Volkswagen Bora 2006 Workshop Manual Download Page 77

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7.3.4

Vehicles with 1.9 l TDI engine

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1332-

♦ Spring-type clip pliers -VAS

5024-

Removing:
– Disconnect the battery

⇒ page 29

– Pull engine cover upwards -arrows A- and forwards

-arrow B-.

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

7. Starter

Summary of Contents for Bora 2006

Page 1: ...u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Workshop Manual Jetta 2005 Bora 2006 Electrical System Edition 05 2005 Service Service Department Technical Information ...

Page 2: ...op Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 27 Starter current supply CC 90 Instruments GCI 92 Windscreen wash wipe system 94 Lights lamps switches outside 96 Lights lamps switches inside 97 Wiring Technical information should always be available to the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure vehicl...

Page 3: ...necting battery 29 4 2 Connecting battery 29 5 Removing and installing battery 31 5 1 Models with a petrol engine 31 5 2 Models with a diesel engine 32 6 Torque settings battery 36 7 Starter 37 7 1 Checking starter B 37 7 2 Removing and installing starter automatic gearbox 38 7 3 Removing and installing starter automated shift gearboxes 58 7 4 Removing and installing starter manual gearbox 76 8 To...

Page 4: ...ng reservoir for windscreen and headlight washer systems 166 2 3 Removing and installing washer pump V5 168 2 4 Removing and installing windscreen washer spray jets 169 2 5 Adjusting front windscreen washer system spray jets 169 3 Headlight washer system 170 3 1 Assembly overview headlight washer system 171 3 2 Removing and installing headlight washer system pump V11 171 3 3 Removing and installin...

Page 5: ...ght in tailgate 214 6 6 Removing and installing tail light bulb carrier in tailgate 215 7 Number plate lights 217 7 1 Removing and installing number plate light X 217 8 Additional brake light 218 8 1 Removing and installing high level brake light bulb M25 218 9 Steering column switch 219 9 1 Assembly overview steering column switch 220 9 2 Removing and installing steering column switch 220 9 3 Ste...

Page 6: ...oor E52 and rear right window regulator switch in door E54 254 5 Lights and switches in luggage compartment 256 5 1 Removing and installing luggage compartment light W3 256 5 2 Removing and installing rear lid lock unit F256 257 6 Lights and switches in roof trim 258 6 1 Removing and installing front interior light and reading light vehicles with no sliding sunroof 258 6 2 Removing and installing ...

Page 7: ... engine compartment 288 5 Control units 292 5 1 Onboard supply control unit J519 292 5 2 Data bus diagnostic interface J533 294 5 3 Central control unit for convenience system J393 295 5 4 Trailer detector control unit J345 299 6 Wiring harness and connector repairs 302 6 1 Safety instructions 302 6 2 General notes concerning repairs to vehicle electrical system 302 6 3 Notes on repairs to wiring ...

Page 8: ...s n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Jetta 2005 Bora 2006 Electrical System Edition 05 2005 vi Contents ...

Page 9: ...lete vehicle electrical system Note Observe Self study programme No 234 vehicle batteries 1 2 Types of battery 1 2 1 Low maintenance battery Low maintenance battery with liquid electrolyte wet battery These batteries are recognised by the removable cell plugs Lead acid battery electrolyte level must be checked regularly and topped up with distilled water as required These batteries are often equip...

Page 10: ...s sealed and fitted with valves AGM is the abbreviation for Absorbent Glass Mat Note The procedure for checking and testing gel and absorbent glass mat batteries is identical Always replace an absorbent glass mat battery with another absorbent glass mat battery 1 2 4 Gel battery Maintenance free battery with a contained electrolyte Lead acid battery where the electrolyte is contained within a gel ...

Page 11: ...t is prohibited to cause sparks through grinding welding cutting operations and use naked lights in the vicinity of batteries Smoking is also prohibited Sparks must also prevented through electrostatic discharge therefore al ways earth through vehicle body etc before touching battery Only work on batteries in well ventilated and suitable rooms 1 3 2 Safety markings on battery Safety markings on ba...

Page 12: ...minal clamps and battery terminals the following should be observed The battery terminal clamps should only be fitted by hand and without using force Battery terminals should not be coated with grease The battery terminal clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it Once the battery terminal clamps have been tightened to the specified to...

Page 13: ... and safety regula tions page 2 It is essential first to check the external condition the terminals of the battery and that the battery is seated securely visually before performing more extensive tests Caution The battery will be damaged if the battery is not secured correctly Vibrations shorten the life of the battery there is a danger of an explosion the cell plates may be damaged and the secur...

Page 14: ...eries with a magic eye are produced in two versions Low maintenance page 1 Maintenance free page 1 Note Because the magic eye is located in only one cell the display applies only to this cell An exact determination of battery s con dition is only possible through a load test page 12 Before performing a visual check tap the magic eye lightly and carefully with the handle of a screwdriver The air bu...

