VW Golf manuals

Volkswagen Golf Service & Repair Manual: Incorporation of high-voltage heater (PTC) - Z115- into coolant circuit

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Coolant circuit / 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 vehicles with a high-voltage system and an auxiliary heater installed as optional equipment, the high-voltage heater (PTC) -Z115- can be used for heating the passenger compartment instead of the auxiliary heater. For additional information, refer to → Auxiliary heater, supplementary heater; Rep. gr.00.
In vehicles with a high-voltage system and without an auxiliary heater installed as optional equipment, the passenger compartment can be heated via the “Stationary air conditioning” function and the - Z115- when the ignition is switched off and at low ambient temperatures (or cooled via the air conditioning system at high ambient temperatures).
Fill coolant and bleed coolant circuit → Rep. gr.19.
Incorporation of heat exchanger for air conditioning system and high-voltage heater (PTC) - Z115- into coolant circuit of engine → Rep. gr.19 (coolant hose schematic diagram).
   
  Note
The -arrows- indicate the direction of coolant flow.

Incorporation of high-voltage heater (PTC) - Z115- into coolant circuit

1 -  Heat exchanger for heater in air conditioning unit
Incorporation of heat exchanger into coolant circuit of engine → Rep. gr.19 (coolant hose schematic diagram).
2 -  High-voltage heater (PTC) - Z115- (with high-voltage heater (PTC) control unit - J848-)
Check; vehicle diagnostic tester in “Guided fault finding” mode (of air conditioning system) and → Current flow diagrams, Electrical fault finding and Fitting locations
Removing and installing → Chapter
For additional information on vehicles with an “auxiliary heater” as optional equipment, refer to → Auxiliary heater; Rep. gr.00.
3 -  Coolant valve for gearbox -N488-
Removing and installing → Rep. gr.19
4 -  Coolant supply to gearbox
Incorporation of auxiliary heater into coolant circuit of engine (and gearbox) → Rep. gr.19 (coolant hose schematic diagram).
5 -  Coolant supply from engine
Incorporation of auxiliary heater into coolant circuit of engine → Rep. gr.19 (coolant hose schematic diagram).
6 -  Coolant return to the engine
Incorporation of auxiliary heater into coolant circuit of engine → Rep. gr.19 (coolant hose schematic diagram).
  Note
Depending on the engine, a valve may be installed in the coolant return section between the coolant changeover valve 2 -N633- and the engine. The valve prevents coolant from flowing from the engine to the -N633- when the engine is running → Rep. gr.19 (coolant hose schematic diagram).
7 -  Coolant changeover valve 2 -N633-
Incorporation of auxiliary heater into coolant circuit of engine → Rep. gr.19 (coolant hose schematic diagram).
Removing and installing → Rep. gr.19.
  Note
The -N633- is activated by the respective engine control unit (e.g. by engine control unit -J623-), if heat output is required from the air conditioning system and if the vehicles is in electric drive mode → Current flow diagrams, Electrical fault finding and Fitting locations and vehicle diagnostic tester in “Guided fault finding” mode.
If there are customer complaints about poor heat output of the air conditioning system when engine is running and/or at standstill (irrespective of whether -Z115- is activated or not), make sure the coolant changeover valve 2 is installed with correct orientation and that it works properly → Current flow diagrams, Electrical fault finding and Fitting locations and vehicle diagnostic tester in “Guided fault finding” mode.
To ensure that the coolant heated by the -Z115- is conveyed through the heat exchanger of heater and air conditioning unit, the coolant pump for high-temperature circuit -V467- and the coolant valve for gearbox -N488- must be activated as well (by the respective engine control unit). To ensure that the coolant flows into the correct direction, the non-return valves installed in the coolant circuit must be installed correctly and they must work properly. For additional information refer to → Rep. gr.19 (coolant hose schematic diagram); vehicle diagnostic tester in “Guided fault finding” mode and → Current flow diagrams, Electrical fault finding and Fitting locations.
8 -  Coolant pump for high-temperature circuit -V467-
Incorporation into coolant circuit of engine → Rep. gr.19 (coolant hose schematic diagram)
Removing and installing → Rep. gr.19
  Note
The -V467- is activated by the respective engine control unit (e.g. by engine control unit -J623-), if heat output from the air conditioning system is required → Current flow diagrams, Electrical fault finding and Fitting locations and vehicle diagnostic tester in “Guided fault finding” mode.
If there are customer complaints about poor heat output of the air conditioning system when engine is running and/or at standstill (irrespective of whether -Z115- is activated or not), make sure the -V467- is installed with correct orientation and that it works properly → Current flow diagrams, Electrical fault finding and Fitting locations and vehicle diagnostic tester in “Guided fault finding” mode.
To ensure that the coolant heated by the -Z115- is conveyed through the heat exchanger of heater and air conditioning unit, the coolant changeover valve 2 -N633- and the coolant valve for gearbox -N488- must be activated as well (by the respective engine control unit). To ensure that the coolant flows into the correct direction, the non-return valves installed in the coolant circuit must be installed correctly and they must work properly. For additional information refer to → Rep. gr.19 (coolant hose schematic diagram); vehicle diagnostic tester in “Guided fault finding” mode and → Current flow diagrams, Electrical fault finding and Fitting locations.
9 -  Coolant return from gearbox
Incorporation of auxiliary heater into coolant circuit of engine (and gearbox) → Rep. gr.19 (coolant hose schematic diagram).
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