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Epic fail aux heater

Started by simonlap, November 18, 2012, 12:53:54 PM

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November 18, 2012, 12:53:54 PM
Well, do I realy need the auxiliary heater?
Was obviously not working so I take the whole thing off and clamp the coolant pipes and fuel supply, the end cap is rotten to the core so have to drill out the star bolts, get the cap off and take out the glow plug only to find that the replacement is so wrong in every way. At this point my car is slowly bleeding coolant and I need to use the car so I have to cut one of the existing aux pump hoses and join it onto the end of the return pipe. So now, no aux heater, fuel pipe to heater blocked up with a screw, 1 pipe cut to bypass the coolant back into the system, 1 filthy rotten aux pump on the bench with corroded wiring and two drilled off bolts sticking out of the pump body, I'm wet through with coolant and I choose the coldest morning of the year to fail. Nice.
Anyone got a complete spare D5W Z? or do I forget the whole aux heater thing and drive a cold motor?
November 18, 2012, 02:21:23 PM #1
A piece of 22mm pipe is usually what you need to link the two hoses together, what type plug do you have and what type did they give you?
If there's enough bolt head sticking out you may be able to remove with a small pair of mole grips, after giving a good soaking with penetrating fluid then heating the the whole unit in an oven, I got three out of four out this way.
At Fords you are looking at just over Ã,£500 for a new unit probably cheaper at VW.
There are various places on the net also, try ebay as well, if your going s/hand make sure model number is 25-2163 with the VW symbol.
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
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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.
November 18, 2012, 04:48:55 PM #2
yep ive got 1 with a new plug fitted to it.

vw t5 camper van.
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rip bruv 11/5/17
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November 18, 2012, 07:05:20 PM #3
Gregers, sernt you mail.
The old one looks like it's been in the ocean for 20 or more years, I'm sure there was a barnacle on it.
November 19, 2012, 07:58:11 PM #4
simon think you need to try sending again as i aint got it m8.
vw t5 camper van.
reality is for people with no imagination
rip dad 21/12/10
rip mum 3/5/16
rip bruv 11/5/17
The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max
November 03, 2013, 08:20:39 PM #5
hello to everyone I have a problem with my aux heat I read most of posts but can't find right answer. Prob is that I can't fire up this think fuel is coming, glow plug working, air in/out are clean, and when it start working I get only cloud of white smoke and nothing else, after couple times of this I get this fault ''01409 - Repeated Flame-Out''. This going again and again. Any help please.
November 03, 2013, 08:32:44 PM #6
Hello and  welcome5

Flame out's are most commonly caused by a failing glow plug, it can also be caused intermittent fuel starvation this can happen if you constantly run with less than a quarter of a tank of fuel and if you park facing downhill makes the situation worse because the fuel pick up pipe is at the rear of the tank
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
November 03, 2013, 09:11:35 PM #7
when I look today in that heater plug was disconnected from it and when I connect it start doing this. before that I check glow plug it was working now car sitting strait and in it bit more than quarter tank. I think this heater was disconnected and i don't now for how long and maybe that can cause this problems?
November 03, 2013, 09:38:40 PM #8
It's possible, but I suspect it is more likely that it was disconnected because it was smoking - hence the repeated flame-outs.
November 03, 2013, 10:12:31 PM #9
so what I have to do, to get it work? Cause look's like all good but miss fire.
November 03, 2013, 10:27:27 PM #10
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
November 04, 2013, 09:46:07 PM #11
well today I change the glow plug and it's the same so it means is not a glow plug fault. What else could cause this problem? ???  :'(
November 04, 2013, 11:06:44 PM #12
I assume you cleared the fault codes after replacing the glow plug?
November 04, 2013, 11:53:31 PM #13
Which part number glow plug have you just fitted.

How long have you run heater after fitting new glow plug, it needs to run a good 20 minutes to burn off old fuel in the chamber

Does the heater reach full speed (sounds like a jet engine noise)

Does the heater shut down before it gets to full speed and then it tries to restart again after a few minutes

Can you hear the ticking noise from the dosing pump next to the diesel tank

Does your auxiliary coolant pump (run on pump) work. (fitted to bulkhead behind fuel filter)
2016 Vauxhall Insignia Elite Nav in White 2.0CDTI Manual.
2023 VW Transporter T6.1 SE In Silver 2.9TDI 150PS. 7 Speed DSG Wheelchair accessible day vehicle.


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.
November 04, 2013, 11:59:40 PM #14
Firstly, well done on getting the glowplug replaced! My original heater is still in a process of disassembly to replace it.

When you fitted the new glow plug, did you notice if there was a lot of black soot on the burner gauze (the glow plug sits in the middle of it). I believe that if the gauze is particularly gungy it can cause excessive smoking. Warning - if you take the burner apart, you'll need to get new gaskets.
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