -D4W- and in the n-AG. Volkswagen AG do
wage
D3W- receives data from the electrical and electronicy Vcompo‐
olks es n
ot g
nents: ise
d b ua
ran
r tee
ho
♦ Coolant temperature sender for heater -G241-
sa
ut or
ac
s
♦ Flame monitor -G64- ce
le
un
pt
an
d
itte
♦ Overheating sensor -G189- y li

rm
ab
pe
ility
This data is processed by the heater control unit -J162- in the -
ot
B4W-/ -D4W- and -D3W-. The heater control unit -J162- then
wit
, is n
h re
controls the combustion air blower -V6- , the glow plug for heater
hole
-Q9- and the metering pump -V54- . The heater control unit -J162-
spec
is equipped with a fault memory and recognises the fault that is

es, in part or in w
t to the co
currently present during the heating period. The current fault can
be read as a fault code using diagnostic tester -5019- . Therefore,
please connect the diagnostic tester -5019- immediately.
rrectness of i
If fault code numbers are displayed, then the causes of the faults
l purpos
must be rectified according to the instructions in the fault table.

The fault code numbers of the diagnostic tester must be cleared
after the repair. After a road test, please use the diagnostic tester
nform
ercia
-5019- to read the heater control unit -J162- in the -B4W-/ -D4W-
or -D3W- again.
m
a
com
tion in
The meanings of the fault code numbers are described in the fault
r
te o
thi
table ⇒ page 28 .
s
iva
do
r
3.1.1 Test prerequisites

rp
cum
fo
en
ng
t.
yi
♦ Fuses OK ⇒ Current flow diagrams, Electrical fault finding and
Co
Cop py
Fitting locations
t. rig
gh ht
pyri by
Vo
o
♦ Fuel in tank
c by lksw
cted agen
Prote AG.
♦ 12 volt voltage
3. Auxiliary heater -B4W/ D4W-, vehicles ▸ 05.2000 25

Sharan 1996 ➤
♦ Coolant temperature is less than 75 oC. Exception: if the tem‐

perature at the flame monitor -G64- is greater than 70 oC, then
the flame monitor -G64- is cooled for 4 minutes at the high
blower speed of the combustion air blower -V6- . The auxiliary
heater then restarts.
♦ The coolant expansion tank is sufficiently filled.
AG. Volkswagen AG d
agen oes
lksw not
Note d by Vo gu
ara
rise nte
ho eo
♦ The coolant circuit must be free of air for the auxiliary heater
s aut ra
c
to heat properly. The diagnostic tester -5019- indicatess air in
ce
e
the coolant circuit.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
3.1.2 Operating diagnostic tester -5019-
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ The heater control unit -J162- in the -B4W-/ -D4W- or -D3W-
rrectness of i
detects one or more faults. The last fault which occurred is
stored as a current fault in the fault memory of the heater con‐
l purpos
trol unit -J162- .

♦ The heater control unit -J162- can store up to 5 faults. It is not
nform
ercia
possible to select the fault memories F1 to F5.

m
at
♦ The current fault is stored in the last vacant memory location
om
ion
F1 to F5. The memory location F5 is overwritten if all memory
c
in t
or
locations are occupied.
his
ate
do
priv
cum
or
1 - “DIAG” display: 3-digit fault code number is displayed by the

f
en
ng
fault memory.
t.
yi Co
Cop py
t. rig
2 - “Flash” display: flashing code is displayed by the fault memory yri
gh by
ht
(not used). cop Vo
by lksw
cted agen
Prote
3 - Display of the selected fault memory: AF - Current fault, F1 -
AG.
Stored fault no. 1, F2 - Stored fault no. 2, F3 - Stored fault no. 3,

F4 - Stored fault no. 4, F5 - Stored fault no. 5
4 - Display of the 3-digit fault code number.
5 - Display for “Auxiliary heater on”.
6 - Button “>” for scrolling up through the stored faults F1 to F5.
7 - Button “<” for scrolling down through the stored faults F1 to
F5.
8 - Button “L” for deleting the stored faults. (Press both buttons
for at least 2 seconds.) Continuous shut-down is revoked when
the fault memory is cleared.
9 - Button “D” displays the 3-digit fault code of the fault memory.

Sharan 1996 ➤
AG. Volkswagen AG d
lksw
agen Supplementary
oes
not heating - Edition 06.2007
Vo gu
d by ara
e
3.1.3 Connecting diagnostic tester -5019- ris nte
tho eo
au ra
s c
1 - Basic unit -5019/1- s
ce
le
un
pt
2 - Diagnosis cable for auxiliary heater -5019/2-
an
d
itte
y li
rm
ab
A - 8-pin connector housing, bypass connection
pe
ility
ot
wit
B - 8-pin connector housing, bypass connection , is n
h re
hole
C - 8-pin connector housing, connection for basic unit -5019/1-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect connector from auxiliary heater.

– First, only connect diagnosis cable to auxiliary heater using
connector housings -A- and -B- without basic unit -5019/1- .
Then connect basic unit -5019/1- to connector housing -C-.
Note
♦ Comply with the connection sequence, otherwise faults might

be displayed that do not exist.
♦ The auxiliary heater starts without having been switched on.
After 40 seconds, the combustion air blower -V6- can be heard
operating.
♦ If the auxiliary heater does not start and the combustion air
blower -V6- does not operate after 40 seconds, then the heater
control unit -J162- has permanently switched off.
♦ If the auxiliary heater does not start in a vehicle with a diesel
engine then the ambient temperature switch -F38- in the ple‐
num chamber must be electrically bypassed.

Sharan 1996 ➤
– Electrically bypass ambient temperature switch -F38- (part

number: 701 959 625) in vehicles with a diesel engine. Fitting
location: in plenum chamber.
– Call up fault memory.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
3.1.4 Calling up fault memory of heater control
wit
is n
unit -J162-
h re
ole,
spec
– Please press button “D”. The 3-digit fault code number ap‐
t to the co
pears.
– Please press buttons “>” and “<” to obtain all fault code num‐
bers.
rrectne
– Refer to the following fault table to determine the cause of the
s
fault corresponding to the fault code number and the fault rec‐
s o
tification description.
cial p
f inform
mer
atio
om
3.1.5 Fault table

n
c
i
or
n thi
te
sd
va
Fault code number Possible cause of fault Fault rectification with remarks
i
o
pr
cum
and meaning
r
fo
en
ng
t.
yi
000
Co
Cop py
ht. rig
No malfunction rig ht
py by
co Vo
001
by lksw
cted agen
Prote AG.
Overvoltage warning Controller Renew
(> 16 V)
002
Undervoltage warning 2nd. battery Charge
(< 10.2 V)
010
Overvoltage shut-off 2nd. battery Voltage was present for longer than 20 sec‐
(> 16 V) onds
011
Undervoltage shut-off 2nd. battery Voltages were present for longer than 20 sec‐
(< 10.2 V) onds
012
Overheating Temperature at flame monitor -G64- Air in coolant circuit, bleed ⇒ page 30
or overheating sensor -G189- too
high (> 125 °C).
014
Evaluation of temper‐ Air in coolant circuit, flame monitor - Bleed ⇒ page 30 , check flame monitor -G64-
ature difference be‐ G64- defective, overheating sensor - ⇒ page 45 , check overheating sensor -
tween flame monitor - G189- defective G189- ⇒ page 46
G64- and overheating
sensor -G189-
015
Continuous shut- Air in coolant circuit, Bleed ⇒ page 30 Clear fault memory
down ⇒ page 26
017

Sharan 1996 ➤
and meaning
Overheating Temperature too high (> 130 °C) at Air in coolant circuit, bleed ⇒ page 30 Check
overheating sensor -G189- and cool‐ overheating sensor -G189- ⇒ page 46 Check
ant temperature sender for heater - coolant temperature sender for heater -G241-
G241- ⇒ page 46 Clear fault memory ⇒ page 26
020
Glow plug for heater - Defective Renew
Q9-
021
Short circuit on the Short circuit on the connection or in Renew if necessary.
glow plug for heater - the glow plug
Q9-
030
Combustion air blow‐ Blocked Renew
er -V6-
032
AG. Volkswagen AG d
Combustion air blow‐ Open agen
circuit Checknot the connection, replace if necessary
sw oes
olk
er -V6- d byV gu
ara
e nte
ris
038 utho eo
ra
a
Fresh air blower -V2- ss Open circuit c Check,
ce
le
Renew if necessary.
un
039
pt
an
d
itte
y li
Fresh air blower -V2- Short circuit
rm
ab
pe
ility
041
ot
wit
, is n
Circulation pump - Open circuit Check, replace if necessary
h re
V55-
hole
spec
042 and bleed coolant circuit ⇒ page 30
es, in part or in w
t to the co
Circulation pump - Short circuit
V55-
047
rrectness of i
Metering pump -V54- Short circuit Check,
l purpos
048 Renew if necessary.

Metering pump -V54- Open circuit
nform
ercia
050
m
a
com
tio
Continuous shut- Unsuccessful start attempts Erase fault memory ⇒ page 26 .

n in
r
down
te o
thi
s
iva
051
do
r
rp
cum
Time overrun When blowing flame monitor -G64- Check flame monitor -G64- ⇒ page 45 .
fo
en
ng
cold with combustion air blower -V6-

t.
yi Co
Cop py
052
t. rig
gh ht
pyri by
Time overrun Safety time exceeded after several Check: exhaust pipe fuel volume, combustion
co Vo
by lksw
cted
start attempts air induction
agen
Prote AG.
053
Flame failure from the Metering pump -V54- (quantity deliv‐ Check,
high control level ered) Exhaust pipe (blocked) Com‐
bustion air (insufficient)
054 Flame monitor -G64- (values) Replace if necessary ⇒ page 48
Flame failure from The fault memory is cleared if the start
medium control level is successful.
056 Heater is permanently switched off.
Flame failure from low Clear fault memory after checking Switch on heater once again.
control level and replacing.
060

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Sharan 1996 ➤ autho eo
ra
Supplementary heating - Edition 06.2007 ss c
ce
e
nl
pt
du
an
itte
y li
erm
and meaning
ab
ility
ot p
Coolant temperature Open circuit Check water temperature,
wit
, is n
sender for heater -
h re
hole
G241-
spec
es, in part or in w
061 Check coolant temperature sender for heater -
t to the co
G241- ,
Coolant temperature Short circuit Replace if necessary ⇒ page 45
sender for heater -
rrectness of i
G241-
l purpos
064
Flame monitor -G64- Open circuit Flame monitor -G64-
nform
ercia
065 Checking ⇒ page 45
m
at
Flame monitor -G64- Short circuit
om
ion
c
in t
071
or
his
ate
Overheating sensor - Open circuit Check,
do
priv
c
G189-
um
for
en
g
072
n
t.
yi Co
op py
Overheating sensor - Short circuit Replace if necessary ⇒ page 44
t. C rig
gh ht
yri
G189- p by
co Vo
by lksw
090
cted agen
Prote AG.
Heater control unit - Error in microprocessor, (memory Replace if necessary ⇒ page 43

J162- present)
091
Interference voltage In vehicle electrical system or other Rectify
voltage sources
092 to 103
Heater control unit - Defective Replacing ⇒ page 43 .
J162-
3.2 Bleeding coolant circuit

– Use a lifting platform to position the vehicle on a slant (raise
the engine compartment by approx. 50 cm).
WARNING

– Top up coolant.
– Run the engine to warm it up, switch on the auxiliary heater.
– Use a lifting platform to position the vehicle on a slant (raise
the engine compartment by approx. 50 cm).
– Top up coolant.

Sharan 1996 ➤
3.3 Road test for auxiliary heater in vehicle

without Climatronic
Note
AG. Volkswagen AG d
agen oes
ksw
In a vehicle with a diesel engine, by pull the ambient temperature guar
Vol not
switch -F38- off the connector isedhousing and electrically bypass the an
tee
contacts of the connector t or
hhousing. Otherwise the auxiliary heater
u or
will not start at temperatures
ss
a
above 5 °C. ac
ce
le
un
pt
an
Ambient temperature switch -F38- with bracket -arrow- (part num‐
d
itte
y li
ber 701 959 625)
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
t to the co
rrectness o
cial p
f inform
– Set fresh air blower switch
mer
atio
– Turn rotary knob for temperature flap -1- clockwise to stop.
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Turn rotary knob for flap position -2- clockwise to stop.