Page 15: ...tery housing The electrolyte level is OK when the fluid level is at the max marking If the electrolyte level is below the max marking Replenished with distilled water page 7 Check electrolyte level in the cells Switch off the ignition and all electrical consumers If fitted remove the protective foil on the cell sealing plug Note The foil with the warning notices must remain on the battery Remove c...

Page 16: ...g bottle VAS 5045 The construction of the filler neck prevents an overfilling of the battery cells Check the electrolyte level of the battery page 7 Switch off the ignition and all electrical consumers If fitted remove the protective foil on the cell sealing plug Note The foil with the warning notices must remain on the battery Remove cell sealing plugs Replenish with distilled water using battery...

Page 17: ...sealing plug Note The foil with the warning notices must remain on the battery Remove cell sealing plugs Draw electrolyte off a cell using a hydrometer until the float swims unhindered The electrolyte density is determined by the float position in the battery electrolyte The value can be read from the float scale Electrolyte density Charge Voltage 1 28 g cm3 100 12 7 V 1 21 g cm3 60 12 3 V 1 18 g ...

Page 18: ...esult No load voltage Charge Condition of battery 11 70 V 0 Discharged no capacity Heavily discharged page 27 12 20 V 50 Over a period of time sulphate crystals build up which can only be reversed using a considerable amount of energy At the same time the active mass expands greatly which can cause cracks which leads to heavy corrosion at the positive plate 12 35 V 65 On batteries with a magic eye...

Page 19: ... safety regula tions page 2 It is not necessary to remove or disconnect battery when using battery tester with printer VAS 5097 A Battery tester with battery tester with printer VAS 5097 A can be used to test 12 V starter batteries according to 80 499 A A low temperature test current according to DIN Deutsche Industrie Norm German Industrial Standard 1 95 574 A A low temperature test current accor...

Page 20: ...rnal test point in engine compartment 8 Button to advance paper 9 Printer 2 6 2 Battery load test using battery tester with printer VAS 5097 A WARNING Danger of injury Observe warning notices and safety regula tions page 2 Special tools and workshop equipment required Battery tester with printer VAS 5097 A Perform battery load test Switch off the ignition and all electrical consumers Check no load...

Page 21: ...12 The green LED lights up page 12 The test program runs through automatically The test result is printed out by the printer page 14 Switch off unit page 12 Remove test terminals Note The test is completed after about 20 seconds The result of the test is printed out by the printer Perform test once only Repeating the test falsifies the results 2 6 3 Table low temperature test current Low temperatu...

Page 22: ...volt age quickly drops below the minimum voltage This low voltage value remains over a long period and the voltage only increases again slowly after the test has been completed Perform test once only Repeating the test falsifies the results 2 7 1 Comments concerning test print out 1 Measuring range set on tester 2 Diagram arrow indicates battery condition 3 Test result 4 Battery voltage during loa...

Page 23: ...ctions for battery charger VAS 5095 A Observe battery manufacture s handling instructions 3 1 1 Description of battery charger VAS 5095 A Battery charger VAS 5095 is suitable for charging Wet batteries genuine VW batteries from 2004 with transpar ent battery housing and black cover Absorbent glass mat batteries genuine VW batteries from 2004 with black housing The battery charger charges without p...

Page 24: ...he battery must have a temperature of at least 10 C If the battery has cell sealing plugs do not open them while the battery is being charged Switch off the ignition and all electrical consumers Check setting for battery type on type of battery switch page 15 Must be set to 2 4 V C Volt Cells Connect red terminal clamp of charger unit to positive ter minal on battery Connect black terminal clamp o...

Page 25: ...ent is automatically adapted to suit the charge condition of the battery Note Observe notes in chapter page 27 The battery voltage must be at least 0 6 V Charge battery page 16 3 1 4 Charging battery in support mode with battery charger VAS 5095 A WARNING Danger of injury Observe warning notices and safety regula tions page 2 When in support mode the battery charger VAS 5095 A replaces a defective...

Page 26: ...d of 0 6 A e g parking light must be switched on otherwise support mode is not possible During the support mode the current draw is limited to 5 A Switch on vehicle parking light Exchange battery page 31 Switch off charging unit page 15 Remove charger unit terminals from battery terminals Set support mode normal mode change over switch to page 15 normal mode again 3 1 5 Charging battery in buffer ...

Page 27: ...nal information refer to Operating in structions for battery charger VAS 5900 Note Observe Operating instructions for battery charger VAS 5900 Observe battery manufacture s handling instructions 3 2 1 Description of battery charger VAS 5900 Battery charger VAS 5900 is suitable for charging Wet batteries genuine VW batteries from 2004 with transpar ent battery housing and black cover Absorbent glas...

Page 28: ...it plug to power supply The last selected operating mode will appear on display page 19 Set battery to respective operating mode with INFO In the display the symbol 1 for standard charge for wet batter ies or the symbol 2 for standard charge for gel absorbent glass mat batteries will appear Set battery capacity Ah of battery for charging using respec tive button Up or Down Connect red terminal cla...

Page 29: ... Up or Down until charging sequence starts 2 Displayed battery voltage is not as per nominal voltage charging sequence already started Press START STOP twice Press respective button Up or Down until charging sequence starts again 3 Battery charger does not detect a battery when battery volt age is less than 2 V Display remains unchanged The battery type and ampere hours Ah as set is displayed Endi...

