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Author Topic: Replacing the dreaded Aux Heater...  (Read 2444 times)

Offline KingyMAK

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Replacing the dreaded Aux Heater...
« on: February 25, 2017, 07:33:15 PM »
Hey guys (and girls if there's any about!);

I'm looking into a Galaxy up for breaking near me on a 2001 plate, and my Sharan is a 04 plate.

I believe I have the D5Z-F in mine, but I guess the Galaxy will have the earlier model?

Are they fairly easily interchangeable or does it need a whole new loom wiring up?
Am I stuck with trying to get a new or used-working D5Z-F?

Kind of stuck on deciding if I want to replace it or just leave it broke!

Offline insanitybeard

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Re: Replacing the dreaded Aux Heater...
« Reply #1 on: February 25, 2017, 07:51:51 PM »
There was some discussion about trying to retrofit a D5W-Z heater in place of the D5Z-F in this
thread if you haven't seen it.
Always learning..... Often by mistakes!

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #2 on: February 26, 2017, 09:57:47 AM »
Now I was doing some googling last night;

You can buy inline heaters that run on electric, rather than the diesel that these do, some are pricey & some are cheap.
I've attached an image of a Chinese copy one, that I can buy for about £60;
Now I know this isn't the same, but I will be able to make it switchable, and it cuts out a lot of fuss in the long run of replacing the bits in the D5 heater/heaters.

Any ideas, suggestions, etc.?

Offline johnnyroper

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Re: Replacing the dreaded Aux Heater...
« Reply #3 on: February 26, 2017, 10:54:47 AM »
I was sceptical about how well an electric one would work but my x type diesel has got one basically a little housing with 3 glow plugs in it. Even when the weather was super cold heaters on full and warmth could be felt in minutes.
Not too difficult to retrofit I wouldn't have thought would just need a relay to handle to load that could be switched by a temp sensor.

Offline Chrispb

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Re: Replacing the dreaded Aux Heater...
« Reply #4 on: February 26, 2017, 12:26:56 PM »
I fitted one of those with the 3 glow plugs in my Grandsons diesel focus and made a noticeable difference.
the type the OP is showing I do believe is mains electricity powered and has a circulating pump enclosed.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

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Offline johnnyroper

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Re: Replacing the dreaded Aux Heater...
« Reply #5 on: February 26, 2017, 02:28:23 PM »
Ok I see it's one of them ones you leave plugged in overnight so coolant is pre heated prior to starting.

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #6 on: February 26, 2017, 08:28:37 PM »
I may take a punt at this;

I'm getting a few bits off a guy breaking this week, and hoping the heater is functioning!
It's been well looked after till the head boiled due to water pump failing (will this cause a problem with the heater itself?)

Offline johnnyroper

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Re: Replacing the dreaded Aux Heater...
« Reply #7 on: February 26, 2017, 10:08:40 PM »
The heater should not have suffered from head/pump issues as it is self regulated by internal temp sensors that cut it off if over temp.

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #8 on: March 01, 2017, 07:57:43 PM »
Picked up the spare heater, all fully functioning and everything:

Don't think it's going to be the same model as on mine, I'm pulling it out the weekend.

Do the pin-outs on the wiring match up the same or does it need a bit cut-and-shunting to be done on it?

Offline insanitybeard

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Re: Replacing the dreaded Aux Heater...
« Reply #9 on: March 01, 2017, 10:07:57 PM »
Yeah, that's the earlier D5W-Z that you've picked up, so some wiring modification will be required as per the thread I linked earlier, you'll also need the mounting bracket to suit this heater as the D5Z-F one won't fit it.
Always learning..... Often by mistakes!

Offline KingyMAK

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  • Country: United Kingdom
Re: Replacing the dreaded Aux Heater...
« Reply #10 on: March 01, 2017, 10:17:18 PM »
It has everything to go with it thankfully!
Is the bracket for the earlier one a direct fit on the chassis for the newer ones?

Offline insanitybeard

  • Greetings from Mr Chick!
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Re: Replacing the dreaded Aux Heater...
« Reply #11 on: March 01, 2017, 10:22:52 PM »
I would expect so, It's unlikely that they would have altered the mounting points in the floorpan for a different design of bracket.
Always learning..... Often by mistakes!

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #12 on: March 06, 2017, 09:55:43 PM »
Well, I took the old heater off and it was rotten through to bits all through the case, I'm going to pillar drill it apart for spares and wiring.

But it was unusually a D5WZ like the spare I'd got, but my car is an '04 reg?


The other problem I have now is, the cable on the cars loom end has a few frayed apart wires;
Now are the 8-pin D Blocks specially 'criss-crossed' inside for cable joining?



Just before I cut it and put a new 8-point connector on it!