Sharan 1996 ➤
– Switch on auxiliary heater using pre-selection clock -E111- in

moulded headliner. Press button -1- briefly. Symbol -2- for im‐
mediate heating appears.
In the engine compartment, the vacuum-controlled valve -arrow-
blocks the coolant circulation through the radiator (controlled by
the coolant circuit valve -N214- ).
Note
♦ Coolant is pumped through the auxiliary heater. The continued

coolant circulation pump -V51- pumps in the vehicle with en‐
gine codes: ACV (TDI) or AES (VR6).
♦ The additionally installed circulation pump -V55- pumps in ve‐
hicles with other engines
♦ Combustion air blower -V6- and glow plug for heater -Q9- start
after 6 seconds.
Metering pump -V54- pumps 20 to 60 seconds later.

Flame monitor -G64- detects the flame. Full load operating mode
starts. olks
wage es n
o
yV t gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
le
♦ The preheating time finishes after approx. 30 minutes. The

un
pt
an
d
heating enters the run-on phase.

itte
y li
rm
♦ The heating continues to operate when the engine has started. ab

pe
ility
ot
wit
, is n
h re
hole
– Start engine.
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
– In the engine compartment, the vacuum-controlled valve

r
rp
cum
-arrow- opens the coolant circulation through the radiator (con‐

fo
en
ng
trolled by the coolant circuit valve -N214- ).

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

n AG. Volkswagen AG do Sharan 1996 ➤
lkswage es n
ua Supplementary heating - Edition 06.2007
o ot g
byV
d ran
ir se tee
ho
– Switch on the au 2nd heat exchanger (briefly press the switch foror a
t
c
heating, temperature control switch and timer -E13- ). ss
ce
e
nl
pt
– Switch on high temperature and blower speed on warm air du
an
itte
y li
blower switch -E100- .
erm
ab
ility
ot p
– Run the engine to warm it up.
wit
, is n
h re
– Wait for several control processes to be completed.
hole
spec
– End the road test.
es, in part or in w
t to the co
– Wait for auxiliary heater run-on phase.
– Perform diagnosis again with diagnostic tester ⇒ page 25 .
rrectness of i
l purpos
Note
nform
ercia
The auxiliary heater is OK if no fault code appears.

m
at
om
i
– Top up coolant circuit again ⇒ page 30 .
on
c
in t
or
– The ambient temperature switch -F38- must be reconnected
his
ate
do
riv
in the vehicle with a diesel engine and attached in the plenum

p
cum
chamber.
for
en
ng
t.
yi Co
op py
t. C rig
gh ht
yri by
with Climatronic
cop Vo
by lksw
cted agen
Prote AG.
Note
In a vehicle with a diesel engine, pull the ambient temperature

switch -F38- off the connector housing and electrically bypass the
contacts of the connector housing. Otherwise the auxiliary heater
will not start at temperatures above 5 °C.
Ambient temperature switch -F38- with bracket -arrow- (part num‐

ber 701 959 625)
Note
Setting operating and display unit for Climatronic air conditioning

system -E87- :

Sharan 1996 ➤
– Press buttons -1-, -2- and -3- briefly.

moulded headliner.
– Press button -1- briefly.
Symbol -2- for immediate heating appears.

In the engine compartment, the vacuum-controlled valve -arrow-
blocks the coolant circulation through the radiator (controlled by
the coolant circuit valve -N214- ).
Coolant is pumped through the auxiliary heater.
Note
♦ The continued coolant circulation pump -V51- pumps in the

vehicle with engine codes: ACV (TDI) or AES (VR6).
♦ The additionally installed circulation pump -V55- pumps in ve‐
hicles with other engines.
Combustion air blower -V6- and glow plug for heater -Q9- start
after 6 seconds. en AG. V
olkswagen AG
ag does
ksw not
Metering pump -V54- pumps
by
Vol 20 to 60 seconds later. gu
ara
d
ise nte
Flame monitor -G64-
ut
ho detects the flame.
r eo
ra
sa c
Full load operating
s mode starts.
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n

h re

hole
spec
♦ The heating continues to operate when the engine has started.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
– Start engine.
Wait for several control processes to be completed.
– Perform diagnosis again with diagnostic tester ⇒ page 25 .
Note
– Top up coolant circuit again ⇒ page 30 .

– The ambient temperature switch -F38- must be reconnected n AG. Volkswagen AG do
lkswage
in the vehicle with a diesel engine and attached in theVplenum es n
o ot g
chamber. ed
by ua
ra
ris nte
utho eo
ra
3.5 Repairing auxiliary heater -B4W- / -
a c
ss
ce
le
D4W-
un
pt
an
d
itte
y li
Before beginning repair work, perform the following steps:
rm
ab
pe
ility
ot
– Disconnect battery ⇒ Rep. Gr. 27 .
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Before starting electrical welding work on the vehicle, discon‐
nect the positive pole from the battery and connect it to earth
rrectness of i
in order to protect the heater control unit -J162- .
l purpos

gives details of the heater unit type installed in the vehicle
⇒ page 37 .
nform
ercia
♦ The coolant circuit must be bled before testing work and after
m
a
com
t
it is opened ⇒ page 30
ion 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
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤

❑ Checking fuel supply to
auxiliary heater -B4W-
or -D4W- ⇒ page 47 .
❑ In some cases, the me‐
tering pump might tick
audibly but still does not
deliver fuel because
there is air in the intake
connecting pipe. The
heater control unit -
J162- will then switch off
permanently.
❑ The diagnostic tester
-5019- specifies the
fault code 052. Please
erase the fault code and
switch the heater -
B4W-/ -D4W- on several
times.
2 - Heater unit -B4W- / -D4W-
-J162-
❑ Removing and installing AG. Volkswagen AG d
agen oes
ksw
⇒ page 37 byV
ol not
gu
ara
ed
❑ Dismantling and assem‐ horis nte
eo
bling ⇒ page 39 aut ra
c
ss
3 - Exhaust pipe
ce
le
un
pt
an
d
itte
4 - Circulation pump -V55-
y li
rm
ab
❑ This circulation pump -
pe
ility
V55- is only installed if
ot
wit
, is n
the vehicle engine does
h re
hole
not have a continued
spec
coolant circulation
es, in part or in w
pump -V51- .
t to the co
5 - Coolant hoses
❑ Coolant hose routing; connecting auxiliary heater to coolant circuit ⇒ page 47 .
rrectness of i
l purpos
❑ Switch position “on” at temperatures below 5 oC

nform
ercia
❑ Switch position “off” at temperatures above 5 oC

m
❑ Part number 701 959 625

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.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nt
♦ The most importantuttechnical
ho data are shown on upper part of ee or
ss
a ac
ce
e
♦ The date of first use is entered on the lower part of manufac‐

nl
pt
du
an
turer's plate.
itte
y li
erm
ab
♦ Version -B4W- for petrol: 20 1760; version -D4W- for diesel:
ility
ot p
25 1950.
wit
, is n
h re
♦ The year the unit was first put into use must be entered on the
hole
spec
“Genuine part” manufacturer's plate. The heat exchanger for
es, in part or in w
the auxiliary heaters does not have to be renewed after
t to the co
10 years. Legislation in Germany dictates that air heaters must
be renewed.
rrectness of i
♦ The manufacturer's plate must be attached at a clearly visible
location, e.g. on the lock carrier.
l purpos
nf
ercia
3.6 Removing and installing heater unit -
orm
B4W- / -D4W-
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Drain coolant before removing. Fill with new coolant after instal‐
ling and bleed coolant circuit according to instructions
⇒ page 30 .

Sharan 1996 ➤
2 - Blind rivet nut M8
3 - Fuel line
❑ From metering pump to
heater unit
❑ 10 Nm
7 - Exhaust system
❑ 6 Nm
9 - Hexagon nut M8
❑ 10 Nm
10 - Clamping plate
11 - Bracket
15 - Intake hose
❑ Securing ⇒ page 39 .
16 - Heater unit -B4W- / -D4W-
-J162-
❑ Dismantling and assem‐ wage
es n
s
bling ⇒ page 39 yV
olk ot g
ua
d b ran
❑ Removing o
ir se tee
th or
au ac
ss
WARNING
ce
le
un
pt
an
d

itte
y li
ries.
erm
ab
ility
ot p
When the engine is

wit
is n
h re

ole,

spec

t to the co
tem is pressurised.
rrectne
pressure and reduce

temperature before car‐
rying out repairs.
ss o
cial p
f inform
❑ Open radiator cap.

mer
❑ Clamp off coolant hoses to heater unit with hose clamps up to Ø 25 mm -3094- and unfasten hoses.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
WARNING
pressure.
nection.
❑ Disconnect fuel line at heater unit and seal.

❑ Disconnect 8-pin connector (T8) from heater control unit -J162- .
WARNING
gen AG
. Volkswagen AG
wa does
olks not
Parts of the exhaust
ed
by
V
sys‐ gu
ara
tem may hbeor hot.
is nte
eo
ut ra
sa c
Before removing
s ex‐
ce
le
haust system, let it cool

un
pt
an
off.
d
itte
y li
rm
ab
pe
ility

ot
wit
, is n
h re
❑ Unscrew heater unit with bracket for heater unit.

hole
spec
❑ Secure intake hose ⇒ page 39 .

es, in part or in w
t to the co
Securing intake hose

rrectness of i
1 - Heater unit
l purpos
3 - Bracket
nform
ercia
4 - Screw-type clip
m
a
com
tion in
5 - Intake hose
r
te o
thi
s
6 - Sealing ring
iva
do
r
rp
cum
fo
– Push intake hose -5- in direction of -arrow A- until it makes

en
ng
t.
contact with housing of heater unit -1-. Cop
yi Co
py
t. rig
– Fasten screw-type clip -4-. gh ht
pyri by
Vo
co lksw
by
– Push intake hose through sealing ring -6- into bulkhead
Prote
cted AG.
agen
– Insert intake hose into bow of bracket -3-.
3.7 Dismantling and assembling heater unit

-B4W- (petrol)
Note
Dismantling and assembling heater unit -D4W- (diesel)

⇒ page 42 .

. Volkswagen AG
gen AG does
swa
Sharan 1996 ➤ yV
olk not
gu
b ara
Supplementary heating rised
- Edition 06.2007 nte
ho eo
aut ra
1- Water jacket cover ss c
ce
e
nl
pt
2 - Bolt M5×12
du
an
itte
y li
erm
3 - Heat exchanger
ab
ility
ot p
wit
, is n
h re
brush (spark plug
hole
spec
brush).
es, in part or in w
t to the co
tion ⇒ page 43 .
4 - O-ring
rrectness of i
❑ Renew
l purpos
❑ Moisten with coolant ad‐

ditive G12 when instal‐
nform
ercia
ling.
m
at
5 - Seal
om
ion
c
in t
or
mantling.
his
ate
do
priv
c
um
for
flame tube
en
ng
t.
yi Co
op
❑ Clean inside and out‐ C py
ht. rig
side with brass wire rig ht
py by
brush (spark plug co Vo
by lksw
cted
brush).
agen
Prote AG.
❑ Combustion chambers
for petrol and diesel are
different.
er
❑ Rated voltage: 8 volts
❑ Clean glow plug with
brass wire brush (spark
plug brush).
❑ Remove glow plug connection, remove and clean strainer.
❑ 6 Nm
❑ Check under rated voltage 8 V.
9 - Bolt M4×10
❑ 6 Nm
❑ 6 Nm
13 - Combustion air blower -V6-
❑ Replacing ⇒ page 44 .
❑ Do not dismantle further
14 - Cover
15 - Wiring harness
❑ Fold open connector housing to enable sockets to be pressed out.
❑ Pin assignment:

Sharan 1996 ➤
❑ Combustion air blower -V6- : chamber 3 - brown, chamber 4 - black.
❑ Flame monitor -G64- : chamber 13 - brown -, chamber 14 - blue.
❑ Overheating sensor -G189- : chambers 9 + 10 - red.
❑ Coolant temperature sender for heater -G241- : chambers 11 + 12 - blue.
❑ Glow plug for heater -Q9- : chamber 5 - white -, chamber 6 - brown.
16 - Seal
AG. Volkswagen AG d
17 - Flame monitor -G64- agen oes
olksw not
V gu
by
❑ Removing ⇒ page 44 rised ara
nte
o eo
❑ Checking ⇒ page 45 aut
h
ra
ss c
18 - Glow plug connection
ce
le
un
pt
an
❑ Clean strainer itte
d
y li
rm
ab
19 - Water jacket
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
21 - Coolant temperature sender for heater -G241-
rrectness of i
l purpos
22 - Spring
nform
ercia

m
a
com
tion in
r
te o
23 - Screw M5×16
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.