Page 30: ... to maximum specific gravity and the plates will be reac tivated dissipation of sulphur layer Special tools and workshop equipment required Battery charger VAS 5900 Note The battery must have a temperature of at least 10 C If the battery has cell sealing plugs do not open them while the battery is being charged Switch off the ignition and all electrical consumers Connect charger unit plug to power...

Page 31: ...ltage is not as per nominal voltage Press respective button Up or Down until charging sequence starts 2 Displayed battery voltage is not as per nominal voltage charging sequence already started Press START STOP twice Press respective button Up or Down until charging sequence starts 3 Battery charger does not detect a battery when battery volt age is less than 2 V Display remains unchanged The oper...

Page 32: ...y charger to the cor rect type of battery Operating instructions for battery charger VAS 5900 Totally discharged battery is not recognised by battery charger page 27 Do not press START STOP button when charger unit cables are connected incorrectly The charger unit may be damaged Batteries with a voltage of less than 2 Volt will not be recognised automatically by battery charger VAS 5900 Special to...

Page 33: ... seconds The menu charging totally discharged batteries support mode will be activated Press respective button Up or Down to set the respec tive battery voltage 6 V 12 V or 24 V Note If a button is not pressed within 5 seconds the charger will return to the main menu select operating mode Confirm the selected battery voltage with START STOP Then follows the enquiry for is charger cable terminal po...

Page 34: ...e battery whilst it is being exchanged The on board supply remains intact The vehicles electrical equipment e g electric windows can be used Special tools and workshop equipment required Battery charger VAS 5900 Switch off the ignition and all electrical consumers Connect charger unit plug to power supply The last selected operating mode will appear on display page 19 Press START STOP for approx 5...

Page 35: ...e with battery charger VAS 5900 WARNING Danger of injury Observe warning notices and safety regula tions page 2 When the battery is fully charged the battery charger VAS 5900 switches to maintenance mode Proceed as for charging battery page 19 At a charge condition of 100 all bars appear in display Note When a battery is being charged in the buffer mode and a consumer draws current from the batter...

Page 36: ...ge In totally discharged batteries the electrolyte is comprised al most entirely of water because the acid content is so low Totally discharged batteries sulphate that is the entire plate surfaces of the battery harden If a battery is recharged shortly after it has totally lost its charge the sulphation will dissipate If these batteries are not recharged the plates continue to harden and the abili...

Page 37: ...ty regula tions page 2 4 1 Disconnecting battery Note By disconnecting the battery earth wire open circuit safety is ensured when carrying out work on the electrical system The battery positive wire need only be disconnected for re moval of the battery Switch off the ignition and all electrical consumers Release catch arrow and take cover off battery box First unscrew battery earth clamp 1 from ba...

Page 38: ...vates the steering angle sender G85 again Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Fit battery positive clamp 2 to positive terminal of battery and tighten securing bolt to specified torque setting page 36 Fit battery earth clamp 1 to negative terminal of battery and tighten securing bolt to specified torque setting page 36 Carry out the procedur...

Page 39: ...a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 Removing and installing battery WARNING Danger of injury Observe warning notices and safety regula tions page 2 5 1 Models with a petrol engine Special tools and workshop equipment required Torque wrench V A G 1331 Removing Disconnect the battery page 29 Pull panel of battery box out upwards in direction of arrow...

Page 40: ...age from vibration dan ger of explosion The cells in the battery will be damaged if the battery is not secured correctly Damage to battery housing by clamping bracket possi bility of acid leaking therefore subsequent higher costs Poor crash safety Installation is performed in the reverse order of installation when doing this note the following Tighten threaded connections to specified torque setti...

Page 41: ...e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Spring type clip pliers VAS 5024A Removing Disconnect the battery page 29 For vehicles with a 1 9 l TDI engine Pull engine cover upwards arrows A and forwards arrow B Disconnect connector 1 and loosen spring type clip 2 with spring type clip pliers VAS 5024A Pull the vacuum hose arrow ...

Page 42: ... c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew air filter housing securing bolt arrow Unlock lugs arrows and take cover off Pull hose arrow off air filter housing and take hose out Pull air filter housing upwards out of brackets and remove Pull panel of battery box out upwards in direction of arrow Je...

Page 43: ... fitted battery creates the following dangers Shortened service life due to damage from vibration dan ger of explosion The cells in the battery will be damaged if the battery is not secured correctly Damage to battery housing by clamping bracket possi bility of acid leaking therefore subsequent higher costs Poor crash safety Installation is performed in the reverse order of installation when doing...

Page 44: ... t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 6 Torque settings battery Threaded connections Torque settings Battery clamp to battery terminal M6 6 Nm Additional clamp to battery terminal clamp M6 6 Nm Securing bolt of battery holder M8x35 20 Nm Air filter housing to body 10 Nm Jetta 2005 Bora ...

