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Workshop Manual Service

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1. T91 remote control gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note On replacement pay attention to the correct version different models for petrol and diesel as well as for the different types of remote control gt page 84 and Electronic parts catalogue The auxiliary additional heater is fitted with the following electrical components Combustion air blower V6 Glow plug with flame monitor Q8 Overheating fuse S24 Supplementary heater control unit J364 Temperature sensor G18 9 Combustion air blower V6 14 Q Checking gt page 70 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Q Removing and installing 2 page 87 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 10 Heater coolant shutoff valve N279 m Q m Q Actuated in auxiliary heater mode by additional heater control unit J364 Removing and installing 2 page 58 Checking wiring gt page 34 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Operation gt page 112 Hz Currently only fitted to vehicles with Auxiliary heater optional extra Not fitted on vehicles with diesel engine on which auxiliary adal tional heater is only used as ad ditional heater
2. After removing and installing fuel system components the f el pipe to the metering pump V54 is to be filled with fuel and the auxiliary supplementary heater then switched on and operat ed at full load for at least 10 minutes to ensure complete bleeding of the fuel pipe gt page 25 6 2 1 Diverting fuel from fuel tank Fuel for auxiliary additional heater is drawn out of fuel tank via connection A and riser B 4 Note Riser B is attached to fuel delivery unit item C This en sures that auxiliary additional heater operation can still be maintained even if fuel tank is nearly empty To stop any deposits on the bottom of the fuel tank being drawn in by the auxiliary supplementary heater metering pump V54 the riser B ends above the bottom of the tank To prevent fuel tank from emptying completely in auxiliary heater mode auxiliary heater is no longer activated if fuel gauge control unit in dash panel insert J285 is in red zone If the auxiliary additional heater functions correctly when the fuel tank is completely full and problems are encountered if the tank is only partially full fault message No flame or Repea ted flame interruption this is an indication of incorrect routing of suction pipe B f fuel tank is less than 15 full and vehicle is parked for ex ample in an underground garage such that the lowest point of the vehicle is at front left it is possible that no more fuel w
3. control unit defective fault Additional heater control unit J364 is interlocked and the following procedure is required If the fault Control unit defective occurs deactivation of the auxiliary supplementary heater on account of excessive cool ant temperature coolant temperature higher than 125 C for a certain time or briefly higher than 135 C bleed the coolant circuit and check the incorporation of the auxiliary supplemen tary heater into the coolant circuit Ifthe fault Repeated flame interruption occurs check the fuel supply to the auxiliary supplementary heater Perform adaption of the auxiliary supplementary heater to cancel the interlock gt Guided fault finding function of ve hicle diagnostic testing and information system VAS 5051 Erase the fault memory gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Check operation of the auxiliary supplementary heater ees Audi A8 2003 gt 00 1 Servicing auxiliary additional heater 3 COLD Audi A8 2003 gt Auo1 Auxiliary Heater Edition 03 2008 1 2 2 General information on auxiliary supple mentary heater Webasto mcm C C Thermosysteme GmbH 021232 HEIZGERAT Typ Thermo Top Z C D Spannung El Leistung Warmestrom skw Brennstoff zul Betriebs berdruck 25bar Brvizeichen O i ident Nr 98088B Aust 58 Fabr Nr 1F 756821 Inbetriebnahmeja
4. Air in the auxiliary supplementary heater fuel supply can lead to problems n auxiliary supplementary heater operation To stop air being drawn in by the metering pump V54 and con veyed to the auxiliary supplementary heater when the auxili ary supplementary heater is first switched on after working on the fuel tank or fuel delivery unit the fuel diversion pipe is to be filled with fuel bled after working in this area gt page 25 After removing and installing fuel system components the auxiliary supplementary heater is to be switched on and op erated at full load for at least 10 minutes to ensure complete bleeding of the fuel pipe Vehicles with and without auxiliary supplementary heater have different fuel delivery units fitted in the fuel tank gt Fuel supply system Rep Gr 20and gt Electronic parts catalogue The following ar prerequisites for operation of auxiliary additiori al heater No air in the fuel pipe to the auxiliary supplementary heater Fuel pipe flush with bottom of vehicle and routed to protect against mechanical damage Fuel pipe to auxiliary additional heater is protected against heat generation which could affect operation Fuel pipe does not come into contact with hot vehicle compo nents 6 Diverting fuel for auxiliary additional heater 23 C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 1 Fuel delivery unit with con nection for diverting fuel for a
5. Control sequence Possible cause of deviation Continuation of sequence fol nM MM MM MEME MEM T c MINI Auxiliary heater Shutoff signal from front op erating and display unit Cli matronic control unit J255 via data bus system setting is made on MMI Shutoff signal from radio re ceiver R64 Additional heater Shutoff signal from front op erating and display unit Cli matronic control unit J255 interrogation via data bus system Shutoff signalfrom Vehicle diagnostic testing and infor mation system VAS 5051 A via basic setting function dj Note In auxiliary heating mode auxiliary additional heater is de activated automatically after max 60 minutes b y MMI or by operating and display unit Climatronic control unit J255 Auxiliary heater auxiliary ventilation operating time is set on MMI Multi Media Interface f heater is in control interval when switched off it cuts out without burn off and run on Burn off run on sequence gt page 110 Control sequence Possible cause of deviation Continuation of sequence fol a ee deviation IBum off a SE off Monitoring as for no 2 gt page 103 gt page 103 Metering pump V54 off Circulation pump V55 off Actuation of front operating and display unit Climatronic control unit J255 off Actuation of combustion air blower V6 at regulated volt age Actuation of glow plug with flame monitor Q8 post glow
6. The temperature sensor for the coolant temperature in the heater is permanently installed in the additional heater con trol unit J364 cannot be checked or removed Auxilary additional heater is switched on and off via data bus system by MMI Multi Media Interface or front operating and display unit Climatronic control unit J255 f auxiliary heating auxiliary ventilation function has been set via Timer function in MMI Multi Media Interface or if auxili ary heating auxiliary ventilation is activated via remote control air conditioner front operating and display unit Climatronic control unit J255 determines on thecbasis of set specified temperatures and measured actual temperature whether auxiliary heater is switched on or only auxiliary ventilation function is activated On vehicles in which auxiliary additional heater is actuated as additional heater currently only vehicles with diesel engine actuation is implemented by air conditioner front control and display unit Climatronic control unit J255 via data bus sys tem if additional heating output is required to attain set tem perature in passenger compartment This Supplementary heating function can be deactivated by the driver via the MMI f no additional heat output is required Heater may remain in full load part load operation control mode or control interval for lengthy periods depending on amount of heat generated
7. Climatronic control unit J255 on aux iliary heater only As soon as coolant temper ature exceeds 30 C 13 Functional description of auxiliary additional heater 1 03 WOW Audi A8 2003 gt Auol Auxiliary Heater Edition 03 2008 Actuation of glow plug with of glow plug with flame monitor Q8 regula ted Actuation of combustion air blower V6 regulated Actuation of metering pump V54 regulated Actuation of coolant shutoff valve N279 regulated auxiliary heater only Stabilisation time dj Note Sta Start of full load heating Switching of glow plug with flame monitor Q8 from glow plug to flame monitor Interrogation of resistance of glow plug with flame monitor Q8 remains hot sequence page 109 Resistance of glow plug with glow plug wih page103 flame monitor Q8 outside specified range Resistance of glow plug with flame monitor Q8 outside specified range even after start repetition Actuation of circulation pump V55 is governed by encoding and adaption Actuation of heater coolant shutoff valve N279 is tempera ture dependent gt page 112 Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation deviation 4 Full load heating max heating load heating max heating output Monitoring as for no 2 4 Note Voltage at heater remains in excess of that required
8. Connectors are released by pressing them towards compo nent and releasing catch whilst pressing connector e g pull on tab Connector C to heater coolant shutoff valve N279 is only fitted on vehicles with auxiliary additional heater Release clip A hexagon nut on exhaust silencer B e g on vehicles with 6 cyl or 8 cyl petrol engine and bolt on exhaust silencer gt page 82 Remove hexagon nut C accessible from wheel housing and detach together with corresponding washer 4 Note Illustration shows exhaust system for auxiliary heater in vehi cle with 8 cyl petrol engine For other engines exhaust sys tem arrangement differs from this illustration Bonded rubber element D remains installed Detach fuel pipe A from auxiliary additional heater and seal off pipe Remove bolts B e 9 Removing and installing auxiliary additional heater 67 ID Audi A8 2003 gt Au Auxiliary Heater Edition 03 2008 4 Note Illustration shows auxiliary heater in vehicle with 8 cyl petrol engine For other engines arrangement may differ from this illustration nstead of bolts B and rubber elements C hexagon nuts and bonded rubber elements may be fitted Remove auxiliary additional heater Installing Install in reverse order paying attention to the following Webasto mom C C Thermosysteme GmbH 021232 HEIZGER T Typ Thermo Top Z C
9. No interruption of heating Coolant temperature increa ses and reaches 75 C 2 page 103 Voltage drops below speci fied cut out voltage Flame goes out Coolant temperature re mains below 75 C Full and partial load operation sequence s page 09 1 04 Rep Gr 82 Auxiliary heating Terminatien of starting pro cedure 1 x repeated start ing 2 page 103 Terminatien of starting pro cedure entry in fault memo ry fault off 2 page 103 Burn off entry in fault mem ory fault off Burn off and re start gt page 103 Heater remains in full load mode until switched off Audi A8 2003 gt GANN Auxiliary Heater Edition 03 2008 Auer Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation Part load heating approx 50 load heating approx 500 000 ooo of heating output Monitoring as for no 4 gt page 104 2 page 104 Actuation of metering pump Coolant temperature re Heater remains in part load V54 with reduced clock fre mains between 73 and 81 C operation until switched off quency Actuation of combustion air blower V6 at reduced volt age Coolant temperature drops Switching from part load to below 73 C full load operation gt page 104 Coolant temperature increa ses and reaches 81 C gt page 105 E ci Full and partial load operation sequence page 109 Control sequence Possible cause of deviat
10. e g vehicles with 6 cyl or 8 cyl petrol engine On vehicles with e g 6 cyl or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine check the tailpipe C on installing the noise insulation It must be positioned centrally in the opening of the noise insulation B to permit stress free fitting of the rubber grommet A Check position of air intake and intake air silencer of auxiliary additional heater unimpeded air intake must be possible After installing auxiliary additional heater perform following checks make following settings depending on repair work per formede lt c Guided fault finding function ofvehicle diagnostic testing and information system VAS 5051 Check or enter the encoding of the supplementary heater con trol unit J364 Interrogate the adaption of the supplementary heater control unit J364 and adapt the supplementary heater control unit J364 if necessary paying attention to possible customer specific settings Use the Adaption function to match any remote control units to the supplementary heater control unit J364 Interrogate the fault memory of the supplementary heater con trol unit J364 and erase any faults displayed Interrogate the adaption of the supplementary heater control unit J364 and if necessary reset the adaption in the adaption channels Pipe filling and Metering pump actuation time in pipe filling function Start the engin
11. 11 Additional heater control unit J364 m Ld Control unit is permanently connected to auxiliary additional heater and cannot currently be replaced as a separate item dismantling and assembling auxiliary additional heater gt page 84 Ifthe auxiliary supplementary heater is replaced together with the supplementary heater control unit J364 check operatiom ofiatdeasttoneshand transmitter and re adapt all hand transmitters if necessary gt page 20 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Checking power supply gt page 34 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 On replacing the auxiliary supplementary heater pay attention to the correct version different models for petrol and diesel as well as the two remote control versions gt page 84 and gt Electronic parts catalogue 12 Auxiliary additional heater exhaust gas outlet Q Outlet of exhaust gas from exhaust pipe must not be impeded e g by parking front end of vehicle over edge of pavement 13 Duplicate auxiliary additional heater rating plate m 14 D Oooo Indicates auxiliary additional heater model in addition to technical data Metering pump V54 Removing and installing gt page 32 Diverting fuel for the auxiliary supplementary heater gt page 23 Checking fuel delivery gt page 27 Checking actuation gt pag
12. 19 Spacer Q Arrangement in exhaust system gt page 83 Q Illustration shows spacer installed in vehicles with 6 cyl diesel engine at start of production Q On vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine not fitted different exhaust routing gt page 76 and gt page 82 20 Insulating sleeve Q Arrangement in exhaust system gt page 83 Q Illustration shows insulating sleeve installed in vehicles with 6 cyl diesel engine at start of production Q For vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine not fitted different exhaust routing gt page 76 and page 82 21 Cable ties Q Arrangement in exhaust system gt page 83 Q Illustration shows cable tie installed in vehicles with 6 cyl diesel engine at start of production Q For vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine not fitted different exhaust routing gt page 76 and page 82 10 Dismantling and assembling auxiliary additional heater 15 CAVV Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 10 2 Removing and installing auxiliary sup plementary heater exhaust system For vehicles with 6 cyl or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine 4 Note For vehicles with 6 cyl diesel engine which built at start of production exhaust system from model year 2004 gradual introduction with d
13. 2 Actuation of glow plug with flame monitor Q8 regula ted Actuation of combustion air blower V6 regulated Actuation of metering pump V54 regulated Stabilisation time 4 Note Start of full or part load heat ing depending on coolant temperature Switching of glow plug with flame monitor Q8 from glow plug to flame monitor Interrogation of resistance of glow plug with flame monitor Q8 remains hot Heating then as for no 4 page 103 Resistance of glow plug with flame monitor Q8 outside specified range Resistance of glow plug with flame monitor Q8 outside specified range also after re peated starting The starting procedure from the control interval corresponds to that on initial activation gt page 109 However as the heater has already attained operating temperature the times for the various sequences differ trom those on initial activation e g pre heating 20 instead of 40 sec fuel conveyed for 30 instead of 56 sec Control sequence Possible cause of deviation Continuation of sequence fol E E E aln Me Terminatien of starting pro cedure 1 x repeated start ing 2 page 103 Terminatien of starting pro cedure entry in fault memo ry fault off 9 jSwilhoff tm respet io the conecness of information in tis document Copyright by AUDI AG 1 06 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer
14. B Spannung El Leistung 12V 40W W rmestrom Brennstott C Benzin zul Betriebs berdruck Pr fzeichen WR S292 Ident Nr 98088B Ausf 58 Fabr Nr 1F 756821 Inbetriebnahmejahr 2001 2002 2003 68 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Different auxiliary supplementary heater versions are availa ble Heed the exact assignment when replacing an auxiliary supplementary heater gt page 1 and gt Electronic parts cata logue After installation check exhaust pipe coolant hoses fuel pipe and wires to auxiliary additional heater there must be no con tact with other components Before starting up auxiliary additional heater also prior to start up via Basic setting function bleed coolant circuit 2 page 60 If auxiliary additional heater has been replaced enter year of l AB210040 initial commissioning for newly installed heater on rating plate of heater and on new duplicate rating plate illustration shows rating plate for auxiliary heater in vehicle with petrol engine Check installation position of brackets spacers on corrugated exhaust pipe they must be attached such they prevent pipe contact with other components When installing the noise insulation check exhaust tailpipe A of auxiliary additional heater it must be positioned so that it can be secured to the noise insulation B without pretension
15. C and corresponding glow plug with flame monitor Q8 have also been modified gt page 87 Remove auxiliary additional heater gt page 64 Detach add on components from auxiliary additional heater gt page 73 and gt page 76 Detach cover for connector console and detach connector for combustion air blower from connector console gt page 86 Remove bolts A Detach combustion air blower B from heater unit E 4 Note Before fitting combustion air blower replace moulded gasket between combustion air blower and heater When inserting the fuel pipe C ensure that grommet D is properly seated in combustion air blower B 10 14 Removing and installing burner element Remove combustion air blower V6 gt page 87 Remove bolts A Pull burner element B with glow plug with flame monitor Q8 upwards out of heater unit C 10 Dismantling and assembling auxiliary additional heater 87 TI Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 4 Note Before installing burner element replace moulded gasket be tween burner element and heater Remove glow plug with flame monitor Q8 gt page 88 f burner element is defective also replace glow plug with flame monitor Q8 Problems with auxiliary additional heater operation may be encountered in cold weather on vehicles with diesel engines using predominantly vegetable oil or rape
16. Electronic parts catalogue Q The Telestart T90 T91 version can be deactivated by the supplementary heater control unit J364 thus reducing the no load current input Q In the case of auxiliary supplementary heaters with a supplementary heater control unit J364 with data level 0250 hardware software version the fault Link with remote control implausible signal may erroneously be displayed If applicable check the encoding of the supplementary heater control unit J364 and operation of the remote control If no fault is found erase the fault memory this fault then has no influence on operation of the auxiliary supplementary heater Q Adaption of the remote control receiver version is to be performed in the supplementary heater control unit J364 Adaption function gt Guided fault finding function of vehicle diagnostic testing and in formation system VAS 5051 Q If auxiliary heater is switched off due to undervoltage of energy management control unit J644 in ve hicles fitted with Telestart T70 receiver additional heater control unit J364 additionally stores fault No auxiliary heating radio receiver communication 12 Block diagram of auxiliary additional heater actuation with remote control 95 11 Audi A8 2003 gt Au o Auxiliary Heater Edition 03 2008 Q Checking signals from the remote control receiver for auxiliary heater
17. N279 Q Actuated in auxiliary heating mode by additional heater control unit J364 gt page 112 Q Removing and installing gt page 58 80 Rep Gr 82 Auxiliary heating Audi A8 2003 gt GAN Auxiliary Heater Edition 03 2008 Aue 12 Washer 13 Hexagon nut 14 Clamp 15 Coolant hose 16 Hexagon bolt 17 Hexagon bolt Q Special bolt with self tapping thread 18 Bolt clip 19 Coolant pipe 10 4 Attaching intake hose with intake air si lencer 1 Note Intake hose A is attached to the intake air silencer B To facilitate fitting and attachment of intake hose A with clamp to auxiliary additional heater intake pipe two cuts of approx 10 mm each can be made dimension X using side cutting pliers 10 5 Attaching bracket for auxiliary additional heater with bonded rubber element Hexagon combi nut with washer B Bonded rubber element C CUR Bonded rubber element C is bolted to brace D and remains in vehicle when removing auxiliary adaditional heater Tolerance equalisation between vehicle and bracket is ach ieved via oversize hole for threaded pin of bonded rubber element in bracket A ies 10 Dismantling and assembling auxiliary additional heater 81 C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 10 6 Types of bracket for auxiliary additional heater 4 Note Bracket A is installed in vehicles with 6 cyl or 8 cyl pet
18. T90 type In Model Year 2008 production is gradually being switched from the Teles art T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue MWith the Telestart T9054 191 remote con trol receivers the supplementary heater controbuniti J364 provides feedback to the remote control hand transmitter To enable the auxiliary supplementary heater to implement the additional functions of the Telestart T90 T91 feedback of confirmation of reception of activation and deactivation sig nals use is made of a modified remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with index J as of hardware and software number 07 10 the auxiliary supplementary heater is designed for the Telestart T90 T91 remote control The auxiliary supple mentary heater must however have been adapted accordingly by way of the Adaption function gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Whentransmitting hold radio remote control with transmission aerial upwards On pressing remote control hand transmitter buttons ensure sufficient distance from vehicle aerial problems with reception may be encountered if radio signal is too strong if necessary cover transmission aerial with hand or maintain minim
19. n auxiliary additional heater and engine and supplied by heat exchangers of air conditioner unit Circulation pump V55 can be activated to assist engine cool ant pump even with auxiliary additional heater switched off page 61 To ensure best possible combustion in heater metering pump V54 clock frequency and combustion air blower V6 volt age are regulated over the entire sequence The temperatures given in the functional sequence and func tion chart are approximate fthe heater has been interlocked fully deactivated on ac count of a fault e g flame interruption or overheating it cannot be re activated until the fault memory has been read out the content of the fault memory erased and depending on the cause of the trouble the interlock cancelled by way of the Adaption function gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 ffirst attempted start does not produce a flame additional heater control unit J364 terminates sequence and attempts another start after any combustion residue has been blown out with combustion air blower V6 Additional heater control unit prium is deactivated if repeated starting also fails to produce a flame fthe heater is to be switched off during the start procedure the instantaneous position reached in the start sequence gov erns whether the heater is switched off immediately or whether run on
20. page 44 fvalue displayed by CO2 measuring instrument fluctuates slightly calculate mean value from highest and lowest meas ured values fvalue displayed by CO2 measuring instrument fluctuates considerably more than approx 0 6 depending on measuring instrument check position of probe in exhaust pipe of auxiliary additional heater If the measurement is outside the permitted range Check fresh air intake hose with intake silencer and auxiliary additional heater exhaust system for dirt or cross sectional constriction and clean components concerned replace if nec essary Check fuel delivery for metering pump V54 gt page 27 Ifthe CO2 content of the exhaust gas and the delivery of the metering pump V54 are in the lower specified range replace metering pump V54 gt page 32 If CO2 content in exhaust gas is not OK but fuel delivery is OK Check fresh air intake hose with intake silencer and auxiliary additional heater exhaust system for dirt or cross sectional constriction and clean components concerned replace if nec essary If no fault is found Checkthe combustion air blower V6 2 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Adjust CO2 content in exhaust gas gt page 44 f CO2 content in exhaust gas cannot be adjusted replace combustion air blower V6 gt page 87 If starting problems ar