Sharan 1996 ➤
3.8 Dismantling and assembling heater unit -D4W- (diesel)
1 - Water jacket cover

2 - Bolt M5×12
3 - Heat exchanger
brush (spark plug
brush).
tion ⇒ page 43 .
4 - O-ring
❑ Renew n AG. Volkswagen AG do
wage
❑ Moisten with coolant ad‐ olks es n
ot g
yV
ditive G12 when instal‐ d b ua
ran
ir se
ling. tho tee
or
au ac
5 - Seal ss
ce
le
un
pt
an
d
itte
mantling.
y li
erm
ab
ility
ot p
flame tube
wit
is n
h re
ole,
spec
brush (spark plug
t to the co
brush).
rrectne
different.
s
s o
er
cial p
f inform
8 - Bolt M5×12
mer
atio
m
9 - Bolt M4×10
o
n
c
i
or
n thi

te
sd
iva
❑ 6 Nm
pr
cum
r
fo
en
ng

t.
yi Co
op py
❑ 6 Nm t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
AG.
13 - Combustion air blower -V6-

14 - Cover
15 - Wiring harness
❑ Fold open connector housing to enable sockets to be pressed out.
❑ Pin assignment:
❑ Combustion air blower -V6- : chamber 3 - brown, chamber 4 - black.
❑ Flame monitor -G64- : chamber 13 - brown, chamber 14 - blue.
❑ Overheating sensor -G189- : chambers 9 + 10 - red.
❑ Coolant temperature sender for heater -G241- : chambers 11 + 12 - blue.
❑ Glow plug for heater -Q9- : chamber 5 - white, chamber 6 - brown.

Sharan 1996 ➤
16 - Seal
❑ Clean glow plug with brass wire brush (spark plug brush).
❑ 6 Nm
❑ Check under rated voltage 8 V.
19 - Water jacket
21 - Coolant temperature sender for heater -G241- gen AG. Volkswagen AG
a does
❑ Removing ⇒ page 45 ksw not
y Vol gu
db ara
❑ Checking ⇒ page 46 orise nte
e th or
au
22 - Spring ss ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
23 - Screw M5×16
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert heat exchanger -2- into water jacket -1- until centring
-arrows- engages.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv

um
for
en
ng
t.
yi Co
op
Before beginning repair work, perform the following jobs: C py
t. rig
gh ht
yri
– Remove heater unit ⇒ page 37 .
p by
o Vo
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Dismantle and assemble heater unit -B4W- or heater unit -

D4W- ⇒ page 39 or ⇒ page 42
– Pull 8-pin connector (T8) off (snapped in).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
3.10 Renewing combustion air blower -V6-
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fold open connector housing -2- on both sides.
l purpos
– Press out brown cable in chamber 3.
nf
ercia
– Press out black cable in chamber 4.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
3.11 Removing flame monitor -G64- rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.

– Press out brown cable in chamber 13.
– Press out blue cable in chamber 14.
3.12 Removing overheating sensor -G189-


Sharan 1996 ➤

D4W- ⇒ page 39 or ⇒ page 42 .
– Remove overheating sensor -G189- -arrow-.
– Press out red cables in chambers 9 + 10.
3.13 Removing coolant temperature sender

for heater -G241-
. Volkswagen AG
gen AG does
– Dismantle and assemble heater unitV-B4W-
olks
wa or heater unit - not
D4W- ⇒ page 39 or ⇒ page 42 .ed by gu
ara
nte
is
or eo
– Remove coolant temperature
au sender for
th heater -G241- ra
-arrow-. ss c
ce
le
un
pt
an
d
itte
y li
erm
– Press out blue cables in chambers 11 + 12.
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss

o
cial p
f in
– Dismantling and assembling heater unit ⇒ page 64

form
mer
atio
– Unscrew glow plug wiring -1-.

om
n
c
i
or
– Remove glow plug for heater -Q9- (6 Nm).

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.15 Checking flame monitor -G64-

– Remove heater unit -B4W- or -D4W-.
– Remove heater control unit -J162- .
– Pull connector housing off control unit.

Sharan 1996 ➤
– Measure resistance between chamber 13 and chamber 14 at

brown and blue cable:
R = resistance in Ω
t = temperature in oC
– Please measure resistance at prevailing temperature.
Evaluation:
♦ Defective > 3040 Ω = open circuit
♦ Defective < 780 Ω = short circuit
3.16 Checking overheating sensor -G189-

– Remove heater unit -B4W- or -D4W-.
– Remove heater control unit -J162- .
red cables.
R = resistance in KΩ
Evaluation:
♦ Defective > 2M Ω = open circuit
3.17 Checking coolant temperature sender

for heater -G241- agen
AG. Volkswagen AG d
oes
olksw not
V
– Remove heater unit -B4W- or -D4W-. ed by gu
ara
ris nte
o eo
– Remove heater control unit -J162- . aut
h
ra
ss c
ce
le
un
pt
an
d

itte
y li
erm
blue cables.
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
Evaluation:
rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
46
cted agen
Prote
Rep. Gr.82 - Supplementary heating
AG.
Sharan 1996 ➤
3.18 Connecting auxiliary heater -B4W-aganden AG. V

olkswagen AG
does
-D4W- to coolant circuit db
y Volksw not
gu
ar
e an
ris tee
tho or
WARNING au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
The cooling system is pressurised. When the engine is warm,
pe
ility
the coolant temperature may be above 100 °C.
ot
wit
, is n
h re
If necessary, release pressure and reduce temperature before hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
to heat properly. The diagnostic tester -VAS 5019- indicates
air in the coolant circuit.
nform
ercia

m
a
com
tion in
r

te o
thi
s
iva
do
1 - Auxiliary heater -B4W- or -D4W-
r
rp
cum
fo
en
2 - Circulation pump -V55- is not installed in vehicles with engine
ng
t.
yi Co
codes ACV- (TDI) and AES- (VR6); the function is performed by t. Cop py
continued coolant circulation pump -V51- .
rig
gh ht
pyri by
Vo
o
by c
3 - 2nd heat exchanger (extra equipment)
lksw
cted agen
Prote AG.
4 - Heat exchanger (standard)
5 - Coolant shut-off valve (controlled by coolant circuit valve -
N214- ).
6 - Engine
3.19 Fuel supply to auxiliary heaters -B4W- /

-D4W-
3.19.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place 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

Sharan 1996 ➤
any parts which have not been stored in their packaging (e.g.
in a tool box).
♦ Fuel hoses and pipes may be shortened only with a clean
sharp knife. Cutting points must not be soiled or deformed.
Cutting points and surfaces must be free of burrs.
3.19.2 Testing quantity of fuel delivered

♦ Hand multimeter -V.A.G 1526B-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Auxiliary measuring set -V.A.G 1594/C-
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
♦ Current flow diagram

ng
t.
yi Co
op py
♦ Commercially available measuring glass (0 ml to 25 ml) t. C rig
gh ht
pyri by
♦ Fuel hose, length approx. 200 mm
co Vo
by lksw
cted agen
Prote AG.
Note
A second mechanic may be required to switch on the auxiliary

heater -B4W- / -D4W- as it may be necessary to raise the vehicle
to check the quantity of fuel delivered.
3.19.3 Test prerequisites:

• Resistance of metering pump = 10 Ω.
• Voltage at metering pump = 11 to 13 volts.
• No fault stored in fault memory.
• Fuel lines are not damaged or leaking.
• Fuel tank sufficiently filled (fuel gauge on dash panel insert not
in red area).

Sharan 1996 ➤
3.19.4 Checking:
WARNING

– Remove fuel line from pressure connection of metering pump

and fit a new fuel hose (length approx. 20 cm) from pressure
connection to measuring glass (capacity approx. 25 ml).
– Switch auxiliary heater on (with the help of a second mechanic,
if required). The metering pump will start to deliver after
40 seconds.
– Hold measuring glass at same height as heater unit.
– After approx. 40 seconds, the fuel line is filled and bled.
– Switch auxiliary heater off and empty measuring glass.
– Switch auxiliary heater on again.
– The auxiliary heater switches off automatically after 90 sec‐
AG. Volkswagen AG d
onds. lksw
agen oes
n o ot g
yV ua
– Read measuring glass. Quantity
ris
ed
b
delivered: petrol = 9.3 ml to ran
tee
10.7 ml; diesel = 6.7 mlutto
h 9 ml
o
or
sa ac
– If quantity delivered iss not within specifications, renew meter‐
ce
le
ing pump -V54- .

un
pt
an
d
itte
y li
erm
ab
3.19.5 Fuel take-off

ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
♦ Fuel lines are secured with O-type clips. These O-type clips
must always be replaced with screw-type clips.
rrectne
♦ Start vehicle engine if fuel tank was empty. Then start auxiliary
heater several times until heater does not switch off by itself.
ss
♦ Observe the rules for cleanliness when doing all work on the
o
cial p
fuel supply system ⇒ page 47 .

inform
mer
♦ The metering pumps for the auxiliary heaters -B4W- and -

atio
D4W- have different fuel delivery rates: note part number.

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
1 - Fuel line
❑ From fuel tank to fuel
pump
2 - Fuel return
3 - Hose clamp
4 - T-piece
6 - Heater unit
AG. Volkswagen AG d
7 - Metering pump -V54- ksw
agen oes
not
Vol gu
❑ Removing and installing ed b y ara
nte
⇒ page 50 ho
ris eo
ut ra
❑ Dismantling ss
a c
⇒ page 51
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
❑ Checking fuel quantity
wit
delivered ⇒ page 48 .
is n
h re
ole,
8 - Fuel line
spec
❑ From fuel pump to heat‐
t to the co
er unit
9 - Fuel line
rrectne
❑ From T-piece to fuel
pump
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
-V54-
cted agen
Prote AG.
1 - Bracket
3 - Screw-type clip
4 - Fuel line to heater unit
5 - Fuel line, return from engine to fuel tank
6 - Fuel line, supply from fuel tank to engine fuel pump
7 - Fuel line from T-piece connection in supply fuel line, from fuel
tank to engine fuel pump
3.20.1 Removing
– Pull connector off.

Sharan 1996 ➤
WARNING

AG. Volkswagen AG d
agen
w oes
olks not
yV gu
Then release pressure by carefully loosening the
se
d bconnection. ara
nte
ri
ho eo
aut ra
ss c
– Detach fuel hoses -4- and -7- from fuel pump and seal.
ce
e
nl
pt
du
an
– Remove fuel pump from bracket -1-.
itte
y li
erm
ab
3.20.2 Installing
ility
ot p
wit
, is n
h re
– Ensure proper fitting position ⇒ page 51
hole
spec
es, in part or in w
t to the co
2 - Strainer
rrectness of i
3 - Hose connection
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Checking installation position of metering pump -V54-
3.21 Regulation of auxiliary heaters -B4W-

and -D4W-
Auxiliary heater -B4W- / -D4W- is intended to heat the coolant and
thereby assist the heating output of the engine. It can also be used
as an auxiliary heater when the engine is switched off.
in heating circuit:
The auxiliary heater controls three heating levels: 4000 watts,
3300 watts and 1600 watts.