Page 45: ...r i g h t b y V o l k s w a g e n A G 7 Starter Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 7 1 Checking starter B Connect the vehicle diagnosis testing and information system VAS 5051A to page 281 Select guided fault finding in Vehicle Diagnosis Testing and In formation System VAS 5051A Using the Go to key select Function component selection and th...

Page 46: ... o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 2 Removing and installing starter auto matic gearbox 7 2 1 Vehicles with 1 6 l injection engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Release spring type clip 1 using spring type clip pliers VAS 5024 and re...

Page 47: ...t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull air filter housing on right side upwards off rubber mounting arrow Remove air filter housing from vehicle Push down protective cap in direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise i...

Page 48: ... e n A G Remove lower securing bolt of starter arrow Unscrew securing nut 1 from upper starter securing bolt Remove wiring retainer 2 Remove upper securing bolt of starter arrow Unscrew earth wire securing nut 1 and place earth wire 2 to one side Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded conne...

Page 49: ... o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench V A G 1331 Torque wrench V A G 1332 Removing Disconnect the battery page 29 Push down protective cap in direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove noise insulation General Body Repairs Exterio...

Page 50: ... s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew securing nut 1 from lower starter securing bolt Remove wiring retainer 2 Remove lower securing bolt of starter arrow Unscrew securing nut 1 from upper starter securing bolt Remove wiring retainer 2 Remove upper securing bolt of starter arrow Jetta 2...

Page 51: ... o p y r i g h t b y V o l k s w a g e n A G Unscrew earth wire securing nut 1 and place earth wire 2 to one side Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified torque settings page 97 7 2 3 Vehicles with 2 0 l FSI engine Special tools and workshop equipment required Torque...

Page 52: ... c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector arrow Unclip vacuum hose from its mounting arrow Loosen spring type clip arrow from hose 1 using spring type clip pliers VAS 5024 Pull hose 1 off air filter housing Open retainer arrow on front side of air filter housing and take hose 1 off J...

Page 53: ... f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew air filter housing securing bolt arrow Pull air filter housing on right side upwards off rubber mounting arrow Loosen spring type clip 1 using spring type clip pliers VAS 5024 Pull hose 2 off pipe union Carefully lift air filter housing upwards out of the vehicle taking into consideration the lengt...

Page 54: ... t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove air filter housing from vehicle Push down protective cap in direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew securing nut 1 from lower starter securing bolt Remov...

Page 55: ... a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew securing nut 1 from upper starter securing bolt Remove wiring retainer 2 Remove upper securing bolt of starter arrow Unscrew earth wire securing nut 1 and place earth wire 2 to one side Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When installing note the ...

Page 56: ... s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 2 4 Vehicles with 2 5 l injection engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Pull engine cover off upwards arrows Jetta 20...

Page 57: ...C o p y r i g h t b y V o l k s w a g e n A G Separate connector 1 release spring type clip 2 with spring type clip pliers VAS 5024 and pull off vacuum hose 3 Pull air filter housing upwards out of brackets and remove Push down protective cap direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove noise insulation General Body Repairs Ext...

Page 58: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove lower securing bolt of starter arrow Unscrew nut 1 from upper starter securing bolt Remove wiring retainer 2 Remove upper securing bolt of starter arrow Remove starter from vehicle downwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded co...

Page 59: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 2 5 Vehicles with 1 9 l TDI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Pull engine cover upwards arrows A and forwa...

Page 60: ... w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector 1 and loosen spring type clip 2 with spring type clip pliers VAS 5024 Pull the vacuum hose arrow off air filter housing Unscrew air filter housing securing bolt arrow Unlock lugs arrows and take cover off Jetta 2005 Bora 200...

Page 61: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull hose arrow off air filter housing and take hose out Pull air filter housing upwards out of brackets and remove Push down protective cap direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front N...

Page 62: ... p y r i g h t b y V o l k s w a g e n A G Remove lower securing bolt of starter arrow Unscrew nut 1 from upper starter securing bolt Remove wiring retainer 2 Remove upper securing bolt of starter arrow Unscrew earth wire securing nut 1 and place earth wire end 2 in direction of battery to side Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When ins...

Page 63: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 2 6 Vehicles with 2 0 l SDI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Pull engine cover upwards arrows A and forwa...

Page 64: ... e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release spring type clip 1 using spring type clip pliers VAS 5024 and disconnect connector 2 Remove securing bolt 3 Pull vacuum hose off arrow Pull air filter housing on right side upwards off rubber mounting arrow Remove air filter housing from vehicle Push down protective cap in direction o...

Page 65: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew securing nut 1 from lower s...

Page 66: ... a g e n A G Unscrew starter securing bolt arrow Remove starter from vehicle downwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified torque settings page 97 7 3 Removing and installing starter auto mated shift gearboxes 7 3 1 Vehicles with 1 6 l injection engine Special tools and workshop equipment required ...

Page 67: ... t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release spring type clip 1 using spring type clip pliers VAS 5024 and remove securing bolt 2 Release hose 3 and pull it off the air filter housing Pull air filter housing on right side upwards off rubber mounting arrow Remove air filter housing from vehicle Push down protective cap in direction of arrow from solenoi...

