VOLKSWAGEN GOLF 2004 (05) PDF Document

The auxiliary heater must not be in operation or switched on in areas in which there is a risk of fire or explosion.

The auxiliary heater must not be in operation or switched on (including via a preset switch-on time) in closed rooms without an exhaust extraction system.

When working on a fuel system, always observe applicable safety regulations and rules for cleanliness.

If fuel system components (e.g. metering pump, fuel lines, fuel gauge sender) are removed or opened, the vehicle engine must not be started.

Before beginning repair work on the auxiliary heater:

• WARNING: Danger of scalding injuries. The cooling system is pressurised. When the engine is warm, the coolant temperature may be above 100° C. If necessary, release pressure before carrying out repairs.

After completing repair work on the auxiliary heater or the fuel system, check the operation of the auxiliary heater.

After carrying out repairs on the auxiliary heater, carry out the self-diagnosis using vehicle diagnosis, testing and information system VAS 5051 or later models.

The starting conditions for the auxiliary heating (preheater) on a VOLKSWAGEN GOLF 2004 are:

• Engine type OK (diesel/petrol)
• Terminal 15 (ignition) on
• Engine revs > 400 rpm.
• Coolant temperature < 69 °C
• On vehicles with ECON button: Button not pressed and temperature setting not on “cold”
• Ambient temperature <= 5° C
• Fuel gauge not in reserve range
• On-board network manager not active
• No crash switch-off
• No fault memory entries blocking start procedure

The starting conditions for the supplementary heating function on a VOLKSWAGEN GOLF 2004 with auxiliary heating are:

• Engine type OK (diesel/petrol)
• Auxiliary heater coded in Gateway
• No undervoltage shutdown
• Fuel gauge not in reserve range
• No crash switch-off
• No fault memory entries blocking start procedure

The rules for cleanliness when working on the auxiliary heater and the fuel system of a VOLKSWAGEN GOLF 2004 are:

• Thoroughly clean all connections and adjacent areas before disconnecting.
• Place parts that have been removed on a clean surface (use sheeting or paper, but no fluffy cloths) and cover.
• Carefully cover opened components or seal if the repair cannot be carried out immediately.
• Install clean parts only:
• Remove genuine parts from their packages only immediately before installing them.
• Do not use any parts which have not been stored in their packaging (e.g. in a tool box).
• If fuel line has been opened:
• do not work with compressed air.
• do not move vehicle.
• do not start engine.
• Do not switch auxiliary heater on.

The special tools and workshop equipment required for repairing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 are:

• Torque wrench -V.A.G 1410- (4…20 Nm)
• Hose clamps up to 25 mm Ø -3094-

Before beginning repair work on the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004, the following steps must be performed:

• Disconnect the battery.

Important notes when working on the auxiliary heater components on the VOLKSWAGEN GOLF 2004 are:

• The illustration shows the Golf V. The installation positions of the auxiliary heater components on the Golf VI are identical.
• A manufacturer’s plate is fitted on the auxiliary heater unit. This manufacturer’s plate provides information about which version is installed in vehicle, for example, diesel Thermo Top V.
• The coolant circuit must be bled after it is opened.

The procedure for removing the exhaust system for auxiliary heating on a VOLKSWAGEN GOLF 2004 is:

• Remove front part of front right wheel housing liner.
• Loosen securing clamp on exhaust pipe -1- and remove bolts -2- and -3- (6 Nm).
• Remove exhaust system.

Caution: The exhaust system must be routed so that wiring harness does not touch exhaust system (danger of short circuit).

If the remote control receiver for auxiliary coolant heater -R149- is renewed, the remote controls must be re-taught. Start “Basic settings” function using vehicle diagnosis, testing and information system -VAS 5051- or later model and then select channel 04.

