VOLKSWAGEN GOLF 2009 (02) 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.

If the ECON button (depending on vehicle equipment) is pressed, the auxiliary heater will not operate as a supplementary heater.

Read self-diagnosis of auxiliary heater using vehicle diagnosis, testing and information system -VAS 5051- or later models.

If parts of the fuel system were removed or renewed, ensure that all components for fuel delivery to the auxiliary heater are properly installed.

Following repair work in the vicinity of the auxiliary heater fuel line, check:

• that the fuel line fits flush with the vehicle underbody and is protected from mechanical damage.
• that the auxiliary heater fuel line is protected from heating which might disturb operation.
• that the fuel line does not come in contact with vehicle parts which heat up.

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° С

Fuel gauge not in reserve range

On-board network manager not active

No crash switch-off

No fault memory entries blocking start procedure

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

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.

Torque wrench -V.A.G 1410- (4…20 Nm)

Hose clamps up to 25 mm Ø -3094-

The coolant circuit must be bled after it is opened.

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.

Press button -3-, the warning lamp -2- must light up red.

The auxiliary heater switches to run-on and then off.

Press button -1-, the warning lamp -2- must light up green.

Press button -3-, the warning lamp -2- must light up red.

The auxiliary heater switches to run-on and then off.

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.

Resistance of metering pump -V54- 5.2 +/- 5%Ω

Voltage at metering pump -V54- 9.5 to 16.5 Volt.

No fault stored in fault memory.

Fuel lines are not damaged or leaking.

Ambient temperature approx. 20 °C

Fuel tank sufficiently filled (fuel gauge on dash panel insert not in red area).

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- .

No bubbles are to be delivered.

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.

Start conditions are found on page 2 of the manual for the VOLKSWAGEN GOLF 2009 auxiliary heater.

Press instant heating button -E537–1-.

Press instant heating button -E537–1-.

Press instant heating button -E537–1-.

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- depend 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.

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.

Air in the coolant circuit or the auxiliary heater can cause the auxiliary heater to overheat. The fault “control unit defective” will be stored in the auxiliary heater. If this fault occurs several times in a row, the auxiliary heater will be blocked electronically. This blockage can be removed using the vehicle diagnosis, testing and information system -VAS 5051- or a later model. Start the function “adaptation” in the vehicle diagnosis, testing and information system -VAS 5051-.

Fill coolant circuit → Rep. Gr. 19.

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

For Climatic 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 → Rep. Gr. 19 .

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, 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.