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Author Topic: vw Sharan Mk2 coolant heater for cold hell on earth  (Read 4638 times)

Offline Kristaps Baltais

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vw Sharan Mk2 coolant heater for cold hell on earth
« on: October 27, 2016, 09:29:09 pm »
Hi guys. Newbie here. Just bought my 2004 vw Sharan 1.9tdi with quite a run on odo 305000km.
As far as i know it runs good but with standard Mk2 issues, like klunk while shifting gears - today found out that it was not inner shaft stub, but gearbox mount or whatever its name is in english.
Have also a whine in gearbox while shifting in 5th and while foot of pedal - hope a shim in gearbox will fix it.
No operational auxiliary heater - that one will take apart when will find long enough house bypass it
And some other unimportant stuff.
Since I live far behind polar circle, where temp. drops under -40C in winter, other engine heating element needed to be found. Everyone here uses either Webasto or DEFA.  Found out with my first diesels that DEFA is best for extreme temperature drops, is easy to mount and is cheap if you choose just basic heating functions. DEFA Heater model for Mk2 1.9 tdi is 411761
It took only about 20 min to fit it on my Sharan. Heater element comes with clear instructions and all necessary elements to fit with your exact engine model. It connects on a hose that goes to engine oil cooler element. if you are handy enough that could be done just form the top without crawling under your car.
Buying this car after knowing all common problems feels bit sadistic, but then again, my main income is from growing potatoes in arctic.

Offline insanitybeard

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #1 on: October 27, 2016, 11:44:49 pm »
 [W3]  I pity you up in the Northern latitudes at this time of year, it's bad enough in the UK! So you've also got the issue with the roll restrictor rubber bush pulled out as well...... and you can't buy just the bush from VW, you have to buy the whole arm  ::) Still, as your Sharan has done nearly 200000 miles that's not bad going!
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Offline johnnyroper

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #2 on: October 28, 2016, 12:15:50 am »
Not familiar with this DEFA set up,how does it actually work? Am I right in assuming it does not actually heat but takes a coolant feed off oil cooler inlet and is then piped towards heater matrix?

-40 is super cold I would be looking to get the boost heater working if it was me,although at that temp I cannot see it making a great deal of difference but every little helps.

Offline Kristaps Baltais

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #3 on: October 28, 2016, 08:49:58 am »
Its not so bad in such cold,if you are smart enough :D
If I remember correct DEFA is Norwegian company. It basicly use heather spiral that runs from 220v to heat coolant or oil. Mine has 550w power, not enough but will do ok i guess. In my experiance oil heater heats better and faster, but couldnt find one for my model already and its bit harder to attach. With full setup you can get engine preheater, battery charger, saloon heater, remote control with automation and gps tracking with phone controls. Costs about 650eur i guess. Park your car, plug in and next morning come back to warm and nice both engine and saloon. Saves your engine in cold climates.
Buying this car after knowing all common problems feels bit sadistic, but then again, my main income is from growing potatoes in arctic.

Offline johnnyroper

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #4 on: October 28, 2016, 10:59:12 am »
Take your word for that I struggle in the UK winters so 40 below would finish me off.

Ok thanks I get it now it basically plumbs in to cooling circuit and car is plugged in to mains overnight and hey presto instant heat next morning.

Offline Kristaps Baltais

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #5 on: October 28, 2016, 11:12:47 am »
We have timers in power outlet. 1 hour before start is enough with -20. Ill test it when it gets colder and tell you results. Problem with auxilary heater is that it wil drain battery if motor is not runing, so it not work to start a car in coooool mornings.
And i wouldnt say thats its instant heat. Its more like to help engine start better in cold weather. For warm saloon you would need to put in saloon blower. It is good investment for diesels in long run. If you have more questions ill be glad to help out. Mine costed about 140eur+ plus you need to get a cable to pug in for power outlet. I got them from my other diesels. And im thinking about taking 4amp charger box from my b5 to charge battery just a little while its heating up.
Buying this car after knowing all common problems feels bit sadistic, but then again, my main income is from growing potatoes in arctic.