21. 03 2008 Use the input keypad in the display zone to alter the value for this adaption channel for re adaption of the supplementary heater control unit J364 and thus the CO content in the ex haust gas gt Guided fault finding function of vehicle diag nostic testing and information system VAS 5051 4 Note The CO 2 content of the exhaust gas changes by approx 0 05 by vol per unit higher display value lower CO 2 content or lower display value higher CO 2 content Example Measured CO content in exhaust gas is 8 8 by vol 185 is displayed as adaption value New adaption value 169 for CO2 content in exhaust gas of 9 6 by volume 4 Note fthe CO2 content in the exhaust gas is to be increased a lower value must be entered in the adaption channel the com bustion air blower V6 is actuated at a slightly lower voltage and less air is thus conveyed to the combustion chamber gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 fthe CO2content in the exhaust gas is to be reduced a higher value must be entered in the adaption channel the combus tion air blower V6 is actuated at a higher voltage and more air is conveyed to the auxiliary supplementary heater If the value in the adaption channel is increased by 10 units the CO2 content in the exhaust gas is decreases by approx 0 5 volume If the value in the adaption c
22. Adap tion of a fourth remote control unit causes the first matched remote control to be erased Remote control adaption is performed in auxiliary heating ra dio receiver R64 If this is replaced all remote control units must be consecutively re adapted The auxiliary heater remote control hand transmitter is to be adapted using the Adaption function by way of the supple mentary heater control unit J364 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Should it not be possible to activate the auxiliary heater by way of the remote control check the fuel level in the fuel tank there must be a sufficient amount of fuel and the operating status of the vehicle transpor atiorrmodemustnotbe active 4f these two shut off criteria were recently active e g on a new vehicle it may be necessary to briefly interrupt the power s p ply to the auxiliary heater and the remote control receiver for auxiliary heater R64 to re establish proper operation auxili ary heater reset 20 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 1 11 Auxiliary Heater Edition 03 2008 Auer 5 4 Activating deactivating auxiliary heater auxiliary ventilation via Multi Media In terface MMI 5 4 1 Requirements Auxiliary heater adapted in the front operating and display unit Climatronic control unit J255 checking and performing en coding gt Guided fault finding function
23. R64 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 reading measured value block 4 Note The remote control hand trans mitter is adapted in the remote control receiver for auxiliary heater R64 and not in the sup plementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 The signals from the remote con trol hand transmitter are only re layed by the remote control re ceiver for auxiliary heater R64 The signals are then processed by the supplementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and informa tion system VAS 5057 reading measured value block Depending on vehicle equip ment the remote control receiv er for auxiliary heater R64 may be connected to an additional roof aerial instead of to the aerial in the rear window via the aerial amplifier R24 gt Communica tion Rep Gr 91 4 6 pin connector to auxiliary heating radio receiver R64 m m m Contact 1 Power supply terminal 30 Contact 2 Signal wire to auxiliary additional heater to additional heater control unit J364 Checking output for activation and deactivation signal to the supplementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051
24. Renew Q Different versions with additional holes for lo cating pins gt page 87 and gt Electronic parts cata logue 5 Glow plug with flame moni tor Q8 Q with internal filament sheathed element Q Different versions for at tachment with bolt or clip gt page 88 Q Different design de pending on production period gt page 87 and gt Electronic parts cata logue Q Checking page 70 Q Removing and installing gt page 88 S 7 3 6 Clamp Q For securing glow plug with flame monitor Q8 in burner element Q Removing and installing gt page 88 Q Different versions page 87 and gt Electronic parts catalogue 7 Clip Q For securing wiring for glow plug with flame monitor Q8 to burner element 8 Burner element Different versions for vehicles with petrol or diesel 2 Electronic parts catalogue Different design depending on production period gt page 87 and Electronic parts catalogue m m Q With certain restrictions diesel fuel version can also be designed for auxiliary additional heater operation with vegetable oil or rape oil methylester fuels gt page 5 m m Different methods of attachment of the glow plug with flame monitor Q8 with screw or clip gt page 88 Removing and installing gt page 87 9 Moulded gasket Q Renew 10 Burner housing heat exchanger and additional heater control unit J364 Q Do not dismantle 10 Dismantling and a
25. additional heater operation with vegetable oil or rape oil methylest er fuel only Problems with auxiliary additional heater operation may be en countered in cold weather on vehicles with diesel engines if use is predominantly made of vegetable oil or rape oil methylester as fuel Reason On account of the physical properties deposits may form dur ing operation at the evaporation fabric in the burner element These deposits can then cause combustion problems if the vehicle is run for lengthy periods on vegetable oil or rape oil methylester Ifitis still possible to start auxiliary additional heater such residue can be dissolved and thus eliminated to a certain ex tent via petrol combustion 7 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas 49 05 Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 4 Note f evaporation fabric in burner element is so clogged that no flame can be produced replace burner element gt page 64 Preconditions Fault memory interrogated and any auxiliary additional faults displayed located and eliminated gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Coolant temperature is lower than 30 C at start of test Removing deposits Switch off ignition Remove the cover beneath the fuel filter this illustration shows the layout for vehicles with petrol engine vehicles with
26. be fitted with the version approved for this vehicle gt page 16 and gt Electronic parts catalogue Depending upon decision of front operating and display unit Cli ma tronic control unit J255 The front operating and display unit Climatronic control unit J255 starts up without transmitting a request for activation of the auxiliary heater via the convenience data bus system to the supplementary heater control unit J364 auxiliary venti lation mode The front operating and display unit Climatronic control unit J255 transmits the request for activation of the auxiliary heat er via the convenience data bus system to the supplementary heater control unit J364 Additional heater control unit J364 activates auxiliary heater and as soon as coolant temperature in auxiliary heater exceeds approx 30 C provides feedback to front operating and display unit Climatronic control unit J255 which starts up On vehicles fitted with a remote control receiver for auxiliary heater R64 of the Telestart T90 T91 type the supple mentary heater control unit J364 provides the remote control 94 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer hand transmitter with feedback gt Owner s manual and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 1 Rear window aerial module Q The d
27. control action in auxiliary heater mode gt Guided fault finding function of ve hicle diagnostic testing and information system VAS 5051 for the air conditioner 1 3 Note on operation of auxiliary additional heater in vehicles with diesel engine Problems with auxiliary additional heater operation may be en countered in cold weather usually the only conditions under which auxiliary additional heater is switched on or actuated as 1 Servicing auxiliary additional heater 5 GARD Audi A8 2003 gt Auc Auxiliary Heater Edition 03 2008 additional heater if use is made of vegetable oil or rape oil meth ylester as fuel Reason Dueto the physical properties deposits may form in the aux iliary additional heater combustion chamber burner element gt page 87 during operation with vegetable oil or rape oil methylester These deposits can then cause combustion prob lems if the vehicle is run for lengthy periods on vegetable oil or rape oil methylester no flame formation and deflagration in combustion chamber At low temperatures below 0 C the fluidity of vegetable oil and rape oil methylester deteriorates to a far greater extent than that of diesel fuel thus resulting in a reduced supply of fuel and problems with auxiliary additional heater operation 6 Rep Gr 82 Auxiliary heating ees Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue 2 Safety precautions when working on vehic
28. diesel engine are not fitted with a fuel filter A at this location 2 Fuel supply system Rep Gr 20 Detach the fuel pipe C from the metering pump V54 and seal it with a plug 50 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Pourapprox 1 litre of fuel petrol into container D e g bottle for additional heater VAS 5086 4 Note Container D must contain a riser which reaches to bottom of container There must be an opening in container lid to prevent a vacuum from forming when fuel is removed Attach the container D bottle for supplementary heater VAS 5086 to the vehicle in the area of the metering pump V54 Squeeze the container D until fuel reaches the end of the hose C and then connect the hose C to the metering pump V54 On vehicles with additional heater without Auxiliary heater op tional extra heater without circulation pump V55 Start the engine Set maximum heat output on front operating and display unit Climatronic control unit J255 temperature preselection Hi Open all windows Start supplementary heater self diagnosis and switch on the supplementary heater by way of the Basic setting function vehicles with supplementary heater only no Auxiliary heat er optional extra gt Guided fault finding function of vehicle diagnostic testing and info
29. diesel engine 9 to 12 CO by volume For vehicles with petrol engine 8 to 11 CO2 by volume f new CO2 measured value corresponds to desired setting Switch off auxiliary additional heater Terminate self diagnosis and unplug the diagnostic connector gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note If the auxiliary supplementary heater has been switched on via the Basic setting function it can also be switched off again by way of the Basic setting function gt Guided fault finding func lion of vehicle diagnostic testing and information system VAS 5051 If setting for CO2 content is not achieved within permissible adap tion value range Check fresh air intake hose and auxiliary additional heater ex haust system for dirt or cross sectional constriction and clean relevant components or replace if necessary If no fault is found Check fuel delivery of metering pump V54 gt page 27 Check the combustion air blower V6 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Ifno fault is found and CO2 content in exhaust gas cannot be adjusted dismantle auxiliary additional heater and clean com bustion chamber gt page 84 If there are no major deposits in combustion chamber replace combustion air blower V6 T 3 Removing residue from burner element of auxiliary
30. different remote control versions gt page 84 and Electronic parts catalogue The radio remote control for the auxiliary heater and auxiliary additional heater is available in various versions Exclusive use was made up to 05 2004 of the Telestart T70 remote control version As of 05 2004 the Telestart T90 version was gradually introduced instead In Model Year 2008 production Is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue To enable the auxiliary supple mentary heater to implement the additional functions of the Telestart T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modi fied remote control receiver for auxiliary heater R64 and a moditied auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with index J as of hardware and software number 0710 the auxiliary sup plementary heater is designed for the Telestart T90 T91 remote control gt Electronic parts catalogue and gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5057 Ifthe auxiliary supplementary heater is replaced together with the supplementary heater control unit J364 check opera tion of at least one remote control hand transmitter ifoperation is not OK all hand tr
31. fault memory If a specific fault e g no flame on starting occurs 3 times in succession interlocking is implemented in additional heater control unit J364 This interlock must be cancelled by way of the Adap tion function gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Atstart of production auxiliary additional heater was installed with additional heater control unit J364 with data level less than 0280 hardware and software version The fault Link with remote control implausible signal may erroneously be displayed with these auxiliary supplementary heaters If nec essary check operation of remote control if a fault is found erase fault memory this fault will then have no effect on op eration of auxiliary additional heater Atstart of production auxiliary additional heater was installed with additional heater control unit J364 with data level less than 0280 hardware and software version With these aux iliary additional heaters incorrect control unit installed fault petrol version for vehicle with di sel engine and vice versa can be erroneously displayed If applicable check the assign ment of the supplementary heater control unit J364 display in measured value block If the type of fuel indicated corre sponds to the vehicle erase the fault memory this fault then has no influence on auxiliary supplementary heater operation g
32. in the heater 2 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 It may be necessary to change the adaption in order to erase certain faults which result in interlocking gt Guided fault find ing function of vehicle diagnostic testing and information system VAS 5051 Proceed as follows if the fault Group convenience data bus no communication no link cannot be erased gt Guided fault find ing function of vehicle diagnostic testing and information system VAS 5051 iFirstinterrupt thedinkcbetween the data bus system and the auxiliary supplementary heater unplug the6 pin connector from the supplementary heater control unit J364 for at least one minute gt Current flow diagrams Electrical fault finding and Fitting locations The next step is to unplug the power supply connection of the auxiliary supplementary heater unplug the 2 pin connector from the supplementary heater control unit J364 Then plug first the 2 pin and then the 6 pin connector back in at the sup plementary heater control unit J364 Interrogate the fault memory and erase the fault gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5051 Depending on the version of the supplementary heater control unit J364 certain faults occurring several times in succession cannot be erased immediately e g the repeated flame interrup tion
33. m m As of Model Year 2009 modified front operating and display units Climatronic control unit J255 are being gradually introduced gt Electronic parts catalogue and gt Air conditioning Rep Gr 87 These operating and displa units have for example an button instead of the but ton gt Owner s manual On vehicles with a front operat ing and display unit Climatronic control unit J255 with no set ur button the additional air con ditioner and auxiliary supple mentary heater functions are selected by way of the Multi Me dia Interface MMI terminal gt Owners manual and gt Operat ing instructions for Infotain ment MMI Pay attention to correct assign ment of the front operating and display unit Climatronic control unit J255 to control unit 1 for in formation electronics J794 gt Electronic parts catalogue dif ferent versions In the event of incorrect assignment the variz ous air conditioner and auxiliary supplementary heater functions cannot be displayed in the MMI and selected 1 2 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note As of Model Year 2009 modified front operating and display units Climatronic control unit J255 are being gradually introduced gt Electronic parts catalogue and gt Air conditioning Rep Gr 87 These front operating and dis play units have for example an button ins
34. mode The coolant temperature increases or remains constant The entire coolant drawn in by the circulation pump V55 comes from the air conditioner pump valve unit E The auxiliary supplementary heater is in auxiliary heating full load mode The coolant temperature increases or remains constant and the proportion of the coolant drawn in by the cir culation pump V55 which flows back to the auxiliary supple mentary heater via the engine is regulated by the supplementary heater control unit J364 F All the coolant drawn in by the circulation pump V55 flows back via the engine to the auxiliary supplementary heater The coolant temperature continues to increase less heat is emitted by the air conditioner heat exchangers than is generated by the auxiliary supplementary heater or for example with the engine running G All the coolant drawn in by the circulation pump V55 flows back via the engine to the auxiliary supplementary heater The coolant temperature decreases more heat is emitted by the air conditioner heat exchangers or the engine than is generated by the auxiliary supplementary heater and the engine H The coolant temperature drops below 65 C 1 1 2 Rep Gr 82 Auxiliary heating A Audi A8 2003 gt 10 uxiliary Heater Edition 03 2008 Auer 4 Note Depending on ambient temperature and amount of heat dis sipated by air conditioner heat exchanger heater coolant shutof
35. oil methylester as fuel gt page 5 Check the burner element and replace this as well in the event of a defective glow plug with flame monitor Q8 if deposits have formed in the burner element which affect heater oper ation and cannot be removed with workshop equipment As of 02 2003 modified auxiliary supplementary heaters were gradually introduced gt page 87 These heaters feature a modified burner element C a modified clip B pay attention to correct installation position and an appropriately adapted glow plug with flame monitor Q8 A Observe assignment these components can only be installed together no mixed installation possible gt Electronic parts catalogue Different replacement burner element versions are available for attachment of the glow plug with flame monitor Q8 with a screw or clip Heed the assignment gt page 88 and gt Electronic parts catalogue With certain restrictions diesel fuel versions of burner element can also be designed for auxiliary additional heater operation with vegetable oil or rape oil methylester fuels gt page 5 Re placement burner elements for diesel are available which are not designed for operation of auxiliary additional heater with vegetable oil or rape oil fuels Therefore observe assignment gt Electronic parts catalogue 10 15 Removing and installing glow plug with flame monitor Q8 88 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00
36. pipe in position 6 6 Checking actuation and electrical con nections of auxiliary additional heater Special tools and workshop equipment required Vehicle diagnostic testing and information system VAS 5051 A with multimeter leads VAS 5051 7 probe VAS 5051 8 and current probe 50 A VAS 5051 9 Voltage tester V A G 1527 B Adapter set V A G 1594 C Test conditions All fuses OK as per current flow diagram gt Current flow dia grams Electrical fault finding and Fitting locations Battery A adequately charged Fault memory interrogated and any faults displayed eliminated gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 34 Rep Gr 82 Auxiliary heating ees Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note Electrical check function is not described in this Workshop Manual The Manual merely gives a brief outline of the check ing of individual components Electrical checking is to be performed as described in the gui ded fault finding routine gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 Switch off ignition Move the lock carrier to service position gt General body re pairs exterior Rep Gr 50 Remove the right headlight gt Electrical system Rep Gr 94 6 Diverting fuel for auxiliary additional heater 35 05 Audi A8 2003 gt A
37. pump V55 4 Note Illustration shows auxiliary additional heater as installed e g in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel en gine at start of production For auxiliary additional heaters instal led in vehicles with 6 cyl diesel engine gradual conversion in Model Year 2004 8 cyl diesel engine or 10 or 12 cyl engine the design of the exhaust system Items 8 to 11 and 13 to 19 differs from this illustration gt page 76 10 Dismantling and assembling auxiliary additional heater TT C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 1 Auxiliary additional heater CQ Detaching and re at taching bracket coolant shutoff valve and intake air silencer gt page 80 QO Different design of burn er unit and different con trol unit for vehicles with petrol or diesel engine gt page 84 and gt Electronic parts cata logue 2 Clamp 3 Coolant hose 4 Rubber grommet Q Fitted between circula tion pump and corre sponding bracket 5 Circulation pump V55 Q Wiring to connector con sole 2 page 84 Q bracket must be detach ed from auxiliary addi tional heater to replace circulation pump 6 Bracket L For circulation pump 7 Bolt 8 Snap on nut 9 Tailpipe x m ae thermal insulation 12 11 10 10 Clip 11 Corrugated exhaust pipe Q Different versions gt page 76 and gt page 82 Q Illustration sh
38. reading measured value block If the remote control receiver is in energy saving mode no signal is supplied after on pressing the remote control hand transmitter ON or OFF button gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 reading measured value block Contacts 3 4 and 5 Vacant Contact 6 Earth 5 Wiring to additional heater control unit J364 a Incorporated into vehicle wiring harness gt Current flow diagrams Electrical fault finding and Fitting lo cations 6 Connection to vehicle wiring harness Q Incorporation into vehicle electrical system gt Current flow diagrams Electrical fault finding and Fitting locations 7 6 pin connector to additional heater control unit J364 a 96 Contact 1 Rep Gr 82 Auxiliary heating Auxiliary Heater Edition 03 2008 Aud Q Audi A8 2003 gt 00 Signal wire from remote control receiver for auxiliary heater R64 input for activation and deactivation signal in supplementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 reading measured value block If the remote control receiver is in energy saving mode no signal is supplied after on pressing the remote control hand transmitter ON or OFF button gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 reading measured value
39. t C Temperature of coolant in heater A Commencement of starting coolant temperature in heater must be less than 73 C B Starting C Full load operation D Part load operation E Control interval i F Starting from control interval G Shut off on account of excess temperature 1 Start of full load operation 2 Switchover from full to part load operation 3 Switchover from part load operation to control interval 4 End of control interval 13 Functional description of auxiliary additional heater 1 1 1 WMD Audi A8 2003 gt Avo Auxiliary Heater Edition 03 2008 13 3 1 Heater coolant shutoff valve N279 ac tuation A This proportion of the coolant in is conveyed in the large coolant circuit If coolant shutoff valve N279 is not actuated 100 of cool ant flows in large circuit via engine If coolant shutoff valve N279 is permanently actuated 100 of coolant flows in small circuit directly from pump valve unit to auxiliary additional heater Heater coolant shutoff valve N279 is actuated by additional heater control unit J364 in accordance with coolant temper ature and request set B Temperature of coolant in auxiliary supplementary heater in C C ON signal for auxiliary supplementary heater also as sup plementary heater via data bus system D The auxiliary supplementary heater is in auxiliary heating full load
40. with 6 cyl or 8 cyl diesel engine and 10 or 12 cyl petrol engine Remove the noise insulation General body repairs exterior Rep Gr 63 Remove the front right wheel housing liner gt General body repairs exterior Rep Gr 63 Dissipate the pressure in the coolant circuit by opening the cap at the coolant expansion tank 2 Engine mechanics Rep Gr 19 A82 10040 Ifthe vehicle is fitted with an air cleaner above the auxiliary supplementary heater remove the cleaner together with the air cleaner housing Injection and ignition system Rep Gr 24 and gt Injection and glow plug system Rep Gr 23 Remove the secondary air pump V101 on the appropriate vehicles gt Engine mechanics Rep Gr 26 Move the lock carrier to service position gt General body re pairs exterior Rep Gr 50 9 Removing and installing auxiliary additional heater 65 Y Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 On vehicles with e g 6 cyl or 8 cyl diesel engine and 10 cyl or 12 oyl petrol engine unfasten the clip A and remove the bolts B or D if the holder E is to be removed as well On vehicles with e g 6 cyl or 8 cyl diesel engine and 10 cyl or 12 oyl petrol engine remove the exhaust system C A82 10041 On vehicles with e g 6 cyl or 8 cyl petrol engine release clip A and remove exhaust tailpipe B Remove right headlight
