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What are the safety measures for working on VOLKSWAGEN GOLF VARIANT 2007 vehicles with auxiliary heaters?
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, be aware of the danger of scalding injuries because the cooling system is pressurised and 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 completing repairs on the auxiliary heater, carry out self-diagnosis using vehicle diagnosis, testing and information system -VAS 5051B-.
What should be noted when performing general repairs on VOLKSWAGEN GOLF VARIANT 2007 vehicles with auxiliary heaters?
One method of switching off the auxiliary heater is to press the ECON button.
Read self-diagnosis of auxiliary heater using vehicle diagnosis, testing and information system -VAS 5051B-.
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.
What are the rules for cleanliness when working on the auxiliary heater and the fuel system of a VOLKSWAGEN GOLF VARIANT 2007?
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).
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.
What steps should be performed before beginning repair work on the auxiliary heater Thermo Top V for a VOLKSWAGEN GOLF VARIANT 2007?
Disconnect the battery → Rep. Gr. 27.
The coolant circuit must be bled after it is opened → Rep. Gr. 19.
Cooling system is pressurized when engine is warm. If necessary, release pressure before carrying out repairs.
What special tools and workshop equipment are required for repairing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Torque wrench -V.A.G 1410- (4…20 Nm)
Hose clamps up to 25 mm Ø -3094-
Vehicle diagnosis, testing and information system -VAS 5051B- or earlier model
Drip tray for workshop hoist -VAS 6208-
What are the components of the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
1 – Auxiliary heater Thermo Top V (With auxiliary heating control unit -J364- Removing page 10)
2 – Fuel line with quick-release coupling (Routing of fuel line page 27.)
3 – Exhaust system (Removing and installing page 8)
4 – Air intake silencer (Removing and installing page 14)
5 – Circulation pump -V55- (Removing and installing page 14)
6 – Chafing protection
7 – End pipe
What is the procedure for removing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007 if it is to be renewed?
If the Thermo Top V is to be renewed, first connect vehicle diagnosis, testing and information system -VAS 5051B- and start the “Renew heater” function under the guided functions.
What special tools and workshop equipment are required for removing and installing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Torque wrench -V.A.G 1410- (4…20 Nm)
Hose clamps up to 25 mm Ø -3094-
Vehicle diagnosis, testing and information system -VAS 5051B- or earlier model
What warnings must be observed when removing the exhaust system for the auxiliary heater on a VOLKSWAGEN GOLF VARIANT 2007?
Danger of burn injuries. Parts of the exhaust system may be hot. Before removing exhaust system, let it cool off.
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.
What is the procedure for removing the air intake silencer as an ancillary of the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Unclip air intake silencer -1- from bracket -2- and pull off intake pipe -3-.
What is the procedure for installing the air intake silencer as an ancillary of the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Push air intake silencer onto intake pipe -3- far enough that it can be clipped into bracket -2-.
What special tools and workshop equipment are required for removing the circulation pump -V55- as an ancillary of the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Hose clamps up to 25 mm Ø -3094-
Drip tray for workshop hoist -VAS 6208-
What should be noted after installing the circulation pump -V55- on a VOLKSWAGEN GOLF VARIANT 2007?
After installing circulation pump -V55-, bleed coolant circuit → Rep. Gr. 19.
What warnings must be observed when removing the silencer with bracket for the auxiliary heater on a VOLKSWAGEN GOLF VARIANT 2007?
Danger of burn injuries. Silencer could be hot. Before removing silencer, let it cool off.
What should be observed when installing the bracket for the auxiliary heater on a VOLKSWAGEN GOLF VARIANT 2007?
When installing bracket -1-, observe centring tabs.
What special tools and workshop equipment are required for dismantling and assembling the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Torque wrench -V.A.G 1410- (4…20 Nm)
Hose clamps up to 25 mm Ø -3094-
What is the procedure for removing the auxiliary heater Thermo Top V on a VOLKSWAGEN GOLF VARIANT 2007?
Remove auxiliary heater Thermo Top V⇒ page 10 .
Loosen securing clamp -E- and remove silencer with bracket -D- page 15
Remove bracket -H- → page 16.
Pull off connectors -A-, -B- and -C-.
Before opening system, wrap a cloth around the connection and release pressure by carefully loosening the connection due to danger of fuel escaping as the fuel system is under pressure.
Open O-type clip and pull fuel line -F- off connection. Renew O-type clip with screw-type clip.
Seal fuel lines using suitable plugs.
Unclip cover -G- -arrows-.
What are the internal components of the auxiliary heater on a VOLKSWAGEN GOLF VARIANT 2007?
1 – Cover for auxiliary heating control unit -J364-. (Removing and installing ⇒ page 16)
2 – Temperature sensor -G18- (Removing and installing ⇒ page 19)
3 – Overheating sensor -G189- (Removing and installing ⇒ page 19)
4 – Combustion tube (Removing and installing ⇒ page 16)
5 – Heat exchanger (Removing and installing ⇒ page 16)
6 – 7 Nm Qty. 3
7 – Retaining spring
8 – 4 Nm
9 – Seal (Must be renewed after every opening.)
10 – Cover (Removing and installing ⇒ page 16)
11 – Coolant connection (Mark fitting position.)
12 – 4 Nm
13 – Retaining plate
14 – Coolant connection (Mark fitting position.)