Offline Kristaps Baltais

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #6 on: November 29, 2016, 12:37:20 pm »
A bit of update from not so cold place this winter.
I have tried to pre heat car one hour before driving at -20c and it just started like it was around +5 outside, so it is a win for me. I guess it will work ok in -40c also.
Other problem that i fixed was auxiliary heater. Driving only 15km twice a day couldnt quite get engine temperature up more than half way in sub zero temperatures. Bought code reader and found out flame out code, erased it and blower started without any white smoke, but after a while got overheat code. My code reader is quite compact so i was driving around for couple days just erasing codes on my way :D till i got time to check run on pump. As i suspected brushes was gone, but i marked that there was sound couple times from it when i bought car. Anyhow,  since i live in tundra and did not wanted to order proper brushes and remove that little peace of sh pump again  I made some adjustments for brushes I had for alternator(reminds me time i fixed fathers in law alternator with brushes from my old washing machine). And woila, no more flame outs or other fault codes.
Still temp was not rising as fast as wanted and termostat needed to be changed also. Now it is warm and cozy, but not good enough. Im up to put some pipe isolation under my car to save some warm in.
« Last Edit: November 29, 2016, 12:40:41 pm by Kristaps Baltais »
Buying this car after knowing all common problems feels bit sadistic, but then again, my main income is from growing potatoes in arctic.

Offline Mirez

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #7 on: November 29, 2016, 04:23:38 pm »
Good work!

I lagged the coolent pipes from front to rear when I fitted the programmable heater as you loose a lot of heat from that length run.
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Offline Chrispb

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #8 on: November 29, 2016, 07:03:14 pm »
Good work!

I lagged the coolent pipes from front to rear when I fitted the programmable heater as you loose a lot of heat from that length run.
Did you use something special or the house hold foam lagging.
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Offline Kristaps Baltais

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #9 on: November 29, 2016, 07:23:24 pm »
i bought simple household ones, since coolant temp is over 80c it should dry out all excess water whenever you drive car. so rust shouldnt be a problem.
Buying this car after knowing all common problems feels bit sadistic, but then again, my main income is from growing potatoes in arctic.

Offline Mirez

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #10 on: November 29, 2016, 07:51:50 pm »
Standard closed foam central heating lagging
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Offline mike wilson

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #11 on: November 30, 2016, 09:08:15 am »
Anyhow,  since i live in tundra and did not wanted to order proper brushes and remove that little peace of sh pump again  I made some adjustments for brushes I had for alternator(reminds me time i fixed fathers in law alternator with brushes from my old washing machine). And woila, no more flame outs or other fault codes.

As a general principle, it's not good practice to swap brushes between generators and motors.  You can reduce carrying capacity and increase wear of either the brush, the commentator/slip ring or both.  Here's a useful document

http://www.argointl.com/wp-content/uploads/2014/03/necp-How_to_Select_Brushes_for_Motors_and_Generators2.pdf

Offline Kristaps Baltais

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #12 on: November 30, 2016, 10:28:19 am »
As a general principle, it's not good practice to swap brushes between generators and motors.  You can reduce carrying capacity and increase wear of either the brush, the commentator/slip ring or both.  Here's a useful document

http://www.argointl.com/wp-content/uploads/2014/03/necp-How_to_Select_Brushes_for_Motors_and_Generators2.pdf

Totally agree with you, but run on pump is quite small so it does not use big carrying capacity and brushes from alternator was ordered indeed a bit softer (slip rings on that alternator was worn) cause it is always easier to change brushes than slip rings. Just talked with my father in law and they have had look on alternator and brushes not so long ago, everything seems ok and without any wear after more than 2 years of driving around with washing machine brushes. He got notice from me when we did change on brushes, but so far so good.
Buying this car after knowing all common problems feels bit sadistic, but then again, my main income is from growing potatoes in arctic.

Offline mike wilson

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Re: vw Sharan Mk2 coolant heater for cold hell on earth
« Reply #13 on: December 01, 2016, 08:56:12 am »
On something with intermittent use like that pump, there is probably no real-world effect.  I wouldn't swap brushes between alternator and starter motor types, though.

 

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