41. 03 2008 10 9 Routing wiring to circulation pump V55 Insert wiring A into groove as shown 10 10 Dismantling and assembling auxiliary 4 Note additional heater On replacing the auxiliary supplementary heater pay attention to the correct version different models for petrol and diesel as well as the different remote control versions gt Electronic parts catalogue and gt Guided fault finding function of vehi cle diagnostic testing and information system VAS 5057 There are different versions of the auxiliary heater remote control and of the auxiliary supplementary heater Exclusive use was made up to 05 2004 of the Telestart T70 remote control version As of 05 2004 the Teles art T90 version was gradually introduced instead In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue To enable the auxiliary supple mentary heater to implement the additional functions of the Telestart T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modi fied remote control receiver for auxiliary heater R64 and a moditied auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with index J as of hardware and software number 0710 the auxiliary sup plementary heater is desi
42. 1 version can be deactivated by the supplementary heater control unit J364 thus reducing the no load current input gt Guided fault finding function of ve hicle diagnostic testing and information system VAS 5057 The no load current input of th remote contro receivers Tel estart T70 and Telestart T90 T91 versions is less than 7 MA the current input increases as soon as a transmission signal is received Remote control hand transmitter adaption is performed in the remote control receiver for auxiliary heater R64 If the re mote control receiver for auxiliary heater R64 is replaced all remote control hand transmitters must be consecutively re adapted gt Guided fault finding function of vehicle diagnos tic testing and information system VAS 5051 Depending on vehicle equipment the remote control receiver for auxiliary heater R64 may be connected to an additional roof aerial instead of to the aerial in the rear window via the aerial amplifier R24 gt Communication Rep Gr 91 and gt Current flow diagrams Electrical fault finding and Fitting lo cations 12 Block diagram of auxiliary additional heater actuation with remote control 99 COLD Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 1 00 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 13 Functional description of auxiliary additional heater 4 Note
43. 5 increases flow of coolant through the air conditioner heat exchanger at low engine speeds and thus improves heat output Circulation pump V55 is activated by additional heater con trol unit J364 as soon as all activation conditions are met To 8 Incorporation of auxiliary additional heater into coolant circuit 61 QU Audi A8 2003 gt Auo1 Auxiliary Heater Edition 03 2008 stop circulation pump being constantly switched on and off it remains activated for at least 30 s even if for example in the event of rapid changes in vehicle speed a request is only applied for several seconds e g on accelerating after stand ing at traffic lights The supplementary heater control unit J364 only switches on the circulation pump V55 if the activation conditions stored in the supplementary heater control unit J364 are satisfied gt Guided fault finding function of vehicle diagnostic testing a oe system VAS 5051 reading measured value ock 62 Rep Gr 82 Auxiliary heating ees Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue 9 Removing and installing auxiliary additional heater 63 TI Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 Removing and installing auxiliary ad ditional heater 4 Note On replacing the auxiliary supplementary heater pay attention to the correct version different models for vehicles with petrol and diesel engine as well as for the
44. Auxiliary Heater Edition 03 2008 Auer 4 Note Different burner element versions for securing glow plug with flame monitor Q8 using bolt or clamp are available as re placement parts gt Electronic parts catalogue Clamp B dissipates the heat generated at the glow plug with flame monitor Q8 better than clamp C therefore install only those burner elements in which glow plug is secured clamp As of 02 2003 modified auxiliary supplementary heaters were gradually introduced at the factory with a burner element C the clip B and the glow plug A These components are adapted to one another and may only be installed together no mixed installation permitted Remove burner element gt page 87 Remove clamp B Pull glow plug with flame monitor A out of burner element 10 Dismantling and assembling auxiliary additional heater 89 SG Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 4 Note Check burner element and also replace element n event of a defective glow plug with flame monitor Q8 if deposits have formed in burner element which would affect operation and cannot be removed using workshop equipment Observe secure attachment of clamp B Route wiring A as shown and fix in position in clip D Check for secure attachment of grommets C following in stallation With the version gradually introduced as of 02 2003 pay at tention to the corr
45. Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note On vehicles with a diesel engine and supplementary heater no Auxiliary heater optional extra it may be necessary to switch off the eng ne and wait for the coolant to cool down sufficiently Setting work can then be performed without interruption with the engine running initial coolant temperature less than 40 C and air conditioner set to Hi Auxiliary supplementary heater in full load operation for at least one minute since the setting was last changed Read the measured value for the CO carbon dioxide con tent in the exhaust gas off the CO2 measuring instrument as of approx 5 minutes after switch on the auxiliary supplemen tary heater must be in full load operation Setting for CO2 content in exhaust gas 9to 12 by vol CO2 for vehicles with diesel engine 8to 11 by vol CO for vehicles with petrol engine 4 Note fvalue displayed by CO2 measuring instrument fluctuates slightly calculate mean value from highest and lowest meas ured values fvalue displayed by CO2 measuring instrument fluctuates considerably more than approx 0 6 depending on measuring instrument check position of probe in exhaust pipe of auxiliary additional heater 7 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas 47 WMD Audi A8 2003 gt Avo Auxiliary Heater Edition
46. Service Workshop Manual Audi A8 2003 gt Auxiliary Heater Edition 03 2008 Service Department Technical Information Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 82 Auxiliary heating Technical information should always be available to the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure vehicle road worthiness and safety In addition the normal basic safety precautions for working on motor vehicles must as a matter of course be observed All rights reserved No reproduction without prior agreement from publisher Copyright 2010 Audi AG Ingolstadt A0051006220 Audi A8 2003 gt GANN Auxiliary Heater Edition 03 2008 Aue 1 1 1 1 2 1 3 2 3 4 5 5 1 5 2 5 3 5 4 6 6 1 6 2 6 3 6 4 6 5 6 6 7 7 1 7 2 7 3 8 8 1 8 2 8 3 8 4 8 5 8 6 9 9 1 9 2 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12 10 13 10 14 Contents 82 Auxiliary heating Agr re mm ee 1 Servicing auxiliary additional heater 0 ee 1 Contact corrosion B 1 F B BAB PB Be 1 Notes on auxiliary additional heater 2 0 ee 1 Note on operation of auxiliary additional heater in vehicles with diesel engine 5 Safety precautions when working on vehicles fitted with auxili
47. al heater control unit J364 to a different type of fuel e g from petrol to diesel and vice versa As however the internal design of the auxiliary additional heater differs depending on type of fuel auxiliary additional heater conversion work is also required if itis to be fitted in a vehicle using the other type of fuel Attention is therefore to be paid to the rating plate affixed to the auxiliary additional heater di d Ifthe assignment of the auxiliary supplementary heater rating plate differs from the information given on the fault reader display check the assignment reading measured value block The corresponding type of fuel must be displayed Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Heaters of type Z C D without circulation pump V55 are installed as additional heater on vehicles with 6 cyl or 8 cyl diesel engine As additional heater the unit has no circulation pump V55 and no heater coolant shutoff valve N279 Front operating and display unit Climatronic control unit J255 activates the additional heater as soon as the specified acti vation conditions are met gt Air Conditioner Rep Gr 87 If vehicles with 6 cyl or 8 cyl diesel engine are fitted with an auxiliary heater as optional extra this will be a heater of type Z C D with circulation pump V55 and heater coolant shut off valve N279 This auxiliary additional
48. ansmitters are to be re adapted by way of the supplementary heater control unit J364 gt page 20 and Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 If the assignment of the supplementary heater control unit J364 rating plate differs from the information given on the fault reader display check the display in the measured value block gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 If the auxiliary supplementary heater has been replaced to gether with the supplementary heater control unit J364 perform auxiliary supplementary heater self diagnosis after installing the auxiliary supplementary heater interrogate fault memory check encoding and adaption etc gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 f auxiliary additional heater components have been replaced e g combustion air blower V6 check and if necessary ad Just CO2 content in auxiliary additional heater exhaust gas gt page 39 If depending on the version of the supplementary heater con trol unit J364 the auxiliary supplementary heater cannot be activated on a new vehicle or in the case of a newly installed auxiliary supplementary heater the component protection function may be active if a large number of faults occurred simultaneously at some point this fault is no longer displayed althou
49. ary Heater Edition 03 2008 Switch on the exhaust emission test station VAS 6300 and insert the appropriate exhaust probe hose B in the auxiliary supplementary heater exhaust pipe A 4 Note Hose B of exhaust probe must not stop exhaust gas emerging from exhaust pipe A during test Switch on ignition vehicles with auxiliary additional heater Start engine vehicles with diesel engine with additional heater only without auxiliary heater optional extra Set maximum heat output on front operating and display unit Climatronic control unit J255 Restrict fresh air blower speed by setting front operating and display unit to approx 50 96 of maximum fresh air blower speed Switch on the auxiliary supplementary heater by way of one of the two rotary knobs pushbuttons of the front operating and display unit Climatronic control unit J255 via the Multi Me dia Interface MMI or by way of the vehicle diagnostic testing and information system VAS 5051 A Basic setting func tion on vehicles with auxiliary h ater 5 Owner s manuals Operating instructions for Infotainment MMI and 2 G ided fault finding function of vehicle diagnostic testing and infor mation system VAS 5051 Switch on the supplementary heater by way of the vehicle di agnostic testing and information system VAS 5051 A Basic setting function vehicles with diesel engine with supplemen tar
50. ary additional heater 7 Notes on general repair work on vehicles fitted with auxiliary additional heater 8 Rules for cleanliness when working on auxiliary additional heater and fuel system 9 Layout of components for auxiliary additional heater in vehicle 10 Auxiliary heater remote control buttons and indicator lamp luus 16 Checking and replacing auxiliary heater remote control batteries 20 Adaption of remote control h nd trarismiitter in additional heater controlunit J364 o9 59 20 Activating deactivating auxiliary heater auxiliary ventilation via Multi Media Interface MMI Da Diverting fuel for auxiliary additional heater 2 0 0 0 ee 23 Filling fuel pipe to metering pump V54 with fuel bleeding lessen 25 Diverting fuel for auxiliary additional heater from fuel tank 0000s 25 Checking fuel delivery of metering pump V54 2 ke 27 Removing and installing metering pump V54 ow ee 32 Routing of fuel pipe to auxiliary additional heater 00000 eee eee eee 34 Checking actuation and electrical connections of auxiliary additional heater 34 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas 39 Checking CO2 content in auxiliary additional heater exhaust gas ss 41 Adjusting CO2 content in auxiliary additional heater exhaust gas 00005 44 Re
51. ater R64 may be connected to an additional roof aerial instead of to the aerial in the rear window via the aerial amplifier R24 gt Communication Rep Gr 91 The auxiliary heater radio remote control is available in various versions Exclusive use was made up to 05 2004 of the Telestart T70 version As of 05 2004 the Telestart T90 version was gradually introduced instead In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue To enable the auxiliary heater to implement the additional functions of the Telestart T90 Telestart T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modified remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt page 10 and gt Electronic parts catalogue 5 Clock m Q m Installed in dash panel insert Depending on the version the Auxiliary heater optional extra must have been adapted by way of the Adaption function in the control unit with display in dash panel insert J285 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 If there is insufficient fuel in the tank fuel gauge in red zone the auxiliary heater cannot be switched on the tick in the MMI for the Immediate au
52. ation into en gine coolant circuit gt Engine mechanics Rep Gr 19 6 A82 0425 54 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 8 2 Incorporation of auxiliary supplementa ry heater into coolant circuit Vehicles with 6 8 or 10 cyl engine 4 Note fvehicles with diesel engine are fitted with auxiliary heater as optional extra this is also actuated as additional heater Actuation of auxiliary heater as additional heater is not inten ded for vehicles with petrol engine Tubing from engine to auxiliary additional heater and from pump valve unit to engine differs depending on engine ver sion gt Engine mechanics Rep Gr 19 All components not mentioned gt Engine mechanics Rep Gr 19 Upto Model Year 2005 auxiliary supplementary heaters were fitted on which there was a delay of 10 seconds between the reception of a corresponding request from the front operating and display unit Climatronic control unit J255 and imple mentation of the heating mode deactivation time by the sup plementary heater control unit J364 With such auxiliary supplementary heaters theres a risk of overheating of the coolant i the auxiliary heater under certain usage conditions In the event of a complaint of this nature the adaption is there fore to be checked and corrected if necessary gt Guided fault finding function of vehicle diagnostic t
53. auxiliary addi tional heater Make sure there is no air in the fuel pipe to the auxiliary sup plementary heater that the fuel pipes are flush with the floor of the vehicle and are routed so as to protect them from mechanical damage thatthe fuel pipe to the auxiliary additional heater is protected from heat generation that could impair operation the fuel pipe does not come into contact with hot vehicle com ponents When performing repair work in area of fuel delivery unit en sure correct routing of fuel diversion pipe for auxiliary addi tional heater in fuel tank If pipe is not routed properly metering pump V54 may only supply fuel if tank is completely full if this is not the case no fuel is supplied and auxiliary additional heater is deactivated omiaccountiof asfault If there is not enough fuel in the tank fuel gauge in control unit in dash panel insert J285 in red zone additional heater control unit J364 does not activate auxiliary heater Prior to activation and during auxiliary supplementary heater operation the supplementary heater control unit J364 inter rogates the energy management control unit J644 by way of the data bus system As soon as the energy management control unit J644 transmits energy saving information on ac count of inadequate charging of the battery A or insufficient electrical system voltage the supplementary heater control unit J364 switches off the
54. auxiliary supplementary heater After removing and installing fuel system components the auxiliary supplementary heater is to be switched on and op erated at full load for at least 10 minutes to ensure complete bleeding of the fuel pipe 8 Rep Gr 82 Auxiliary heating Audi A8 2003 gt GANN Auxiliary Heater Edition 03 2008 Aue 4 Rules for cleanliness when working on auxiliary additional heater and fuel system Thoroughly clean all unions and the adjacent areas before disconnecting Place dismantled components on a clean surface use plastic sheeting or paper lint free cloths and cover over Carefully cover over or seal open components if repairscannot be performed immediately Only install clean components Do not remove replacement parts from their wrapping until immediately prior to installation Donotuse parts that have been stored without their packaging e g in tool boxes etc When the fuel system is open Do not work with compressed air Do not move the vehicle Do not start the engine Do not activate auxiliary additional heater also applies to ac tivation via self diagnosis Basic setting function 4 Rules for cleanliness when working on auxiliary additional heater and fuel system 9 TI Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 Layout of components for auxiliary additional heater in vehicle 4 Note Fitting locat
55. ber element gt page 82 and gt page 81 10 Hexagon bolt Q Special bolt with self tapping thread 11 Snap on nut 12 Tailpipe Q With thermal insulation mat 13 Clip 14 Corrugated exhaust pipe cy Different versions 2 pade 82 Q Illustration shows corrugated pipe installed in vehicles with 6 cyl diesel engine at start of production Q For vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine gt page 76 and gt page 82 15 Hexagon nut Q Illustration shows hexagon bolt installed in vehicles with 6 cyl diesel engine at start of production Q For vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine exhaust silencer is secured in position at a different location using a hexagon bolt page 76 and gt page 82 16 Exhaust silencer 17 Exhaust pipe Q 90 angled Q Illustration shows exhaust pipe installed in vehicles with 6 cyl diesel engine at start of production Q For vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine there is no exhaust pipe elbow at exhaust silencer gt page 76 and gt page 82 18 Corrugated exhaust pipe Q Different versions page 82 Q Illustration shows corrugated pipe installed in vehicles with 6 cyl diesel engine at start of production Q For vehicles with 6 cyl engine from model year 2004 gradual introduction or 8 cyl engine gt page 76 and gt page 82
56. block Electrical checking at the connector gt page 34 and Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Further pin assignment gt page 34 and gt Current flow diagrams Electrical fault finding and Fitting loca tions 8 Additional heater control unit J364 d m Adaption of remote control hand transmitter via the supplementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 If auxiliary heating auxiliary ventilation is operated via remote control front operating and display unit Climatronic control unit J255 determines whether Auxiliary heater or Auxiliary ventilation mode is activated Remote control adaption is performed in the remote control receiver for auxiliary heater R64 If this is replaced all remote control hand transmitters must be consecutively re adapted gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Different models depending on the version of the remote control Telestart T70 or T90 T91 gt Electronic parts catalogue 12 Block diagram of auxiliary additional heater actuation with remote control 97 f Audi A8 2003 gt Auxiliary Heater Edition 03 2008 4 Note nModel Year 2008 production is gradually being switched from the Telestart T90 version of the remote
57. c tions A and B With certain engine versions connection A is sealed by means of a cap e g in vehicles with 12 cyl engine In these vehicles coolant from engine flows to auxiliary additional heater via a T piece installed between connection B and auxiliary additional heater In auxiliary heater mode heater coolant shutoff valve N279 is actuated by additional heater control unit J364 until coolant temperature in auxiliary heater has reached a specified value gt page 112 The display in the measured value block for actuation of the heater coolant shut off valve N279 differs and depends on the vehicle model and the version of the supplementary heater control unit J364 On the Audi A8 at present for example a display of 100 indicates that 100 of the coolant is being conveyed in the large circuit and that the heater coolant shut off valve N279 is not being actuated gt Vehicle diagnostic testing and information system VAS 5051 A Guided fault finding function Removing Special tools testers and auxiliary equipment required Hose clamps up to 40 mm 3093 or hose clamps up to 25 mm 3094 4 Note On removal note down bolt lengths and assignment for re installation All cable ties and other wiring harness fasteners released or cut open on removing shutoff valve must be re attached in same position on installation Switch off ignition Dissipate pressure in
58. cator lamp C lights or flashes briefly approx 3 s after pressing buttons A or B as a functional check or as a check of set activation time depending on version gt Owner s Man ual Relevant button must be pressed for at least 3 s for remote control to detect actuation of buttons and transmit radio signal gt Owner s Manual The remote control unit is a transmitter and receiver The ve hicle is fitted with different versions of the remote control receiver for auxiliary heater R64 Telestart T70 and Tele start T90 T91 However only the Telestart T90 T91 version transmits confirmation of reception of the activation or deactivation signal as feedback gt page 99 and gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5057 n Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Teles art T91 type gt page 10 and Electronic parts cata logue Keep remote control vertical transmission aerial at top whilst pressing buttons When pressing remote control buttons ensure adequate dis tance from vehicle aerial excessively strong radio signal can lead to reception problems if necessary cover transmission aerial with hand or maintain minimum distance of 10 m from vehicle The remote control receiver for auxiliary heater R64 can be switched to power saving mode by the sup
59. chanics Rep Gr 19 7 Coolant supply from engine Q Incorporation into engine coolant circuit gt Engine mechanics Rep Gr 19 8 Circulation pump V55 Q Under certain conditions circulation pump is also actuated with engine running to assist engine coolant pump page 61 56 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 8 3 Incorporation of auxiliary supplementa ry heater into coolant circuit Vehicles with 12 cyl engine dj Note Actuation of auxiliary heater as additional heater is not inten ded for vehicles with petrol engine Tubing from engine to auxiliary adaitional heater and from pump valve unit to engine differs depending on eng ne ver sion gt Engine mechanics Rep Gr 19 For all components not mentioned refer to gt Engine me chanics Rep Gr 19 Upto Model Year 2005 auxiliary supplementary heaters were fitted on which there was a delay of 10 seconds between the reception of a corresponding request from the front operating and display unit Climatronic control unit J255 and imple mentation of the heating mode deactivation time by the sup plementary heater control unit J364 With such auxiliary supplementary heaters there is a risk of overheating of the coolant in the auxiliary heater under certain usage conditions In the event of a complaint of this nature the adaption is there fore to be checked and corrected i
60. control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue At present a maximum of 3 re mote controls can be adapted in the remote control receiver for auxiliary heater R64 Adaption ofa fourth remote control causes the first matched remote control to be erased The signals from the remote con trol hand transmitter are only re layed by the remote control re celver for auxiliary heater R64 The signals are then processed by the supplementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and informa tion system VAS 5051 reading measured value block The remote control receiver for auxiliary heater R64 can be de activated by the supplementary heater control unit J364 thus reducing the no load current in put gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 reading measured value block Checking signals fromthe re mote control receiver for auxili ary heater R64 gt Guided fault finding function of vehicle diagnostic testing and informa tion system VAS 5051 reading measured value block 98 Rep Gr 82 Auxiliary heating e Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 12 1 Fitting location for auxiliary heating radio receiver R64 4 Note The remote control receiver A is installed in the passenger compartment on the left in