Sharan 1996 ➤
The heating levels cannot be set manually. The heater control unit
-J162- controls the heat requirement.
The heater control unit -J162- calculates the heat requirement
based on the temperatures measured by the coolant temperature
sender for heater -G241- .
The auxiliary heater reduces its power if the coolant temperature
is 85 °C. The heater interrupts control. Then the 100 second run-
on phase starts. The combustion air blower -V6- runs at its highest
level during the run-on phase. The circulation pump -V55- or con‐
tinued coolant circulation pump -V51- continues to run until the
next control start.
The control start begins at a coolant temperature of 65 °C at the
highest level and the highest speed of the combustion air blower
-V6- .
If the heater unit is switched off or if a malfunction shut-off occurs,
the run-on phase of the combustion air blower -V6- takes place
at low speed.
The flame is monitored by the flame monitor -G64- , the maximum
permitted temperature is monitored by the overheating sensor -
G189- . Both influence the heater control unit -J162- which
switches off when there are malfunctions.
The start is repeated if the heater does not ignite within 90 sec‐
onds after fuel pumping starts. A malfunction shut-off occurs if the
heater does not ignite after another 90 seconds.
A new start is performed initially if the flame goes out by itself
during operation. The malfunction shut-off occurs if the heater gen AG
. Volkswagen AG
does
does not ignite within 90 seconds after the fuel pumpingVis swa
olkswitch‐ not
gu
ed on or if the heater ignites but goes out again. The d bmalfunction
y ara
se nte
shut-off can be revoked by switching off and back thori on again. eo
au ra
The overheating sensor -G189- is triggered in ss the event of over‐ c
ce
e
heating (lack of water, air in the coolant circuit). The fuel supply
nl
pt
du
is interrupted. The malfunction shut-off then occurs. Once the
an
itte
y li
cause of overheating has been eliminated, the auxiliary heater
erm
ab
can be restarted by switching off and back on again. Prerequisite:
ility
ot p
the auxiliary heater has cooled down sufficiently!

wit
, is n
The malfunction shut-off occurs if the voltage drops below approx. h re

hole
spec
10 volts or rises above approx. 16 volts.
es, in part or in w
t to the co
The auxiliary heater does not start if the glow plug for heater -Q9-
is defective.
rrectness of i
The speed-controlled combustion air blower -V6- is permanently

monitored. The malfunction shut-off takes place in the event of a
l purpos
fault if it does not start or becomes blocked.

Check the following in case of a sooty flame: eliminate obstacles
nform
ercia
to the combustion air supply and in the exhaust gas pipe. Check
the quantity delivered by the metering pump -V54- , renew it if
m
at
om
necessary. Clean deposits off the heat exchanger for the auxiliary
ion
c
heater, replace if necessary.

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.

Sharan 1996 ➤
4 Auxiliary heater -B5W- S / -D5W- S,

vehicles 06.2000 ▸
4.1 Repairing auxiliary heater -B5W- S / -

D5W- S
Before beginning repair work, perform the following steps:
– Disconnect battery ⇒ Rep. Gr. 27 .
Note agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
♦ Before starting electrical welding
rised
work on the vehicle, discon‐ nte
nect the positive pole fromut the battery and connect it to earth
ho eo
ra
in order to protect thes heater control unit -J162- .
s a c
ce
e
nl
pt
du
an
provides information about the type of heater unit installed in
itte
y li
erm
the vehicle: petrol -B5W- S ⇒ page 55 or diesel -D5W- S
ab
ility
⇒ page 55
ot p
wit
, is n
♦ The coolant circuit must be bled before testing work and after
h re
hole
it is opened ⇒ page 76
spec
es, in part or in w
♦ Components identified with * are checked by the self-diagnosis
t to the co
function.
rrectness of i
control unit vehicle diagnostic, testing and information system
-VAS 5051A- .
l purpos
♦ Vehicles with engine code AYL (6 cyl.) are equipped with a

vacuum switch for auxiliary heater -F359- . This vacuum
nf
ercia
o
switch for auxiliary heater -F359- switches off the auxiliary
rm
m
atio
heater when there is no vacuum. The reason for this is that the
om
two pneumatic valves in the coolant circuit (big / small coolant

n in
or c
circuit) are controlled by vacuum to close them. If there is no

thi
te
sd
vacuum, the auxiliary heater operates in the big coolant circuit.

iva
o
r
On starting the engine, the engine control unit operates with

rp
cu
o
implausible temperature values and will not let the engine

f
en
ng
t.
yi
start. The vacuum switch for auxiliary heater -F359- is located
Co
op py
behind the engine control unit.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
4. Auxiliary heater -B5W- S / -D5W- S, vehicles 06.2000 ▸ 53

Sharan 1996 ➤
swage es n
1 - Metering pump -V54- byV
olk ot g
ua
ed ran
❑ Installationhor position: in
is tee
front ofau fuel tank on the
t or
ac
right
ss
ce
le
un
❑ Fuel supply to auxiliary
pt
an
d
itte
heater ⇒ page 76 .
y li
erm
ab
❑ In some cases, the me‐
ility
ot p
tering pump might tick
wit
is n
audibly but still does not
h re
ole,
deliver fuel because
spec
there is air in the intake

connecting pipe. The
t to the co
control unit will then
switch off permanently.
rrectne
– As a result, read fault
memory using vehicle
s
diagnosis, testing and
s o
information system -
cial p
f in
VAS 5051A- .
form
mer
atio
– Please clear fault mem‐
om
n
ory and switch heater on
c
i
or
n
several times.
thi
te
sd
iva
o
r

p
cum
r
fo
⇒ page 78 .
en
ng
t.
yi Co
op
2 - Heater unit *
C py
t. rig
gh ht
yri
p by
co Vo
by lksw
-J162- Prote
cted AG.
agen

⇒ page 61
bling ⇒ page 64
3 - Exhaust system
⇒ page 56
❑ Securing exhaust pipe to heater unit ⇒ page 56 .
❑ Installation position: fitted in front of heater unit in driving direction.
5 - Coolant hoses
❑ Coolant hose routing; connecting auxiliary heater to coolant circuit ⇒ page 72 .
6 - Valve for coolant circuit -N214-
❑ Only in vehicles with engine codes: AYL, ASZ
7 - Pre-selection clock -E111-
❑ Installation position: front left in plenum chamber
❑ Only in vehicles with TDI engines
❑ Switch position -On- at temperatures lower than approx. 10 °C.
❑ Check the switch positions with vehicle diagnosis, testing and information system -VAS 5051A- in “Gui‐
ded fault finding” function
❑ Part number 701 959 625

Sharan 1996 ➤
❑ Check with vehicle diagnosis, testing and information system -VAS 5051A- in “Guided fault finding”
function
Manufacturer's plate for petrol -B5W- S
Note

♦ Only the 20 1809 version for -B5W- S is factory-fitted in the
Sharan 06.2000 ▸.
♦ The heat exchanger for the auxiliary heaters does not have to
be renewed after 10 years. Legislation in Germany dictates
Manufacturer's plate for diesel -D5W- S
Note

♦ Only the 25 2164 version for -D5W- S is factory-fitted in the
Sharan 06.2000 ▸. n AG. Volkswagen AG do
lkswage es n
♦ The heat exchanger for the auxiliary heaters by Vdoes not have to
o ot g
ua
be renewed after 10 years. Legislationorisine Germany dictates
d ran
tee
auth or
ac
ss
ce
le
un
pt
4.2 Removing ambient temperature switch -
an
d
itte
y li
rm
ab
F38-
pe
ility
ot
wit
, is n
– Unclip ambient temperature switch -F38- -1- from bracket at

front left in plenum chamber. h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
– Disconnect connector from ambient temperature switch -F38-

nform
ercia
and remove ambient temperature switch -F38- .

m
a
com
ti
4.3 Removing circulation pump -V55-

on 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
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Loosen bolts -1- for bracket.
pe
ility
ot
wit
, is n
WARNING
h re
hole
spec
es, in part or in w
t to the co
The cooling system is pressurised. When the engine is warm,
the coolant temperature may be above 100 °C.
rrectness of i
l purpos
nform
ercia
– Please disconnect coolant hoses from circulation pump with

hose clamps up to Ø 25 mm -3094- .
m
a
com
– Disconnect connector from circulation pump -V55- . tion in

r
te o
thi
s
iva
– Pull circulation pump -V55- out of bracket -arrows-.

do
r
rp
cum
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
op Vo
by c lksw
to heat properly.
cted agen
Prote AG.
4.4 Removing pre-selection clock -E111-

– Carefully lever pre-selection clock out from trim with screw‐
driver.
– Pull off connectors.


Sharan 1996 ➤
WARNING

Before removing silencer, let it cool off.
AG. Volkswagen AG d
agen oes
olksw not
1 - Heater unit d by V gu
ara
ise nte
❑ With heater controlthunit
or eo
-J162- ss au ra
c
ce
e
2 - Clip
nl
pt
du
an
itte
3 - Silencer y li
erm
ab
❑ Securing silencer to ility
ot p
heater unit ⇒ page 58

wit
, is n
h re
hole

spec
es, in part or in w
❑ 6 Nm
t to the co

6 - Bracket
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.

Sharan 1996 ➤
4.5.1 Securing silencer to heater unit

– Push silencer -1- in direction of arrow until it contacts com‐
bustion air blower housing -2-.
4.6 Road test for auxiliary heater Vol
kin
swavehicle
ge es n
ot g
without Climatronic by ua
ed ran
ris tee
tho or
s au ac
s
ce
Note
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
will not start at temperatures above approx. 10 °C.
h re
ole,
spec
The ambient temperature switch -F38- with bracket -arrow- is lo‐
t to the co
cated at front left in the plenum chamber (part number
701 959 625) or, on more recent vehicles, behind the wiper motor.
rrectne
Note
ss o
cial p
f
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– Set fresh air blower switch

en
ng
t.
yi Co
op
– Turn rotary knob for temperature flap -1- clockwise to stop.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
– Turn rotary knob for flap position -2- clockwise to stop.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
-arrow- blocks the coolant circulation through the radiator
spec
(controlled by the coolant circuit valve -N214- ).
es, in part or in w
t to the co
– Combustion air blower -V6- and glow plug for heater -Q9- start
after 6 seconds.
rrectness of i
– Metering pump -V54- pumps 20 to 60 seconds later.
l purpos
– Flame monitor -G64- detects the flame. Full load operating

mode starts.
nf
ercia
orm
m
Note
atio
om
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
♦ The heating continues to operate when the engine has started.
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
– Start engine. yri
p by
co Vo
by lksw
cted agen
Prote AG.


Sharan 1996 ➤
– Switch on 2nd heat exchanger. Briefly press the switch for

heating, temperature control switch and timer -E13- (button
-1-).
– Set high temperature and blower speed on warm air blower
switch -E100- .
– Read fault memory again using vehicle diagnosis, testing and
information system -VAS 5051A- .
Note

– The ambient temperature switch -F38- must olks
wbe
agereconnected es n
ot g
in the vehicle with a diesel engine andd attached
by
V in the plenum ua
ran
chamber. or
ise tee
th or
au ac
ss
ce
e
nl
pt
du
with Climatronic
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
es, in part or in w
t to the co
will not start at temperatures above approx. 10 °C.
rrectness of i
The ambient temperature switch -F38- with bracket -arrow- is lo‐
l purpos
cated at front left in the plenum chamber (part number

701 959 625) or, on new vehicles, behind the wiper motor.
nform
mercia
at
Note
om
ion
c
in t
or
his
ate

do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Start engine. Prote AG.
– Set operating and display unit for Climatronic air conditioning

system -E87- .
– Press button -1- for defrosting the windscreen.
– Use button -2-, pushbutton for “warmer” in passenger com‐
partment, to set maximum heating power “HI”.

Sharan 1996 ➤
– Use button -3-, pushbutton for “warmer” in driver's area, to set

maximum heating power “HI”.