The removal procedure is:

• Remove rear right seat belt behind luggage compartment trim.
• Remove bolts -1- and -2- and pull out retaining plate with remote control for auxiliary water heater -R149- and aerial filter -R87-.
• Pull off connectors -1- and -2-.
• Pry up retaining tab and pull out remote control receiver for auxiliary coolant heater -R149- in -direction of arrow-.

The installing procedure is:

• Ensure that the connectors and retaining tab are properly seated.

The special tools and workshop equipment required for removing and installing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 are:

• Torque wrench -V.A.G 1410- (4…20 Nm)
• Hose clamps up to 25 mm Ø -3094-
• Vehicle diagnosis, testing and information system -VAS 5051- or successor models.

If the Thermo Top V is to be renewed on a VOLKSWAGEN GOLF 2004, first connect vehicle diagnosis, testing and information system -VAS 5051- (or later model) and call up the “Renew heater” function under the guided functions.

The components of the auxiliary heater Thermo Top V shown in the diagram for a VOLKSWAGEN GOLF 2004 are:

1. Auxiliary heater Thermo Top V (With auxiliary heating control unit -J364- Removing page 11)
2. Fuel line with quick-release coupling (Routing of fuel line page 40)
3. Air intake silencer (Removing and installing page 14)
4. Exhaust system (Removing and installing page 8)
5. Circulation pump -V55- (Removing and installing page 15)
6. Exhaust pipe
7. Chafing protection

If the Thermo Top V was not renewed on a VOLKSWAGEN GOLF 2004, the following must be noted upon installation:

• After installing auxiliary heater, bleed coolant circuit page 22.
• Then start the auxiliary heater.

To remove the air intake silencer as an ancillary of the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004:

• Unclip air intake silencer -1- from bracket -2- and pull off intake pipe -3-.

To install the air intake silencer as an ancillary of the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004, push air intake silencer onto intake pipe -3- far enough that it can be clipped into bracket -2-.

The special tools required for removing the circulation pump -V55- on a VOLKSWAGEN GOLF 2004 auxiliary heater are hose clamps up to 25 mm Ø -3094-.

The procedure for removing the circulation pump -V55- on a VOLKSWAGEN GOLF 2004 auxiliary heater is:

• Clamp off coolant hoses using hose clamps up to 25 mm Ø -3094-.
• Loosen clip -1-.
• Pull coolant hoses off circulation pump -V55-.
• Pull connector off circulation pump -V55-.
• Remove bolt -2- and remove circulation pump -V55-.

WARNING: Danger of scalding injuries. When the engine is warm, the coolant temperature may be above 100 °C. The cooling system is pressurised. If necessary, release pressure before carrying out repairs.

After installing the circulation pump -V55- on a VOLKSWAGEN GOLF 2004 auxiliary heater, bleed coolant circuit page 22.

WARNING: Danger of burn injuries. Parts of the exhaust system may be hot. Before removing exhaust system, let it cool off.

The procedure for removing the short exhaust pipe from the silencer on the auxiliary heater for a VOLKSWAGEN GOLF 2004 is:

• Separate exhaust pipe from silencer -A- page 15.
• Remove bolt -1- from support -B- and lay exhaust pipe to side.
• Remove bolt -2- from silencer -A-.
• Remove silencer -A-.
• Remove bolts -3- from bracket.
• Separate bracket from centring tabs and remove.
• Install in reverse order.

Note: When installing bracket, observe centring tabs.

The procedure for removing and installing the bracket for the auxiliary heater on a VOLKSWAGEN GOLF 2004 is:

• Remove bolts -2- and remove bracket -1-.
• Install in reverse order.

Note: When installing bracket -1-, observe centring tabs.

The procedure for removing and installing the cover on the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 is:

• Mark fitting position of coolant connections and remove them (bolt 4 Nm).
• Unclip cover at -arrows- and pull cover over locking lugs -A-.
• Install in reverse order.

