Aux Heater ?

[chrispb123456]

It's usually unburnt diesel dripping because of a failed start,when fitting a new plug check or replace the gauze, this sits in the combustion chamber where the plug fits.

Removing the screws can be a problem so soak them well in penetrating fluid first.

You also need to make sure the auxiliary coolant pump is working as this will affect the correct operation of the heater

[xavier]

How full is your diesel tank? I installed a second hand unit recently that seemed to work fine then started to belch grey smoke. I couldn't believe it was the heater, as it sounded like it was trying to start and the smoke suggests the glow plug was getting hot. Anyway, filled up with diesel and problem went away. Think there's either a problem with the pick-up in the tank for the heater or with the dosing pump (though I can hear it clicking).

[BigDog]

Thanks for the responses Chris and Xavier. The fuel gauge is at about 1/4.  I did my pump brushes 13 months ago and its defo still going strong - I tend to be paranoid about listening for it after I switch off.

I got all the screws out OK. The long one was the worst. Having revealed the insides the connections to the glowplug are spot-welded, covered by a bit of heatshrink tubing. I will need to crimp some ring-contacts onto the wires for the new glowplug. This was a bit of a surprise and I am slightly worried whether the new glowplug is going to fit when it arrives (Beru GH001).

I removed the "manifold" which holds the glowplug and gauze after unscrewing the sensor below it.

I think the gauze looks OK, there is no carbonisation on it and it is not distorted. 

I have taken a bunch of photos but upload doesn't seem to be working (they are all <1.3MB)

Matt

[chrispb123456]

How full is your diesel tank? I installed a second hand unit recently that seemed to work fine then started to belch grey smoke. I couldn't believe it was the heater, as it sounded like it was trying to start and the smoke suggests the glow plug was getting hot. Anyway, filled up with diesel and problem went away. Think there's either a problem with the pick-up in the tank for the heater or with the dosing pump (though I can hear it clicking).

Below

[chrispb123456]

Thanks for the responses Chris and Xavier. The fuel gauge is at about 1/4.  I did my pump brushes 13 months ago and its defo still going strong - I tend to be paranoid about listening for it after I switch off.

I got all the screws out OK. The long one was the worst. Having revealed the insides the connections to the glowplug are spot-welded, covered by a bit of heatshrink tubing. I will need to crimp some ring-contacts onto the wires for the new glowplug. This was a bit of a surprise and I am slightly worried whether the new glowplug is going to fit when it arrives (Beru GH001).

I removed the "manifold" which holds the glowplug and gauze after unscrewing the sensor below it.

I think the gauze looks OK, there is no carbonisation on it and it is not distorted. 

I have taken a bunch of photos but upload doesn't seem to be working (they are all <1.3MB)

Matt

The glow plug you have ordered Beru GH001 is the old type with a screw thread on the end, you need a VW number 7M3 963 319A this is the ceramic plug with wires attached and can be used to replace 7D0 963 319 which is the GH001

[BigDog]

Thanks.  Do you think the old plug is actually knackered? I had thought it probably was, because to my mind if the heater is full of diesel or condensation (like mine was)then it seemed unlikely to be a problem with not enough fuel (i.e. dodgy heater fuel pump or pick-up blockage).  The car nearly always gets driven until the low fuel warning comes on and it has never done the flameout thing or much smoke before, but fuel pumps wear out and pick-ups block. I've emailed the place I've ordered the wrong plug off to see if they have the right one in stock and put most of it back together so it can be driven until the right part arrives. All the best,

Matt  

[chrispb123456]

Had you scanned the heater module for fault codes this may have answered your question, you could try connecting directly to a battery for a few seconds, hold the plug body with pliers don't want no burnt fingers.

Of course if the plug is dead nothing will happen.

 

The flame out problem is more common when facing down hill (fuel away from pick up pipe) and the heater has to be running or attempt to start to get this scenario.

Edited February 10, 2014 by chrispb123456

[BigDog]

Like I said up the page, I scanned originally with VAG-COM and got 01409 35-00 "multiple flame-out" code just the once (I can't recall the exact wording but it definately had the word multiple in there). 

Allegedly the right and wrong parts will arrive tomorrow. I will try the battery test, thanks, it's easy to do since I didn't refit the glowplug (I cut the wires). Will let you know results. 