-arrow- blocks the coolant circulation through the radiator
(controlled by the coolant circuit valve -N214- ).
– Combustion air blower -V6- and glow plug for heater -Q9- start
after 6 seconds.
– Metering pump -V54- pumps 20 to 60 seconds later.
– Flame monitor -G64- detects the flame. Full load operating
mode starts.
Note
wage
♦ The preheating time finishes after
olksapprox. 30 minutes. The s not g
e
yV
ise
db u ara
nte
r
ho e
♦ The heating continuess ato
ut operate when the engine has started. or
ac
s
ce
le
un
pt
an
d
– Start engine.
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
– Read fault memory again using vehicle diagnosis, testing and

information system -VAS 5051A- .
nform
mercia
Note
com
tion in
r
te o
thi

s
iva
do
r
rp
cum
fo
– The ambient temperature switch -F38- must be reconnected

en
ng
t.
yi
in the vehicle with a diesel engine and attached in the plenum
Co
op py
chamber. t. C rig
gh ht
pyri by
Vo
co lksw
by
4.8 Removing and installing heater unit
cted agen
Prote AG.

Sharan 1996 ➤
Note
♦ Drain coolant before removing. Fill with new coolant after in‐
stalling and bleed coolant circuit according to instructions.
⇒ page 76
♦ Cooling system is pressurized when engine is warm. If nec‐
essary, release pressure before carrying out repairs.
2 - Blind rivet nut M8 n AG. Volkswagen AG do
lkswage es n
o ot g
yV
3 - Fuel line ir se
d b ua
ran
o tee
❑ From metering
auth pump - or
ac
V54- stos heater unit.
ce
e
nl
pt

du
an
itte
y li
❑ In -B5W- S or -D5W- S
erm
ab
to circulation pump -
ility
ot p
V55- .
wit
, is n
h re
❑ In -D5W- Z to coolant
hole
spec
pipe.
es, in part or in w
t to the co

rrectness of i
❑ 10 Nm
l purpos
7 - Exhaust system
nf
ercia
❑ 6 Nm
orm
m
atio
9 - Hexagon nut M8
om
n in
c
❑ 10 Nm
or
thi
te
sd
a
10 - Clamping plate
iv
o
r
rp
cu
o
m
f
11 - Bracket
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
13 - Coolant hose cop Vo
by lksw
cted agen
❑ From 2nd heat ex‐
Prote AG.
changer
15 - Intake pipe
❑ Securing intake pipe
⇒ page 64

Sharan 1996 ➤
16 - Heater unit
❑ With heater control unit -J162-
❑ Dismantling and assembling ⇒ page 64
❑ Removing:
WARNING
ries.
When the engine is
tem is pressurised.
pressure and reduce
temperature before car‐en AG. Volkswagen AG
rying out repairs. olkswag does
no
yV t gu
db ara
rise nte
❑ Clampingtho off coolant hoses at heater unit and releasing
eo them.
s au ra
c
s
ce
le
un
WARNING pt
an
d
itte
y li
erm
ab
ility
ot p

wit
is n
pressure.
h re
ole,
spec

t to the co

rrectne
nection.
ss o
❑ Disconnect fuel line at heater unit and seal.

cial p
f inform
❑ Disconnect T8 connector (8-pin) from heater control unit -J162- .

mer
atio
om
WARNING
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo

en
ng
t.
yi Co
op py
Before removing silenc‐ . C rig
ht ht
er, let it cool off.
rig by
copy Vo
by lksw
cted agen
Prote AG.
❑ Unscrew heater unit with bracket for heater unit.
❑ Securing intake pipe ⇒ page 64

Sharan 1996 ➤
4.8.1 Securing intake pipe

1 - Heater unit
3 - Bracket
4 - Screw-type clip
5 - Intake pipe
6 - Sealing ring
– Push intake pipe -5- in direction of -arrow A- until it makes
contact with housing of heater unit -1-.
– Push intake pipe through sealing ring -6- into bulkhead
– Fasten screw-type clip -4-.
Note
Components identified with * are checked by the self-diagnosis

function.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
64
agen
Prote AG.
Rep. Gr.82 - Supplementary heating
Sharan 1996 ➤
1 - Water jacket cover wage

es n
lks ot g
Vo
2- Bolt M5×12 ed by ua
ran
ir s tee
o
3- Heat exchanger
auth or
ac
ss
ce
le
un
pt
an
d
itte
tion ⇒ page 66 .
y li
rm
ab
pe
ility
ot
wit
, is n
brush (spark plug
h re
hole
brush).
spec
es, in part or in w
4 - O-ring
t to the co
❑ Renew
❑ Moisten with coolant ad‐
rrectness of i
ditive G12 when instal‐
ling.
l purpos
5 - Seal
nform
ercia

mantling.
m
a
com
tio
6 - Combustion chamber
n in
r
te o
thi
s
iva
do
r
rp
brush (spark plug cum

fo
en
g
brush).
n
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
different.
c by lksw
cted agen
Prote AG.
er
8 - Glow plug for heater -Q9- *
brass wire brush (spark plug brush).
❑ Remove glow plug connection, remove and clean strainer.
❑ 6 Nm
❑ Checking under rated voltage of 8 V
9 - Bolt M4×10
❑ 6 Nm
❑ 6 Nm
12 - Heater control unit -J162- *
13 - Combustion air blower -V6- *
14 - Cover
15 - Wiring harness
Pin assignment:
♦ Combustion air blower -V6- : chamber 14 - brown, chamber 13 - black.

Sharan 1996 ➤
♦ Flame monitor -G64- : chamber 2 - brown, chamber 1 - blue.

♦ Overheating sensor -G189- : chambers 5 + 6 - red.
♦ Coolant temperature sender for heater -G241- : chambers 3 + 4 - blue.
♦ Glow plug for heater -Q9- : chamber 9 - white, chamber 12 - brown.
16 - Seal olks
wage es n
ot g
y V
se
db ua
ran
ri tee
ho
17 - Flame monitor -G64- aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
18 - Glow plug connection
ility
ot p
❑ Clean strainer
wit
, is n
h re
19 - Water jacket
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
m
at
om
22 - Spring
ion
c
in t
r

o
his
ate
do
priv
cum
or
23 - Screw M5×16
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Heat exchanger installation position co Vo
by lksw
cted agen
Prote AG.
-arrows- engages.
4.10 Removing heat exchanger


Sharan 1996 ➤

– Pull combustion chamber -5- out of heat exchanger -2-.
– Use suitable screwdriver carefully to press heat exchanger
-2- through rear water connection (water inlet) -arrow A- out of
water jacket -1- in direction of -arrow B-.
– Before assembling, always replace O-ring -3- and seal -4-, and
observe installation position of heat exchanger ⇒ page 66
AG. Volkswagen AG d
agen oes
ksw
4.11 Removing flame monitor -G64- d byV
ol not
gu
ara
ise nte
r
Before beginning repair work, perform the following
ut
ho jobs: eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Press brown cable out of chamber 2 of connector housing
ility
ot p
-2-.
wit
, is n
h re
– Press blue cable out of chamber 1 of connector housing -2-.
hole
spec
– Unbolt flame monitor -1-.
es, in part or in w
t to the co
Note
rrectness of i
For installation, route glow plug wiring under combustion air blow‐
l purpos
er -V6- -arrow-.
nform
ercia

m
at
om
ion
c
in t
or
his
ate

do
priv
cum
or

f
en
ng
t.
yi Co
op
– Unscrew glow plug wiring -1-. C py
ht. rig
rig ht
by
– Remove glow plug for heater -Q9- . copy Vo
by lksw
cted agen
Prote AG.
Note
♦ The glow plug for heater -Q9- has been modified as a spare
part for the diesel-fuelled heater -D5W- in current production.
♦ This means the removal and installation procedures have
changed.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Sharan 1996 a➤
uth or
ac
ss
ce
e
nl
pt
du
an
– Press glow plug wiring -1- and -2- out of chambers T14c / 9
itte
y li
(white) and T14c / 12 (brown) using ejection tool -VAS
erm
ab
ility
1978/4- .
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Screw new glow plug for heater -Q9- into housing (6 Nm).
m
m
atio
m
– Route glow plug wiring under combustion air blower -V6 -

o
n in
or c
-arrows-.
thi
te
sd
iva
– Clip white cable into chamber T14c / 9 and black cable into
o
r
rp
cu
chamber T14c / 12 of connector housing -1-.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove bolts from control unit.
– Disconnect 14-pin connector (T14 in control unit).
– Carefully remove control unit.


Sharan 1996 ➤

– Press brown cable out of chamber 14 of connector housing
-2-.
– Press black cable out of chamber 13 of connector housing
-2-.
– Remove flame monitor -G64- ⇒ page 67 .
– Remove glow plug for heater -Q9- ⇒ page 67 .
– Remove cross head screws from combustion air blower.
– Remove combustion air blower -V6- together with bracket
-1-.

– Remove water jacket cover ⇒ Item 1 (page 65) . AG. Volkswagen AG d
agen oes
ksw
– Remove spring ⇒ Item 22 (page 66) . by
Vol not
gu
ara
ed
is nte
– Press red cables out of chambers 5 and 6 of connector
hor hous‐ eo
ut
ing -2-. ss a ra
c
ce
le
– Unscrew overheating sensor -G189- -1- in direction of arrow.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
for heater -G241-
rrectness of i
l purpos
nform
ercia
– Remove water jacket cover ⇒ Item 1 (page 65) .

m
a
– Remove spring ⇒ Item 22 (page 66) .
com
tion in
r
– Press blue cables out of chambers 3 and 4 of connector hous‐

te o
thi
s
ing -2-.
iva
do
r
rp
cum
– Pull off coolant temperature sender for heater -G241- -1- in

fo
en
ng
direction of arrow.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove heater control unit -J162- ⇒ page 68 .

Sharan 1996 ➤

brown and blue cable.
t = temperature in °C
Evaluation:
4.18 Checking overheating sensor

wage -G189-
n AG. gen AG Volkswa
does
olks no
V t gu
by
Before beginning repair work, perform
ris the following jobs:
ed
ara
nte
tho eo
– Remove heater unit ⇒ page s61
sa .
u ra
c
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Measure resistance between chamber 5 and chamber 6 at red
wit
cables.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Evaluation:
l purpos

nform
mercia
at
om
io

n
c
in t
or
his
e
for heater -G241-

at
do
priv
cum
or

f
en
ng
t.
yi Co
– Remove heater unit ⇒ page 61 . Cop py
t. rig
gh ht
yri
– Remove heater control unit -J162- ⇒ page 68 . p by
co Vo
by lksw
cted agen
– Pull connector housing off control unit. Prote AG.

blue cables.
Evaluation: defective > approx. 2 MΩ = open circuit; defective <
50 Ω = short circuit
4.20 Checking ambient temperature switch -

F38-

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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
va
♦ Cold spray (commercially available)

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c
The ambient temperature switch -F38- is only installed in vehicles
lksw
cted agen
Prote
with TDI diesel engines.
AG.
4.20.1 Test procedure

– Disconnect 8-pin connector (T8) from heater unit.
– Set measuring range selector switch on hand multimeter -
V.A.G 1526B- to DC voltage measurement, measuring range
20 V.
– Connect hand multimeter -V.A.G 1526B- to chamber -T8/2-
and chamber -T8/6- of disconnected 8-pin connector using
cables from auxiliary measuring set -V.A.G 1594C- .
– Switch on ignition and start engine.
Display on the hand multimeter -V.A.G 1526B- :
♦ At ambient temperatures below approx. 10 °C: approx. 12 V

Sharan 1996 ➤
– Unclip ambient temperature switch -1- from bracket at front left

in plenum chamber. Depending on vehicle equipment, the
ambient temperature switch -1- may be located on the wiper
motor wiring harness or behind the wiper motor.
– Spray ambient temperature switch with cold spray, if neces‐
sary, and observe display on hand multimeter -V.A.G 1526B- .
If values do not change when ambient temperature switch -F38-
is sprayed, or if specified ratedgevalues
n AG. Voare
lkswanot
gen achieved:
AG d
wa oes
olks no
– Check cables and/ord b connectors to ambient temperature
yV t gu
ara
switch -F38- according
orise to current flow diagram. nte
e h
ut or
If cables and/or
ss connectors to ambient temperature switch -F38- c
a a
are OK according to current flow diagram:
ce
le
un
pt
an
d
– Please replace ambient temperature switch -F38- .

itte
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
The ambient temperature switch -F38- switches on the auxiliary
heater only if the engine is running and the coolant temperature
t to the co
is below approx. 77 °C. The ambient temperature must not ex‐
ceed approx. 10 °C.
rrectne
4.21 Connecting auxiliary heaters -B5W- S
and -D5W- S to coolant circuit ss o
cial p
f inform
mer
atio
WARNING
om
n
c
i
or
n thi

te
sd
iva
o
pr

um
r
fo

en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
to heat properly.