The special tools required for dismantling and assembling the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 are:

• Torque wrench -V.A.G 1410- (4…20 Nm)
• Hose clamps up to 25 mm Ø -3094-

The following notes are important after the auxiliary heater has been detached on a VOLKSWAGEN GOLF 2004:

• The coolant circuit must be bled after it is opened page 22.
• After the auxiliary heater has been detached, it must be secured to the body with welding wire to prevent damage to the coolant hoses.

The procedure for removing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 is:

• Remove lower front right wheel housing liner.
• Remove exhaust pipe from silencer on auxiliary heater page 15.
• Clamp off coolant hoses -1- and -2- using hose clamps up to Ø 25 mm -3094- and pull coolant hoses off auxiliary heater. Do not separate coolant hoses that are connected to each other.
• Remove fuel filter with bracket page 20. On vehicles with diesel engine.
• Remove windscreen washer system reservoir.
• Remove securing bolt -1- (8 ± 0.8 Nm) below reservoir for windscreen washer system.
• Remove securing nut nut -1- (8 ± 0.8 Nm) from auxiliary heater -2- on right longitudinal member -3-.
• Remove securing nut -1- (15 ± 1.5 Nm) from auxiliary heater -2- on right longitudinal member -3-.
• Disconnect fuel line at quick-release coupling and seal fuel lines with appropriate plugs.
• Unplug the other connectors at the auxiliary heater.

WARNING: Danger of fuel escaping. Fuel system is under pressure. Before opening system, wrap a cloth around the connection. Then release pressure by carefully loosening the connection.

Caution: Auxiliary heater control unit -J364- could get damaged. Overvoltages can occur at the connectors. First pull out 8-pin connector.

When installing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004, note the following:

• After installing auxiliary heater, bleed coolant circuit page 22.
• Then start the auxiliary heater.

The steps for removing the heater coolant shut-off valve -N279- on a VOLKSWAGEN GOLF 2004 are:

• Remove engine cover.
• Pull out noise insulation and, depending on engine, remove intake hose to turbocharger.
• Remove securing nuts (8 ±0.8 Nm) -A- from bracket for heater coolant shut-off valve -N279–1-.
• Clamp off coolant hoses -B- using hose clamps up to Ø 25 mm -3094-.
• Separate coolant hoses from -B- heater coolant shut-off valve -N279-.
• Unclip connecting wire from retainer and separate connector.
• Remove securing nuts (8 ±0.8 Nm) -A- from heater coolant shut-off valve -N279-.

WARNING: Danger of scalding injuries. The cooling system is pressurised. When the engine is warm, the coolant temperature may be above 100° C. If necessary, release pressure before carrying out repairs.

The procedure for bleeding the coolant circuit for the auxiliary heater on a VOLKSWAGEN GOLF 2004 is:

• Fill coolant circuit.
• Switch on engine and then auxiliary heater. Press, for example, the instant heating button -E537–1-.

Note: Because the heater coolant shut-off valve -N279- (optional) will be actuated depending on the coolant temperature and only with the auxiliary heater switched on, the auxiliary heater must be switched on during the bleeding procedure.

If the coolant temperature does not drop below 76° C within 900 seconds during the controlled waiting period for the Heating/Climatic Golf 2008, the heating unit will start with the normal start procedure in full-load mode when the coolant temperature does drop below 76° C for Preheating mode.

For Climatronic Golf 2009:

• Set temperature on operating unit (heating, Climatic or Climatronic) to highest step and open dash panel vents.
• Run engine at idling speed for 3 minutes and then at a higher speed, about 2,300 rpm, for 3 minutes longer.
• Switch auxiliary heater using instant heating button -E537–1-.
• Turn off engine.
• Check coolant lever in coolant reservoir and top up if necessary.