61. coolant circuit by opening cap at coolant expansion tank gt Engine mechanics Rep Gr 1 Ifthe vehicle is fitted with an air cleaner above the auxiliary supplementary heater remove the cleaner together with the air cleaner housing Injection and ignition system Rep Gr 24 and gt Injection and glow plug system Rep Gr 23 Remove noise insulation and front right wheel housing liner 2 General body repairs Exterior Rep Gr 50 Remove right headlight gt Electrical system Rep Gr 94 Move the lock carrier to service position gt General body re pairs Exterior Rep Gr 50 8 Incorporation of auxiliary additional heater into coolant circuit 59 TI Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 Installing Pinch off the coolant hoses A B and C to the heater coolant shut off valve N279 and D to the auxiliary sup plementary heater Detach coolant hoses B and C from heater coolant shutoff valve N279 Detach coolant hoses A and C from heater coolant shutoff valve N279 Unplug connector C Remove hexagon nuts D Remove heater coolant shutoff valve N279 E Re install components removed in reverse order Bleed the coolant circuit gt page 60 and gt Engine mechan ics Rep Gr 19 If applicable check actuation and operation of the heater cool ant shut off valve N279 gt Guided fault finding function of vehicle diagnostic testing a
62. d by additional heater control unit J364 and there are no auxiliary heater faults present additional heater control unit J364 transmits confirmation and indicator lamp C then flashes green 30 times at approx one Hz 1 pulse per second as acknowl edgement f activation signal has not been properly received by addi tional heater control unit J364 e g on account of excessive distance from vehicle and link cannot be established with control unit indicator lamp C flashes red 30 times Inthe event ofa fault in the vehicle or auxiliary heater auxiliary heater cannot be switched on e g on account of empty fuel tank additional heater control unit J364 transmits a fault message and indicator lamp C flashes red 30 times As a functional check indicator lamp C lights red briefly approx 2 seconds after pressing OFF button B Indicator lamp C then flashes red 30 times at approx one Hz 1 pulse per second f deactivation signal has not been properly received by addi tional heater control unit J364 e g on account of excessive distance from vehicle and link cannot be established with control unit indicator lamp C then flashes red for 10 sec ondas at approx 4 Hz 4 pulses per second The remote control hand transmitter is transmitter and receiv er As of 05 2004 the Audi A8 is gradually being fitted with a remote control receiver for auxiliary heater R64 of the Tele Start
63. de is not required to attain specified temperature in passenger compartment In auxiliary ventilation mode the supplementary heater control unit J364 is only required to switch the signal from the remote control receiver for auxiliary heater R64 to the data bus sys tem fauxiliary ventilation mode has been set in MMI Multi Media Interface or if front operating and display unit Climatronic control unit J255 has decided that auxiliary heating mode is not required to achieve specified temperature in passenger compartment additional heater control unit J364 is not ac tuated 1 08 Rep Gr 82 Auxiliary heating Audi A8 2003 gt iw Auxiliary Heater Edition 03 2008 Auer 13 1 2 Heater starting sequence Sequence Duration Actuation Resistance meas approx urement Combus Metering Glow plug Glow plug with tion air pump with flame flame monitor Q8 blower V54 monitor V6 with Q8 with with Flea 0 Commence starting se OV quence Flame detector interrogation 8V oHz OV V Siabisaon tne V V V V V V Fuel delivery 4to12V 1to3Hz Flame detector interrogation V End of starting sequence Start of Full load combus tion 2 page 109 4 Note 1 Hertz Hz corresponds to 1 pulse per second The voltages times and frequencies listed in the table are ap proximate values regulated by the control unit on the basi
64. ditional heater control functions remain in opera tion during self diagnosis Auxiliary supplementary heater self diagnosis is to be per formed by way of the Guided fault finding function using the vehicle diagnostic testing and information system VAS 5051 A Guided fault finding function of vehicle diagnostic test ing and information system VAS 5051 Auxiliary additional heater self diagnosis can only be started with ignition on data bus diagnostic interface J533 is only active after switching on ignition Once auxiliary additional heater has switched to diagnostic mode self diagnosis can be continued with ignition switched off Different auxiliary supplementary heater versions are availa ble Heed the exact assignment when replacing an auxiliary supplementary heater gt page 1 and Electronic parts cata logue Thedesign of the supplementary heater control unit J364 for petrol or diesel is displayed in the measured value block 2 Rep Gr 82 Auxiliary heating Auxiliary Heater Edition 03 2008 Auer Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 If the auxiliary supplementary heater is to be replaced inter rogate the encoding and adaption of the supplementary heater control unit J364 by way of the Control unit replacement function of the guided fault finding routine prior to removal the supplementary heater control unit J364 is installed
65. e Im See LT 5 mediate auxiliary heater activation function and the symbol for auxiliary heater mode in the clock cannot be activated or go out again gt Electrical system Rep Gr 90 and gt Owner s manual 5 Layout of components for auxiliary additional heater in vehicle 1 1 WW Audi A8 2003 gt Auol Auxiliary Heater Edition 03 2008 Note 2 Front operating and display unit Climatronic control unit J255 Q Actuated by way of the convenience data bus system When operating the auxiliary heater by way of the Timer function or remote control this determines the mode in which the auxiliary supplementary heater starts up auxiliary ventilation or auxiliary heating gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 In order that auxiliary heater can be activated via Timer function or remote control a temperature greater than Lo must be set on front operating and display unit Climatronic control unit J255 To de ice the windows as quickly as possible it is appropriate to set as high a temperature as possible on the front operating and display unit Climatronic control unit J255 before switching off the ignition In auxiliary heater mode front operating and display unit Climatronic control unit J255 adopts last set temperature and regulates passenger compartment temperature according to set specified temper ature
66. e 34 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Checking wiring gt page 34 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 15 Fuel delivery unit m m m Different fuel delivery units depending on the vehicle model petrol or diesel engine FWD or 4WD gt Fuel supply system Rep Gr 20 With connection for diverting fuel for auxiliary additional heater vehicles with auxiliary additional heater only gt Fuel supply system Rep Gr 20 Diverting fuel for auxiliary additional heater gt page 23 DIM After removing and installing fuel system components the auxiliary supplementary heater is to be switched on and operated at full load for at least 10 minutes to en sure complete bleeding of the fuel pipe 5 Layout of components for auxiliary additional heater in vehicle 1 5 TI Audi A8 2003 gt Auer Auxiliary Heater Edition 03 2008 16 Remote control hand transmitter m Q m Q m 5 1 For activating and deactivating auxiliary heater or auxiliary ventilation function of auxiliary additional heater gt page 16 Indicator lamp lights or flashes when buttons are pressed gt Owner s Manual Replacing batteries gt page 20 Relevant button must be pressed for at least 3 s for remote control to detect actuation of buttons and transmit radio signal gt Owner s Manua
67. e and interrogate the fault memory of all control units fitted faults may also have been entered for other control units by way of the convenience data bus Switch on the auxiliary supplementary heater and check both operation and the CO content of the auxiliary supplementary heater exhaust gas 9 Removing and installing auxiliary additional heater 69 TI Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 After replacing certain auxiliary supplementary heater compo nents switch on the auxiliary supplementary heater before handing over the vehicle to the customer and allow the auxil iary supplementary heater to run for a few minutes atleast 10 minutes in full load operation Residue of e g lubricants used during production may still be found in components This res idue evaporates after initial switch on as soon as components have warmed up 4 Note Up to Model Year 2005 auxiliary supplementary heaters were manufactured on which there was a delay of 10 seconds be tween the reception of a corresponding request from the front operating and display unit Climatronic control unit J255 and implementation of the heating mode deactivation time by the supplementary heater control unit J364 With such auxiliary supplementary heaters there is a risk of overheating of the coolant in the auxiliary heater under certain usage conditions Following installation of the auxiliary supplementary heater the adapt
68. e basis of measured values voltage temperature etc 13 1 4 Burn off run on sequence Duration approx Sequence Resistance meas urement Actuation Switching from partial load operation to control interval Switch off of heater during full or part load mode Starting procedure terminated because of fault Cooling down of heater 0 to 8 to 120 sec 12V Switching to control interval OFF 1 1 0 Rep Gr 82 Auxiliary heating Metering Glow plug Glow plug with pump with flame flame monitor Q8 V54 monitor with Q8 with Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note 7 Hertz Hz corresponds to 1 pulse per second The voltages times and frequencies listed in the table are ap proximate values regulated by the control unit on the basis of measured values voltage temperature etc and last operat ing status 13 2 Required heating output between 50 and 100 P kW Heat output in kilowatts t C Temperature of coolant in heater A Commencement of starting Coolant temperature in heater must be below 77 C B Starting C Full load operation D Part load operation tec 1 Start of full load operation 2 Switchover from full to part load operation 3 Switchover from part to full load operation 13 3 Required heating output less than 50 P kW Heat output in kilowatts
69. e diagnostic testing and information system VAS 5051 With ignition switched on front operating and display unit Cli matronic control unit J255 can actuate valves of pump valve unit depending upon set temperature close as heat output is no longer required As coolant can no longer flow through the auxiliary supplementary heater when the valves are closed set the temperature on the front operating and display unit Climatronic control unit J255 for example to Hi Itis sufficient for circulation pump V55 of auxiliary additional heater to be running if auxiliary additional heater is in control interval due to coolant temperature Start engine again and allow it to run for approx 3 minutes at increased idle speed e g 2300 rpm Switch off auxiliary heater Switch off engine Top up coolant if necessary gt Engine mechanics Rep Gr 19 8 6 Note for vehicles with the problem poor heat output with engine running In the event of problems relating to poor or inadequate heat output at low engine speeds on vehicles fitted with an auxiliary heater as optional extra or auxiliary supplementary heater on vehicles with a diesel engine check actuation of the auxiliary supplementary heater circulation pump V55 by the supplementary heater con trol unit J364 gt Guided fault finding function of vehicle diag nostic testing and information system VAS 5051 Actuation of circulation pump V5
70. e encountered with auxiliary additional heater although fuel delivery and CO2 content in exhaust gas are OK Check the glow plug with flame monitor Q8 gt page 70 and gt page 88 7 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas 43 C amp D Audi A8 2003 gt Auo _ Auxiliary Heater Edition 03 2008 Remove any residue from auxiliary additional heater combus tion chamber this is particularly important for vehicles with diesel engines and when running engine and thus auxiliary additional heater on rape oil or vegetable oil methylester fuel 2 page 84 7 2 Adjusting CO2 content in auxiliary addi tional heater exhaust gas Prerequisites for adjusting thex O content oftthe exhaust gas Auxiliary supplementary heater ir full load mode Vehicle diagnostic testing and information system VAS 5051 A connected to vehicle and auxiliary supplementary heater self diagnosis started 2 Guided fault finding function of ve hicle diagnostic testing and information system VAS 5051 44 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer CO measuring instrument ready for operation and exhaust probe B positioned in auxiliary heater exhaust pipe A such that it does not impede emergence of exhaust gas 4 Note fthe auxiliary supplementary heater switches from full to part load operation during CO2 adjustment on account of a
71. e prese lection Hi Additional heater auxiliary heater without circulation pump V55 must only be activated with engine running as heat generated is not dissipated via coolant when engine is stop ped On vehicles with a diesel engine and supplementary heater without the Auxiliary heater optional extra the engine is to be started before switching on the supplementary heater by way of the Basic setting function As of a coolant temperature of greater than 40 C the air conditioner is additionally to be set to Hi gt Guided fault finding function of vehicle diag nostic testing and information system VAS 5051 Inthe Basic setting function the auxiliary supplementary heater can be operated up to a coolant temperature of 110 C and starting from the control interval is possible The oper ating time is then restricted to a maximum of 10 minutes gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Test requirements Atthe start of testing the coolant temperature should be less than 30 C if the starting temperature is too high the auxiliary supplementary heater may switch to part load operation during testing or setting The ambient temperature is less than 25 C Sufficient fuel in tank fuel gauge in dash panel insert not in red zone Battery A vehicle battery fully charged 7 Checking and adjusting CO2 content in a
72. ect installation position see Fig and proper attachment of the clip B Check non insulated part of wiring to glow plug glow plug with flame monitor Q8 A before installing combustion air blower Wires mus t not contact each other or contact other campo nents danger of short circult 90 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 11 Block diagram of auxiliary additional heater 4 Note Incorporation of auxiliary additional heater into vehicle elec trics gt Current flow diagrams Electrical fault finding and Fit ting locations Checking auxiliary supplementary heater components gt page 70 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 At the start of production the design of the supplementary heater control unit J364 for the Supplementary heater with out auxiliary heater version was the same as that of the auxiliary supplementary heater control unit installed with the version for vehicles with diesel engine At a later date the Supplementary heater without auxiliary heater version may be fitted with control units no longer featuring certain functions for the Supplementary heater without auxiliary heater version introduction not yet finalised gt Electronic parts catalogue Climatronic control unit J255 is of different design for petrol and diesel versions certain functio
73. el engine Version 3 additional heater without auxiliary heater is in stalled as standard on vehicles with diesel engine Auxiliary additional heater gt page 64 4 Note Depending on the type of engine use is made of different brackets to secure the auxiliary supplementary heater in po sition in the vehicle gt page 82 and gt Electronic parts catalogue The auxiliary supplementary heater brackets are attached to the vehicle with bolts rubber grommets and bushings as well as with bonded rubber elements If applicable the fastening elements are to be ordered as well on replacing the bracket gt page 82 gt page 81 and gt Electronic parts catalogue Onreplacing the auxiliary supplementary heater pay attention to the correct version different models for vehicles with petrol and diesel engine as well as the two different remote control versions gt page 84 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 There are different versions of the auxiliary heater remote control and of the auxiliary supplementary heater Exclusive use was made up to 05 2004 of the Telestart T70 remote control version As of 05 2004 the Telestart T90 version was gradually introduced instead In Model Year 2008 production Is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electro
74. er 4 Note Onlythe main items in the function sequence are presented on the following pages Sequences taking place in the back ground are marked with a and perceptible sequences au DAP dible or measurable with s As the supplementary heater is only switched on at ambient temperatures below 5 C it must be activated by way of the vehicle diagnostic testing and information system VAS 5051 A Basic setting function for the procedure described on the following pages gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Control sequence Possible cause of deviation Continuation of sequence follow ing deviation 1 Cut in signal Auxiliary heater From front operating and dis play unit Climatronic control unit J255 via data bus system setting is made on MMI From radio receiver R64 Front operating and display unit Climatronic Control unit J255 interrogation via da ta bus system 1 02 Rep Gr 82 Auxiliary heating Front operating and display Auxiliary ventilation summer unit Climatronic control unit mode 2 page 108 J255 decides heating mode is not required to attain specified temperature in passenger compartment From front operating and dis play unit Climatronic control unit J255 interrogation via data bus system From Vehicle diagnostic testing and information sys tem VAS 5051 A v
75. es however involve using the Adap tion function to enter the actuation time of the metering pump V54 and enabling the Pipe filling function in a further adap tion channel gt Guided fault finding function of vehicle diag nostic testing and information system VAS 5051 Forreplacement auxiliary heaters with a new supplementary heater control unit J364 for which basic setting has not yet been performed using the Pipe filling function the value dis played for the pipe filling time may for example not be 0 but rather a different value e g 200 5 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 The delivery rate can only be checked by way of the Basic setting function if the value 0 has been entered in the adap tion channel for enabling Pipe filling When the Pipe filling function is implemented the adaption value is reset to 1 and this function is thus disabled Guided fault tinding function of vehicle diagnostic testing and information system VAS 5057 n the case of replacement auxiliary supplementary heaters with a new supplementary heater control unit J364 for which basic setting has yet to be performed with the Pipe fill ing function the value 0 may also be displayed Following implementation of the Pipe filling function the dis play in the measured value block is reset to the factory setting for t
76. esignation in the current flow diagram de pends on the vehicle equipment e g aerial amplifier R24 2 Cur rent flow diagrams Electrical fault finding and Fitting locations Depending on version vehicles with auxiliary heater remote control have an additional out put gt Electronic parts catalogue QO Depending on version connection for auxiliary heater may for exam ple be marked TS for Telestart Q Fitting location gt Com munication Rep Gr 91 Q Depending on vehicle equipment the remote control receiver for aux iliary heater R64 may be connected to an ad ditional roof aerial in stead of to the aerial in the rear window via the aerial amplifier R24 gt Communication Rep Gr 91 2 Aerial wire from aerial mod ule to auxiliary heating radio receiver R64 3 Auxiliary heating radio re A82 0432 ceiver R64 Q Fitting location removing and installing 2 page 99 Q Transmits appropriate information to additional heater control unit J364 on receipt of radio signals ac tivation or deactivation of auxiliary heating auxiliary ventilation Q Different versions A Telestart T70 remote control receiver was fitted at the start of production A Tel estart T90 remote control receiver was gradually introduced as of 05 2004 In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Tel estart T91 type page 10 and
77. esting and information system VAS 5057 Direction of coolant flow gt With engine running and in supplementary heating mode on vehicles with a diesel engine gt In auxiliary heating mode with no actuation of the heater coolant shut off valve N279 temperature dependent actuation 2 page 112 and 2 page 58 2 In auxiliary heating mode with actuation of the heater coolant shut off valve N279 temperature dependent actuation gt page 112 and gt page 58 8 Incorporation of auxiliary additional heater into coolant circuit 55 C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 1 Auxiliary supplementary heater 2 Air conditioner pump valve unit QO Incorporation into cool ant circuit 2 Air condi tioning Rep Gr 87 3 Right heat exchanger of air conditioner unit 4 Left heat exchanger of air conditioner unit 5 Heater coolant shutoff valve 2 Q Removing and installing gt page 58 Q The shutoff valve is ac tuated by the additional heater control unit J364 gt page 112 Q The illustration shows the shut off valve in non actuated condition coolant flow from con nection 3 to connec tion 4 and from con nection 1 to connec tion 2 CL Actuation of shutoff valve causes coolant to flow from connection 3 to connection 2 6 Coolant return to engine QO Incorporation into en gine coolant circuit A82 0426 Engine me
78. f necessary gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 Direction of coolant flow gt With engine running and in supplementary heating mode if the auxiliary heater was switched on for example via the MMI gt In auxiliary heating mode with no actuation of the heater coolant shut off valve N279 temperature dependent actuation gt page 112 and gt page 58 gt In auxiliary heating mode with actuation of the heater coolant shut off valve N279 temperature dependent actuation gt page 112 and gt page 58 8 Incorporation of auxiliary additional heater into coolant circuit 57 C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 1 Auxiliary additional heater 2 Air conditioner pump valve unit QO Incorporation into cool ant circuit 2 Air condi tioning Rep Gr 87 3 Right heat exchanger of air conditioner unit 4 Left heat exchanger of air conditioner unit 5 Heater coolant shutoff valve N279 Q Removing and installing gt page 58 Q The shutoff valve is ac tuated by the additional heater control unit J364 gt page 112 Q The illustration shows the shut off valve in non actuated condition coolant flow from con nection 3 to connec tion 4 Actuation of shutoff valve causes coolant to flow from connection 3 to connection 2 6 Coolant return to engi
79. f valve N279 actuation may remain in the various op erating statuses for a lengthy period Actuation of heater coolant shutoff valve N279 is also main tained even if engine is started with auxiliary heater running At a coolant temperature of approx 81 C auxiliary adaitional heater switches from control mode to control interval During control interval heater coolant shutoff valve N279 is not ac tuated and coolant flows in large coolant circuit via engine The display in the measured value block for actuation of the heater coolant shut off valve N279 differs and depends on the vehicle model and the version of the supplementary heater control unit J364 On the Audi A8 at present for example a display of 100 96 indicates that 100 96 of the coolant is being conveyed in the large circuit and that the heater coolant shut off valve N279 is not being actuated gt Vehicle diagnostic testing and information system VAS 5051 A Guided fault finding function 13 Functional description of auxiliary additional heater 1 1 3