Could these glow-plugs fail to a higher resistance rather than open circuit, which reduces the temperature below the diesel ignition point, resulting in "smoke without fire" if you get my meaning?

I have seen somewhere, talk of a heater glowplug being "past its best" which implies this increased resistance.

 

The other issue I should really tackle is the thicker red wire insulation has split at the external multi-plug on the heater half and water has started to get inside to the copper conductors, nasty green oxide is visible.  The wire is still connected and has not overheated, so this is a side issue, not the cause (!). 

Ideally I would like to pull out the contact, solder a fresh bit of wire on and make good. Is there a way to release the connector contact without mangling, sometimes you can release these pins using a jewellers screwdriver to press a leaf spring on the contact but not having seen one apart it will be trial and error unless someone has done it already.  Its the male half (heater side) I need to tackle.

 

Matt

[BigDog]

Tested the glowplug and it gets yellow-hot within 10 seconds. So it's fine? I'll heed your advice and fill her up before re-testing. Thanks again.

Matt

[xavier]

I tried the filling her up thing as a long shot and still working for me, maybe the pipe degrades part-way into the tank and can't pick-up the same. Re the wiring, how about just cleaning away the oxide and wrapping some self-aligning tape around the wire? suppoidly better than using insulating tape as water shouldn't get past it.

[chrispb123456]

Have only seen "repeated" flame out 01409 means the same thing anyway.

Have not tried removing the red lead from the plug but have cut the lead from both plugs and bypassed the plug adding in a length of suitable wire with insulated connectors.

May be worth checking filter gauze on the inlet side of dosing pump.

[BigDog]

I ran out of time for further exploration and put a new glow plug in ( cut wires too short on the good old one DOH!) put it all back together after filling the tank.

It seems to be working fine after initial smoke and I've driven it to Austria with no hitches except the door mirror glass loosening and nearly falling off... Fixed that with Superglue gel but got gaffer tape and cable ties in case it gives way... And some strange whirring noises like wheel bearings that came and went... and one limp mode. Now I'm getting off topic.

[cezar]

Hi I hoop some one can help me with my aux heater. I downloaded vag com program I conect to the car alhambra 2004 but when I choose option for aux heater , he show me controler no responce what I can do ? I have glow plug but I want to check where is a problem ? Thx

[SilverBeast]

Assuming you checked with the ignition on, if there is no power to the heater (Fuse out) then it won't respond.  I believe that the Fat red wire that supplies the power to the controller has been known to break down on or near the connector to the heater under the car.

[cezar]

yes it was no power to heater been unplugged well i connect and i read faults 01409 repeated flame-out x2 ,3x shareware version.to decode all DTCs 35-00-please register/activate. i don't now what mean that faults if you can help me. any way i change today and glow plug.but i can find that sensor on viper arm,to checked,i clear that faults.but i can check a heater. if you can help me ,many thx 

[cezar]

Thats the faults .ok thx

[SilverBeast]

Have a look at this post

 

[SilverBeast]

I suggest yours electric secondary coolantg pump is running first though, as the brushes only seem to last around 80K miles. See post here for details,

[cezar]

Ok thx .I will do in next weekend. Many thx

[xavier]

Fix the secondary pump first, clear the heater codes and see if it fires up.

[Afndiesel]

Sorry to drag up a old thread but I wondered if vcds lite (shareware vag com) detects these fault codes, mines not working at all but I have no fault codes.

[SilverBeast]

Yes it can.

 

Does it detect the heater at all?  Earrly MKI galaxy's had a 3KW heater that I don't believe is detected.  Not sure when they switched to the 5KW but I believe it may have been during MKI.  If you are not sure and post the model number on the heater then we will be able to tell you.

[Afndiesel]

Just had a look and it is 3 kW,,,I've just swapped the working one off my alhambra and it still doesn't work. I have looked for a separate water pump but can't see one.I've bridged the sensor too and checked the fuses.must be something I am missing

[xavier]

I'm not sure you can just replace the 3kw one with a 5kw one, I think the ecu needs to be able to talk to it. Might be wrong though!

[Afndiesel]

No I replaced 3kW with a working 3kW, I will try the little diesel prime pump to see if that's working.