The connection diagram points for the coolant hoses in vehicles with auxiliary heater, engine codes BKC, BJB, BLS, BRV on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Heat exchanger for heater
3. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
4. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
5. Cylinder head and cylinder block
6. ATF cooler (Only vehicles with automatic transmission)
7. Engine oil cooler
8. Radiator
9. Circulation pump -V55- (Removing and installing page 15)
10. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine code BMM on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Coolant pipes in bulkhead area
3. Exhaust gas recirculation cooler
4. Intake manifold
5. Heat exchanger for heater
6. Connecting piece
7. Upper coolant pipe
8. Front coolant pipe
9. Oil cooler (For engine oil)
10. Upper coolant hose
11. Radiator
12. Lower coolant hose
13. Thermostat for coolant pump
14. Cylinder head and cylinder block
15. Circulation pump -V55- (Removing and installing page 15)
16. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes BLG, BMY on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Intake manifold
3. Restrictor
4. Heat exchanger for heater
5. Thermostat housing
6. Restrictor
7. Radiator
8. Oil cooler (For engine oil)
9. Continued coolant circulation pump -V51-
10. Turbocharger
11. Cylinder head and cylinder block
12. Circulation pump -V55- (Removing and installing page 15)
13. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes AXX, BPY, BWA on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Heat exchanger for heater
3. ATF cooler (Only for automatic gearboxes)
4. Bypass thermostat (Only for automatic gearboxes)
5. Coolant connection
6. Cylinder head and cylinder block
7. Intake manifold
8. Auxiliary radiator
9. Radiator
10. Continued coolant circulation pump -V51-
11. Thermostat housing
12. Circulation pump -V55- (Removing and installing page 15)
13. Auxiliary heater Thermo Top V (Removing and installing page 11)
14. Turbocharger

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes AZV, BKD, BMN on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Heat exchanger for heater
3. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
4. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
5. Radiator
6. Engine oil cooler
7. Circulation pump -V55- (Removing and installing page 15)
8. Auxiliary heater Thermo Top V (Removing and installing page 11)
9. Water pump
10. Exhaust gas recirculation (water cooled)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes BAG, BKG, BLF, BLN, BLP on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
3. Restrictor
4. Heat exchanger for heater
5. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
6. Exhaust gas recirculation (water cooled)
7. Intake manifold
8. Thermostat housing
9. Radiator
10. Engine oil cooler
11. Cylinder head and cylinder block
12. Circulation pump -V55- (Removing and installing page 15)
13. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes BGU, BSE, BSF and CHGA on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
3. Heat exchanger for heater
4. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21. Not installed in vehicles with engine code CHGA.)
5. Intake manifold
6. Cylinder head and cylinder block
7. Engine oil cooler
8. Radiator
9. Water pump
10. Circulation pump -V55- (Removing and installing page 15)
11. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine code BKD on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Heat exchanger for heater
3. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
4. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
5. Radiator
6. Engine oil cooler
7. Water pump
8. Cylinder head and cylinder block
9. Circulation pump -V55- (Removing and installing page 15)
10. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes AXW, BLX, BLY, BLR on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Heat exchanger for heater
3. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
4. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
5. Intake manifold
6. Engine oil cooler
7. Radiator
8. Circulation pump -V55- (Removing and installing page 15)
9. Auxiliary heater Thermo Top V (Removing and installing page 11)
10. Thermostat housing
11. Cylinder head and cylinder block
12. Exhaust gas recirculation (water cooled)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes BUB, CBRA on a VOLKSWAGEN GOLF 2004 are:

1. Coolant expansion tank
2. Non-return valve (Note fitting position. Arrow on non-return valve points in direction of flow.)
3. Heat exchanger for heater
4. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
5. Thermostat housing
6. Upper coolant hose
7. Radiator
8. Lower coolant hose
9. Continued coolant circulation pump -V51-
10. Oil cooler (For engine oil)
11. Cylinder block
12. Coolant pump
13. Cylinder head
14. Circulation pump -V55- (Removing and installing page 15)
15. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes BVX, BVY, BVZ on a VOLKSWAGEN GOLF 2004 are:

1. Expansion tank
2. Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead. Removing and installing page 21)
3. Heat exchanger for heater
4. ATF cooler (Only vehicles with automatic transmission)
5. Engine oil cooler
6. Intake manifold
7. Radiator
8. Circulation pump -V55- (Removing and installing page 15)
9. Auxiliary heater Thermo Top V (Removing and installing page 11)
10. Thermostat housing
11. Cylinder head and cylinder block
12. Exhaust gas recirculation (water cooled)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine code CAVD on a VOLKSWAGEN GOLF 2004 are:

1. Expansion tank
2. Coolant pump
3. Intake manifold
4. Cylinder head and cylinder block
5. Heat exchanger for heater
6. Thermostat housing
7. Radiator
8. Engine oil cooler
9. Coolant circulation pump -V50-
10. Turbocharger
11. Circulation pump -V55- (Removing and installing page 15)
12. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine code CAXA on a VOLKSWAGEN GOLF 2004 are:

1. Expansion tank
2. Coolant circulation pump -V50-
3. Intake manifold
4. Non-return valve
5. Heat exchanger for heater
6. Thermostat housing
7. Restrictor
8. Engine oil cooler
9. Radiator
10. Auxiliary radiator for charge air system
11. Turbocharger
12. Cylinder head and cylinder block
13. Circulation pump -V55- (Removing and installing page 15)
14. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine code CBAB on a VOLKSWAGEN GOLF 2004 are:

1. Expansion tank
2. Exhaust gas recirculation (water cooled)
3. Cylinder head and cylinder block
4. Heat exchanger for heater
5. Restrictor
6. Engine oil cooler
7. Continued coolant circulation pump -V51-
8. Radiator
9. Coolant pump
10. Temperature sensor
11. Circulation pump -V55- (Removing and installing page 15)
12. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes BXE, BXF, BXJ on a VOLKSWAGEN GOLF 2004 are:

1. Expansion tank
2. Bypass flap
3. Exhaust gas recirculation cooler
4. Heat exchanger for heater
5. Cylinder head and cylinder block
6. ATF cooler (Only on vehicles with automatic gearbox)
7. Upper coolant hose
8. Radiator
9. Lower coolant hose
10. Engine oil cooler
11. Coolant pump/thermostat
12. Circulation pump -V55- (Removing and installing page 15)
13. Auxiliary heater Thermo Top V (Removing and installing page 11)

The connection diagram for coolant hoses also applies to vehicles with gear oil cooler.

The connection diagram points for the coolant hoses in vehicles with auxiliary heating, engine codes CAWB, CBFA, CCTA on a VOLKSWAGEN GOLF 2004 are:

1. Circulation pump -V55- (Removing and installing page 15)
2. Auxiliary heater Thermo Top V (Removing and installing page 11)
3. Coolant pump
4. Thermostat
5. Engine oil cooler
6. Cylinder head and cylinder block
7. Turbocharger
8. Expansion tank
9. Heat exchanger for heater
10. Coolant connection
11. Radiator
12. Continued coolant circulation pump -V51-

When working on the fuel supply/injection system on a VOLKSWAGEN GOLF 2004, carefully follow the “5 rules” below:

• Thoroughly clean all connections and adjacent areas before disconnecting.
• Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
• Carefully cover or seal opened components if the repair cannot be carried out immediately.
• Install clean parts only; remove replacement parts from their packages only immediately before installing them. Do not use any parts which have not been stored in their packaging (e.g. in a tool box).
• Fuel hoses and pipes may be shortened only with a clean sharp knife. Cutting points must not be soiled or deformed. Cutting points and surfaces must be free of burrs.

To start the auxiliary heater for the fuel feed to Thermo Top V on a VOLKSWAGEN GOLF 2004, the following conditions are required:

• Ambient temperature sensor -G17- is pulled off and the coolant temperature is below 50° C.
• If the tank was empty, there may be air in the fuel line for the auxiliary heater. To remove air from the fuel line, start auxiliary heater repeatedly until it does not go out by itself.