Page 68: ...l k s w a g e n A G Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew securing nut 1 from lower starter securing bolt Remove wiring retainer 2 Unscrew starter securing bolt arrow Remove starter from vehicle downwards Installing Installation is carried out in the...

Page 69: ...i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 3 2 Vehicles with 2 0 l FSI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Disconnect connector arrow Jet...

Page 70: ... h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unclip vacuum hose from its mounting arrow Loosen spring type clip arrow from hose 1 using spring type clip pliers VAS 5024 Pull hose 1 off air filter housing Open retainer arrow on front side of air filter housing and take hose 1 off Unscrew air filter housing securing bo...

Page 71: ... d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull air filter housing on right side upwards off rubber mounting arrow Loosen spring type clip 1 using spring type clip pliers VAS 5024 Pull hose 2 off pipe union Carefully lift air filter housing upwards out of the vehicle taking into consideration the length of the hose Separate connector arrow on rear of air filter housing Remove a...

Page 72: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew securing nut 1 from upper starter securing bolt Remove wiring retainer 2 Remove upper securing bolt of starter arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Re...

Page 73: ... r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew securing nut 1 from lower starter securing bolt Remove wiring retainer 2 Remove lower securing bolt of starter arrow Remove starter from vehicle downwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connec...

Page 74: ...h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 3 3 Vehicles with 2 0 l FSI turbo engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Unbolt securing bolts arrow Jetta 2005 B...

Page 75: ...p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector arrow Loosen spring type clips 1 using spring type clip pliers VAS 5024 Pull engine cover off upwards arrows Push down protective cap in direction of arrow from solenoid switch Jetta 2005 Bora 2006...

Page 76: ... o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove upper securing bolt of starter arrow Remove lower securing bolt of starter arrow Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded conn...

Page 77: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 3 4 Vehicles with 1 9 l TDI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Pull engine cover upwards arrows A and forwa...

Page 78: ... w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector 1 and loosen spring type clip 2 with spring type clip pliers VAS 5024 Pull the vacuum hose arrow off air filter housing Unscrew air filter housing securing bolt arrow Unlock lugs arrows and take cover off Jetta 2005 Bora 200...

Page 79: ...t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull hose arrow off air filter housing and take hose out Pull air filter housing upwards out of brackets and remove Push down protective cap direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Remove upper sec...

Page 80: ...o p y r i g h t b y V o l k s w a g e n A G Remove lower securing bolt of starter arrow Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified torque settings page 97 7 3 5 Vehicles with 2 0 l TDI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque ...

Page 81: ... l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull engine cover off upwards arrows Separate connector 1 release spring type clip 2 with spring type clip pliers VAS 5024 and pull off vacuum hose 3 Unscrew air filter housing securing bolt arrow Unlock lugs arrows and take cover off Je...

Page 82: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull hose arrow off air filter housing and take hose out Pull air filter housing upwards out of brackets and remove Push down protective cap in direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unclip hose 1 from hose...

Page 83: ...e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove upper securing bolt of starter arrow Remove lower securing bolt of starter arrow Remove starter from vehicle upwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified t...

Page 84: ... n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 4 Removing and installing starter manual gearbox 7 4 1 Vehicles with 1 6 l engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Push down protective cap direction of ...

Page 85: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew nut 1 from lower starte...

Page 86: ... o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew starter securing bolt arrow Remove starter Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified torque settings page 97 7 4 2 Vehicles with 2 0 l FSI engine Special tools and workshop equipment required Torque wrench V A G 1331 T...

Page 87: ...o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Removing Disconnect the battery page 29 Disconnect connector arrow Unclip vacuum hose from its mounting arrow Loosen spring type clip arrow from hose 1 using spring type clip pliers VAS 5024 Pull hose 1 off air filter housing Open retainer arrow on front side of air fil...

Page 88: ...i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew air filter housing securing bolt arrow Pull air filter housing on right side upwards off rubber mounting arrow Loosen spring type clip 1 using spring type clip pliers VAS 5024 Pull hose 2 off pipe union Carefully lift air filter housing upwards out of the vehicle taking into consideration the length of the hose...

Page 89: ... s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove air filter housing from vehicle Push down protective cap in direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General B...

Page 90: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew securing nut 1 from lower starter securing bolt Remove wiring retainer 2 Unscrew starter securing bolt arrow Remove starter from vehicle downwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specifie...

Page 91: ... i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 4 3 Vehicles with 2 0 l FSI turbo engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Unbolt securing bolts arrow...

Page 92: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector arrow Loosen spring type clips 1 using spring type clip pliers VAS 5024 A Pull engine cover off upwards arrows Push down protective cap in direction of arrow from solenoid switch Jetta 2005 Bora 2006 Electrical ...

Page 93: ...r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew securing nut 1 from lower s...

Page 94: ... t C o p y r i g h t b y V o l k s w a g e n A G Unscrew starter securing bolt arrow Remove starter from vehicle downwards Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified torque settings page 97 7 4 4 Vehicles with 2 5 l engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrenc...