Sharan 1996 ➤

2 - Heater unit
5 - Expansion tank
V50-
mentary heater
AG. Volkswagen AG d
❑ Pneumatically control‐ agen oes
olksw not
V
led by coolantedcircuit
by gu
ara
valve -N214- horis nte
eo
ut ra
❑ Only for ss a66 kW engine c
with unit injectors
ce
e
nl
pt
du
an
8 - ATF cooler
itte
y li
erm
ab
❑ Only vehicles with auto‐
ility
ot p
matic transmission
wit
, is n
h re
9 - Radiator
hole
spec
❑ a = Bottom
es, in part or in w
t to the co
❑ b = Top
10 - Oil cooler
rrectness of i
11 - Thermostat
l purpos
12 - Coolant pump
13 - Cylinder head
nform
ercia

m
at
om
❑ Only 2.0 l and 2.8 l en‐

on
c
in t
gines
or
his
ate
do
riv
15 - Switch-off valve for sup‐

p
plementary heater
um
for
en
ng
t.
❑ Pneumatically controlled by coolant circuit valve -N214-
yi Co
Cop py
❑ Only for 85 kW engine with unit injectors
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.22 Connecting auxiliary heaters -B5W- S, -

D5W- S and -D5Z- F to coolant circuit for
engine code AYL (6 cyl.) from 05.2004
WARNING


Sharan 1996 ➤
Note
to heat properly.

2 - Heater unit
V50-
6 - Expansion tank
mentary heater
❑ Pneumatically control‐
led by coolant circuit
valve -N214-
8 - ATF cooler AG. Volkswagen AG d
agen
❑ Only vehicles with auto‐ Volksw
oes
not
gu
matic transmission d by ara
rise nte
o eo
9 - Radiator auth
ra
ss c
10 - Oil cooler
ce
e
nl
pt
du
an
11 - Coolant pump
itte
y li
erm
ab
12 - Cylinder head
ility
ot p
wit
, is n
13 - Switch-off valve for sup‐
h re
plementary heater
hole
spec
❑ Pneumatically control‐
es, in part or in w
t to the co
led by coolant circuit
valve -N214-
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.

Sharan 1996 ➤

2nd heat exchanger
WARNING

Note
AG. Volkswagen AG d
1 - Coolant pipe, supply agen oes
olksw not
byV gu
ara
2 - Coolant pipe, return ris ed
nte
ho eo
ut
ss a ra
c
❑ From circulation pump -
ce
le
un
pt
V55- to the coolant pipe.
an
d
itte
y li
rm
ab
pe
ility
ot
5 - Heater unit
wit
, is n
h re
hole
6 - Coolant hose, return spec

es, in part or in w

t to the co
heater unit.
rrectness of i
❑ From heater unit to cir‐

culation pump -V55- .
l purpos

nform
ercia

m
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.

Sharan 1996 ➤
4.24 Bleeding coolant circuit in vehicles with

auxiliary heater -B5W- S, -D5W- S or -
D5W- Z
Note
The coolant circuit must be free of air for the auxiliary heater to
heat properly.
AG. Volkswagen AG d
agen oes
lksw not
– Raise front of vehicle approx. 50 cm using lifting platform.
by
Vo gu
ara
ed
ris nte
ho eo
ut
WARNING ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Top up coolant.
rrectness of i
– Lower vehicle again and perform road test until engine rea‐
ches operating temperature (with auxiliary heater switched
l purpos
on).
– Raise front of vehicle approx. 50 cm using lifting platform.
nf
ercia
or
– Top up coolant.
m
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
Repeat procedure until there are no more air bubbles in coolant
o
m
f
en
ng
circuit.
t.
yi Co
Cop py
t. rig
gh ht
4.25 Fuel supply to auxiliary heaters -B5W- pyri by
Vo
o
by c lksw
S, -D5W- S or -D5W- Z
cted agen
Prote AG.
4.25.1 Rules for cleanliness

When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place 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).
♦ Fuel hoses and pipes may be shortened only with a clean
sharp knife. Cutting points must not be soiled or deformed.
Cutting points and surfaces must be free of burrs.

Sharan 1996 ➤
4.25.2 Fuel take-off -B5W- S, -D5W- S or -

D5W- Z
Note
♦ Fuel lines are secured with O-type clips. These O-type clips
must always be replaced with screw-type clips.
♦ Start vehicle engine if fuel tank was empty. Then start auxiliary
heater several times until heater does not switch off by itself.
♦ The arrows in the illustration indicate the fuel flow direction.
♦ Observe the rules for cleanliness when doing all work on the
fuel supply system ⇒ page 47 .
1 - Fuel return
2 - Fuel supply
3 - Quick release coupling
5 - Heater unit
⇒ page 78 wage
es n
lks
❑ Dismantling d byV
o ot g
ua
⇒ page 78 o
ir se
ran
tee
th or
au ac
ss
ce
e
nl
pt
❑ Testing quantity of fuel

du
an
itte
delivered ⇒ page 79
y li
erm
ab
ility
7 - Fuel line
ot p
wit
, is n
❑ From metering pump -

h re
V54- to heater unit.

hole
spec
es, in part or in w
8 - Fuel line
t to the co
❑ From fuel gauge sender

-G- to metering pump -
V54- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤

-V54-
1 - Fuel line from fuel tank
2 - Clamping piece
3 - Bracket
AG. Volkswagen AG d
4 - Fuel line to heater unit agen oes
olksw not
y V gu
d b ara
5- Connector orise nte
th eo
u ra
6- Metering pump s-V54-
sa c
ce
e
nl
pt
du
an
4.26.1 Removing
itte
y li
erm
ab
ility
ot p
– Separate connector -5-.
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Detach fuel hoses -1- and -4- from metering pump and seal
them.
m
at
om
ion
c
– Remove metering pump from bracket -3-.

in t
or
his
ate
do
riv
4.26.2 Installing
p
cum
for
en
ng
t.
yi
– Ensure proper fitting position ⇒ page 79
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
1 - Metering pump -V54- cted agen
Prote AG.
2 - Strainer
3 - Hose connection

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ut
ho eo
ra
Sharan 1996 ➤
a
ss Supplementary
c heating - Edition 06.2007
ce
e
nl
pt
du
Installation position of metering pump -V54-
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
4.27 Testing quantity of fuel delivered
orm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
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.

♦ Commercially available measuring glass (0 ml to 25 ml)
♦ Fuel hose, length approx. 200 mm
Note
A second mechanic may be required to switch on the auxiliary

heater as it may be necessary to raise the vehicle to check the
quantity of fuel delivered.
4.27.1 Test prerequisites:

• Resistance of metering pump -V54- = 10Ω.
• Voltage at metering pump -V54- = 11 to 13 volts.
• No fault stored in fault memory

Sharan 1996 ➤
• Fuel lines are not damaged or leaking. agen

AG. Volkswagen AG d
oes
olksw not
• Ambient temperature approx. 20 °C d by V gu
ara
rise nte
• Fuel tank filled sufficiently (fuelaugauge
tho
on dash panel not in red eo
ra
area) ss c
ce
le
un
pt
4.27.2 Checking:
an
d
itte
y li
rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove fuel line from pressure connection of metering pump

and fit a new fuel hose (length approx. 200 mm) from pressure
nform
ercia
connection to measuring glass (capacity approx. 25 ml).

m
– Switch auxiliary heater on (with the help of a second mechanic,
a
com
tio
if required). The metering pump will start to deliver after
n in
r
45 seconds.
te o
thi
s
iva
do
r
rp
cum
fo
en
– After approx. 40 seconds, the fuel line is filled and bled.
ng
t.
yi Co
op py
– Switch auxiliary heater off and empty measuring glass. t. C rig
gh ht
pyri by
Vo
– Switch auxiliary heater on again.
co lksw
by
cted agen
Prote AG.

– The auxiliary heater switches off automatically after 90 sec‐
onds.
– Read measuring glass. Quantity delivered: petrol = 10.9 ml to
12.1 ml; diesel = 7.5 ml to 8.5 ml
– If quantity delivered is not within specifications, renew meter‐
ing pump -V54- .
Note
♦ If the ambient temperature is above 20 °C, fuel vaporisation

may lead to incorrect measurements.
♦ No bubbles are to be delivered.
4.28 Regulation of auxiliary heaters -B5W- S

and -D5W- S
The auxiliary heater -B5W- S / -D5W- S is intended to heat the
coolant and thereby assist the heating output of the engine. It can
also be used as an auxiliary heater when the engine is switched
off.
in heating circuit:
After the engine is started at an ambient temperature of below
approx. 10 °C and if the coolant temperature is below approx. 77 °
C, the auxiliary heater in vehicles with TDI engines is automati‐
cally switched on via the ambient temperature switch -F38- .

Sharan 1996 ➤

The auxiliary heater controls two heating levels: -B5W- S =
5000 watts or 1500 watts; D5W- S = 5000 watts or 2200 watts.
The heating levels cannot be set manually. The control unit -J162-
controls the heat requirement.
The heater control unit -J162- calculates the heat requirement
based on the temperatures measured by the coolant temperature
sender for heater -G241- .
The auxiliary heater reduces its power if the coolant temperature
is 85 °C. The heater interrupts control. Then the 130 second run-
on phase starts. The combustion air blower -V6- runs at its highest
level during the run-on phase. The circulation pump -V55- con‐
tinues running until thewnext
agen control start. AG does
AG. Volkswagen
ks not
Vol g
The control start ed begins at a coolant temperature of 65
by ua °C at the
ran
highest levelthoand
ris the highest speed of the combustion air tee blower
or
-V6- . s au ac
s
ce
le
If the heater unit is switched off or if a malfunction shut-off occurs,

un
pt
the run-on phase of the combustion air blower -V6- takes place
an
d
itte
y li
at low speed.
rm
ab
pe
ility
The flame is monitored by the flame monitor -G64- , the maximum
ot
wit
, is n
permitted temperature is monitored by the overheating sensor -

G189- . Both influence the heater control unit -J162- which h re
hole
switches off when there are malfunctions. spec

es, in part or in w
t to the co
The start is repeated if the heater does not ignite within 90 sec‐
onds after fuel pumping starts. A malfunction shut-off occurs if the
heater does not ignite after another 90 seconds.
rrectness of i
A new start is performed initially if the flame goes out by itself

l purpos
during operation. The malfunction shut-off occurs if the heater

does not ignite within 90 seconds after the fuel pumping is switch‐
ed on or if the heater ignites but goes out again. The malfunction
nform
ercia
shut-off can be revoked by switching off and back on again.

m
a
com
The overheating sensor -G189- is triggered in the event of over‐

ion in
heating (lack of water, air in the coolant circuit). The fuel supply
r
te o
thi
is interrupted. The malfunction shut-off then occurs. Once the

s
iva
do
cause of overheating has been eliminated, the auxiliary heater

r
rp
can be restarted by switching off and back on again. Prerequisite:

um
fo
en
g
the auxiliary heater has cooled down sufficiently!

n
t.
yi Co
Cop py
The malfunction shut-off occurs if the voltage drops below approx.
ht. rig
rig ht
10.2 volts or rises above approx. 16 volts.
py by
co Vo
by lksw
cted agen
The auxiliary heater does not start if the glow plug for heater -Q9-
Prote AG.
is defective.
The speed-controlled combustion air blower -V6- is permanently
monitored. The malfunction shut-off takes place in the event of a
fault if it does not start or becomes blocked.
Check the following in case of a sooty flame: eliminate obstacles
to the combustion air supply and in the exhaust gas pipe. Check
the quantity delivered by the metering pump -V54- , renew it if
necessary. Clean deposits off the heat exchanger for the auxiliary
heater, replace if necessary.