WARNING: Danger of fuel escaping. Fuel system is under pressure. Before opening system, wrap a cloth around the connection. Then release pressure by carefully loosening the connection.

The procedure for removing the metering pump -V54- on a VOLKSWAGEN GOLF 2004 is:

• Release quick-release coupling on fuel line -1- and seal fuel line to prevent fuel from leaking.
• Loosen O-type clip -3- and seal fuel line to fuel tank to prevent fuel from leaking.
• Detach bracket -2- for metering pump -V54- on fuel tank.
• Pull metering pump -V54- out in direction of -arrow-.
• Disconnect connector on metering pump -V54-.

Note: Renew clamp-type clips using screw-type clips. Ensure the genuine part number is correct. Install in reverse order. Ensure proper installation position of metering pump -V54- .

The test prerequisites for testing the quantity of fuel delivered for the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 are:

The checking procedure for fuel delivery when testing the quantity of fuel delivered for the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF 2004 is:

WARNING: Danger of fuel escaping. Fuel system is under pressure. Before opening system, wrap a cloth around the connection. Then release pressure by carefully loosening the connection.

• Disconnect connector on fuel line for metering pump -V54- and seal using suitable means.
• Hold measuring glass at same height as auxiliary heater.
• Using vehicle diagnosis, testing and information system -VAS 5051- (or later model), open guided function “Check quantity of fuel delivered” (open fuel line from metering pump -V54-) and start.
• After approx. 30 seconds, the fuel line is filled and bled.
• Seal fuel line.
• Empty measuring glass.
• Hold measuring glass at same height as auxiliary heater.
• Using vehicle diagnosis, testing and information system -VAS 5051- (or later model), open guided function “Check quantity of fuel delivered” (open fuel line from metering pump -V54-) and start.
• Fuel delivery finishes after approx. 120 seconds.
• Connect connector to fuel line.
• Read measuring glass. Quantity delivered for petrol and diesel: 22 to 28 ml.
• If quantity delivered is not within specifications, renew metering pump -V54-.

Note: If the ambient temperature is above 20 °C, fuel vaporisation may lead to incorrect measurements. No bubbles are to be delivered.

The functional description of auxiliary heater Thermo Top V operation modes on a VOLKSWAGEN GOLF 2004 is as follows:

Temperature at temperature sensor -G18- less than 50 °C.

Temperature at ambient temperature sensor -G17- must be below approx. +5°C.

Turning on the switch enables operation of the auxiliary heater. The glow plug with flame monitor-Q8-, the combustion air blower -V6- and the circulation pump -V55- begin to operate. After 30 seconds, the metering pump -V54- is switched on and the combustion air blower -V6- is switched off for 3 seconds. Then the combustion air blower -V6- runs up in two stages to nearly full load within 56 seconds. After a stabilisation phase (attaining steady motor speed) of 15 seconds, the combustion air blower -V6- is again brought up to nearly full load in a 50-second stage.

After reaching full-load fuel delivery, the glow plug with flame monitoring -Q8- is switched off and the combustion air blower -V6- is brought up to full load. During the next 45 seconds as well as during normal operation, the glow plug with flame monitoring -Q8- assumes the task of flame monitoring and checks flame development. Then the automatically regulated heating operation begins. If no flame develops or the flame extinguishes, then the fuel supply is interrupted and a malfunction shut-down occurs with the combustion air blower -V6- continuing in run-on mode. If the flame is extinguished during normal operation, a new start is automatically initiated.

8.1.1 Preheating mode:

Once the coolant temperature has reached 84° C, the control unit switches to the energy-saving part load mode. If the coolant temperature continues to rise above 88° C, the control unit switches to the regulated waiting period. If the coolant temperature does not drop below 76° C within 900 seconds during the controlled waiting period, the heating unit will start with the normal start procedure in full-load mode when the coolant temperature does drop below 76° C.

