VOLKSWAGEN GOLF VARIANT 2010 (13) 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 completing repairs on the auxiliary heater, carry out self-diagnosis using vehicle diagnosis, testing and information system -VAS 5051B- .

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.

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.

Torque wrench -V.A.G 1410- (4…20 Nm)

Hose clamps up to 25 mm Ø -3094-

Disconnect the battery.

1 – Auxiliary heater Thermo Top V with auxiliary heating control unit -J364- is located below the front bumper on the right.

2 – Fuel line with quick-release coupling: Routing of fuel line is on the inner side of the wing.

3 – Exhaust system.

4 – Air intake silencer.

5 – Circulation pump -V55-.

6 – Chafing protection.

7 – End pipe.

First connect vehicle diagnosis, testing and information system -VAS 5051B- and start the “Renew heater” function under the guided functions.

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-

After the auxiliary heater has been detached, it must be secured to the body with welding wire to prevent damage to the coolant hoses.

Removing air intake silencer:

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

Installing:

• Push air intake silencer onto intake pipe -3- far enough that it can be clipped into bracket -2-.

Hose clamps up to 25 mm Ø -3094-

Drip tray for workshop hoist -VAS 6208-

Place drip tray for workshop hoist -VAS 6208- under vehicle.

Loosen clip-1-.

• 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.

Pull coolant hoses off circulation pump -V55- .

Pull connector off circulation pump -V55- .

Remove bolt -2- and remove circulation pump -V55- .

Installation is carried out in the reverse order. When installing, note the following:

After installing circulation pump -V55-, bleed coolant circuit.

Removing and installing silencer with bracket:

• WARNING: Danger of burn injuries. Silencer could be hot. Before removing silencer, let it cool off.

Loosen pipe connections from silencer -A-.

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.

Torque wrench -V.A.G 1410- (4…20 Nm)

Hose clamps up to 25 mm Ø -3094-

Remove auxiliary heater Thermo Top V.

Loosen securing clamp -E- and remove silencer with bracket -D-.

Remove bracket -H-.

Pull off connectors -A-, -B- and -C-.

• 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.

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-.

1 – Cover for auxiliary heating control unit -J364-. Removing and installing.

2 – Temperature sensor -G18-. Removing and installing.

3 – Overheating sensor -G189-. Removing and installing.

4 – Combustion tube. Removing and installing.

5 – Heat exchanger. Removing and installing.

6 – 7 Nm Qty. 3

7 – Retaining spring

8 – 4 Nm

9 – Seal. Must be renewed after every opening.

10 – Cover. Removing and installing.

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 is possible only with petrol version.

17 – Burner. Removing and installing.

18 – Combustion air blower -V6-. The combustion air blower -V6- and housing are one component and cannot be dismantled. Removing and installing.

19 – Auxiliary heater control unit -J364-. Removing and installing.

20 – 4 Nm Qty. 4

Remove cover for auxiliary heating control unit -J364-.

Dismantling and assembling auxiliary heater Thermo Top V.

Pull off connectors -A- and -C- and remove bolts -arrows-.

Note:

• During assembly, wiring harness for connector -C- must lie in notch -B-.
• Ensure that side cover for wiring harness is properly seated.

Dismantling and assembling auxiliary heater Thermo Top V.

Using a suitable screwdriver, raise retaining clip -A- on both sides and remove glow plug with flame monitoring -Q8- .

Note:

• During assembly, retaining clip must seat in groove.
• Ensure proper seating of glow plug with flame monitoring -Q8- -B-.

Remove engine cover.

Pull out noise insulation and remove intake hose to turbo-charger.

Place drip tray for workshop hoist -VAS 6208- under vehicle.

Remove securing nuts (10 N) -A- from heater coolant shut-off valve -N279- -1-.

Clamp off coolant hoses -B- using hose clamps up to Ø 25 mm -3094- .

• 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.

Pull coolant hoses -B- off valve.

Unclip connecting wire from retainer and separate connector.

Installing:

Install in reverse order.

Tighten securing nuts -A- on valve -1- to 10 Nm torque.

