Volkswagen Golf Service & Repair Manual: 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- |
| – |
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
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|
| 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. |
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. |
|
|
|
| – |
Remove heat shield -B- and
bracket -C- from high-voltage
heater (PTC) -Z115--D-. |
|
|
|
| – |
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-. |
|
|
|
| – |
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-). |
| Installation is carried out in the reverse order. When
installing, note the following: |
|
|
|
| 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-. |
|
|
|
| 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-.
|
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|
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|
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. |
|
|
|
| – |
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-. |
|
|
|
|
Component |
Specified torque |
| Bolts
-A- |
8 Nm |
| – |
Install bracket -C- with
high-voltage heater (PTC) -Z115-. |
|
|
|
|
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. |
|
|
|
Special tools and workshop equipment
required
Hose clamps, up to 25 mm -3094-
...
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