8.1.2 Auxiliary heating mode:

• Start conditions page 2

To switch on auxiliary heating mode in vehicles without an air conditioning system for the VOLKSWAGEN GOLF 2004, press the instant heating button -E537–1-.

To switch on auxiliary heating mode in vehicles with Climatic, Golf 2008 for the VOLKSWAGEN GOLF 2004, press the instant heating button -E537–1-.

For vehicles with Climatronic, Golf 2008 on the VOLKSWAGEN GOLF 2004, the auxiliary heating mode is switched on by pressing the auxiliary heating button.

To switch on auxiliary heating mode in vehicles with Climatic, Golf 2009 for the VOLKSWAGEN GOLF 2004, press the instant heating button -E537–1-.

The auxiliary heating mode for the VOLKSWAGEN GOLF 2004 is switched off after the unit has been switched off manually (for example, by pressing the instant heat button -E537-), after a maximum operating time of 60 minutes or after the coolant reaches a temperature of 84° C, combustion is ended and the post-operation mode begins. The circulation pump -V55- and the combustion air blower -V6-, however, continue to run to cool down the auxiliary heater (post-operation mode) and are switched off automatically.

The post-operation period of the circulation pump -V55- and the combustion air blower -V6- when switching off auxiliary heating on a VOLKSWAGEN GOLF 2004 depends on the operating mode in which the auxiliary heater was switched off. The post-operation period is 175 seconds when heater is switched off during full-load operation and about 110 seconds for part-load operation. Depending on the control unit software version, slight deviations in the specified post-operation values are possible.

The functional description of the “big” remote control for the auxiliary heater on a VOLKSWAGEN GOLF 2004 is:

• The auxiliary heater can be switched on and off from a distance of up to 600 metres (open grounds) using the remote control. This range is restricted in built-up areas or from buildings.
• The remote control should be held upright when operating the buttons (the radio signals can be received optimally by the vehicle aerial in this way and the greatest transmission range is achieved).
• Following disconnection of the vehicle battery, the auxiliary heater remote control does not have to be re-adapted.
• If the remote control is renewed, initiate the “basic setting” function using vehicle diagnosis, testing and information system -VAS 5051-.

To switch the auxiliary heater on using the “big” remote control on a VOLKSWAGEN GOLF 2004, press button -1-, the warning lamp -2- must light up green. The operating period of the auxiliary heater is determined by the remote control unit when the heater is switched on (a time component is included in the switching signal). This time component is stored permanently in the remote control and cannot be changed.

To switch the auxiliary heater off using the “big” remote control on a VOLKSWAGEN GOLF 2004, press button -3-, the warning lamp -2- must light up red. The auxiliary heater switches to run-on and then off.

When renewing the batteries for the “big” remote control on a VOLKSWAGEN GOLF 2004 auxiliary heater:

• Ensure proper installation position of batteries.
• Only use batteries of the same type with a voltage of 12 Volt.
• Allocation of the remote control to the auxiliary heater remains intact. Re-adapting is not necessary.
• Take off battery cover -1- and remove batteries. Insert new batteries and replace cover.

The warning lamp in the remote control -2- shows you whether the signal from the remote control (press of a button) has been received by the auxiliary heater and whether the battery in the remote control is low. The meanings are:

The safety measures for working on vehicles with electric engine preheater on a VOLKSWAGEN GOLF 2004 are:

• All work on the electrical system must be carried out only by qualified persons in possession of the technical knowledge required.
• WARNING: Danger of electrical shock. Engine preheater operates with 230 V or 115 V current from the mains. Before working on engine preheater, pull plug from mains socket.

The rules for cleanliness when working on the engine preheater for a VOLKSWAGEN GOLF 2004 are:

• Thoroughly clean all connections and adjacent areas before disconnecting.
• Place parts that have been removed on a clean surface (use sheeting or paper, but no fluffy cloths) and cover.
• Carefully cover opened components or seal if the repair cannot be carried out immediately.
• Install clean parts only:
• Remove replacement parts from their packages only immediately before installing them.
• Do not use any parts which have not been stored in their packaging (e.g. in a tool box).

