VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Coolant circuit / Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

Special tools and workshop equipment required
Commercially available Torx socket bit “TS30H” with hole in front face
Hose clamps, up to 25 mm -3094-
Engine bung set -VAS 6122-
Cooling system tester -V.A.G 1274 B-
Pliers for spring-type clips -VAS 5024A-
Removing
–  Switch off ignition.
–  Observe safety precautions → Chapter „Safety precautions when handling refrigerants“.
–  Comply with notes → Chapter „Working on refrigerant circuit“.
–  Observe safety precautions → Chapter „Safety precautions when working on the cooling system“.
–  Observe safety precautions when working on the high-voltage system → Chapter „Safety precautions when working on high-voltage system“.
–  Observe safety precautions when working in the vicinity of high-voltage components → Chapter „Safety precautions when working in the vicinity of high-voltage components“.
–  Observe the risk category of the high-voltage system → Rep. gr.00.
Danger to life due to high voltage.There is a risk of severe or fatal injury due to electric shock.The high-voltage system must be de-energised by a suitably qualified technician.
   
–  Now de-energise the high-voltage system → Rep. gr.93.
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.
–  Open filler cap -arrow- for coolant expansion tank of coolant circuit for engine.
–  Remove rear nose insulation → General body repairs, exterior; Rep. gr.66.
  Note
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

The high-voltage heater (PTC) -Z115- is installed to the underbody in the centre tunnel near the catalytic converter together with the bracket and the heat shield -C-.
–  Remove bolts -A- and -B-.
–  Carefully tilt high-voltage heater (PTC) -Z115- with bracket and heat shield -C- downwards.
–  Remove bolts -D-.
  Note
In the factory, the heat shield is bolted on with self-tapping pan head bolts (M6 x 12) -D-. A Torx socket bit “TS30H” with a hole in front face is required to remove and install these bolts.
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

–  Remove heat shield -B- and bracket -C- from high-voltage heater (PTC) -Z115--D-.
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

–  Clamp off coolant hoses -A- and -B- using hose clamps -3094--D-.
  Note
The high-voltage heater (PTC) -Z115--E- is designed for a particular direction of flow of the coolant. Therefore, the coolant hoses must not be interchanged when connecting them.
In vehicles with an auxiliary heater installed as optional equipment, a non-return valve is installed on coolant line -C- → Auxiliary heater, supplementary heater; Rep. gr.82.
–  Disconnect coolant hoses -A- and -B- from connections on high-voltage heater (PTC) -Z115--E-.
–  Seal open connections for coolant hoses on high-voltage heater (PTC) -Z115--E- with clean plugs from engine bung set -VAS 6122-.
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

–  Remove connectors -A- (for low voltage) and -B- (high-voltage cable) from high-voltage heater (PTC) -Z115-.
–  Cover high-voltage cable connector and its counterpart on -Z115--G- to protect them from being damaged or soiled (e.g. with clean plugs from engine bung set -VAS 6122-).
Unscrew nut -F- (or -E-), and remove earth cable -C- (or earth cable -C- with bracket -D-).
Installing
Installation is carried out in the reverse order. When installing, note the following:
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

The heat shield -B- and bracket -C- are bolted to high-voltage heater (PTC) -Z115--D- with self-tapping pan head bolts (M6 x 12) -A-. If a new high-voltage heater (PTC) -Z115--D- is installed, there is no thread provided at the bolting points. To ease the installation of the bolts when installing a new -Z115--D-, start bolts -A- and screw them in approx. 6 mm before installing -Z115--D-.
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

Check contact surface for earth cable -C- on bracket -D- and for bracket -D- on -Z115--G- before bolting on earth cable, and clean them as necessary.
  Note
Check bolting points on -Z115--G- and on bracket -D- as well as earth cable -C- on nut -F- before installing. The contact surfaces must be clean, rust- and grease-free. Otherwise, repair contact surfaces using contact surface cleaning set -VAS 6410-.
Bolt bracket -D- and earth cable -C- to -Z115--G-.
Specified torques:
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

Component Specified torque
Nut -E- and -F- (thread M6) 8 Nm
 
–  Connect connectors -A- (for low voltage) and -B- (high-voltage cable) to -Z115--G-.
–  If necessary, fill coolant in coolant expansion tank for engine → Rep. gr.19.
   
–  Attach coolant hose -A- to -Z115--E-.
–  Carefully open hose clamp -D- on coolant hose -A-, and let coolant flow into heat exchanger -Z115--E-.
–  As soon as coolant escapes from the coolant hose connection -B- on -Z115--E- (the -Z115--E- is completely filled with coolant), install coolant hose -B- to -Z115--E-.
  Note
To make sure the -Z115--E- is completely filled with coolant, hold connection for coolant hose -B- as high as possible when the coolant flows in.
If the -Z115--E- has been removed and installed as described above, there should not be any air in the coolant circuit of the engine. If, however, there is still air in the coolant circuit, bleed coolant circuit → Rep. gr.19.
–  Remove both hose clamps -D-.
–  Check contact surface for bracket -C- on -Z115--D- and on heat shield -B- before bolting on, and clean them as necessary.
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

–  Install heat shield -B- and bracket -C- to high-voltage heater (PTC) -Z115--D-.
  Note
The heat shield -B- and bracket -C- are bolted to high-voltage heater (PTC) -Z115--D- with self-tapping pan head bolts (M6 x 12) -A-.
Torque setting:
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

Component Specified torque
Bolts -A- 8 Nm
 
     
–  Install bracket -C- with high-voltage heater (PTC) -Z115-.
Specified torques:
 

Removing and installing high-voltage heater (PTC) -Z115- / high-voltage heater (PTC) -J848

Component Specified torque
Bolts -A- 8 Nm
Bolts -B- 20 Nm
 
–  Reinstall all components which have been removed or detached.
–  If necessary, fill coolant in coolant expansion tank for coolant circuit of engine → Rep. gr.19.
–  Remove hose clamp -3094-, and reinstall all components which have been removed or detached.
–  After the high-voltage heater (PTC) -Z115- has been installed, switch on ignition and activate the vehicle's drive system (the engine must not be running), set the air conditioning system to max. heat output, and operate the air conditioning system for 2 minutes with this setting.
   
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