80. gh it is still active If necessary perform re adaption of the component protection function as for a newly installed auxiliary supplementary heater to cancel component protec lion gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 64 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 9 1 Removing and installing auxiliary addi tional heater Special tools and workshop equipment required Hose clamps up to 40 mm 3093 or hose clamps up to 25 mm 3094 4 Note On removal note down bolt lengths and assignment for re installation All cable ties and other wiring harness fasteners released or cut open on removing auxiliary adaitional heater must be re attached in same position on installation Removing Interrogate encoding and adaption of additional heater control unit J364 in Control unit replacement function of guided fault finding routine 2 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Switch off ignition and auxiliary additional heater Detach auxiliary additional heater exhaust tailpipe A from noise insulation B by removing screws C version for e g vehicles with 6 cyl or 8 cyl petrol engine Detach auxiliary additional heater rubber grommet A for ex haust tailpipe C from noise insulation B version for e g vehicles
81. gned for the Telestart T90 T91 remote control gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5057 There are different versions of the supplementary heater con trol unit J364 for petrol and diesel certain functions are set differently e g pre heating times gt Electronic parts cata logue At the start of production the design of the supplementary heater control unit J364 for the Supplementary heater with out auxiliary heater version was the same as that of the auxiliary supplementary heater control unit installed with the version for vehicles with diesel engine Ata later date the Supplementary heater without auxiliary heater version may be fitted with control units no longer featuring certain functions for the Supplementary heater without auxiliary heater version introduction not yet finalised gt Electronic parts catalogue Removing auxiliary supplementary heater gt page 64 Detaching add on components from additional heater gt page 73 84 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Detaching add on components from auxiliary additional heat er 2 page 76 1 Bolt 2 Combustion air blower V6 Q Checking page 70 Q Removing and installing gt page 87 Q Different versions gt page 87 and gt Electronic parts cata logue 3 Seal 4 Moulded gasket Q
82. gnostic testing and information system VAS 5051 To stop too much fuel being conveyed into the auxiliary supple mentary heater the supplementary heater control unit J364 is programmed as follows It may only be possible to perform Pipe filling once in the Basic setting function in the course of guided fault finding depending on the version of the supplementary heater control unit J364 not necessary for all versions of the supplemen tary heater control unit J364 terminate guided fault finding and re start if necessary gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Once Pipe filling has been performed in the Basic setting function the supplementary heater control unit J364 resets the time entered in the adaption channel for Pipe filling to 0 actuation time of the metering pump V54 in the Pipe filling function and in a further adaption channel the value is set to 1 pipe filling disabled as already implemented Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note For the actual test it is therefore necessary to exit from guided fault finding and fo repeat the entire procedure for test purposes 6 3 4 Testing Test preparation performed page 27 and fuel pipe completely filled 2 page 28 Select the supplementary heater control unit J364 in the Guided fault finding func
83. gt Electrical system Rep Gr 94 A82 10042 Mark positions of coolant hoses A to D for auxiliary addi tional heater Pinch off the coolant hoses A B and C to the heater coolant shut off valve N279 and D to the auxiliary sup plementary heater Detach coolant hoses A to D 4 Note This illustration shows an auxiliary supplementary heater the supplementary heater version is not fitted with a heater coolant shut off valve N279 On vehicles with diesel engine fitted only with an additional heater auxiliary heater without circulation pump and heater coolant shutoff valve N279 only 2 coolant hoses must be clamped off and detached from engine to additional heater C and from additional heater to pump valve unit D gt En gine mechanics Rep Gr 19 J 66 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Release and unplug the connector A Release and consecutively unplug the connectors B and 4 Note Pay attention to the correct sequence when unplugging con nectors A and B If connector B is unplugged first a fault may be stored n the supplementary heater control unit J364 and this can only be erased after unplugging the connectors and plugging them back in in the right order Plug in connector B and then connector A at thecsupple mentary heater control unit J364
84. h bonded rubber element 81 Types of bracket for auxiliary additional heater 2 0 0 0 c eee eee eee 82 Auxiliary additional heater exhaust system llle 82 Attaching spacer and insulating sleeve to exhaust system of auxiliary additional heater 83 Routing wiring to circulation pump V55 l isllssleeeee ee 84 Dismantling and assembling auxiliary additional heater llle 84 Removing and installing connector console cover 00000 cece eee 86 Assignment of auxiliary additional heater connector console lsluus 86 Removing and installing combustion air blower V6 1 anaana aaa 87 Removing and installing burner element 0000 eee 87 Removing and installing glow plug with flame monitor Q8 00 0005 88 10 15 Contents COLD Audi A8 2003 gt Auc Auxiliary Heater Edition 03 2008 11 11 1 11 2 12 12 1 13 13 1 13 2 13 3 Contents Block diagram of auxiliary additional heater 0 0 00 eens 91 Incorporation of auxiliary additional heater into vehicle electrics su 91 Fitting location of temperature sensor G18 in auxiliary additional heater 93 Block diagram of auxiliary additional heater actuation with remote control 94 Fitting location for auxiliary heating radio receiver R64 ww ee 99 Functional description of auxiliary additional heater 0 ee 101 Sequence of operati
85. h off ignition Remove cover beneath fuel filter illustration shows layout for vehicles with petrol engine vehicles with diesel engine do not have a fuel filter A at this location gt Fuel supply system Rep Gr 20 On vehicles with petrol engine detach fuel filter A from fuel tank or remove fuel filter gt Fuel supply system Rep Gr 20 Unplug connector from metering pump V54 B Unfasten clip and detach fuel pipe C Seal fuel pipe C Unfasten clip and detach fuel pipe D Seal fuel pipe D Remove the metering pump V54 B from the rubber element holder E Installing Installation is carried out in the reverse order note the following Replace the hose clamps on the fuel lines and secure them using suitable pliers Make sure fuel pipes are not twisted Secure fuel pipes at attachment points provided Different metering pump versions may be fitted depending on the type of fuel petrol or diesel other version for vehicles with diesel engine gradually being introduced Attention is there fore to be paid to correct assignment gt Electronic parts catalogue 4 Note Metering pump type DP 2 is fitted on vehicles with petrol and diesel engine less running noise under Audi A8 operating conditions in comparison with type DP 30 2 particularly when using petrol Metering pump version type DP 30 2 intended only for ve hic
86. hannel is reduced by 10 units the CO2 content in the exhaust gas is increased by approx 0 5 volume With additional heater control unit J364 fitted at present val ues from 100 to 250 can be entered Values entered via the keypad or bar which are not within the specified limits are dis played but not implemented fthe value entered is too high or too low the display Is auto matically reset to the initial value or to the lowest highest value still permitted The value applicable prior to adjustment remains stored if the auxiliary supplementary heater is shut off during the Adap tion function CO2 adjustment or on exiting from full load mode In this case repeat the procedure again Adopt and store the entry gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Wait at least one minute for exhaust gas value to adjust to new setting Read the measured value for the CO carbon dioxide con tent in the exhaust gas off the CO2 measuring instrument as of approx 1 minute after confirmation of the last entry the auxiliary supplementary heater must be in full load operation 48 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue If the new CO2 measured value does not correspond to the de sired setting repeat the adjustment procedure Setting for CO2 content in exhaust gas For vehicles with
87. he auxiliary heater On completion of the necessary work the auxiliary heater must therefore be actuated with the Basic setting function gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 The metering pump V54 is actuated for 30 s at 5 hertz 5 pulses per second in the Pipe filling function if e g 30 has been entered in the adaption channel for the Pipe filling func tion the fuel pipe is then completely filled with fuel Once Pipe filling function has been started it cannot be aborted and is implemented in full by control unit regardless of any entries made via tester There may be several reasons for the display Function un known or cannot be implemented at present appearing in the display zone gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5057 Wait until the display changes from Pipe filling to End with certain control units Function unknown or cannot be imple mented at present is displayed on completion of actuation gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 6 Diverting fuel for auxiliary additional heater 29 C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 Drain measuring cup B and reattach Terminate guided fault finding gt Guided fault finding func tion of vehicle dia
88. heater exhaust gas 5 1 WMD Audi A8 2003 gt Avo Auxiliary Heater Edition 03 2008 Set maximum heat output on front operating and display unit Climatronic control unit J255 temperature preselection Hi 4 Note So as not to overload the vehicle battery it is appropriate to con nect a suitable battery charger to it Switch on the auxiliary supplementary heater by way of the front operating and display unit Climatronic control unit J255 on the MMI Multi Media Interface or via the Multi Media Interface MMI depending on the vehicle model Owner s manual and gt Operating instructions for Infotainment MMI Switch off ignition Open all windows if necessary Run auxiliary additional heater with petrol for at least 30 min 52 Rep Gr 82 Auxiliary heating ees Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 8 Incorporation of auxiliary additional heater into coolant circuit 4 Note Up to Model Year 2005 auxiliary supplementary heaters were fitted on which there was a delay of 10 seconds between the re ception of a corresponding request from the front operating and display unit Climatronic control unit J255 and implementation of the heating mode deactivation time by the supplementary heat er control unit J364 With such auxiliary supplementary heaters there is a risk of overheating of the coolant in the auxiliary heater under certain u
89. heater is also oper ated as additional heater At present the Supplementary heating function of the auxil iary supplementary heater is only available for vehicles with a diesel engine It is switched in automatically by the air condi tioner front operating and display unit Climatronic control unit J255 by way of the convenience data bus system provided that the front operating and display unit Climatronic control unit J255 is in operation Off mode not selected and that this function has not been deactivated via the MMI Multi Me dia Interface gt Owner s manual gt Operating instructions for Infotainment MMI and gt Air conditioning Rep Gr 87 With the Adaption function it is possible to make an entry in the front operating and display unit Climatronic control unit J255 for deactivation of the supplementary heater on select ing Econ mode on the front operating and display unit Climatronic control unit J255 0or for deactivation of the sup plementary heaterimthe MMI MultiMedia Interface i s Air conditioning Rep Gri 8fand s Guided fault finding func tion of vehicle diagnostic testing and information system VAS 5051 for the air conditioner The Adaption function can be used to enter various changes relating to auxiliary supplementary heater actuation in the front operating and display unit Climatronic control unit J255 It is also possible to alter certain settings for
90. hr 2001 2002 2003 There are different versions of the auxiliary additional heater Pay attention to the exact assignment when replacing an aux Webasto aem C C iliary supplementary heater gt Electronic parts catalogue Thermosysteme GmbH 021232 aan s HEIZGERAT Typ The heater rating plate indicates the version concerned Spannung El Leistung Warmestrom 5KW i i D ili i Brennstoff Benzin Rating plate for diesel Thermo Top Z C D auxiliary addi AE iab Oe INS I NR tional heater or additional heater only only for vehicles with Pr fzeichen ATA S292 Dessins A rceten pumps E 0000000 0 a Rating plate for petrol Thermo Top Z C B auxiliary heater only for vehicles with petrol engine j 4 Note The most important technical data can be found in the upper section of the rating plate The year of initial commissioning is entered below the techni cal data The year of initial commissioning must be entered on the Genuine replacement part rating plate 4 Rep Gr 82 Auxiliary heating eee Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue A second rating plate duplicate A is affixed to the bonnet in the engine compartment next to air conditioner label B In cases of doubt concerning auxiliary additional heater model always observe rating plate attached to auxiliary additional heater Adaption function can be used to switch addition
91. ia basic setting function Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Control sequence Possible cause of deviation Continuation of sequence follow ingdeviaion P Additional heater heater Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation deviation Initiation Initiation of start procedure start procedure Interrogation of fault memory Interrogation of voltage at heater Interrogation of information from energy management control unit J644 Monitoring of all electrical components and input sig nals Interrogation of glow plug with flame monitor Q8 Interrogation of coolant tem perature in heater less than Fault interlock entered Voltage is or becomes lower than specified cut out volt age Fault detected Resistance of glow plug with flame monitor Q8 outside specified range Coolant temperature great er than 81 C Termination of starting pro cedure fault off Termination of starting pro cedure entry in fault memo ry fault off see above see above Switching to control interval 2 page 105 81 C Control sequence Possible cause of deviation Continuation of sequence fol plowing deviation deviation Monitoring as for no 2 gt page 103 2 page 103 Circulation pump V55 on with auxiliary additional heater e Actuation of front operating and display unit
92. if necessary gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Ifan attempt is made to match a remote control hand trans mitter on a vehicle with supplementary heater only no auxili ary heater the fault memory entry Remote control receiver for auxiliary heater no communication is made in the sup plementary heater control unit J364 This fault can no longer be erased As it has no connection with any supplementary heater function however this fault memory entry does not have any influence on operation and can therefore be ignored At start of production auxiliary additional heater was installed with additional heater control unit J364 with data level up to and including 0280 hardware and software version With these control units faults data bus diagnostic interface J533 central convenience system control unit J393 energy management control unit J644 with the fault type no signal no commu nication can be displayed and cannot initially be erased For these faults proceed as follows Erase the fault memory Terminate guided fault finding Switch off all electrical equipment and lock the vehicle Waitatleast 5 minutes the data bus system must be switched to idle state Interrogate the fault memory and erase the faults displayed 1 2 1 Notes on auxiliary supplementary heat er guided fault finding Auxiliary ad
93. ifferent exhaust routing installed gt page 73 On vehicles with 10 cyl petrol engine the exhaust system dif fers from the version shown however the detachment and attachment operations are identical 1 Clip 2 Exhaust pipe Q with heat insulation 3 Bolt 4 Bracket 5 Exhaust silencer 6 Tailpipe 7 Rubber grommet Ly Inserted in noise insula tion 482 10043 10 3 Detaching and re attaching add on components from to auxiliary additional heater Removing auxiliary supplementary heater gt page 64 76 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note At the start of production the design of the supplementary heater control unit J364 for the Supplementary heater with out auxiliary heater version was the same as that of the auxiliary supplementary heater control unit installed with the version for vehicles with diesel engine At a later date the Supplementary heater without auxiliary heater version may be fitted with control units no longer featuring certain functions for the Supplementary heater without auxiliary heater version introduction not yet finalised gt Electronic parts catalogue Additional heater control unit J364 is of different design for petrol and diesel versions certain functions are set differently e g pre heating times gt Electronic parts catalogue Onreplacing the auxiliary supplementar
94. ill be conveyed To ensure auxiliary additional heater operation even under un favourable operating conditions the fuel diversion pipe can be lengthened to cope with such exceptional circumstances Pro ceed as described below To avoid having to replace the entire fuel delivery unit in these vehicles if problems occur the suction pipe B can be exten ded using a fuel resistant hose A e g N 101 207 01 The hose A should be cut to length so that when it is pushed approx 5 cm onto suction pipe B it just touches bottom of fuel tank To ensure that fuel diversion is still possible if hose A rests vertically on bottom of fuel tank D end of hose E must have depicted swallow tail shape Push hose A onto suction pipe B and secure in position with clip C 26 Rep Gr 82 Auxiliary heating vL A82 0422 poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 6 3 Checking fuel delivery of metering pump V54 AN WARNING Observe the applicable rules for cleanliness take the appro priate precautions and heed the relevant safety measures when working on open fuel system gt Fuel supply system Rep Gr 20 6 3 1 Test requirements Coolant temperature less than 30 C The ambient temperature is less than 25 C EXT A higher ambient temperature can lead to errors as regards measured fuel quantity on account of fuel evaporation Sufficient fuel in
95. ine gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Self diagnosis is to be performed on completion of auxiliary supplementary heater repair work check encoding interrog ate fault memory and perform adaption gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Avoid repeated activation of auxiliary additional heater without intermediate heater operation repeated deactivation of auxil iary additional heater during start sequence can cause fuel to accumulate in combustion chamber and result in intense aux iliary additional heater smoke generation on subsequent at tempted starting 2 Safety precautions when working on vehicles fitted with auxiliary additional heater T Wu Audi A8 2003 gt Auc Auxiliary Heater Edition 03 2008 3 Notes on general repair work on ve hicles fitted with auxiliary additional heater Disconnect the negative and positive terminals of the battery A before starting electric welding work on the vehicle If coolant has been drained bleed auxiliary additional heater after filling cooling system gt page 60 If parts of fuel system have been removed or replaced ensure that all components used for diverting fuel to auxiliary addi tional heater are properly installed Then activate auxiliary additional heater and check operation After performing repairs in area of fuel pipe to
96. ion Continuation of sequence fol Ee e oq ig veto Burn off run on Monitoring as for no 2 gt page 103 Metering pump V54 off Actuation of combustion air blower V6 at regulated volt age Actuation of glow plug with flame monitor Q8 post glow regulated Actuation of glow plug with flame monitor Q8 off Interrogation of resistance of Resistance of glow plug with Burn off entry in fault mem glow plug with flame monitor flame monitor Q8 outside ory fault off Q8 becomes colder specified range 2 page 105 4 Note Burn off frun on sequence gt page 110 Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation Control interval Monitoring as for no 2 gt page 103 gt page 103 13 Functional description of auxiliary additional heater 1 05 51 Audi A8 2003 gt Auol Auxiliary Heater Edition 03 2008 Coolant temperature drops below 77 C page 106 Coolant temperature contin ues to increase engine runs and heats up coolant Coolant temperature re mains between 77 and 81 C The coolant temperature rises above 125 C for a cer tain time or briefly above 135 C Heater remains in control in terval until switched off Fault entry in fault memory off fault interlock Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation Starting from control interval Monitoring as for no
97. ion is therefore to be checked and corrected if nec essary gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 After removing and installing fuel system components or the auxiliary supplementary heater the auxiliary supplementary heater is to be switched on and operated at full load for at least 70 minutes to ensure complete bleeding of the fuel pipe 9 2 Checking components of auxiliary addi 4 Note tional heater The Electrical check function for the auxiliary supplementary heater is not described in this Workshop Manual This Work shop Manual only gives a brief outline of the checking of individual components Electrical checking of the auxiliary supplementary heater is to be performed as described in the guided fault finding routine gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Special tools and workshop equipment required Voltage tester V A G 1527 B Adapter set V A G 1594 C Checking Remove auxiliary additional heater 2 page 64 Detach holder from auxiliary additional heater gt page 73 and gt page 76 TO Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Use screwdriver to lever off cover A Checking glow plug with flame monitor Q8 gt page 71 Checking combustion air blower V6 gt page 71 9 Checking circu
98. ions 36 Rep Gr 82 Auxiliary heating ees Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note Depending on last operating status and coolant temperature in auxiliary adaitional heater no load current input of auxiliary additional heater may be up to max 60 mA for a period of up to 5 hours following switch off During this period cooling of coolant is calculated by additional heater control unit J364 for time following switch off At the latest 5 hours after switch off no load current input of additional heater control unit J364 is less than 2 mA The no load current input of the remote control receivers for auxiliary heater R64 Telestart T70 and Telestart T90 T91 version is less than 1 mA the current input increases as soon as a transmission signal is received Checking connection between auxiliary supplementary heater and metering pump V54 Vehicle diagnostic testing and information system VAS 5051 A measurement mode Multimeter resist ance measurement 0 100 Q Connection Checking of Test conditions Specification Measures to be taken if read t heat ing d t match ifi at heater Aiditional pera ing does peas specifi tions Connecor Wiring to metering Ignition switched Greater than 3 Use current flow diagram B contact pump V54 off and less than to check and repair wiring 6 and con 200 gt Current flow diagrams nec
99. ions of various relays and fuses for auxiliary adai tional heater gt Current flow diagrams Electrical fault finding and Fitting locations Auxiliary supplementary heater self diagnosis procedure gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 The auxiliary heater radio remote control is available in various versions Exclusive use was made up to 05 2004 of the Tel estart T70 version As of 05 2004 the Telestart T90 version was gradually introduced instead gt Electronic parts cata logue To enable the auxiliary heater to implement the addi tional functions of the Telestart T90 feedback of confirma tion of reception of activation and deactivation signals use is made of a modified remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Elec tronic parts catalogue In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Teles art T91 type Thanks to the identical transmission pro tocol the hand transmitters and the remote control receiver for auxiliary heater R64 of the two Telestart T90 and T91 versions can exchange information with one another the T90 remote control receiver for auxiliary heater R64 can be actuated by the T91 hand transmitter and vice versa with no loss of function In the case of vehicles fitted with the Telesta
