Volkswagen Workshop Service and Repair Manuals

Removing auxiliary heater Thermo Top V   Note If the Thermo Top V is to be renewed, first connect vehicle diagnosis, testing and information system -VAS 5051B- or later model and start the „Renew heater“ function under the guided functions. Special tools and workshop equipment required

t  Torque wrench -V.A.G 1410- (4…20 Nm)

t  Hose clamps up to 25 mm Ø -3094-

t  Vehicle diagnosis, testing and information system -VAS 5051B- or later model.   Note t  The coolant circuit must be bled after it is opened → Chapter. t  After the auxiliary heater has been detached, it must be secured to the body with welding wire to prevent damage to the coolant hoses. –  Remove section of front right wheel housing liner → Rep. gr.66.   WARNING Danger of burn injuries. Parts of the exhaust system may be hot. Before removing exhaust system, let it cool off. –  Remove exhaust pipe from silencer on auxiliary heater → Chapter.   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 and reduce temperature before carrying out repairs. –  Clamp off coolant hoses -1- and -2- using hose clamps up to 25 mm Ø -3094- and pull coolant hoses off auxiliary heater.

Do not separate coolant hoses that are connected to each other. –  Remove fuel filter with bracket → Rep. gr.20. On vehicles with diesel engine.

–  Remove windscreen washer system reservoir → Rep. gr.92. –  Remove securing bolt -1- (8± 0.8 Nm) below reservoir for window washer system.

–  Remove securing 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-.   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 fuel line at quick-release coupling and seal fuel lines with appropriate plugs.   Caution Auxiliary heater control unit -J364- could be damaged. Overvoltages can occur at the connectors. First disconnect 8-pin connector. –  Unplug the other connectors at the auxiliary heater.