Offline johnnyroper

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Re: Replacing the dreaded Aux Heater...
« Reply #13 on: March 06, 2017, 10:06:55 PM »
I had same problem with mine they were damaged too close to plug so I chopped plugs off and fed wires through grommet and in to car,lift the plastic trim off sill and solder the wires in to the loom.

Sounds like yours has had a replacement old type heater fitted previously?

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #14 on: March 06, 2017, 10:11:34 PM »
I was planning on putting them into some sort of junction box and attaching it to the brack that the heater attaches to.

Yeah the wires are damaged right up against the plug.

How did you overcome it? Did you add a new connector just inside, and did you just match up 1-1, 2-2, etc or is there a special sort of connector they use at VAG?


And don't think it's been replaced in the past the state of it, it had a dole rotten right through it (like the exhaust port at blocked up and gathered heat and soot up, and then the state of the bracket was horrific! Fell to bits removing it!

Offline insanitybeard

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Re: Replacing the dreaded Aux Heater...
« Reply #15 on: March 06, 2017, 10:45:43 PM »
The changeover from factory fitted D5W-Z heaters to the later D5Z-F model was in around 2004 so depending on exact build date you could have either model fitted on an '04 plate. If yours has actually got the earlier D5W-Z installed then there's no reason to think that it's not original.

Due to their exposed position the alloy casings and steel screws do seem prone to corroding with the alloy turning to white powder and the fasteners seizing solid into said alloy casings and then shearing off when you attempt to remove them- when I eventually fit my new heater I'm gonna ditch the standard fasteners for stainless ones!
Always learning..... Often by mistakes!

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #16 on: March 06, 2017, 11:19:29 PM »
That's exactly what happened around the exhaust port join; it's now literally a hole...
White powder but loads of soot built up which made me think the heat and water caused the damage.

I'm going to finish tapping a few holes and adding some new screw/bolts in, but I want to add some of the 'anti-lock' compounds you can get rather than a thread lock in case I need to take it apart again at some point, if you'd think that'd be wise?

Still wondering about the connector if anyone's got a clue?

Seems they have cables that don't do anything that go into the connector?

Offline johnnyroper

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Re: Replacing the dreaded Aux Heater...
« Reply #17 on: March 07, 2017, 05:49:11 AM »
I didn't bother with a replacement connector,once the plastic sill trim is off the wires leading to heater are easily visible.
I just cut plug off car loom pulled wires through then also cut heater plug off and pulled wiring through.
Once wiring was through I cut to length and soldered together. Cannot remember if loom is same colour as heater or if I used the 2 pieces of plug to match up wire colours before I joined them.

Offline insanitybeard

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Re: Replacing the dreaded Aux Heater...
« Reply #18 on: March 07, 2017, 10:31:58 AM »
It depends on whether you're happy to just solder the lot together, me being me I'd prefer to have a connector to make removal of the heater easy should it need to come out again- to that end you can buy a male/ female connector assembly from good ol' [eBay] here, the only thing is you may need to fit both parts of the connector as although it's a similar pattern to the O.E heater connectors they may not mate directly if you were to try replacing only the male or female part and plugging it to either of your existing connectors.

There's a bit more info regarding D5W-Z wiring including diagrams here if you've not seen it.

And yes, I'd certainly be adding high temp anti-seize copper grease to any fasteners you disturb, even if you choose to replace the standard ones with stainless!
Always learning..... Often by mistakes!

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #19 on: March 08, 2017, 12:05:25 PM »
I was planning on using a junction box for extra protection & follow this wiring diagram here as it seemed to fit the wiring on D5WZ?
I'm assuming that 1-1, 2-2, etc. And there's not special crossover pins or suchlike? As that link you posted for eBay looked like standard 8-pin D-Plug connectors?

Offline KingyMAK

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Re: Replacing the dreaded Aux Heater...
« Reply #20 on: March 08, 2017, 08:54:06 PM »
Day for fitting is Friday.

It's my next day off work and hopefully I won't get roped into anything by the missus and the kids!   ;D

I'm going to replace the hose/pipes too, but measuring them seems to bring up at around 26-28mm hose.

Euros stock up 19mm then 32mm.

Is it a specific pipe size we need or what? Seems like they really wanted to do us over on replacing parts of these heaters!  :(

Offline insanitybeard

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Re: Replacing the dreaded Aux Heater...
« Reply #21 on: March 09, 2017, 06:12:03 PM »
What dimension are you referring to here? And you're talking about the hoses connecting to the heater unit itself? I can only assume it's the outside diameter of the hose? If so, it's the bore size that's important- when I removed the heater from my car and bypassed the pipework I found 3/4" bore hose was about the size needed, which I've just confirmed by checking the diameter of the aluminium pipe spigots on the heater itself.
Always learning..... Often by mistakes!

 

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