100. is necessary burning off cooling down The heater switches to control interval if the coolant tempera ture exceeds 81 C before reaching full load mode e g with a hot engine Various auxiliary supplementary heater functions are con E n 1 0 1 stantly monitored during operation the auxiliary suppl PnBnctional description of auxiliary additional heater tary heater is switched off as soon as a fault occurs Auxiliary adaitional heating operation can be monitored v a 05 Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 dj Note As additional heater can only be switched on with engine run ning circulation pump V55 is not necessary Circulation pump does however operate in additional heater mode if ve hicle is fitted with auxiliary additional heater As the additional heater only operates when the engine is run ning it is scarcely perceptible in heating mode Heater run on is audible if engine is switched off 13 1 Sequence of operation 13 1 4 Prerequisites for sequence described on the following pages when switching on heater e Coolant circuit bled and coolant temperature less than 20 C Battery A vehicle battery sufficiently charged e Sufficient fuel in tank No faults stored in fault memory of heater Ignition off and auxiliary heating mode set heater with cir culation pump V55 Engine running heater without circulation pump V55 addi tional heat
101. l If the auxiliary supplementary heater is replaced together with the supplementary heater control unit J364 check operation of at least one hand transmitter and re adapt all hand transmitters if necessary gt page 20 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 The auxiliary heater radio remote control is available in various versions Exclusive use was made up to 05 2004 ofthe Telestart T70 version As of 05 2004 the Telestart T90 version was gradually introduced instead In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and Electronic parts catalogue To enable the auxiliary heater to implement the additional functions of the Telestart T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modified remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 The remote control hand transmitter version can be seen after removing the batteries gt page 16 from the sticker indicating the part number gt Electronic parts catalogue Auxiliary heater remote control buttons and indicator lamp 4 Note The auxiliary heater radio rem
102. lation pump V55 only fitted with auxiliary heater optional extra 2 page 72 Checking glow plug with flame monitor Q8 Unplug connector C from auxiliary additional heater Measure the resistance at connector C between contact 1 and the heater housing Specification oQ Measure the resistance at connector C between contacts 1 and 2 Specification Less than 1 Q Rated value 0 236 Q 0 033 O at 25 C EE Resistances of less than 1 Q can no longer be measured with the required accuracy using workshop equipment This test can therefore only be used to detect major component dam age C B A s Resistance characteristic curve of glow plug with flame mon itor Q8 enables additional heater control unit J364 to detect whether a flame has formed in heater fa voltage of 9 V is applied to the glow plug with flame de tector the current input is between 9 and 12 A Checking combustion air blower V6 9 Removing and installing auxiliary additional heater T1 WOO Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 Unplug connector B from auxiliary additional heater Measure the resistance at connector B between contact 1 and the heater housing Specification oQ dj Note lf a voltage of 12 V is applied to combustion air blower V6 the current input is between 2 and 3 A The internal resistance of the combustion air b
103. lay different versions the de sired functions can be set by turning one of the two rotary knobs pushbuttons of the front operating and display unit Cli matronic control unit J255 or the rotary knob pushbutton for MMI operation gt Owner s manual and gt Operating instruc tions for Infotainment MMP On vehicles with a front operating and display unit Climatronic control unit J255 with a button the auxiliary heating auxiliary ventilation functions cannot be controlled by way of the rotary knob pushbutton for MMI operation installed in the centre console gt Owner s manual The function selected can be activated by pressing the same rotary knob pushbutton of the front operating and display unit Climatronic control unit J255 or the rotary knob pushbutton for MMI operation Auxiliary heating auxiliary ventilation is controlled via settings made on MMI display A full description of auxiliary Us a a ventilation control is given in the owner s manual gt Owner s manual and gt Operating instructions for Infotainment MMI 22 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 6 Diverting fuel for auxiliary additional heater AN WARNING Observe the applicable rules for cleanliness take the appro priate precautions and heed the relevant safety measures when working on open fuel system gt Fuel supply system Rep Gr 20 4 Note
104. lementary heater Select the Adaption function gt Guided fault finding func tion of vehicle diagnostic testing and information system VAS 5051 Use the input keypad to enter the adaption channel for adjust ing the CO2 content in the exhaust gas and confirm the entry gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 46 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note The hose B of the exhaust probe must not stop exhaust gas emerging from the exhaust pipe A during testing and setting There may be several reasons for the display Function unknown or cannot be implemented at present appearing in the display zone of the vehicle diagnostic testing and information system gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Auxiliary supplementary heater in starting routine Wait until the auxiliary supplementary heater switches to full load mode Auxiliary supplementary heater in part load mode or control in terval Switch off the auxiliary supplementary heatercby wayiofthe front operating and display unit Climatronic control unit J255 and on again using the vehicle diagnostic testing and infor mation system Basic setting function In this setting full load operation is then possible up to a coolant temperature of 110 C gt
105. les fitted with auxiliary addition al heater Auxiliary additional heater must not be switched on in areas where there is a danger of fire or explosion switch off auxiliary additional heater e g by pressing Econ or OFF button on front operating and display unit Climatronic control unit J255 for air conditioner or on Multi Media Interface Auxiliary additional heater must not be switched on in en closed areas without the use of an exhaust gas extractor Always observe the relevant safety regulations when working on the fuel system gt Fuel supply system Rep Gr 20 Engine must not be started if parts of the fuel system e g metering pump fuel pipe or fuel gauge sender have been re moved or opened After completing repair work on auxiliary additional heater or fuel system operation of auxiliary additional heater must be checked Before starting repair work on auxiliary additional heater Dissipate pressure in cooling system by opening the plug on the coolant expansion tank Interrupt power and fuel supply for auxiliary additional heater e g by removing fuse for auxiliary additional heater 2 Cur rent flow diagrams Electrical fault finding and Fitting locations If the auxiliary supplementary heater is to be replaced inter rogate the encoding and adaption of the supplementary heater control unit J364 by way of the Control unit replacement function of the guided fault finding rout
106. les with diesel engine not to be fitted on vehicles with petrol engine 6 Diverting fuel for auxiliary additional heater 33 Y Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 6 5 Routing of fuel pipe to auxiliary addition al heater 4 Note Fit the metering pump V54 and the corresponding fuel pipes such that they do not make contact with other components noise The sections of the fuel pipe are to be butt jointed to stop va pour bubbles accumulating at the connections The fuel pipe between the metering pump V54 and the auxiliary supplementary heater A is routed on the floor of the vehicle The brackets B not only hold the fuel pipe to the auxiliary addi tional heater A in position but also the fuel pipes to the engine gt Fuel supply system Rep Gr 20 Fuel pipe A must be routed such that it does not come into con tact with components which become warm and must be protected against heat generation which could affect operation In area behind front right wheel housing liner fuel pipe to auxiliary additional heater A is routed as illustrated for vehicles with petrol engine routing may differ from that shown in the case of vehicles with diesel engine Fuel pipe A and fuel hose B must be routed so that they do not come into contact with components which become warm and must be protected against heat generation which could affect op eration Brackets C and D hold fuel
107. liary additional heater 79 C amp D Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 10 3 2 Detaching and re attaching bracket coolant shutoff valve and intake air si lencer 1 Auxiliary additional heater Q Different design of burn er unit and different con trol unit for vehicles with petrol or diesel engine gt page 84 and gt Electronic parts cata logue Q Dismantling and assem bling gt page 84 2 Intake air silencer Q Air intake must be unim peded if necessary check for dirt and clean QO Attaching page 81 3 Clamp 4 Intake hose QO Attaching page 81 5 Bracket Q For intake air silencer 6 Bolt 7 Bracket Q For auxiliary additional heater Q Different versions gt page 82 Q Illustration shows brack et for vehicles with 6 cyl or 8 cyl petrol engine and for vehicles with 6 cyl diesel engine at start of production for 17 16 8 9 14 15 14 482 0436 which rubber grommets and bushings are used for attachment in vehicle gt page 82 8 Rubber grommet Q Not fitted if bracket for auxiliary additional heater is secured in position in vehicle with bonded rubber element page 82 and gt page 81 9 Bushing Q Not fitted if bracket for auxiliary additional heater is secured in position in vehicle with bonded rubber element page 82 and gt page 81 10 Bushings Q Install in correct position 11 Heater coolant shutoff valve
108. lower V6 is between 3 and 6 Q 40 Q if the combustion air blower has not been in operation for a lengthy period Since resistances of less than 10 Q can no longer be measured with the required degree of accuracy using workshop equipment internal re sistance testing can only be used to detect serious component damage Checking circulation pump V55 4 Note A circulation pump is only fitted with auxiliary or auxiliary addi tional heater version Heaters used exclusively as additional heat er have no circulation pump V55 Unplug connector A from auxiliary additional heater Measure the resistance at connector A between the two con tacts contacts 1 and 2 and the heater housing Specification oQ dj Note lf a voltage of 12 V is applied to circulation pump V55 the current input is between 1 and 1 5A Internal resistance cannot be measured at recirculation pump V55 this is prevented by the electronics in the circulation pump T2 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue 10 Dismantling and assembling auxili ary additional heater There are different versions of the auxiliary additional heater Version 1 auxiliary heater without additional heater is in stalled as optional extra on vehicles with petrol engine Version 2 auxiliary additional heater is installed as optional extra on vehicles with dies
109. maximum heating output e g temperature prese lection Hi on front operating and display unit Climatronic 60 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue control unit J255 on vehicles with auxiliary heater auxiliary additional heater on vehicles with diesel engine Allow engine to run for approx 3 minutes at increased idle speed e g 2300 rpm Activate auxiliary additional heater Switch off the engine leave the ignition switched off lfapplicable wait until the front operating and display unit Cli matronic control unit J255 is started up by the auxiliary supplementary heater and then set the air conditioner to max imum heat output e g Hi temperature setting Wait roughly 5 minutes leave auxiliary additional heater Switched on 4 Note Auxiliary adaitional heater may not start depending on coolant temperature may switch to control interval gt page 101 fairis present in coolant circuit auxiliary adaitional heater may overheat and Control unit defective fault is stored If this fault occurs once or several times in succession depending on the auxiliary supplementary heater version the supple mentary heater control unit J364 is interlocked and the fault cannot be erased again until the interlock has been cancelled by way of the Adaption function gt Guided fault finding function of vehicl
110. moving residue from burner element of auxiliary additional heater operation with vegetable oil or rape oil methylester fuel only llli 49 Incorporation of auxiliary additional heater into coolant circuit 53 Incorporation of supplementary heater into coolant circuit 00 005 53 Incorporation of auxiliary supplementary heater into coolant circuit 55 Incorporation of auxiliary supplementary heater into coolant circuit 57 Operation of and removing installing heater coolant shutoff valve N279 1 eee 58 Bleeding coolant circuit as cesis bus ee aba ed duet Rai ale bh edeed beAek du 60 Note for vehicles with the problem poor heat output with engine running 61 Removing and installing auxiliary additional heater eee es 64 Removing and installing auxiliary additional heater lille 65 Checking components of auxiliary additional heater llle 70 Dismantling and assembling auxiliary additional heater lessen 73 Detaching and re attaching add on components from to additional heater 73 Removing and installing auxiliary supplementary heater exhaust system 76 Detaching and re attaching add on components from to auxiliary additional heater 76 Attaching intake hose with intake air silencer llis 81 Attaching bracket for auxiliary additional heater wit
111. n Unfasten the clip C and detach the fuel pipe Connect the fuel pipe detached to the diesel extraction unit VAS 5226 Connect the diesel extraction unit VAS 5226 to the workshop compressed air system gt Fuel supply system Rep Gr 20 Completely fill the fuel pipe detached with fuel by briefly ex tracting the air Re connect the fuel pipe detached to the metering pump After re installing all the components removed switch on the De d auxiliary supplementary heater and let it operate in full load mode for roughly 10 minutes 6 2 Diverting fuel for auxiliary additional heater from fuel tank AN WARNING Observe the applicable rules for cleanliness take the appro priate precautions and heed the relevant safety measures when working on open fuel system gt Fuel supply system Rep Gr 20 6 Diverting fuel for auxiliary additional heater 25 TI Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 4 Note Vehicles with no auxiliary supplementary heater are fitted with a fuel delivery unit with no additional connection for auxiliary supplementary heater fuel diversion and with no suction pipe in the fuel tank gt Electronic parts catalogue Incorrect routing of fuel diversion pipe in fuel tank can lead to auxiliary aaditional heater operating problems if fuel tank is not completely full fault message No flame or Repeated flame interruption
112. n ex cessive coolant temperature full load operation of the auxili ary supplementary heater can be maintained up to a coolant temperature of approx 110 C and for max approx 10 minutes z by making an entry in the Basic setting function gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5057 f there is not sufficient time the process can be repeated Adjusting Necessary test requirements satisfied gt page 39 Preliminary work performed as described gt page 40 Switch on the auxiliary supplementary heater by way of one of the two rotary knobs pushbuttons of the front operating and display unit Climatronic control unit J255 via the Multi Me dia Interface MMI or by way of the vehicle diagnostic testing and information system VAS 5051 A Basic setting func tion on vehicles with auxiliary heater gt Owner s manual gt Operating instructions for Infotainment MMI and gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5051 Switch on the supplementary heater by way of the vehicle di agnostic testing and information system VAS 5051 A Basic setting function vehicles with diesel engine with supplemen tary heater only no Auxiliary heater optional extra gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Check CO2 carbon dioxide conte
113. nated With the supplementary heater control unit J364 fitted at present the maximum value which can be entered is 255 When checking the delivery rate the metering pump V54 is actuated for 250 s at 5 hertz 5 pulses per second The metering pump V54 actuation time is entered in seconds in the adaption channel When the Pipe filling function is next selected in Basic setting the metering pump V54 is actu ated for this period The Pipe filling function can however only be performed in Basic setting if this has been enabled ina further adaption channel gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 Depending on the supplementary heater control unit J364 rounding errors on conversion after entering the encoded dis play value e g 250 may lead to the following message being displayed Note Value to be stored 250 value actually stored 249 f this display appears enter e g 251 instead of 250 if necessary to store the exact value and confirm the display Values entered which are not within the specified limits are displayed but not implemented fthe value entered is too high or too low the display is auto matically reset to the lowest or highest value still permitted Inthe Pipe filling routine of the Basic setting function the metering pump V54 is actuated at a frequency of 5 hertz 5 pulses per
114. nd information system VAS 5051 8 5 Bleeding coolant circuit Bleed engine coolant circuit as specified Engine mechan ics Rep Gr 19 4 Note Up to Model Year 2005 auxiliary supplementary heaters were fitted on which there was a delay of 10 seconds between the re ception of a corresponding request from the front operating and display unit Climatronic control unit J255 and implementation of the heating mode deactivation time by the supplementary heat er control unit J364 With such auxiliary supplementary heaters there is a risk of overheating of the coolant in the auxiliary heater under certain usage conditions In the event of a complaint of this nature the adaption is therefore to be checked and corrected if necessary gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 Further procedure for vehicles with diesel engine and additional heater without Auxiliary heater optional extra No additional operations are required constant flow through additional heater with engine running Further procedure for vehicles with auxiliary heater for petrol en gines or auxiliary additional heater for diesel engines On vehicles with heater coolant shutoff valve N279 switch auxiliary additional heater on and off again after approx 3 min following initial starting of engine in warm up phase Once engine has reached operating temperature set air con ditioner to
115. ne QO Incorporation into en gine coolant circuit gt Engine mechanics Rep Gr 19 7 Cap 8 Coolant supply from engine Q Incorporation into engine coolant circuit gt Engine mechanics Rep Gr 19 amp 82 10033 9 Connector for coolant hoses 10 Circulation pump V55 Q Under certain conditions circulation pump is also actuated with engine running to assist engine coolant pump page 61 8 4 Operation of and removing installing heater coolant shutoff valve N279 Function 4 Note Currently only fitted to vehicles with Auxiliary heater optional extra Not fitted on vehicles with diesel engine on which the auxiliary supplementary heater is only used as supplementary heater vehicles without Auxiliary heater optional extra 58 Rep Gr 82 Auxiliary heating e Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer If voltage is not applied to heater coolant shutoff valve N279 large coolant circuit coolant can flow from connection C from pump valve unit to connection D to engine Coolant from engine flows via connection A to connection B and from there to auxiliary additional heater If voltage is applied to heater coolant shutoff valve N279 small coolant circuit coolant can flow from connection for hose C from pump valve unit to connection B to auxiliary additional heater There is no flow regulating component fitted between conne
116. ngine Exhaust gas corrugated pipe A Exhaust silencer B Corrugated exhaust pipe C with exhaust tailpipe Hexagon bolt D n 4 Note Arrangement of exhaust system gt page 82 Onvehicles with 10 cyl petrol engine the design differs from this illustration however the detachment and attachment op erations are identical 10 8 Attaching spacer and insulating sleeve to exhaust system of auxiliary additional heater 4 Note Illustration shows arrangement of exhaust system for vehicles With 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production Coolant hose A and corrugated exhaust pipe B must not make contact Spacer C must be attached so that contact between exhaust system and coolant hose A is precluded in the event of vi bration The insulating sleeve D is held in position with two temper ature resistant cable ties E gt Electronic parts catalogue fcoolant hose makes contact with exhaust pipe it will be damaged as a result of the high temperatures at the exhaust system during auxiliary additional heater operation Illustration shows exhaust system installed in vehicles with 6 cyl or 8 cyl petrol engine and a coolant hose as installed in vehicles with auxiliary heater or auxiliary additional heater 10 Dismantling and assembling auxiliary additional heater 83 TI Audi A8 2003 gt Ave Auxiliary Heater Edition
117. nic parts catalogue To enable the auxiliary supple mentary heater to implement the additional functions of the Teles art T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modi fied remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with index J as of hardware and software number 0710 the auxiliary sup plementary heater is designed for the Telestart T90 T91 remote control gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5057 10 1 Detaching and re attaching add on components from to additional heater Removing additional heater gt page 64 10 Dismantling and assembling auxiliary additional heater T3 CAVV Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 4 Note At the start of production auxiliary heater control unit J364 was identical with auxiliary additional heater control unit in Stalled with version for vehicles with diesel engine At a later date control units may be fitted which no longer feature certain functions with the additional heater version introduction not yet finalised gt Electronic parts catalogue n contrast to the auxiliary additional heater the additional heater has no circulation pump V55 Illustration shows additional heater a
118. noise under Audi A8 operating con ditions in comparison with type DP i particularly when using pet rol 24 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue Q Checking fuel delivery 2 page 27 Q Checking actuation gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 5 Fuel pipe Q Routing of fuel pipe between metering pump and auxiliary additional heater page 34 and gt Fuel supply system Rep Gr 20 6 Auxiliary additional heater QO Different versions for vehicles with petrol or diesel engine gt page 84 6 1 Filling fuel pipe to metering pump V54 with fuel bleeding 4 Note Air in the auxiliary supplementary heater fuel supply can lead to problems in auxiliary supplementary heater operation To stop air being drawn in by the metering pump V54 and con veyed to the auxiliary supplementary heater when the auxili ary supplementary heater is first switched on after working on the fuel tank or fuel delivery unit the fuel diversion pipe is to be filled with fuel bled after working in this area After working on the fuel system switch on the auxiliary sup plementary heater and let it run for some time in full load mode to check operation at least 10 minutes Bleeding fuel pipe Auxiliary supplementary heater switched off the metering pump V54 is not actuated Switch off ignitio
119. ns are set differently e g pre heating times gt Electronic parts catalogue 11 1 Incorporation of auxiliary additional heater into vehicle electrics 4 Note Incorporation of auxiliary additional heater into vehicle electrics gt Current flow diagrams Electrical fault finding and Fitting loca tions 11 Block diagram of auxiliary additional heater 91 TI Audi A8 2003 gt Auxiliary Heater Edition 03 2008 1 Additional heater control unit J364 with connector con sole m Control unit is fitted with temperature sensors for determining coolant temperature and to safeguard against over heating Additional heater con trol unit J364 design may vary between aux iliary additional heater and additional heater without auxiliary heat er additional heater ver sion does not feature certain functions Additional heater con trol unit J364 is con nected to burner hous ing heat exchanger and is not to be replaced as individual component at present 2 Circulation pump V55 m m Only fittediion auxiliary addition l heater ver sion Not fitted on vehicles with additional heater without Auxiliary heat er optional extra 3 Combustion air blower V6 4 Glow plug with flame moni tor Q8 5 2 way connector m m Contact 1 Auol y A82 0167 Power supply terminal 30
