Servicing diesel electric heater -D2L- — VW

Warning!
Always disconnect the battery earth strap before working on the electrical system.
Note:

Before disconnecting battery obtain radio anti-theft coding.
A manufacturer's plate is attached to the heater unit. This plate gives details of heater unit type installed in vehicle => Fig.
1
.

Heater
Removing => Fig.
3
Dismantling and assembling => Page
82-53

Bracket
Temperature control switch -E13-
Removing => Fig.
4
Operation and functions => Fig.
5

Pre-selection clock -E111-
Removing => Fig.
6
Operation and functions => Page
82-17
The pre-selection clock is an optional extra and is not installed in all models

Resistance wire relay -J116-
Under driver's seat in vehicles without rotating seat
Behind lower left B pillar trim in vehicles with rotating seat

Glow plug monitor relay -J195-
Under driver's seat in vehicles without rotating seat
Behind lower left B pillar trim in vehicles with rotating seat

Heater control unit -J65-
Under driver's seat in vehicles without rotating seat
Behind lower left B pillar trim in vehicles with rotating seat, ; removing => Fig.
7
Replacing fuse -S23- => Fig.
8

Fuse box
On lower left B pillar in vehicles with rotating seat
Replacing heater fuse -S62- => Fig.
9
Fuse situated under driver's seat in vehicles without rotating seat

Gasket
Lower elbow
Gasket
Gasket
Vent upper part
Removing => Fig.
10

Vent lower part
Removing => Fig.
10

Outlet duct
Removing => Fig.
11

Intake duct
Removing => Fig.
11

Intake hose
Removing => Fig.
11

Fuel pump -G23-
Dismantling => Fig.
13
Checking installation position => Fig.
14
Checking fuel quantity delivered => Fig.
15

Combustion air intake connection
Removing => Fig.
11

Combustion air intake hose
Removing => Fig.
11

Combustion air pipe connection
Removing => Fig.
11

Exhaust pipe
From chassis No. 70 ZNH 057 927 a lengthened two piece exhaust pipe is installed

Removing and installing => Fig.
12

Clip
Bracket

Fig.1
Manufacturer's plate

Notes:

Only D2L version 25 172 501 is installed during manufacture in Transporter 1991▸ .
Enter date of first use on lower part of manufacturer's plate.
The heat exchanger can be used for 10 years and must then be replaced after date has expired =>Fig.
2
.
Diesel electric heater with other version numbers are repaired by authorized Eberspächer workshops.

Fig.2
Manufacturer's plate "original replacement part"

Note:

After installing a new heat exchanger the replacement part manufacturer's plate is to be attached by the original manufacturer's plate and the initial use date entered.

Fig.3
Removing heater unit

Remove lower left B pillar trim

=> General body repairs, camper equipment; Repair group 75
General body repairs, camper equipment

Disconnect connectors -T10- and -T1a- behind lower left B pillar trim.
Remove earth connection from earth point (34) behind lower left B pillar trim.
Remove intake hose -4- on heater unit -6-.
Pull wiring loom out of intake hose.
Remove outlet duct -5- on heater unit.
Pull combustion air intake connection -3- off heater unit.
Pull fuel line -2- between fuel pump and heater unit off.
Disconnect exhaust pipe -1-.
Remove four hexagon bolts -arrows-, push heater unit forwards and take out.

Fig.4
Removing temperature control switch -E13-

Carefully lever temperature control switch out from trim with a screwdriver -arrows-.
Pull connectors off.

Fig.5
Temperature control switch -E13-,

Operation and functions

1 - Temperature control switch -E13-

The heater starts at maximum heater output. After completion of the glow phase the heater will regulate to the temperature control switch settings. If the interior temperature is lower than the set values, then the heater will operate at maximum output. If the specifications are exceeded then the heater will operate at a reduced heater output (part load).

2 - Heater switch -E16-

Switch position · Function
left · ventilating
centre · off
right · heating

3 - In-operation lamp (green) -K89-

Lights up during heating and ventilation operations but not during run-on.
Light intensity signals:
bright: max. heater output
darker: reduced heater output, ventilating

4 - Malfunctions lamp (red) -K88-

Flashes if malfunctioning (overheating), extinguished, after rectifying fault by switching off and on again.

Fig.6
Removing pre-selection clock -E111-

Carefully lever pre-selection clock out from trim with a screwdriver -arrows-.
Pull connector off.

Fig.7
Removing heater control unit -J65-

Remove left lower B pillar trim

=> General body repairs, camper equipment; Repair group 75
General body repairs, camper equipment

Pull control unit -1- upwards in direction of arrow.
Pull connectors -2- off.

Fig.8
Replacing fuse -S23-

1 -
Combustion, fresh and heated air blower fuse -V81-

Note:

The control unit has an electronic low and excess voltage protection. If the operating voltage is less than 10.2 V or over 15 V for longer than 20 seconds then the control unit will switch the heater off.

Fig.9
Replacing heater fuse -S62-

The heater fuse -S62- (-1-) is located in the fuse box on the lower left B pillar.
Use a 25 A fuse.

Fig.10
Removing vent

1 -
Vent, upper part
2 -
Vent, lower part
3 -
Outlet duct

Remove vent upper part screws.
Release retainer -arrow- using a screwdriver and take off vent upper part.
Remove vent lower part.

Fig.11
Removing intake hose, outlet duct and combustion air hose

1 - Combustion air pipe connection

Pull off.

2 - Combustion air hose

3 - Combustion air intake connection

Unclip from cross-member and then screw out of combustion air hose.

4 - Outlet duct

Unclip from floor panel and pull off heater unit; first remove vent upper and lower part (in passenger compartment).

5 - Intake hose

Disconnect connectors -T10- and -T1a- behind lower left B pillar trim.
Remove earth connection from earth point (34) behind lower left B pillar trim.
Loosen intake air hose clip and pull intake hose off.

Pull wiring loom out of intake duct and intake hose.

6 - Intake duct

Disconnect connectors -T10- and -T1a- behind lower left B pillar trim.
Remove earth connection from earth point (34) behind lower left B pillar trim.
Loosen intake air hose clip and pull intake hose off.
Pull wiring loom out of intake duct.
Remove screws -arrows- and take out intake duct.

Fig.12
Removing and installing exhaust pipe

1 -
Front exhaust pipe
2 -
Bracket
3 -
Clip
4 -
Combi bolt M6x15
5 -
Rear exhaust pipe
6 -
Self-tapping screw

Fig.13
Dismantling fuel pump -G23-

1 -
Fuel pump
2 -
Strainer
3 -
Hose connection

Fig.14
Checking fuel pump installation position

Positioned 15° to 90°

Fig.15
Checking fuel quantity delivered

Check prerequisites:

Intake and outlet ducts are not blocked.
Combustion air and exhaust system is not blocked.
A voltage of between 11 V and 13 V exists between control unit -J65- contacts 3 and 4.

Note:

During measurements hold measuring container at a height of glow plug.

Checking:

Select DC measurement range 20 V on hand multimeter V.A.G 1526 A.
Connect test probes to control unit -J65- contacts 3 (-) and contact 4 (+).
Place fuel line in measurement container (10 ml - 25 ml).
Switch heater on.

Bleed fuel hose.
Switch heater off and empty measurement container.
Switch heater on again.
As soon as fuel is delivered start stop watch.
Read off voltage figures on hand multimeter V.A.G 1526 A.
Switch heater off after one minute.
Read off fuel delivered and compare measured value with diagram.

The quantity of fuel delivered is OK if the measured values lie within the hatched area of the diagram.