The procedure for removing the connector for the mains plug on a VOLKSWAGEN GOLF 2004 electric engine preheater is:

• Pull vent grille -1- out of fasteners in front bumper cover.
• Remove bolts from connector -2- and separate earth wire from longitudinal member behind it.
• Remove noise insulation.
• Separate electrical wiring.

WARNING: Danger of electrical shock. Engine preheater operates with 230 V or 115 V current from the mains. Before working on socket for engine preheater, pull plug from mains socket.

When installing the electrical wiring for the connector for the mains plug on a VOLKSWAGEN GOLF 2004 electric engine preheater:

• Caution: The electrical wiring can be pulled off. The motor moves relative to the body during load changes. Route the electrical wiring with slack between the engine and the body.

Note: When installing, ensure that cover of connector opens upwards. The electrical wiring must not come in contact with hot, turning or sharp-edged components.

To check the connector for the electric engine preheater on a VOLKSWAGEN GOLF 2004 using a hand multimeter -V.A.G 1526B-, perform the following checks:

Checking for single phase 230 V or 115 V:

• Measure between pin -1- and -2-. Specification: < Ω
• Measure between pin -1- and -3-. Specification: < Ω
• Measure continuity from pin -3- to negative terminal of vehicle battery (vehicle earth). Specification: 0-1 Ω.

If value deviates from specification, check inventive wiring as well as earth connection for damage. Renew defective wiring harness with a genuine part.

To test the safety switch (optional) for the electric engine preheater on a VOLKSWAGEN GOLF 2004:

Checking:

• Connect safety switch between adapter cable and extension cord.
• Push plug into mains socket.
• After a short time, the heating element will heat up and the sound of boiling water can be heard.
• Push the Test button -1-. The switch -2- will jump back to the “0-OFF” position.
• The engine preheater is switched off. The engine preheater can be switched on again by manually moving switch -2- to the “I-ON” position.

The special tools and workshop equipment required for removing and installing the engine preheater on a VOLKSWAGEN GOLF 2004 are:

• Hose clamps up to 40 mm Ø -3093-
• Drip tray -V.A.G 1306-

The assembly overview for the engine preheater on a VOLKSWAGEN GOLF 2004 includes:

1. Engine preheater
2. Bracket
3. Nut (40 Nm)
4. Clip
5. To coolant pipe
6. 220 V or 115 V connecting cable
7. Catch
8. Bracket
9. To coolant hose on top of radiator
10. Left air intake grille

Installation position of heater element: Note locating element -arrow-.

The warnings when removing the engine preheater on a VOLKSWAGEN GOLF 2004 are:

• WARNING: Danger of electrical shock. Engine preheater operates with 230 V or 115 V current from the mains. Before working on engine preheater, pull plug from mains socket.
• WARNING: Danger of scalding injuries. When the engine is warm, the coolant temperature may be above 100° C. The cooling system is pressurised. If necessary, release pressure before carrying out repairs.

When installing the engine preheater on a VOLKSWAGEN GOLF 2004 after removing it:

• Ensure proper seating of yellow “pull-off protection”.

Note: The coolant circuit must be bled after it is opened page 22. O-type clips are to be replaced with screw-type clips.

The connections for the engine preheater into the cooling circuit for the 2.0 I FSI on a VOLKSWAGEN GOLF 2004 are:

1. Coolant return line
2. Heating element
3. Coolant supply line

The connections for the engine preheater into the cooling circuit for the 1.9 I TDI on a VOLKSWAGEN GOLF 2004 are:

1. Coolant return line
2. Heating element
3. Coolant supply line

The connections for the engine preheater into the cooling circuit for the 1.6 I MPI on a VOLKSWAGEN GOLF 2004 are:

1. Coolant return line
2. Heating element
3. Coolant supply line