15 – Retaining clip
16 – Glow plug with flame monitoring -Q8- (Removing and installing page 19 is possible only with petrol version. Ensure correct seating.)
17 – Burner (Removing and installing page 16)
18 – Combustion air blower -V6- (The combustion air blower -V6- and housing are one component and cannot be dismantled. Removing and installing page 16)
19 – Auxiliary heater control unit -J364- (Removing and installing page 18)
20 – 4 Nm Qty. 4
What is the procedure for removing and installing the auxiliary heater control unit -J364- on a VOLKSWAGEN GOLF VARIANT 2007?
Remove cover for auxiliary heating control unit -J364-.
Dismantling and assembling auxiliary heater Thermo Top V ⇒ page 16.
Pull off connectors -A- and -C- and remove bolts -arrows-.
During assembly, wiring harness for connector -C- must lie in notch -B-.
Ensure that side cover for wiring harness is properly seated.
What should be noted when removing and installing the glow plug with flame monitoring -Q8- on a diesel version of the auxiliary heater on a VOLKSWAGEN GOLF VARIANT 2007?
With the diesel version, a heating element for preheating fuel -Z66- is permanently installed on the combustion tube. The wires are connected to wires of glow plug with flame monitoring -Q8-. With this version, the entire combustion tube must be renewed if the glow plug with flame monitoring -Q8- is defective.
The figure shows the diesel version with heating element for preheating fuel -Z66- on combustion tube.
Using a suitable screwdriver, raise retaining clip -A- on both sides and remove glow plug with flame monitoring -Q8- .
During assembly, retaining clip must seat in groove.
Ensure proper seating of glow plug with flame monitoring -Q8- -B-.
What is the procedure for removing and installing the temperature sensor -G18- and overheating sensor -G189- on a VOLKSWAGEN GOLF VARIANT 2007?
Dismantling and assembling auxiliary heater Thermo Top V ⇒ page 16.
Remove bolt -1- and remove retaining spring -2-.
Pull out temperature sensor -G18- -3-and overheating sensor -G189- -4- using needle-nose pliers.
When assembling, ensure that retaining spring is in proper position -2-.
Sensors cannot be renewed separately.
What safety measures must be observed when working on the engine preheater for the VOLKSWAGEN GOLF VARIANT 2007?
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.
What are the rules for cleanliness when working on the engine preheater for the VOLKSWAGEN GOLF VARIANT 2007?
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).
What is the procedure for removing the connector for the mains plug on the VOLKSWAGEN GOLF VARIANT 2007?
Pull vent grille -1- out of fasteners in front bumper cover → Rep. Gr. 63.
Remove bolts from connector -2- and separate earth wire from longitudinal member behind it.
Remove noise insulation → Rep. Gr. 50 .
Separate electrical wiring.
What should be ensured when installing the connector for the mains plug on the VOLKSWAGEN GOLF VARIANT 2007?
When installing, ensure that cover of connector opens upwards.
The electrical wiring must not come in contact with hot, turning or sharp-edged components.
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.
What are the specifications for checking the connector on the VOLKSWAGEN GOLF VARIANT 2007 using a hand multimeter -V.A.G 1526C-?
Check between pin -1- (Single phase 230 V or 115 V) and -3- (Earth conductor). Specification: ∞ Ω
Check between pin -2- (Neutral conductor) and -3- (Earth conductor). 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 wiring as well as earth connection for damage. Renew defective wiring harness with a genuine part.
How do you test the safety switch (optional) on the VOLKSWAGEN GOLF VARIANT 2007?
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.
What special tools and workshop equipment are required for removing and installing the engine preheater on a VOLKSWAGEN GOLF VARIANT 2007?
Hose clamps up to 40 mm Ø -3093-
Drip tray for workshop hoist -VAS 6208-
What warnings must be observed when removing the engine preheater on a VOLKSWAGEN GOLF VARIANT 2007?
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.
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.
What should be noted after installing the engine preheater on a VOLKSWAGEN GOLF VARIANT 2007?
The coolant circuit must be bled after it is opened → Rep. Gr. 19.
O-type clips are to be replaced with screw-type clips.
How is the coolant return line connected for the 2.0 I FSI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The coolant return line is item 1 in the diagram for the 2.0 I FSI engine connection.
How is the heating element connected for the 2.0 I FSI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The heating element is item 2 in the diagram for the 2.0 I FSI engine connection.
How is the coolant supply line connected for the 2.0 I FSI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The coolant supply line is item 3 in the diagram for the 2.0 I FSI engine connection.
How is the coolant return line connected for the 1.9 I TDI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The coolant return line is item 1 in the diagram for the 1.9 I TDI engine connection.
How is the heating element connected for the 1.9 I TDI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The heating element is item 2 in the diagram for the 1.9 I TDI engine connection.
How is the coolant supply line connected for the 1.9 I TDI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The coolant supply line is item 3 in the diagram for the 1.9 I TDI engine connection.
How is the coolant return line connected for the 1.6 I MPI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The coolant return line is item 1 in the diagram for the 1.6 I MPI engine connection.
How is the heating element connected for the 1.6 I MPI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The heating element is item 2 in the diagram for the 1.6 I MPI engine connection.
How is the coolant supply line connected for the 1.6 I MPI engine when connecting the engine preheater into the cooling circuit of a VOLKSWAGEN GOLF VARIANT 2007?
The coolant supply line is item 3 in the diagram for the 1.6 I MPI engine connection.
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