120. nt in auxiliary additional heater exhaust gas gt page 41 7 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas 45 TIT Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 4 Note Auxiliary adaitional heater must have been operating for at least 1 minute in full load mode to enable adjustment to be implemented When adjusting the CO2 content in the exhaust gas the CO2 measuring instrument must be ready for operation and the exhaust measurement probe B fitted in the exhaust pipe A of the auxiliary heater such that it does not stop exhaust gas emerging If the auxiliary heater switches from full to part load operation during CO2 adjustment on account of an excessive coolant temperature full load operation of the auxiliary heater can be maintained up to a coolant temperature of approx 10 C and for max approx 10 minutes in the Basic setting function If this period is not sufficient the procedure can be repeated gt Guided fault finding function of vehicle d agnostic testing and information system VAS 5051 Alteration of the CO2 content of the exhaust gas involves changing the actuation voltage for the combustion air blower V6 by way of the Adaption function gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 Exit from the Basic setting function if this function has been used to activate the auxiliary supp
121. of vehicle diagnostic testing and information system VAS 5051 The auxiliary heater can only be switched on by the supple mentary heater control unit J364 the Auxiliary heating on function can only be activated if There is sufficient fuel in the fuel tank With the ignition on the fuel gauge A must not be in the red zone 2 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 reading measured value block No faults must be stored in additional heater control unit J364 The battery A vehicle battery is sufficiently charged There are no faults stored in the vehicle data bus system 5 4 2 Switching auxiliary heating auxiliary ventilation on and off Switch on ignition Depending on the vehicle model auxiliary heating auxiliary ven tilation is set with the ignition switched on either by way of the front operating and display unit Climatronic control unit J255 version with button or via the rotary knob pushbutton for operation of the MMI version with no button on the front operating and display unit and the MMI Multi Media Interface display 5 Layout of components for auxiliary additional heater in vehicle 2 1 WO Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 dj Note After pressing the setup button on the front operating and pose y unit dit control unit J255 or by selecting the A C function on the MMI disp
122. on ssa adesse ow Re ae pau D eae Beaks 102 Required heating output between 50 and 100 96 000 eee 111 Required heating output less than 5096 2 ce ees 111 ra te Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue 82 Auxiliary heating 1 Servicing auxiliary additional heater 1 1 Contact corrosion Contact corrosion can occur if use is made of unsuitable con necting elements bolts nuts washers rivets plugs grommets adhesives etc For this reason only connecting elements with a special surface coating are fitted at the factory e g bolts which can be recog nised at present from their greenish colour as well as non conductive rubber components plastic parts and adhesives Always use genuine parts Always fit new parts in cases of doubt about reusability Accessories must be approved by Audi AG Damage caused by contact corrosion is not covered by warranty 1 2 Notes on auxiliary additional heater Various encoding options are provided in the additional heater control unit J364 Only undervoltage shutoff at a fixed value is however to be encoded for the supplementary heater gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 encoding control unit Ifa fault occurs several times in succession e g fault flame interruption auxiliary additional heater is interlocked Reac tivation is only possible after erasing
123. only no Auxiliary heater optional extra are not fitted with a cir culation pump V55 On such vehicles the engine must be running to circulate the auxiliary supplementary heater coolant and to prevent overheating Select the Guided fault finding function gt Guided fault find ing function of vehicle diagnostic testing and information system VAS 5051 Read out the fault memories of all systems with self diagnosis capability paying particular attention to the following vehicle systems gt Guided fault finding function of vehicle diagnos tic testing and information system VAS 5051 Dash panel insert Air conditioner heater electronics Supplementary auxiliary heater Energy management control unit J644 9 9 9 9 Data bus diagnostic interface J533 Eliminate the cause of any faults displayed in the vehicle sys tems and erase the fault memory gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Select the supplementary heater control unit J364 in the Guided fault finding function gt Guided fault finding func tion of vehicle diagnostic testing and information system VAS 5051 40 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Switch on the exhaust emission test station VAS 6300 and insert the appropriate exhaust probe hose B in the auxiliary supplementary heater exhau
124. ont operating and display unit Climatronic control unit J255 on the basis of the actual temperatures measured and the speci fied temperature set gt Air conditioning Rep Gr 87 There are different versions of the auxiliary heater remote control and of the auxiliary supplementary heater Exclusive use was made up to 05 2004 of the Telestart T70 remote control version As of 05 2004 the Teles art T90 version was gradually introduced instead In Model Year 2008 production Is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue To enable the auxiliary supple mentary heater to implement the additional functions of the Teles art T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modi fied remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with index J as of hardware and software number 0710 the auxiliary sup plementary heater is designed for the Telestart T90 T91 remote control gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5057 Different auxiliary heater remote control hand transmitter ver sions are available Telestart T90 T91 and T70 The Audi A8 is only to
125. ote control is available n various versions Exclusive use was made up to 05 2004 of the Tel estart T70 version As of 05 2004 the Telestart T90 version was gradually introduced instead In Model Year 2008 pro duction is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue To enable the auxiliary heater to implement the additional functions of the Telestart T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modi fied remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue and gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5051 The remote control version can be seen after removing the batteries gt page 20 from the sticker arrow indicating the part number Electronic parts catalogue The range of the remote control is approx 600 m The range can be significantly reduced due to obstacles e g buildings between the remote control and the vehicle 1 6 Rep Gr 82 Auxiliary heating A82 10020 ee Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 5 1 1 Telestart T70 remote control hand transmitter version A On button B Off button C Indicator lamp only flashes red 4 Note Indi
126. ows corrugated pipe installed in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production Q For vehicles with 6 cyl diesel engine from model year 2004 gradual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine the exhaust routing is different gt page 76 and page 82 12 Coolant hose 13 Hexagon nut Q Different versions gt page 76 and gt page 82 Q Illustration shows exhaust routing in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production Q For vehicles with 6 cyl diesel engine from model year 2004 gradual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine the exhaust routing is different gt page 76 and page 82 14 Exhaust silencer 15 Exhaust pipe Q 90 angled Q For vehicles with 6 cyl diesel engine from model year 2004 gradual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine the exhaust silencer is not fitted with an angled exhaust pipe 2 page 76 and page 82 78 Rep Gr 82 Auxiliary heating Auxiliary Heater Edition 03 2008 Aud Audi A8 2003 gt Yi 16 Corrugated exhaust pipe m Q m Different versions gt page 82 Illustration shows exhaust routing in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production For vehicles with 6 cyl diesel engine from model year 2004 g
127. page 64 Use screwdriver to lever off cover A 10 12 A Assignment of auxiliary additional heat er connector console Connector A for circulation pump V55 4 Note Only fitted on Auxiliary heater or Auxiliary additional heater version Connector B for combustion air Blower V6 Connector C for glow plug with flame monitor Q8 86 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 10 13 Removing and installing combustion air blower V6 4 Note Delivery of combustion air blower is subject to certain toleran ces During production of auxiliary adaitional heater CO2 con tent in exhaust gas is set on a test stand at additional heater control unit J364 Replacement of combustion air blower on these heaters could lead to CO2 content in exhaust gas ex ceeding permitted range After replacing combustion air blower CO2 content in exhaust gas must be checked and if necessary adjusted gt page 39 j As of 02 2003 modified auxiliary supplementary heaters were gradually introduced On these heaters the combustion air blower V6 A and the burner housing E are each fitted with an additional locating pin F and G In addition combustion air blower V6 A is attached to burner housing E using only 4 bolts Additional bores are provided in gasket B for locating pins Furthermore burner element
128. plementary heater control unit J364 radio signal can no longer be received the no load current input decreases from approx 1 mA to approx 0 04 mA gt Guided fault finding function of vehicle diagnos tic testing and information system VAS 5051 reading meas ured value block 5 1 2 Telestart T90 T91 remote control hand transmitter version 4 Note In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type page 10 and Electronic parts catalogue 5 Layout of components for auxiliary additional heater in vehicle 1 T Y Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 A On button B Off button C Indicator lamp flashes red or green 1 8 Rep Gr 82 Auxiliary heating ee Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer dj Note In order that remote control detects pressing of a button and transmits a radio signal the relevant button must be pressed for approx 2 seconds Owner s Manual fremote control batteries are discharged to such an extent that radio signal can no longer be transmitted with sufficient strength indicator lamp C no longer illuminates on pressing ON button A or OFF button B Asa functional check indicator lamp C lights green briefly approx 2 seconds after pressing ON button A factivation signal has been properly receive
129. r is ensured due to pre tension Moulded gaskets provide seal between cover frame of addi 4 dm tional heater control unit J364 and burner housing These connections must be absolutely leakproof and are thus checked for leaks during auxiliary additional heater produc tion As checking cannot be performed as part of service work bolts arrows of control unit cover must not be removed This is also the reason why additional heater control unit J364 cannot currently be replaced as a separate component 11 Block diagram of auxiliary additional heater 93 0 Audi A8 2003 gt Ave Auxiliary Heater Edition 03 2008 12 Block diagram of auxiliary additional 4 Note heater actuation with remote control At present the remote control is only available for vehicles with auxiliary heater optional extra or with auxiliary supplemen tary heater optional extra The remote control receiver for auxiliary heater R64 is in Stalled in the passenger compartment on the left in the direc tion of travel beneath the trim in the area next to the seat backrest gt page 99 and gt Communication Rep Gr 91 Auxiliary heater remote control hand transmitter only transmits on off signal Whether auxiliary heating mode is necessary to attain the specified temperatures set in the front operating and display unit Climatronic control unit J255 or whether auxili ary ventilation mode is sufficient is determined by the fr
130. radual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine the exhaust routing is different gt page 76 and page 82 17 Spacer m Q m Arrangement in exhaust system gt page 83 Illustration shows exhaust routing in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production For vehicles with 6 cyl diesel engine from model year 2004 gradual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine not fitted different exhaust routing gt page 76 and gt page 82 18 Insulating sleeve m Q m Arrangement in exhaust system gt page 83 Illustration shows exhaust routing in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production For vehicles with 6 cyl diesel engine from model year 2004 gradual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine not fitted different exhaust routing gt page 76 and page 82 19 Cable ties m Q d Arrangement in exhaust system gt page 83 Illustration shows exhaust routing in vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production For vehicles with 6 cyl diesel engine from model year 2004 gradual introduction or 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine not fitted different exhaust routing gt page 76 and page 82 10 Dismantling and assembling auxi
131. regulated Actuation of glow plug with flame monitor Q8 off 13 Functional description of auxiliary additional heater 1 07 Wi Audi A8 2003 gt Aun Auxiliary Heater Edition 03 2008 Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation Interrogation of resistance of of resistance of glow plug with flame monitor Q8 becomes colder OFF Resistance of glow plug with glow plug with Burn off entry in fault mem flame monitor Q8 outside ory fault off specified range Control sequence Possible cause of deviation Continuation of sequence fol lowing deviation deviation Auxiliary ventilation with auxiliar ventilation with auxiliary additional heater only heater only er in signal From radio receiver R64 Front operating and display unit Climatronic control unit J255 interrogation via da ta bus system Front operating and display unit Climatronic control unit J255 interrogation via data bus system Auxiliary ventilation mode Cut out signal From radio receiver R64 Information to front operating and display unit Climatronic control unit J255 via data bus system e Actuation of front operating and display unit Climatronic control unit J255 off dj Note Front operating and display Auxiliary heating winter unit Climatronic control unit mode gt page 102 J255 decides heating mo
132. rical system Rep Gr 94 Detach the fuel pipe A from the auxiliary supplementary heater Attach measuring cup B in area of fuel pipe A e g with wire and insert fuel pipe into cup Extend fuel pipe A if necessary with hose C 6 3 3 Complete filling of fuel pipe Test requirements satisfied page 27 and test preparation per formed gt page 27 Switch ignition on and all electrical equipment off Select the function Supplementary auxiliary heater guided fault finding on the vehicle diagnostic testing and information system VAS 5051 A gt Guided fault finding function of ve hicle diagnostic testing and information system VAS 5051 4 Note Auxiliary supplementary heater self diagnosis can only be started with the ignition switched on the data bus diagnostic interface J533 is only active when the ignition is on Once the auxiliary supplementary heater has switched to diagnostic mode it is pos sible to continue with self diagnosis even with the ignition switch ed off 28 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Completely fill the fuel pipe A from the metering pump V54 to the graduated beaker B with fuel 2 Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note The delivery rate can only be checked by way of the Basic setting function This do
133. rmation system VAS 5051 Run additional heater with petrol for at least 30 min cane fthe coolant temperature increases to above 75 C within 30 minutes and the supplementary heater switches to part load operation it can be switched on again by way of the Basic setting function and operated up to a coolant temperature of 110 C starting from the control interval is possible For this purpose the supplementary heater is first to be switched off by way of the Basic setting function and then switched on again by way of the Basic setting function gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 As the supplementary heater operating time is limited to max 70 minutes in the Basic setting function in which the heater s operated up to a coolant temperature of 110 C the Basic setting function is to be implemented a total of 3 times in this case For this purpose the supplementary heater is first to be switched off on completion of the activation time and at the end of the run on time by way of the Basic setting function and then back on again by way of the Basic setting function On vehicles with auxiliary additional heater heater with circula tion pump V55 Special tools and workshop equipment required Battery charger 60 A VAS 5904 Switch on ignition 7 Checking and adjusting CO2 content in auxiliary additional
134. rol engine and for vehicles with 6 cyl diesel engine at start of production exhaust silencer is attached to bracket Bracket B is installed in vehicles with 6 cyl gradual intro duction in model year 2004 8 cyl diesel engine and 10 cyl or 12 cyl petrol engine the exhaust silencer is not attached to the bracket different exhaust routing gt page 76 and gt page 82 Auxiliary additional heater brackets A and B are secured in position in vehicle at holes C and D with bolts rubber grommets and bushings Hole E is used for attachment with bonded rubber element washer and hexagon nut tolerance equalisation between vehicle and bracket is achieved via hole E If applicable the fastening elements are also to be or dered on replacing the bracket gt page 81 and gt Electronic SS D parts catalogue 10 7 Auxiliary additional heater exhaust sys tem 10 7 1 Exhaust system for vehicles with 6 cyl or 8 cyl petrol engine and 6 cyl diesel engine at start of production Corrugated exhaust pipe A with spacer and insulating sleeve Exhaust silencer B Corrugated exhaust pipe C with exhaust tailpipe A82 0439 82 Rep Gr 82 Auxiliary heating Pou Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 10 7 2 Exhaust system for vehicles with 6 cyl diesel engine gradual introduction in model year 2004 8 cyl diesel engine and 10 cyl or 12 cyl petrol e
135. rt T91 remote control version use is however only ever to be made of the components developed for the Telestart T91 version slightly larger range gt Electronic parts catalogue Different auxiliary heater remote control hand transmitter ver sions are available Telestart T90 T91 and T70 The Audi A8 is only to be fitted with the version approved for this vehicle gt page 16 and Electronic parts catalogue 1 0 Rep Gr 82 Auxiliary heating Audi A8 2003 gt I Auxiliary Heater Edition 03 2008 Aue 1 Multi Media Interface MMI Q MMIlis used to enter and display the various aux iliary additional heater and auxiliary ventilation actuation functions Q After pressing the Set up button on the front operating and display unit Climatronic control unit J255 or selecting the A C function via the Multi Media Inter face MMI terminal the various auxiliary heating and auxiliary ventilation actuation functions are presented on the MMI display gt Owner s man ual and gt Operating in structions for Infotain ment MMI Q Operation of the auxili ary supplementary heater via the MMI and the corresponding dis plays are described in the owner s manual gt Owner s manual and gt Operating instructions for Infotainment MMP Q If there is insufficient fuel in the tank fuel gauge in red zone the auxiliary heater cannot be switched on the tick in the MMI for th
136. s installed e g in vehicles with 6 cyl diesel engine at start of production For additional heaters which are installed in e g vehicles with 8 cyl diesel engine or in vehicles with 6 cyl diesel engine gradually intro duced in model year 2004 design of exhaust system differs Items 11 to 27 from this illustration gt page 76 1 Additional heater Q The design may differ for vehicles with diesel engine with auxiliary supplementary heater and supplementary heater without auxiliary heater gt page 84 and gt Electronic parts cata logue Q Dismantling and assem bling 2 page 84 2 Intake air silencer Q Air intake must be unim peded if necessary check for dirt and clean QO Attaching page 81 3 Clamp 4 Intake hose O Attaching gt page 31 5 Bracket Q For intake air silencer 6 Bolt 7 Bracket Q For additional heater Q Different versions 2 page 82 Q Illustration shows brack et for vehicles with 6 cyl diesel engine for which rubber grommets and bushings are used for attachment in vehicle 8 Rubber grommet Q Not fitted if bracket for additional heater is secured in position in vehicle with bonded rubber element gt page 82 and page 81 74 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue 9 Bushing QO Not fitted if bracket for additional heater is secured in position in vehicle with bonded rub
137. s of measured values voltage temperature etc 13 1 3 Heater full part load heating sequence Sequence Duration Actuation Resistance meas approx urement Metering Glow plug Glow plug with pump with flame flame monitor Q8 V54 monitor with Q8 with End of starting sequence 12V 3Hz ov yes Fullload combustion Untilccoolant 12M 3 Hz OV yes temperaturedn heater reaches 75 C e Switching from full load to part 5 seconds from 12 V from 3 Hz OV yes load mode to to 7V 1 5 Hz Part load heating Until coolant 7M 1 5 Hz OV yes temperature in heater drops below 73 C or reaches 81 C 13 Functional description of auxiliary additional heater 1 09 CAVV Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 Duration approx Sequence Resistance meas urement Actuation Switching from part load to full load operation if coolant tem perature drops below 73 C Full load heating 2 page 109 Switching from part load op eration to control interval if coolant temperature reaches 81 C Burn off run on 2 page 110 4 Note 1 Hertz Hz corresponds to 1 pulse per second Up to 50 sec Metering pump Glow plug Glow plug with with flame flame monitor Q8 monitor Q8 with from 7 V The voltages times and frequencies listed in the table are ap proximate values regulated by the control unit on th
138. s per sec x 250 sec Re install all the components removed on completion of the envisaged work If the fuel delivery rate is outside the tolerance range Check the fuel pipe from the fuel tank via the metering pump V54 to the auxiliary supplementary heater for damage and proper routing gt page 23 f no fault is found replace metering pump V54 gt page 32 Inthe event of auxiliary additional heater starting problems despite correct fuel delivery check CO2 content in exhaust gas gt page 39 Ifthe fuel delivery is in the lower tolerance range less than 74 ml and there are starting problems with the auxiliary supple mentary heater or Poor heat output has been registered gt page 61 replace the metering pump V54 if necessary gt page 32 6 4 Removing and installing metering pump V54 4 Note Fit the metering pump V54 and the corresponding fuel pipes such that they do not make contact with other components noise The sections of the fuel pipe are to be butt jointed to stop va pour bubbles accumulating at the connections 32 Rep Gr 82 Auxiliary heating ee Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer AN WARNING Observe the applicable rules for cleanliness take the appro priate precautions and heed the relevant safety measures when working on open fuel system gt Fuel supply system Rep Gr 20 Removing Switc
139. sage conditions In the event of a complaint of this nature the adaption is therefore to be checked and corrected if necessary gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 8 1 Incorporation of supplementary heater into coolant circuit 4 Note Vehicles with diesel engine without Auxiliary heater optional extra are fitted with additional heater auxiliary heater without circulation pump V55 fvehicles with diesel engine are fitted with auxiliary heater as optional extra this is also actuated as additional heater For all components not mentioned refer to gt Engine me chanics Rep Gr 19 Tubing from engine to additional heater and from pump valve unit to engine differs depending on engine version Engine mechanics Rep Gr 19 gt Direction of coolant flow with engine running and in additional heater mode 8 Incorporation of auxiliary additional heater into coolant circuit 53 COLD Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 1 Additional heater 2 Air conditioner pump valve unit QO Incorporation into cool ant circuit 2 Air condi tioning Rep Gr 87 3 Right heat exchanger of air conditioner unit 4 Left heat exchanger of air conditioner unit 5 Coolant return to engine CD Incorporation into en gine coolant circuit gt Engine mechanics Rep Gr 19 6 Coolant supply from engine D Incorpor