Page 95: ... e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull engine cover off upwards arrows Separate connector 1 release spring type clip 2 with spring type clip pliers VAS 5024 and pull off vacuum hose 3 Push down protective cap direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connect...

Page 96: ...i g h t b y V o l k s w a g e n A G Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew nut 1 from lower starter securing bolt Remove wiring retainer 2 Unscrew starter securing bolt arrow Remove starter Installing Installation is carried out in the reverse order W...

Page 97: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 4 5 Vehicles with 1 9 l TDI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Pull engine cover upwards arrows A and forwa...

Page 98: ... w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector 1 and loosen spring type clip 2 with spring type clip pliers VAS 5024 Pull the vacuum hose arrow off air filter housing Unscrew air filter housing securing bolt arrow Unlock lugs arrows and take cover off Jetta 2005 Bora 200...

Page 99: ...o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull hose arrow off air filter housing and take hose out Pull air filter housing upwards out of brackets and remove Push down protective cap direction of arrow from solenoid switch Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew earth wire f...

Page 100: ...d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew nut 1 from lower starter securing bolt Remove wiring retainer 2 Unscrew starter securing bolt arrow Remove starter Installing Installation is carried out in the reverse order When installing note the fo...

Page 101: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 4 6 Vehicles with 2 0 l SDI engine Special tools and workshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Spring type clip pliers VAS 5024 Removing Disconnect the battery page 29 Pull engine cover upwards arrows A and forwa...

Page 102: ...n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release spring type clip 1 using spring type clip pliers VAS 5024 and disconnect connector 2 Remove securing bolt 3 Pull vacuum hose off arrow Pull air filter housing on right side upwards off rubber mounting arrow Remove air filter housing from vehicle Push down protective cap direction of ...

Page 103: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew positive wire 1 and disconnect connector from ter minal 50 2 Unscrew earth wire from starter securing bolt arrow Unscrew starter securing bolt arrow Remove noise insulation General Body Repairs Exterior Rep Gr 50 Body front Noise insulation Unscrew nut 1 from lower starte...

Page 104: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew starter securing bolt arrow Remove starter Installing Installation is carried out in the reverse order When installing note the following Tighten threaded connections to specified torque settings page 97 Jetta 2005 Bora 2006 Elect...

Page 105: ... i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 Torque settings starter Threaded connections Torque settings Starters on automatic manual gearboxes M12 75 Nm Starter on automated shift gearboxes M10 60 Nm Earthing wire to starter securing bolt M8 15 Nm Wiring retainer on starter securing bolt M8 15 Nm Positive wire to starter solenoid switch M8 15 Nm Air filter h...

Page 106: ...Vehicle electrics electronics fail completely breakdown Danger of fires from sparks Damage to electronic components and control units due to excessive voltage The tightening torque for the securing nut of the B wire arrow an be found in the following table Tightening torques page 145 9 2 Checking ribbed belt poly V belt Crank engine at vibration damper belt pulley using a socket Fit ribbed belt po...

Page 107: ...fault finding in Vehicle Diagnosis Testing and In formation System VAS 5051A Using the Go to key select Function component selection and the following menu items one after the other Body Electrical System 27 Starter current supply Electrical components C Alternator 9 4 Alternator 1 6 l injection engine 9 4 1 Assembly overview 1 Hexagon head collared bolt M8x108 23 Nm 2 Hexagon head collared bolts ...

Page 108: ...g voltage regulator page 142 14 Alternator Removing and installing alternator page 100 15 Poly V belt Checking page 98 16 Compact bracket For alternator and air conditioner compressor Tightening sequence page 145 17 Tensioning element for poly V belt 18 Hexagon head collared bolt M8x90 23 Nm 9 4 2 Removing and installing alternator 1 6 l injection engine Caution Disconnecting and connecting the ba...

Page 109: ...gine cover off upwards arrows Disconnect connector of DF wiring 1 and pull protective cap 2 off Unscrew B wiring arrow off alternator Caution Mark top and direction of rotation of poly V belt before remov ing When installing observe direction of rotation marked on removal Installing opposite to the direction of rotation leads to belt damage Mark direction of rotation of poly V belt Release poly V ...

Page 110: ...nbolt securing bolts arrow Take hose retainer together with tensioning element out of the vehicle Remove alternator securing bolts arrows Unscrew wiring bracket arrow from alternator Remove alternator Installing Installation is carried out in the reverse order When installing note the following Caution When reinstalling used ribbed belts poly V belts observe the direction of rotation marked on rem...

Page 111: ... of the alternator housing for approx 4 mm in direction of arrow Position wiring bracket arrow on rear of generator at 3 o clock Tighten threaded connections to specified torque settings page 145 Caution Observe instructions on connecting battery terminals page 4 Connect the battery page 29 Start the engine and check belt running Switch off the engine 9 4 3 Ribbed belt routing 1 6 l injection en g...