Sharan 1996 ➤
4.29 Start sequence

AG. Volkswagen AG d
agen oes
4.29.1 Pin assignment for 8-pin connector (T8i) by
Volksw not
gu
ara
on heater unit (harness end) ed
ris nte
ho eo
aut ra
1 - Terminal 30 ss c
ce
e
nl
pt
2 - Terminal 31
du
an
itte
y li
erm
6 - Ambient temperature switch -F38- (TDI only)
ab
ility
ot p
7 - Pre-selection clock -E111-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.29.2 Start signals
rrectness of i
♦ Terminal 30 from 2nd battery
l purpos
♦ “Heater on” signal from pre-selection clock -E111-
nform
ercia
♦ Temperature at coolant temperature sender for heater -G241-

below approx. 77 °C
m
at
om
io
♦ Temperature at ambient temperature switch -F38- below ap‐
n
c
in t
or
prox. 10 °C (TDI only)
his
ate
do
priv
cum
for
Note
en
ng
t.
yi Co
Cop py
t. rig
If the temperature at the flame monitor -G64- is greater than 70 ° gh ht
yri by
C, it will be cooled for 4 minutes at a higher blower speed. Then
op Vo
by c lksw
the unit will start.
cted agen
Prote AG.

heater control unit -J162- within 130 seconds after the heating
has switched on, that the flame is burning normally. If this not the
case then the heater unit will automatically attempt a second start.
If, after the second start, the flame still does not burn normally,
the heater will remain switched off until the auxiliary heater is
switched on again.
50% of fuel (reduced pulse frequency).
♦ The coolant temperature sender for heater -G241- or the over‐
heating sensor -G189- detects a temperature above 125 °C.
♦ There is a temperature difference of more than 15 °C between
the coolant temperature sender for heater -G241- and the
overheating sensor -G189- .
♦ The heater control unit -J162- detects a fault; read out the fault
memory using the vehicle diagnosis, testing and information
system -VAS 5051A- .

Sharan 1996 ➤
5 Auxiliary heater -D5Z- F, vehicles

05.2004 ▸
5.1 Repairing auxiliary heater -D5Z- F

The external components, sensors and actuators are identical
with the auxiliary heaters -B5W- S / -D5W- S.
– Repairing auxiliary heater -D5Z- F ⇒ page 53
5.2 Removing ambient temperature switch -

F38-
Removing ambient temperature switch -F38- ⇒ page 55

Removing circulation pump -V55- ⇒ page 55

– Removing and installing exhaust system ⇒ page 56 .

without Climatronic
. Volkswage
The external components, gen AG and actuators
wasensors
n AG d
oesare identical
olks-B5W- S / -D5W- S.
with the auxiliary heaters
V
not
gu
by d a ran
ise
– Road test ufor
tho auxiliary heater in vehicle without Climatronic
r tee
or
⇒ page s58
s a ac
ce
le

un
pt
an
d
itte
with Climatronic
y li
rm
ab
pe
ility

ot
wit
, is n

h re
hole
spec
– Road test for auxiliary heater in vehicle with Climatronic

es, in part or in w
⇒ page 60
t to the co
5.7 Removing and installing heater unit

rrectness of i

l purpos
– Removing and installing heater unit ⇒ page 61

nform
ercia

m
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.
5. Auxiliary heater -D5Z- F, vehicles 05.2004 ▸ 83

Sharan 1996 ➤
1 - Bolt M5×80
❑ Qty. 4
❑ 4.5 Nm
2 - Cover for combustion air
blower -V6-
3 - Bolt M4×16
❑ Qty. 4
❑ 2 Nm
4 - Top cover for combustion
air blower -V6-
5 - Combustion air blower -V6- AG. Volkswagen AG d
agen oes
❑ Replacing ⇒ page 87 . olksw not
byV gu
ara
d
❑ Do not dismantle further orise nte
eo
h
ut ra
6 - Glow plug for heater -Q9- ss a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
brass wire brush (spark
wit
is n
plug brush).
h re
ole,
❑ Checking under rated
spec
voltage of 8 V
t to the co
7 - Combustion chamber
rrectne
brush (spark plug
brush).
ss o
cial p
f in
form
mer
different.
atio
om
n
c
i
or
n thi
e
t
sd
iva
o
pr
9 - Wiring harness cum

r
fo
en
ng
t.
yi
Pin assignment:
Co
op py
♦ Combustion air blower -V6- : chamber 14 - brown, chamber 13 - black.
. C rig
ht ht
rig by
py
♦ Flame monitor -G64- : chamber 2 - brown, chamber 1 - brown.
co Vo
by lksw
cted agen
Prote AG.
♦ Overheating sensor -G189- : chamber 10 - black, chamber 11 - black.
♦ Coolant temperature sender for heater -G241- : chamber 7 - white, chamber 8 - white.
♦ Glow plug for heater -Q9- : chamber 3 - brown, chamber 6 - white.
10 - Bolt M4×16
❑ Qty. 4
❑ 2 Nm
11 - Cover for heater control unit -J162- .

Sharan 1996 ➤
14 - 2-pin connector
❑ To circulation pump -V55- .
wage heater
❑ Only for vehicles with auxiliary es n
olks o V t gu
by ara
15 - 4-pin connector rised nte
tho eo
❑ From vehicles auwiring harness ra
c
s
❑ Only for vehicles with auxiliary heater
ce
e
nl
pt
du
an
16 - 8-pin connector
itte
y li
erm
ab
❑ To heater control unit -J162-
ility
ot p
wit
17 - Water jacket
, is n
h re
hole
spec
es, in part or in w
18 - Heat exchanger
t to the co
❑ Note installation position ⇒ page 85 .
rrectness of i
l purpos
19 - O-ring
❑ Renew
nform
ercia
❑ Moisten with coolant additive G12 when installing.

m
at
om
20 - Seal
ion
c
in t
r

o
his
ate
do
riv

p
cum
or
f
en
ng
t.
yi Co
❑ Checking ⇒ page 89 Cop py
t. rig
gh ht
yri
22 - Seal p by
o Vo
by c lksw
cted
agen
Prote AG.
23 - Seal

-arrows- engages.


Sharan 1996 ➤

– Pull combustion chamber -5- out of heat exchanger -2-.
Volkswa
– Use suitable screwdriver carefullyswtoagpressen AG. heat exchanger
gen AG
doe
-2- through rear water connection Volk (water inlet) -arrow A- outs n
ofot gua
by
water jacket -1- in direction
ir se of -arrow B-.
d ran
te
tho eo
– Before assembling, salways
sa
u
replace O-ring -3- and seal -4-, and ra
c
observe installation position of heat exchanger ⇒ page 85
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
5.10 Removing and installing flame monitor -
spec
es, in part or in w
G64-
t to the co
rrectness of i
5.10.1 Removing
l purpos

♦ Ejection tool -VAS 1978/4-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Press both brown cables for flame monitor -G64- out of cham‐
o
m
f
en
ng
bers 1 and 2 of 14-pin connector housing to heater control unit

t.
yi Co
op
-J162- .
C py
t. rig
gh ht
yri by
– Pull flame monitor -G64- -1- out using standard cable tie. cop Vo
by lksw
cted agen
Prote AG.
5.10.2 Installing
– Fit new graphite seal -2- on flame monitor -G64- -1-.
Note
The finless side of the graphite seal -2- must point towards the
collar of flame monitor -G64- -1-.
– Insert flame monitor -G64- in groove -3-.
Caution
The sealing surfaces could get damaged.

This can cause the heater unit to malfunction.
Do not use any other sharp-edged tools.

Sharan 1996 ➤
– Press graphite seal in direction of -arrow- using screwdriver.

– Press glow plug wiring out of 14-pin connector housing to
heater control unit -J162- , chambers 3 and 6, using ejection
tool -VAS 1978/4- .
– Remove glow plug for heater -Q9- .
– When installing, pay attention to position of seal -1- on cables
to glow plug for heater -Q9- .
– Lock white cable in chamber 6 and brown cable in chamber 3
of 14-pin connector housing to heater control unit -J162- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte

y li
erm
ab
ility

ot p
wit
is n

h re
ole,
spec
– Remove cover for combustion air blower -V6-

⇒ Item 4 (page 84) .

t to the co
– Disconnect connector to heater control unit -J162- -2-.

rrectne
– Remove bolts from heater control unit -J162- -1-.

– Carefully remove control unit -3-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required Prote
cted AG.
agen

Sharan 1996 ➤
AG. Volkswagen AG d
♦ Ejection tool -VAS 1978/4- ksw
agen oes
not
Vol
y gu
Before beginning repair work, perform the following ise
djobs:
b ara
nte
or eo
h
– Remove heater unit ⇒ page 83 . s aut ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Press brown cables for flame monitor -G64- out of chambers 1
, is n
h re
and 2 of 14-pin connector housing to heater control unit - hole
J162- .
spec
es, in part or in w
t to the co
– Press black cable out of chamber 13 of 14-pin connector
housing to heater control unit -J162- .
– Press brown cable out of chamber 14 of 14-pin connector
rrectness of i
housing to heater control unit -J162- .
l purpos
– Remove Torx screws -1- from combustion air blower -V6- .

– Remove combustion air blower -V6- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Press black cables out of chambers 10 and 11 of 14-pin con‐
nector housing to heater control unit -J162- .
– Unscrew Torx screw -1- and remove retaining clip.
– Pull overheating sensor -G189- -1- out.

for heater -G241-

Sharan 1996 ➤

– Press white cables out of chambers 7 and 8 of 14-pin con‐
nector housing to heater control unit -J162- .
– Unscrew Torx screw -1- and remove retaining clip.
– Pull coolant temperature sender for heater -G241- -1- out.
5.16 Checking
swa
gen flame monitor
AG. Volkswagen AG
doe-G64-
s
k not
Vol g
Before beginning
se
d b repair work, perform the following
y ua jobs:
ran
i tee
th heater unit ⇒ page 83 . or
– Remove
au
or
ac
ss
ce
e
nl
pt
du

an
itte
y li
erm
ab
– Pull connector housing -2- off heater control unit -J162- -3 -.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio

om
brown cables.
n in
or c
thi
e
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
ht
Evaluation:
rig by
copy Vo
by lksw
cted
agen
Prote AG.


Sharan 1996 ➤
– Pull connector housing -2- off heater control unit -J162- -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
black cables.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Evaluation:
rrectness of i
l purpos
nform
ercia

m
at
om
io
for heater -G241-

n
c
in t
or
his
ate

do
priv
cum
or

f
en
ng
t.
yi Co
op
– Pull connector housing -2- off heater control unit -J162- -3-. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

white cables.
Evaluation:
♦ Defective > approx. 2M Ω = open circuit

AG. Volkswagen AG d
Sharan 1996 ➤
sw agen
Supplementary heatingoe-s Edition 06.2007
olk not g
yV ua
db ran
ir se
5.19 Checking ambient temperature switch - autho tee
or
ac
F38- ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Checking ambient temperature switch -F38- ⇒ page 70
ot
wit
, is n
h re
5.20 Connecting auxiliary heater -D5Z- F to
hole
spec
coolant circuit
es, in part or in w
t to the co
Connecting auxiliary heater -D5Z- F to the coolant circuit is the
same as for auxiliary heaters -B5W- S / -D5W- S ⇒ page 72 .
rrectness of i
l purpos
2nd heat exchanger
nform
ercia
In the case of auxiliary heater -D5Z- F, the coolant hose routing

in vehicles with a 2nd heat exchanger is the same as for auxiliary
m
a
heaters -B5W- S / -D5W- S ⇒ page 75 .
com
tion in
r

te o
thi
s
iva
auxiliary heater -D5Z- F
do
r
rp
cum
fo
en
g
Bleeding the coolant circuit in vehicles with auxiliary heater -D5Z-

n
t.
yi Co
op
F is the same as for auxiliary heater -B5W- S, -D5W- S or -D5W- C py
t. rig
Z ⇒ page 76 .
gh ht
pyri by
Vo
co lksw
by
5.23 Fuel supply to auxiliary heater -D5Z- F
cted agen
Prote AG.

with auxiliary heater -B5W- S, -D5W- S or -D5W- Z ⇒ page 76 .