1 – Coolant expansion tank

2 – Heat exchanger for heater

3 – Non-return valve

4 – Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead)

5 – Cylinder head and cylinder block

6 – ATF cooler (Only vehicles with automatic transmission)

7 – Engine oil cooler

8 – Radiator

9 – Circulation pump -V55-

10 – Auxiliary heater Thermo Top V

11 – Water pump

12 – Intake manifold

13 – Exhaust gas recirculation (water cooled)

1 – Coolant expansion tank

2 – Heat exchanger for heater

3 – Non-return valve

4 – Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead)

5 – Radiator

6 – Engine oil cooler

7 – Circulation pump -V55-

8 – Auxiliary heater Thermo Top V

9 – Water pump

10 – Exhaust gas recirculation (water cooled)

1 – Coolant expansion tank

2 – Non-return valve

3 – Restrictor

4 – Heat exchanger for heater

5 – Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead)

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-

13 – Auxiliary heater Thermo Top V

1 – Coolant expansion tank

2 – Non-return valve

3 – Heat exchanger for heater

4 – Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead)

5 – Intake manifold

6 – Cylinder head and cylinder block

7 – Engine oil cooler

8 – Radiator

9 – Water pump

10 – Circulation pump -V55-

11 – Auxiliary heater Thermo Top V

1 – Coolant expansion tank

2 – Heat exchanger for heater

3 – Cylinder head and cylinder block

4 – Coolant connection

5 – Radiator

6 – Continued coolant circulation pump -V51-

7 – Thermostat housing

8 – Circulation pump -V55-

9 – Auxiliary heater Thermo Top V

1 – Coolant expansion tank

2 – Heat exchanger for heater

3 – Non-return valve

4 – Heater coolant shut-off valve -N279- (Location: secured to engine compartment bulkhead)

5 – Intake manifold

6 – Engine oil cooler

7 – Radiator

8 – Circulation pump -V55-

9 – Auxiliary heater Thermo Top V

10 – Thermostat housing

11 – Cylinder head and cylinder block

12 – Exhaust gas recirculation (water cooled)

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.

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 get air out of fuel line, start auxiliary coolant heater repeatedly until it does not go out by itself.

1 – Quick-release coupling of fuel line (For auxiliary coolant heater Thermo Top V on inner side of wing).

2 – Quick-release coupling of fuel line (On auxiliary coolant heater).

3 – Auxiliary heater Thermo Top V

4 – Quick-release coupling of fuel line (For auxiliary coolant heating Thermo Top V on metering pump -V54-).

5 – Metering pump -V54- (Located on the fuel tank on the right-hand side).

6 – Fuel gauge sender -G- (Located on right side under bench seat).

Engine and gearbox lifter -V.A.G 1383 A-

Metering pump -V54- and the associated components are one spare part.

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

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

Quantity delivered for petrol and diesel: 22 to 28 ml

If the ambient temperature is above 20 °C, fuel vaporisation may lead to incorrect measurements.

No bubbles are to be delivered.

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).

Functional description of auxiliary heater Thermo Top V:

• 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.

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.

Press immediate heating button -1-.

Press immediate heating button -1-.

Press immediate heating button -1-.

Once the coolant temperature has reached 82 °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 70 °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 65 °C.

When switched off manually or after a maximum operating time of 60 minutes or 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.

Note:

• 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 110 seconds for part-load operation.
• Depending on the control unit software version, slight deviations in the specified post-operation values are possible.

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.

Note installation position of batteries.

Only use batteries of the same type with a voltage of 12 volts.

Allocation of the remote control to the auxiliary heater remains intact. Re-adapting is not necessary.

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.

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).

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.

When installing, ensure that cover of connector opens upwards.

The electrical wiring must not come in contact with hot, turning or sharp-edged components.

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.

Checking:

1- Single phase 230 V or 115 V

2- Neutral conductor

3- Earth conductor

Measure between pin -1- and -3-. Specification: ∞ Ω

Measure between pin -2- 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 wiring as well as earth connection for damage. Renew defective wiring harness with a genuine part.

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.

Hose clamps up to 40 mm Ø -3093-

Drip tray for workshop hoist -VAS 6208-

Remove noise insulation.

• 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.

Remove yellow “pull-off protection” -4- from electrical connector and pull off connector. Seal connector to prevent ingress of coolant (danger of short circuit).

Clamp off coolant hoses -1- and -2- with hose clamps up to 40 mm Ø -3093-.

Place drip tray for workshop hoist -VAS 6208- under vehicle.

• 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.

Loosen O-type or screw-type clips and pull coolant hoses off heating element -3-.

Install in reverse order.

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

Note:

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

1 – Coolant return line

2 – Heating element

3 – Coolant supply line

1 – Coolant return line

2 – Heating element

3 – Coolant supply line

1 – Coolant return line

2 – Heating element

3 – Coolant supply line