Page 112: ... Idler roller 4 Washer 5 Valve gear casing 6 Hexagon head collared nut M8 7 Cross head screw M5x21 4 5 Nm 8 Hexagon nut flat M8 9 Plain washer M5 10 Protective cap 11 Phillips screws M4x19 2 Nm 12 Cross head screw M4x13 2 Nm 13 Voltage regulator Removing and installing voltage regulator page 142 14 Alternator Removing and installing alternator page 105 15 Poly V belt Checking ribbed belt poly V be...

Page 113: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 20 Nm 1 4 turn 90 further 21 Spacer sleeve 9 5 2 Removing and installing alternator 1 6 l FSI engine Special tools and workshop equipment required Torque wrench V A G 1331 Locking pin T10060 A Removing Disconnect the battery page 29 Remove upper securing bolt of alternator arrow Remove noise insulatio...

Page 114: ...turning the tensioning device with an open ended spanner AF 16 in direction of arrow Lock tensioning element with retaining pin T10060 A Remove ribbed belt Remove air conditioner compressor Heating air condition er Rep Gr 87 Repair work on refrigerant circuit must be carried out in workshops with trained personnel only work shop service centres for air conditioning system Removing and installing c...

Page 115: ...rrow on rear of generator at 9 o clock Tighten threaded connections to specified torque settings page 145 Start the engine and check belt running 9 5 3 Ribbed belt routing 1 6 l FSI engine Models without air conditioning system 1 Ribbed belt poly V belt pulley Coolant pump 2 Tensioning roller 3 Ribbed belt poly V belt pulley Alternator 4 Poly V belt 5 Ribbed belt poly V belt pulley Crankshaft Mode...

Page 116: ...ollared bolts M8x90 23 Nm 2 Hexagon head collared bolts M8x50 23 Nm 3 Transport bracket 4 Tensioning element for poly V belt 5 Compact bracket For alternator and air conditioner compressor Tightening sequence page 146 6 Hexagon head collared bolts M10x45 52 Nm 7 Protective cap 8 Hexagon head collared nut M8 9 Cross head screw M5x21 4 5 Nm 10 Hexagon nut flat M8 11 Plain washer M5 12 Phillips screw...

Page 117: ... n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 6 2 Removing and installing alternator 2 0 l FSI engine Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Special tools and workshop equipment required Torque wrench V A G 1331 Locking pin T10060 or locking pin T10060 A Spring type clip pliers VA...

Page 118: ... w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull engine cover off upwards arrows Disconnect connector arrow Unclip vacuum hose from its mounting arrow Loosen spring type clip arrow from hose 1 using spring type clip pliers VAS 5024 A Pull hose 1 off air filter housing Jetta 2005 Bora 2006...

Page 119: ... o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Open retainer arrow on front side of air filter housing and take hose 1 off Unscrew air filter housing securing bolt arrow Pull air filter housing on right side upwards off rubber mounting arrow Loosen spring type clip 1 using spring type clip pliers VAS 5024 A Pull hose 2 off pipe union Carefully lift air filter housin...

Page 120: ...n rear of air filter housing Remove air filter housing from vehicle Remove upper intake manifold Disconnect connector of DF wiring 1 and pull protective cap 2 off Unscrew B wiring arrow off alternator Caution Mark top and direction of rotation of poly V belt before remov ing When installing observe direction of rotation marked on removal Installing opposite to the direction of rotation leads to be...

Page 121: ... i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Lock tensioning element with retaining pin T10060 A Remove ribbed belt Remove securing bolts of tensioning element arrows Take tensioning element together with lifting eye 1 out of the vehicle Remove alternator securing bolts arrows Unscrew wiring bracket arrow from alternator Take alternator out of the vehicle Installing I...

Page 122: ...rque settings page 145 Caution When reinstalling used ribbed belts poly V belts observe the direction of rotation marked on removal Ensure before installing ribbed belt that all ancillaries al ternator air conditioner compressor are secured tightly Ensure ribbed belt poly V belt is seated correctly in belt pulley when installing Tighten threaded connections to specified torque settings page 145 Ca...

Page 123: ...ning roller 2 Ribbed belt pulley Alternator 3 Ribbed belt pulley Air conditioner compressor 4 Poly V belt 5 Ribbed belt pulley Crankshaft 9 7 Alternator 2 0 l FSI turbo engine 9 7 1 Assembly overview 1 Hexagon head collared bolts M8x45 23 Nm 2 Hexagon head collared bolts M8x90 23 Nm 3 Compact bracket For alternator and air conditioner compressor Tightening sequence page 146 4 Hexagon head collared...

Page 124: ...w a g e n A G 12 Voltage regulator Removing and installing voltage regulator page 142 13 Alternator Removing and installing alternator page 116 14 Poly V belt Checking page 98 15 Tensioning element for poly V belt 9 7 2 Removing and installing alternator 2 0 l turbo FSI engine Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Special tools and workshop eq...

Page 125: ... a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Removing Disconnect the battery page 29 Unbolt securing bolts arrow Disconnect connector arrow Loosen spring type clips 1 using spring type clip pliers VAS 5024 A Pull engine cover off upwards arrows Jetta 2005 Bora 2006 ...