-V54-
– Removing and installing metering pump -V54- ⇒ page 78

– Testing quantity of fuel delivered ⇒ page 79
5.26 Regulation of auxiliary heater -D5Z- F

– Regulation of auxiliary heater ⇒ page 80

Sharan 1996 ➤
AG. Volkswagen AG d
agen
5.27 Start sequence yV
olksw
oes
not
gu
d b ara
e
5.27.1 Pin assignment for 8-pin connector on ris nte
ho eo
ut ra
heater unit (harness end) s a c
s
ce
le
un
pt
1- Terminal 30
an
d
itte
y li
erm
ab
2- Terminal 31
ility
ot p
wit
3- Metering pump -V54- +
is n
h re
ole,
4- Metering pump -V54- -
spec
5- Diagnosis
t to the co
6- Terminal 15
rrectne
7- Alternator D+
8- Diagnosis
ss o
cial p
f i
nform
mer
atio
om
n
c
i
♦ “Ignition on” signal from terminal 15
or
n thi
te
sd
va
♦ “Engine running” signal from alternator D+

i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
o Vo
prox. 10 °C (TDI only) by c lksw
cted agen
Prote AG.
Note
If the temperature at the flame monitor -G64- is greater than 70 °


switched on again.
♦ The coolant temperature sender for heater -G241- or the over‐
heating sensor -G189- detects a temperature above 125 °C.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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
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.

Sharan 1996 ➤
6 Auxiliary heater -D5S- F / -B5S- F,

vehicles 05.2004 ▸
Note
Vehicles with engine code AYL (6 cyl.) are equipped with a vac‐
uum switch for auxiliary heater -F359- . This vacuum switch for
auxiliary heater -F359- switches off the auxiliary heater when
there is no vacuum. The reason for this is that the two pneumatic
valves in the coolant circuit (big / small coolant circuit) are con‐
trolled by vacuum to close them. If there is no vacuum, the
auxiliary heater operates in the big coolant circuit. On starting the
engine, the engine control unit operates with implausible temper‐
ature values and will not let the engine start. The vacuum switch
for auxiliary heater -F359- is located behind the engine control
unit.
6.1 Repairing auxiliary heater -D5S- F / -

B5S- F
Volkswa
The external components, sensors and actuators are
agen
AG.identical
gen AG
does
ksw
with the auxiliary heaters -B5W- S / -D5W-
by V S.
ol not
gu
a d ran
ise
Repairing auxiliary heaters -D5S- F
tho/ -B5S- F ⇒ page 53
r tee
or
u ac
sa
6.2 Removing ambient
s
temperature switch -
ce
le
un
pt
F38-
an
d
itte
y li
rm
ab
pe
ility
with auxiliary heaters -B5W- S / -D5W- S.
ot
wit
, is n
Removing ambient temperature switch -F38- ⇒ page 55 h re

hole
spec
es, in part or in w
t to the co

rrectness of i
Removing circulation pump -V55- ⇒ page 55

l purpos
6.4 Removing pre-selection clock -E111-

nform
ercia

m
a
com
tion in
Removing pre-selection clock -E111- ⇒ page 56

r
te o
thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
with the auxiliary heaters -B5W- S / -D5W- S. t. Cop py
rig
gh ht
Removing and installing exhaust system ⇒ page 56 . yri
p by
o Vo
by c lksw
cted agen
Prote AG.
without Climatronic
Road test for auxiliary heater in vehicle without Climatronic
⇒ page 58

Sharan 1996 ➤

with Climatronic
. Volkswagen AG
does gen AG
Road test for auxiliary
Vol
kswheater in vehicle with Climatronic
a
not
⇒ page 60 ed b y gu
ara
ris nte
tho eo
6.8 ss
au Removing and installing heater unit ra
c
ce
e

nl
pt
du
an
itte
y li
erm
ab
Removing and installing heater unit ⇒ page 61
ility
ot p
wit
, is n
h re
hole
spec
Dismantling and assembling the heater unit is the same as for
es, in part or in w
auxiliary heater -D5Z- F ⇒ page 83 .
t to the co
rrectness of i
with auxiliary heater -D5Z- F.
l purpos
Removing heat exchanger ⇒ page 85
nf
ercia
o
6.11 Removing and installing flame monitor -
rm
m
atio
G64-
om
n in
or c
thi

te
sd
a

iv
o
r
rp
cu
o
Removing and installing flame monitor -G64- ⇒ page 86

f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
– Remove glow plug for heater -Q9- ⇒ page 87 .


– Renew combustion air blower -V6- ⇒ page 87 .

– Remove overheating sensor -G189- ⇒ page 88 .

for heater -G241-
6. Auxiliary heater -D5S- F / -B5S- F, vehicles 05.2004 ▸ 95

Sharan 1996 ➤
– Remove coolant temperature sender for heater -G241-

⇒ page 88 .

– Check flame monitor -G64- ⇒ page 89 .

– Check overheating sensor -G189- ⇒ page 89 . agen
AG. Volkswagen AG d
oes
olksw not
V
6.19 Checking coolant temperature sender by gu
d ara
ise nte
r
for heater -G241- ho eo
aut ra
ss c
ce
le
un
pt
with auxiliary heater -D5S- F / B5S- F.
an
d
itte
y li
erm
ab
– Check coolant temperature sender for heater -G241-
ility
ot p
⇒ page 90 .
wit
is n
h re
6.20 Checking ambient temperature switch -
ole,
spec
F38-
t to the co
rrectne
Checking ambient temperature switch -F38- ⇒ page 70
6.21 Connecting auxiliary heater -D5S- F / -
ss o
cial p
f
B5S- F to coolant circuit
inform
mer
Connecting auxiliary heater -D5S- F / -B5S- F to the coolant circuit
atio
m
is the same as for auxiliary heater -B5W- S / -D5W- S

o
n
c
i
⇒ page 72 .
or
n thi
te
sd
va

i
o
pr
cum
r
fo
2nd heat exchanger en

ng
t.
yi Co
Cop py
In the case of auxiliary heater -D5S- F / -B5S- F, the coolant hose
t. rig
gh ht
yri
routing in vehicles with a 2nd heat exchanger is the same as for p by
o Vo
by c lksw
auxiliary heater -B5W- S / -D5W- S ⇒ page 75 . Prote
cted AG.
agen

auxiliary heater -D5S- F / -B5S- F
Bleeding the coolant circuit in vehicles with auxiliary heater -D5S-
F / -B5S- F is the same as for auxiliary heater -B5W- S, -D5W- S
or -D5W- Z ⇒ page 76 .
6.24 Fuel supply to auxiliary heater -D5S- F /

-B5S- F
with auxiliary heater -B5W- S, -D5W- S or -D5W- Z ⇒ page 76 .

-V54-
Removing and installing metering pump -V54- ⇒ page 78

agen
AG. Volkswagen AG d
oes
Sharan 1996 ➤
olksw Supplementary
not heating - Edition 06.2007
byV gu
ara
ed
ris nte
tho
eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Testing quantity of fuel delivered ⇒ page 79
ility
ot p
wit
6.27 Regulation of auxiliary heater -D5S- F /
, is n
h re
hole
-B5S- F
spec
es, in part or in w
t to the co
Regulation of auxiliary heater ⇒ page 80
rrectness of i
6.28 Start sequence
l purpos
6.28.1 Pin assignment for 8-pin connector on
nform
ercia
heater unit (harness end)

m
at
om
io
1- Terminal 30
n
c
in t
or
his
e
2- Terminal 31
at
do
priv
c
3- Fresh air blower -V2-
um
for
en
ng
t.
yi
4- Metering pump -V54- +
Co
Cop py
ht. rig
5- Diagnosis
rig ht
py by
co Vo
by lksw
cted
6- Criterion for supplementary heating
agen
Prote AG.
7- Pre-selection clock -E111-

8- Diagnosis

1- Circulation pump -V55- signal +
2- Vacant
3- Circulation pump -V55- from onboard power supply +
4- Circulation pump -V55- from onboard power supply -

1- To circulation pump -V55- +
2- To circulation pump -V55- -

♦ “Heater on” signal from pre-selection clock -E111-
6. Auxiliary heater -D5S- F / -B5S- F, vehicles 05.2004 ▸ 97

Sharan 1996 ➤

prox. 10 °C (TDI only)
Note
If the temperature at the flame monitor -G64- is greater than 70 °


switched on again.
♦ The flame monitor -G64- registers that the flame is not burning gen AG. Volkswagen AG d
normally within 130 seconds. Vol
ksw
a oes
not
y gu
db ara
♦ The coolant temperature sender for heater -G241-oor
ris the over‐
e nte
eo
heating sensor -G189- detects a temperature above
auth 125 °C. ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg 00056607220

3 Auxiliary heater -B4W/ D4W-, vehicles ▸ 05.2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 Road test for auxiliary heater in vehicle without Climatronic . . . . . . . . . . . . . . . . . . . . . . . . 31

3.4 Road test for auxiliary heater in vehicle with Climatronic . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.9 Removing heater control unit J162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.20 Checking ambient temperature switch F38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.21 Connecting auxiliary heaters -B5W- S and -D5W- S to coolant circuit . . . . . . . . . . . . . . . . 72

4.26 Removing and installing metering pump V54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.28 Regulation of auxiliary heaters -B5W- S and -D5W- S . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.1 Repairing auxiliary heater -D5Z- F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.2 Removing ambient temperature switch F38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.3 Removing circulation pump V55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.8 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.2 Removing ambient temperature switch F38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.1 Repairing auxiliary heater -D3W- (sup‐

2 Rep. Gr.82 - Supplementary heating

❑ Removing and installing

❑ Securing rear exhaust

❑ Coolant hose routing; cum

❑ Switch position -On- at

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

1. Auxiliary heater -D3W- (supplementary heater), vehicles: ▸ 05.00 3

Removing ambient temperature switch -F38-

In vehicles from model year 10.1998, the wiper motor

Special tools and workshop equipment required

4 Rep. Gr.82 - Supplementary heating

Securing front exhaust pipe to auxiliary heater

– Push exhaust pipe -1- in direction of arrow until it contacts

combustion air blower housing -2-.

1. Auxiliary heater -D3W- (supplementary heater), vehicles: ▸ 05.00 5

Securing rear exhaust pipe eton Asilencer

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

♦ Hose clamps up to 25 mm Ø -3094-

♦ If coolant is in the system, seal coolant hoses using hose

6 Rep. Gr.82 - Supplementary heating

♦ Hose connections are secured

4 - Coolant hose, supply

12 - Self-tapping screw 4.8x16

13 - Coolant hose, return

❑ In vehicles with a 2nd heat exchanger: supply to 2nd heat exchanger

14 - Self-tapping screw 4.8x16

❑ With heater control unit -J162-

❑ Dismantling and assembling ⇒ page 9

1. Auxiliary heater -D3W- (supplementary heater), vehicles: ▸ 05.00 7

Danger of fuel escaping.

Fuel system is under

❑ Pull fuel line off auxiliary heater and seal it.

❑ Disconnect 8-pin connector (T8) from heater control unit.

Danger of burn injuries.

❑ Unfasten silencer on bracket.

8 Rep. Gr.82 - Supplementary heating

Securing intake hose

– Push intake hose -5- in direction of -arrow A- until it makes

contact with auxiliary heater housing -1-.

– Push intake hose through sealing ring -6- into bulkhead