Volkswagen Golf Service & Repair Manual: Removing and installing auxiliary heater

Volkswagen Golf Service & Repair Manual / Auxiliary heater / Aux. heater/heater booster / Auxiliary heater / Removing and installing auxiliary heater

Special tools and workshop equipment required

Torque wrench -V.A.G 1410- (4…20 Nm)

Removing and installing auxiliary heater

Hose clamps, up to 25 mm -3094-

Removing and installing auxiliary heater

Pliers for spring-type clips -VAS 5024A-

Removing and installing auxiliary heater

Drip tray for workshop hoist -VAS 6208-

Vehicle diagnostic tester

Note

There is an identification plate attached to the auxiliary heater. This identification plate indicates which heater version is installed in the vehicle: → Chapter

Coolant circuit must be bled after it is opened → Rep. gr.19.

Cooling system is pressurized when engine is warm. If necessary, release pressure and reduce temperature before carrying out repairs.

After the auxiliary heater has been disconnected, it must be secured to the vehicle body with welding wire. This prevents damage to the coolant hoses.

If the auxiliary heater is to be renewed, first connect the vehicle diagnostic tester and start the “Renew heater” function under "Guided Functions".

Removing

Before beginning repair work, perform the following steps:

–	Connect vehicle diagnostic tester, and select the function “Renew heater unit” in “Guided fault finding” or “Guided functions” mode.

Note

If possible, certain settings and adaption values for the auxiliary heater that is to be renewed are read out and stored via this function. The stored values can then be imported again to be used for the new auxiliary heater; vehicle diagnostic tester in “Guided fault finding” or “Guided functions” mode.

–	Switch off electrical consumers.

–	Switch off ignition.

–	Remove ignition key.

Note

Fit all cable ties and other fasteners for wiring harness at the same places from which they were detached or cut during removal of the auxiliary heater.

–	Remove front noise insulation → General body repairs, exterior; Rep. gr.66.

–	Detach front right wheel housing liner and remove front section → General body repairs, exterior; Rep. gr.66.

Danger of severe burns from hot exhaust system. Burns to hands and other body parts possible.Allow exhaust system to cool.

–	Remove exhaust system of auxiliary heater → Chapter.

–	Place drip tray underneath vehicle.

When the engine is warm, the cooling system is under pressure. Danger of scalding due to steam and hot coolant. There is a risk of injury to the skin and parts of the body due to scalding.Always wear safety gloves.Always wear safety goggles.Proceed as follows to release the pressure: cover the cap of the coolant expansion tank with a cloth, and open it carefully.

Further safety precautions for working on the cooling system → Rep. gr.00.

Removing and installing auxiliary heater

–	Clamp off coolant hoses with hose clamps, up to Ш 25 mm -3094-, release spring-type clips -1- and pull coolant hoses off coolant pipes.

–	Unfasten fuel line at clip -3-.

Note

Observe safety precautions for working on the fuel supply system → Chapter and → Rep. gr.00.

The fuel system is pressurised.Danger of injury through fuel spray.Always wear safety goggles.Always wear safety gloves.To release pressure, wrap a clean cloth around the connection and carefully loosen the connection.

–	Unclip fuel line -4- from auxiliary heater and disconnect it at quick-release coupling. Seal fuel lines using suitable plugs.

Should it be difficult to access securing nuts -2- due to the version of the headlight, remove headlight → Electrical system; Rep. gr.94.

–	Unscrew securing nuts -2- and remove auxiliary heater from longitudinal member.

Removing and installing auxiliary heater

–	Carefully swivel auxiliary heater towards rear and release and disconnect connector -1- (6-pin) first and then connector -2-.

–	Detach auxiliary heater and set it down carefully.

Installing

Note

When carrying out assembly work, particularly in the engine compartment due to the restricted space, observe the following points:

Install all sorts of lines (e.g. for fuel, coolant and refrigerant) as well as electric wiring so that the original routing is restored.

Make sure there is sufficient clearance between the lines and all moveable and hot components.

Note

If the auxiliary/supplementary heater has been renewed, a vehicle diagnostic tester must be connected before the first use in order to adjust various settings (e.g. “Line filling”) using the “Guided Fault Finding” function.

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

–	Install auxiliary heater and fit and secure coolant hoses (do »NOT« open hose clamps, up to Ш 25 mm -3094-).

Removing and installing auxiliary heater

–	Open O-type clip -3- and hold hose -4- so that it points vertically upwards.

–	Open hose clamp -2- until coolant emerges from auxiliary heater.

–	Close hose clamp -2-.

–	Open hose clamp -1- until coolant emerges from coolant hose -4-.

–	Close hose clamp -1-.

–	Fit hose -4- and remove hose clamps, up to Ш 25 mm -3094-.

–	Bleed coolant circuit of auxiliary heater → Chapter.

Note

If additional air entered cooling system during assembly, entire coolant circuit must be bled → Rep. gr.19.

–	Read event memory and clear entries using vehicle diagnostic tester in “Guided fault finding” mode.

–	Start auxiliary heater and run it at full load for at least 10 minutes so that fuel line is bled completely and you can check operation of auxiliary heater.

–	Set dash panel vent to maximum heating power.

Specified torque

→ Chapter „Assembly overview - auxiliary heater attachments“

Nose insulation; Assembly overview - noise insulation → General body repairs, exterior; Rep. gr.66.

Wheel housing liner; Removing and installing wheel housing liner → General body repairs, exterior; Rep. gr.66.

Removing and installing auxiliary heater

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Dismantling and assembling auxiliary heater

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