Volkswagen Workshop Service and Repair Manuals

Repairing auxiliary heater Thermo Top V Before beginning repair work, perform the following steps: –  Disconnect battery → Rep. gr.27. 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-   Note t  The illustration shows the Golf V. The installation positions of the auxiliary heater components on the Golf VI are identical. t  There is a manufacturer's nameplate on the auxiliary heater unit. This type plate provides information about which version is installed in the vehicle: diesel Thermo Top V → Fig.. t  The coolant circuit must be bled after it is opened → Chapter.

1 -	Fuel gauge sender -G-

q	Installation location: under rear bench seat, right.

q	Removing and installing → Rep. gr.20

2 -	Aerial for telephone, navigation system, auxiliary heating -R66-

q	For vehicles with auxiliary heater and remote control.

3 -	Heater coolant shut-off valve -N279- Golf ►2008

The heater coolant shut-off valve -N279- is fitted only in vehicles with certain engines and with auxiliary heating.

q	Secured to engine compartment bulkhead

q	Removing and installing → Chapter

4 -	Fresh air blower relay -J13-

q	Not in vehicles with Climatronic

q	Location: relay and fuse carrier below dash panel on left

q	Checking → Current flow diagrams, Electrical fault finding and Fitting locations

5 -	Fuse carrier with auxiliary heater operation relay -J485- (only on vehicles with Climatronic)

q	Location: under dash panel on left → Current flow diagrams, Electrical fault finding and Fitting locations

6 -	Coolant temperature sender -G62-

q	Location: on cylinder head connection

7 -	Battery -A-

q	Location: in engine compartment on left

8 -	Ambient temperature sensor -G17-

q	Checking: Vehicle diagnosis, testing and information system -VAS 5051B- or later model.

q	Removing and installing → Fig.

9 -	Circulation pump -V55-

q	Location on auxiliary heater

q	Removing and installing → Chapter

10 -	Auxiliary heater Thermo Top V

q	With auxiliary heating control unit -J364-.

q	Location: below front bumper on right

q	Removing and installing → Chapter

11 -	Exhaust system

q	For auxiliary heating.

q	Removing and installing → Fig.

12 -	Metering pump -V54-

q	Location: right side of fuel tank.

q	Fuel supply to auxiliary heater → Chapter.

q

It is possible that the metering pump ticks audibly but still does not deliver fuel because there is air in the intake. The control unit then switches it off completely. You should therefore read the fault memory using vehicle diagnosis, testing and information system -VAS 5051B- or later model, Self-diagnosis of Thermo Top V auxiliary heater. Erase fault memory and carry out final control diagnosis of Thermo Top V auxiliary heater.

q	Removing and installing → Chapter

q	Testing quantity of fuel delivered → Chapter

13 -	Remote control receiver for auxiliary coolant heater -R149-

q	Removing and installing → Chapter

Manufacturer's plate on heater unit for Thermo Top V, diesel

Manufacturer's plate on heater unit for Thermo Top V, petrol

Manufacturer's plate on heater unit for Thermo Top V, diesel (preheater without auxiliary heating function)

Manufacturer's plate (duplicate) on lock carrier for Thermo Top V, diesel

Manufacturer's plate (duplicate) for Thermo Top V, petrol

Manufacturer's plate (duplicate) on lock carrier for Thermo Top V, diesel (preheater without auxiliary heating function)   Note t  The most important technical data are shown on upper part of manufacturer's plate. t  The date of first use is entered on the lower part of manufacturer's plate. t  The year the unit was first put into use must be entered on the „Genuine part“ manufacturer's plate. The heat exchanger of the coolant heater does not need to be renewed after 10 years. Legislation in Germany dictates only that air heaters must be renewed.

Removing and installing ambient temperature sensor -G17- –  Remove centre vent → Rep. gr.63. –  Unclip ambient temperature sensor -G17--1- and separate connector.

Removing and installing exhaust system   WARNING Danger of burn injuries. Silencer could be hot. Before removing silencer, let it cool off. –  Remove front part of front right wheel housing liner → Rep. gr.66. –  Loosen securing clamp on exhaust pipe -1- and remove bolts -2- and -3- (6 Nm). –  Remove exhaust system.   Caution The exhaust system must be routed so that wiring harness does not touch exhaust system (danger of short circuit).