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Volkswagen Golf Service & Repair Manual: Incorporation of heat exchanger for high-voltage battery into coolant circuit of high-voltage system

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Coolant circuit / Incorporation of heat exchanger for high-voltage battery into coolant circuit of high-voltage system

  Note
Fill coolant and bleed coolant circuit → Rep. gr.19.
The illustration below shows only some of the components of the coolant circuit for the high-voltage system. For components which are not shown here refer to → Rep. gr.19.
Incorporation of heat exchanger for high-voltage battery into coolant circuit → Chapter.
If there is a problem with insufficient cooling output for cooling the components of the high-voltage system and the cooling output of the air conditioning system is OK, check the cooling capacity of the heat exchanger for high-voltage battery using the procedure for testing the cooling output → Chapter. When doing this, verify that the heat exchanger for high-voltage battery is actually cooled down. The operation of the refrigerant shut-off valve for high-voltage battery heat exchanger -N542- and of the restrictor installed in the refrigerant circuit must be OK → Chapter „System overview - refrigerant circuit, Golf GTE“. If no fault in the refrigerant circuit is detected, check the incorporation of the coolant pump for high-voltage battery -V590-, the coolant circulation pump before power and control electronics for electric drive -V508-, the coolant changeover valve 1 -N632- and the coolant valve for high-voltage battery -N688- into the coolant circuit of the high-voltage system as well as the activation and operation of these components → Rep. gr.19 and vehicle diagnostic tester in “Guided fault finding” mode (for the air conditioning system and the hybrid battery energy management system).
   

Incorporation of heat exchanger for high-voltage battery into coolant circuit of high-voltage system

1 -  Coolant valve for high-voltage battery -N688-
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
Removing and installing → Chapter
Check operation and activation of coolant pump for high-voltage battery -V590- and of -N688- → Rep. gr.19 and vehicle diagnostic tester in “Guided fault finding” mode (for the air conditioning system and the hybrid battery energy management system).
2 -  Coolant return from high-voltage battery 1 -AX2-
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
3 -  Coolant supply to high-voltage battery 1 -AX2-
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
4 -  Bleed screw
Bleed coolant circuit → Rep. gr.19.
5 -  Heat exchanger for high voltage battery
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
Check operation and cooling capacity of heat exchanger via the air conditioning system → Chapter „Checking cooling output on vehicles with automatically controlled air conditioning system (with high-voltage system)“ and vehicle diagnostic tester in “Guided fault finding” mode (for the air conditioning system and the hybrid battery energy management system).
Removing and installing → Chapter „Removing and installing heat exchanger for high-voltage battery“
6 -  Coolant pump for high-voltage battery -V590-
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
Removing and installing → Chapter
Checking operation and activation: vehicle diagnostic tester in “Guided fault finding” mode
  Note
The -V590- (and -N688-) are activated by the high-voltage battery 1 -AX2- (battery regulation control unit -J840-), if cooling output for the components of the high-voltage system (the high-voltage battery 1 -AX2-, the power and control electronics for electric drive -JX1- and/or the control unit for high-voltage battery charging unit -J1050-) is requested vehicle diagnostic tester in “Guided fault finding” mode (for the hybrid battery energy management system) and → Rep. gr.19.
If there is a problem with insufficient cooling output for cooling the components of the high-voltage system, check for correct orientation and proper operation vehicle diagnostic tester in “Guided fault finding” mode (for the hybrid battery energy management system) and → Rep. gr.19.
For cooling the power and control electronics for electric drive -JX1- and the control unit for high-voltage battery charging unit -J1050-, the coolant circulation pump before power and control electronics for electric drive -V508- and the coolant changeover valve 1 -N632- must be activated as well (by the respective engine control unit) and they must work properly. For additional information refer to vehicle diagnostic tester in “Guided fault finding” mode (for the hybrid battery energy management system) and → Rep. gr.19.
7 -  Coolant supply from radiator for high-voltage system
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
8 -  Coolant supply to coolant circulation pump before power and control electronics for electric drive -V508-
Incorporation into coolant circuit of high-voltage system → Rep. gr.19
Incorporation of high-voltage heater (PTC) - Z115- into coolant circuit
  Note In vehicles with a high-voltage system, the high-voltage heater (PTC) -Z115- is used as a supplementary heater. In ve ...

Removing and installing coolant valve for high-voltage battery -N688-
Special tools and workshop equipment required     Hose clamps, up to 25 mm -3094-   ...

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