140. second The delivery rate set in the metering pump V54 is approx 0 064 ml per stroke 0 064 1000 litres There may be several reasons for the display Function un known or cannot be implemented at present appearing in the display zone gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5051 Once the Pipe filling function has been started it cannot be terminated It is implemented in full by the control unit regard less of any entries made by way of the tester Wait until set time has elapsed and metering pump V54 is no longer actuated 6 Diverting fuel for auxiliary additional heater 31 05 Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 4 Note Depending on the control unit version the vehicle diagnostic sys tem display switches from e g Pipe filling to End or Function unknown or cannot be implemented at present Terminate guided fault finding gt Guided fault finding func tion of vehicle diagnostic testing and information system VAS 5051 Measure the fuel delivery of the metering pump V54 0n com pletion of the Basic setting Pipe filling function Specification 80 ml 8 ml permissible tolerance range 72 to 88 ml 4 Note One millilitre ml corresponds to 1 1000 litre or crn The specified delivery rate is obtained from the following arith metic value 0 064 ml per stroke x 5 pulse
141. ssembling auxiliary additional heater 85 05 Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 Q Atthe start of production the design of the supplementary heater control unit J364 for the Supple mentary heater without auxiliary heater version was the same as that of the auxiliary supplementary heater control unit installed with the version for vehicles with diesel engine At a later date the Supple mentary heater without auxiliary heater version may be fitted with control units no longer featuring certain functions for the Supplementary heater without auxiliary heater version introduction not yet finalised gt Electronic parts catalogue Q There are different versions of the supplementary heater control unit J364 for petrol and diesel certain functions are set differently e g pre heating times Electronic parts catalogue Q Different versions depending on production period gt page 87 and gt Electronic parts catalogue 4 Note At present the supplementary heat er control unit J364 the burner housing and the heat exchanger are not available as replacement parts on account of component protec tion introduction not yet finalised gt Electronic parts catalogue 11 Cover Q For connector console Q Removing and installing 2 page 86 Q Assignment of connector console gt page 86 10 11 Removing and installing connector con sole cover Remove auxiliary additional heater gt
142. st pipe A 7 1 Checking CO content in auxiliary addi tional heater exhaust gas 4 Note For this test the auxiliary supplementary heater can be switched on by way of the rotary knob pushbutton of the front operating and display unit Climatronic control unit J255 via the Multi Media Interface MMI or using the remote control For activation with remote control the temperature setting on the front operating and display unit Climatronic control unit J255 of the air conditioner must however be Hi as other wise depending on the ambient temperature the auxiliary ventilation function is activated and the auxiliary heater does not start up gt Owner s manual and gt Operating instructions for Infotainment MMI Forthis check the auxiliary supplementary heater can also be switched on by way of the Basic setting function gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5051 Inthe Basic setting function the auxiliary supplementary heater can be operated up to a coolant temperature of 110 C and starting from the control interval is possible In this case the operating time is limited to max 10 minutes Checking Necessary test requirements satisfied gt page 39 Preliminary work performed as described gt page 40 7 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas 4 1 WMD Audi A8 2003 gt Auo Auxili
143. t Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 If depending on the version of the supplementary heater con trol unit J364 the auxiliary supplementary heater cannot be activated on a new vehicle or in the case of a newly installed auxiliary supplementary heater the component protection function may be active if a large number of faults occurred simultaneously at some point this fault is no longer displayed although it is still active If necessary perform re adaption of 1 Servicing auxiliary additional heater 1 CEED Audi A8 2003 gt Auc Auxiliary Heater Edition 03 2008 the component protection function as for a newly installed auxiliary supplementary heater to cancel component protec tion gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Upto Model Year 2005 auxiliary supplementary heaters were fitted on which there was a delay of 10 seconds between the reception of a corresponding request from the front operating and display unit Climatronic control unit J255 and imple mentation of the heating mode deactivation time by the sup plementary heater control unit J364 With such auxiliary supplementary heaters there is a risk of oyerheating of the coolant in the auxiliary heater under certain usage conditions In the event of a complaint of this nature the adaption is there fore to be checked and corrected
144. tank fuel gauge in dash panel insert not in red zone Battery A vehicle battery fully charged Auxiliary additional heater fully installed and connected to ve hicle electrics All auxiliary supplementary heater fuses OK as per current flow diagram gt Current flow diagrams Electrical fault finding and Fitting locations Encoding and adaption of the supplementary heater control unit J364 OK gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5051 Auxiliary additional heater off 6 3 2 Preparation Test requirements satisfied page 27 With the ignition switched off connect up the vehicle diagnos tic testing and information system VAS 5051 A with the diagnostic cable VAS 5051 5A to the 16 pin diagnosis socket in the vehicle gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5051 Switch on ignition Read out the fault memories of all systems with self diagnosis capability paying particular attention to the following vehicle systems Guided fault finding function of vehicleediagnos tic testing and inforrmmation systerm VAS 5051 Dash panel insert Air conditioner heater electronics Supplementary auxiliary heater Data bus diagnostic interface J533 9 9 9 9 Energy management control unit J644 Eliminate the cause of any faults displayed and erase the fault memory gt Guided fault finding f
145. tead of the set up button gt Owner s manual Pay attention to correct assign ment of the front operating and display unit Climatronic control unit J255 to control unit 1 for in formation electronics J794 gt Electronic parts catalogue dif ferent versions In the event of incorrect assignment the vari ous air conditioner and auxiliary supplementary heater functions cannot be displayed in the MMI and selected 3 Aerial selection control unit m m E m Different versions depending on vehicle equipment Designation in current flow diagram e g aerial amplifier R24 gt Current flow diagrams Electrical fault finding and Fitting locations With an additional connection forthe aerial wire to the remote control receiver for auxiliary heater R64 gt page 94 and gt Communication Rep Gr 91 Depending on vehicle equipment the remote control receiver for auxiliary heater R64 may be connected to an additional roof aerial instead of to the aerial in the rear window via the aerial amplifier R24 gt Current flow diagrams Electrical fault finding and Fitting locations and gt Communication Rep Gr 91 4 Auxiliary heating radio receiver R64 m Q m m Fitting location removing and installing gt page 99 and gt Communication Rep Gr 91 Different versions gt page 99 and gt Electronic parts catalogue Depending on vehicle equipment the remote control receiver for auxiliary he
146. tem VAS 5051 Current input of heater coolant shutoff valve N279 is approx 1A 38 Rep Gr 82 Auxiliary heating ees Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 7 Checking and adjusting CO2 content in auxiliary additional heater exhaust gas Special tools and workshop equipment required Exhaust emission test station VAS 6300 4 Note ec Bhe CO2contentin the exhaust gas cambe set inthe Adap tion function 3 Guided fault tinding function of vehicle diagnostic testing and information system VAS 5057 The supplementary heater control unit J364 can be used in the adaption function to alter actuation of the combustion air blower V6 This changes the delivery rate and more or less combustion air is conveyed into the auxiliary supplementary heater Vehicles with a diesel engine are fitted with a supplementary heater with no circulation pump V55 and no heater coolant Shut off valve N279 as supplementary heater without Aux iiary heater optional extra This version acts as additional heater and is only actuated by front operating and display unit Climatronic control unit J255 with engine running if heat generated by diesel engine is not sufficient to warm the pas senger compartment As soon as front operating and display unit Climatronic con trol unit J255 is activated by auxiliary additional heater it must be set to maximum heating output temperatur
147. the direction of travel beneath the trim in the area of the C pillar next to the rear seat backrest Communication Rep Gr 91 There are different versions of the remote control receiver for auxiliary heater R64 The Telestart T70 version was fitted at the start of production The Telestart T90 version was gradually introduced as of 05 2004 In Model Year 2008 pro duction is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue Radio receiver A is clipped into mount B Remove C pillar trim gt Body Repairs Rep Gr 70 On vehicles fitted with a remote control receiver for auxiliary heater R64 of the Telestart T90 type gradual introduction from 05 2004 to Model Year 2008 or of the Telestart T91 type gradual introduction in Model Year 2008 the supple mentary heater control unit 364 provides the remote control hand transmitter with feedback gt Owner s manual and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5057 Adaption of the remote control receiver version is to be per formed in the supplementary heater control unit J364 Tele Start T70 and Telestart T90 T91 versions gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5057 The Telestart T90 T9
148. tion gt Guided fault finding func tion of vehicle diagnostic testing and information system VAS 5051 Check the delivery rate of the metering pump V54 gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5051 Metering pump V54 is actuated at a fixed clock frequency 30 Rep Gr 82 Auxiliary heating eee Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer Observe the fuel entering the graduated beaker B from the fuel pipe C It must not contain any vapour bubbles 4 Note The metering pump V54 is actuated at a fixed clock frequen cy for the set time During this test fuel delivery is independent of instantaneous battery voltage fthe auxiliary supplementary heater does not respond switch on the ignition if applicable before selecting the supplementary heater control unit J364 again with the address word Sup plementary auxiliary heater Auxiliary supplementary heater guided fault finding can only be started with the ignition switched on or within a specified period after switching off the ignition or following the last ex change of data between the tester and a control unit the data bus diagnostic interface J533 is not constantly active On diesel vehicles with supplementary heater without Auxil lary heater optional extra the ignition must be left switched on as otherwise self diagnosis will be termi
149. tor A Electrical fault finding and contact 2 Fitting locations Replace the metering pump V54 4 Note Internal resistance of metering pump V54 4 1 Q 0 2 Q Checking actuation of the metering pump V54 gt Guided fault finding function of vehicle diagnostic testing and infor mation system VAS 5057 Checking actuation of heater coolant shut off valve N279 Vehicle diagnostic testing and information system VAS 5051 A measurement mode Multimeter resistance measurement 0 100 Q Connection at Checking of Test conditions Specification Measures to be taken if heater n reading does not match Additional op specification erations Connecor B Wiring to heater Ignition switch Greater than Use current flow dia contact 4 and coolant shutoff d off 10 and less gram to check and re connector A con valve N279 than 30 Q pair wiring gt Current tact 2 flow diagrams Electri cal fault finding and Fit ting locations Replace heater coolant shutoff valve N279 6 Diverting fuel for auxiliary additional heater 37 WMD Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 4 Note Heater coolant shutoff valve N279 is only fitted on vehicles with Auxiliary heater optional extra Checking actuation of the heater coolant shut off valve N279 gt Guided fault finding function of vehicle diagnostic testing and information sys
150. um dis ance o m from vehicle 19 Sopayout of of aos for auxiliary additional heater in vehicle The remote control receiver for auxiliary heater switched to power saving mode by the supplementary heater control unit J364 radio signal can no longer ben received the 55 Audi A8 2003 gt Aue Auxiliary Heater Edition 03 2008 5 2 Checking and replacing auxiliary heater remote control batteries Carefully detach battery cover A from remote control C 4 Note On fitting pay attention to correct position of batteries marked in battery compartment both positive terminals at same con nection parallel arrangement Always replace both batteries B Only fit batteries B with specifications corresponding to orig inal batteries e g 12V high voltage special batteries of type 23 Such batteries can be obtained for example from elec tronics dealers or from parts range gt Electronic parts cata logue fbattery is not installed properly remote control will not func tion correctly and both batteries soon become discharged 5 3 Adaption of remote control hand trans mitter in additional heater control unit J364 4 Note Keep remote control vertical transmission aerial at top whilst pressing buttons Atpresent a maximum of 3 remote control units can be adap ted in the remote control receiver for auxiliary heater R64 by way of the supplementary heater control unit J364
151. unction of vehicle diagnos tic testing and information system VAS 5051 6 Diverting fuel for auxiliary additional heater 27 05 Audi A8 2003 gt Auo Auxiliary Heater Edition 03 2008 Select the function Supplementary auxiliary heater guided fault finding on the vehicle diagnostic testing and information system VAS 5051 A gt Guided fault finding function of ve hicle diagnostic testing and information system VAS 5051 Check and if necesssary correct the encoding and adaption of the supplementary heater control unit J364 gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note Auxiliary supplementary heater self diagnosis can only be started with the ignition switched on the data bus diagnostic interface J533 is only active when the ignition is on Once the auxiliary supplementary heater has switched to diagnostic mode it is pos sible to continue with self diagnosis even with the ignition switch ed off Switch off ignition Ifthe vehicle is fitted with an air cleaner above the auxiliary supplementary heater for example remove the cleaner to gether with the air cleaner housing a different component may also be fitted here depending on the engine version gt Injec tion and ignition system Rep Gr 24 and 2 Injection and glow plug system Rep Gr 23 f necessary for ease of access remove the righbheadlight gt Elect
152. uo Auxiliary Heater Edition 03 2008 Unplug the connectors B and A from the heater 4 Note Pay attention to the correct sequence when unplugging con nectors B and A If connector A is unplugged first a fault may be stored in the supplementary heater control unit J364 and this can only be erased after unplugging the connectors and plugging them back in in the right order Plug in connector A and then connector B at the supple mentary heater control unit J364 Checking power supply and earth connection to auxiliary sup plementary heater gt page 36 Checking connection between auxiliary supplementary heater and metering pump V54 gt page 37 Checking actuation of heater coolant shut off valve N279 only fitted on vehicles with auxiliary heater as optional extra 2 page 37 Checking power supply and earth connection to auxiliary supple mentary heater Vehicle diagnostic testing and information system VAS 5051 A measurement mode Multimeter voltage meas urement 20 VDC Heater Testing of Speci Remedies if fied val specified value ue not attained Terminal Ignition Use current 30 and switch flow dia earth ed off gram to connec check and tion at repair power supple supply and mentary earth con tact 2 heater nection control gt Current unit J364 flow dia grams Electrical fault finding and Fitting locat
153. used as ad ditional heater 7 Intake air silencer 8 Auxiliary additional heater Ovo Oooo Removing and installing 2 page 64 Incorporation into coolant circuit 2 page 53 Dismantling and assembling gt page 73 Checking electrical components of auxiliary supplementary heater gt page 70 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Block diagram of auxiliary additional heater gt page 91 The radio remote control for the auxiliary heater and auxiliary additional heater is available in various versions Exclusive use was made up to 05 2004 of the Telestart T70 remote control version As of 05 2004 the Telestart T90 version was gradually introduced instead In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and Electronic parts catalogue To enable the auxiliary supplementary heater to implement the additional functions of the Telestart T90 T91 version feedback of confirmation of reception of activation and deactivation signals use is made of a modified remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with index J as of hardware and software number 0710 the auxiliary supplementary heater is designed for the Telestart T90
154. uxiliary additional heater CQ Removing and installing gt Fuel supply system Rep Gr 20 Note This illustration shows he searing flange on a vehicle with petro ens gine and front wheel drive the lay out may differ depending on the vehicle model gt Fuel supply sys tem Rep Gr 20 2 Fuel pipe Q For routing of the fuel pipe between the fuel delivery unit and the me tering pump V54 refer to gt page 34 and 2 Fuel supply system Rep Gr 20 Q Filling the fuel pipe to the metering pump V54 with fuel bleeding 4 6 SRR UU 2 page 25 N HEN io ee 3 Metering pump V54 vehi NA V cles with diesel engine only Removing and installing 2 page 32 Q Different versions intro duction of this version not yet finalised 2 Eu parts cata Q Checking fuel delivery 2 page 27 Q Checking actuation gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 4 Note Metering pump version type DP 30 2 intended only for vehicles with diesel engine not to be fitted on vehicles with petrol engine 4 Metering pump V54 for vehicles with diesel or petrol engine Q Removing and installing gt page 32 Q Different versions this version was fitted for all vehicles at start of production gt Electronic parts cata logue 4 Note This metering pump version type DP 2 is fitted on vehicles with pet rol and diesel engine less running
155. uxiliary additional heater exhaust gas 39 QU Audi A8 2003 gt Avu Auxiliary Heater Edition 03 2008 Auxiliary supplementary heater fully installed and connected to the vehicle electrical system All auxiliary supplementary heater fuses OK as per current flow diagram gt Current flow diagrams Electrical fault finding and Fitting locations Encoding and adaption of the supplementary heater control unit J364 OK gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5051 Auxiliary additional heater off Preparation With the ignition switched off connect up the vehicle diagnos tic testing and information system VAS 5051 A for example with the diagnostic wire VAS 5051 5A to the 16 pin diagnos tic socket in the vehicle z Guided fault finding function of vehicle diagnostic testing and information system MAS 5054 Switch on ignition vehicles with auxiliary supplementary heat er Start engine vehicles with diesel engine with additional heater only without auxiliary heater optional extra 4 Note Auxilary aaditional heater self diagnosis can only be started with ignition on data bus diagnostic interface J533 is only active after switching on ignition Once auxiliary adaitional heater has switched to diagnostic mode self diagnosis can be continued with ignition switched off Vehicles with a diesel engine with supplementary heater
156. via fuse Contact 2 Earth connection 6 6 way connector a 92 Contact 1 Signal wire from auxiliary heating radio receiver R64 Not used on additional heater version fitted on vehicles with diesel engine without Auxiliary heater optional extra Contact 2 Signal wire to convenience data bus system CAN high gt Current flow diagrams Electrical fault finding and Fitting locations Contact 3 Signal wire to convenience data bus system CAN low gt Current flow diagrams Electrical fault finding and Fitting locations Contact 4 Actuation of heater coolant shutoff valve N279 Rep Gr 82 Auxiliary heating poe Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Aue Not used on additional heater version fitted on vehicles with diesel engine without Auxiliary heater optional extra Q Contact 5 Not used at present Q Contact 6 Actuation of metering pump V54 Metering pump delivery rate is controlled by frequency of square wave signal number of voltage pulses per sec 11 2 Fitting location of temperature sensor G18 in auxiliary additional heater amp not uu QYXERNNI 3 Tem i el AJ em perature sensor G18 arrow is attached directly to ad it AC ditional heater con trol unit J364 and cannot be replaced ana C 3d UG separately T UR Tap Clip pre tensions temperature sensor G18 arrow against burner housing heat transfe
157. xiliary heater activation function and the symbol for auxiliary heater mode in the clock cannot be activated or go out again gt Electrical system Rep Gr 91 and gt Owner s manual Depending on operating status of auxiliary additional heater auxiliary heating auxiliary ventilation mode or if timer function has been selected one of the symbols for auxiliary heating auxiliary ventilation is permanently actuated or both symbols flash gt Owner s Manual 5 Layout of components for auxiliary additional heater in vehicle 1 3 0 Audi A8 2003 gt Auol Auxiliary Heater Edition 03 2008 a If remote control is fitted for the auxiliary heater as optional extra this actuates the supplementary heater control unit J364 which in turn transmits the information Switch auxiliary heating auxiliary ventilation on or off via the convenience data bus system to the control unit with display in dash panel insert J285 and the front operating and display unit Climatronic control unit J255 For further infor mation refer to gt page 94 6 Circulation pump V55 m m Checking gt page 70 and gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Removing and installing gt page 76 4 Note Currently only fitted to vehicles with Auxiliary heater optional extra Not fitted to vehicles with diesel engine on which auxiliary adai tional heater is only
158. y heater pay attention to the correct version different models for petrol and diesel as well as the different remote control versions gt Electronic parts catalogue and gt Guided fault finding function of vehi cle diagnostic testing and information system VAS 5057 There are different versions of the auxiliary heater remote control and of the auxiliary supplementary heater Exclusive use was made up to 05 04 ofthe Telestart T70 remote control version As of 05 2004 the Telestart T90 version was grad ually introduced instead In Model Year 2008 production is gradually being switched from the Telestart T90 version of the remote control to the Telestart T91 type gt page 10 and gt Electronic parts catalogue To enable the auxiliary supple mentary heater to implement the additional functions of the Telestart T90 T91 feedback of confirmation of reception of activation and deactivation signals use is made of a modi fied remote control receiver for auxiliary heater R64 and a modified auxiliary supplementary heater gt Electronic parts catalogue As of part number 4E0 265 081 with ndex J as of hardware and software number 0710 the auxiliary sup plementary heater is designed for the Telestart T90 T91 remote control gt Guided fault finding function of vehicle di agnostic testing and information system VAS 5051 10 3 1 Detaching and re attaching exhaust system and circulation
159. y heater only no Auxiliary heater optional extra gt Guided fault finding function of vehicle diagnostic testing and information system VAS 5051 Wait until auxiliary additional heater switches from starting to full load mode approx 4 minutes 4 Note The instantaneous operating status of the auxiliary supplemen tary heater can be seen from the measured value block gt Guided fault finding function of vehicle d agnostic testing and information system VAS 5051 Wait at least another minute after auxiliary additional heater has switched to full load mode Read off measured value for CO2 carbon dioxide content in exhaust gas from CO2 measuring instrument as of approx 4 minutes after switch on auxiliary additional heater must be in full load mode 42 Rep Gr 82 Auxiliary heating Audi A8 2003 gt 00 Auxiliary Heater Edition 03 2008 Auer 4 Note Hose B of exhaust probe must not stop exhaust gas emerging from exhaust pipe A during test Specifications For vehicles with diesel engine 8 to 13 CO2 by volume icForvehicleswithcpetrohienginer 7tovt2s CO by volume 4 Note f measured value is in lower range less than 9 problems with auxiliary additional heater combustion may be encoun tered under unfavourable operating conditions e g high ve hicle speed with auxiliary additional heater switched on Set CO2 content in exhaust gas to a higher value gt

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