Page 126: ...ick release couplings the following points must be observed Unlock connection by pulling the securing clamp arrow Pull hose tube off without assistance of tools Disconnect quick release coupling arrow Loosen spring type clip arrow using spring type clip pliers VAS 5024 A Unbolt securing bolts arrow Take hose out of the vehicle Remove connecting pipe between charge air cooler and tur bocharger Caut...

Page 127: ...s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release poly V belt by turning the tensioning element with an open jaw spanner AF 16 in direction of arrow and lock ten sioning element with retaining pin T10060 A Remove ribbed belt Loosen threaded connections of coolant pipe arrows Note The coolant pipe can remain installed To take out the alternator it must be loosened Remove alter...

Page 128: ...alternator Take alternator out of the vehicle Installing Installation is carried out in the reverse order When installing note the following Caution When reinstalling used ribbed belts poly V belts observe the direction of rotation marked on removal Ensure before installing ribbed belt that all ancillaries al ternator air conditioner compressor are secured tightly Ensure ribbed belt poly V belt is...

Page 129: ...owing points must be observed Fit hose tube without assistance of tools Check for secure fit of the lugs arrow Tighten threaded connections to specified torque settings page 145 Caution Observe instructions on connecting battery terminals page 4 Connect the battery page 29 Start the engine and check belt running Switch off the engine 9 7 3 Ribbed belt routing 2 0 l turbo engine Models without air ...

Page 130: ...compressor 2 Multi point socket head bolt M8x60 25 Nm 3 Multi point socket head bolt M8x110 25 Nm 4 Hexagon socket head bolt M8x30 25 Nm Qty 4 5 Protective cap for alternator 6 Phillips screws M4x20 2 Nm 7 Protective cap for carbon brushes 8 Voltage regulator Removing and installing voltage regulator page 142 9 Alternator Removing and installing alternator page 127 10 Poly V belt Checking page 98 ...

Page 131: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench V A G 1331 Locking pin T10060 A Disconnect the battery page 29 Take the engine cover off upwards and forwards Bring lock carrier into service position General body repairs exterior Rep Gr 50 Lock carrier service position Take off poly V belt Rep Gr 13 Disconnect connector ...

Page 132: ...rotation leads to belt damage Remove upper and lower idler roller and tensioning roller for alternator poly V belt and coolant pump Rep Gr 13 Remove alternator securing bolts arrows Unscrew wiring bracket from alternator arrow Take alternator out upwards Installing Installation is carried out in the reverse order When installing note the following Caution When reinstalling used ribbed belts poly V...

Page 133: ... to specified torque settings page 145 Caution Observe instructions on connecting battery terminals page 4 Connect the battery page 29 Start the engine and check belt running Switch off the engine 9 8 3 Ribbed belt routing 2 5l engine Models with air conditioning system 1 Upper idler roller 2 Belt pulley Alternator 3 Lower idler roller 4 Poly V belt for alternator and coolant pump 5 Belt pulley Ai...

Page 134: ...ollared bolts M8x45 20 Nm 2 Tensioning element for poly V belt 3 Hexagon head collared bolts M8x90 20 Nm 4 Compact bracket For alternator and air conditioner compressor Tightening sequence page 148 5 Hexagon head collared bolts M10x65 40 Nm 6 Hexagon head collared bolts M10x45 40 Nm 7 Hexagon bolt with washer and threaded piece M4x20 M4x15 2 Nm 8 Protective cap for alternator 9 Phillips screws M4x...

Page 135: ... n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 9 2 Removing and installing alternator 1 9 l TDI engine Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Removing Special tools and workshop equipment required Torque wrench V A G 1331 Locking pin T10060 A Disconnect the battery page 29 Pull eng...

Page 136: ...Note All hoses of the charge air system are secured with hose clips or with quick release couplings When using quick release couplings the following points must be observed Unlock connection by pulling the securing clamp arrow Pull hose tube off without assistance of tools Disconnect connectors 1 Unclip fuel hoses 2 and take charge air hose out Pull vacuum hose 1 off Disconnect connector 2 Remove ...

Page 137: ...nscrew charge air pipe securing bolt arrow Disconnect connector of charge air pipe arrow Take charge air pipe out upwards Disconnect connector of DF wiring 1 and pull protective cap 2 off Unscrew B wiring arrow off alternator Pull fuel filter off the retainer and place to side fuel hoses re main connected Caution Mark top and direction of rotation of poly V belt before remov ing When installing ob...

Page 138: ...nner AF 16 in direction of arrow Lock tensioning element with retaining pin T10060 A Remove ribbed belt Remove alternator securing bolts arrows Unscrew wiring bracket from alternator arrow Remove alternator Installing Installation is carried out in the reverse order When installing note the following Caution When reinstalling used ribbed belts poly V belts observe the direction of rotation marked ...

Page 139: ...ernator housing for approx 4 mm in direction of arrow Position wiring bracket arrow on rear of generator at 9 o clock Note All hoses of the charge air system are secured with hose clips or with quick release couplings When using quick release couplings the following points must be observed Fit hose tube without assistance of tools Check for secure fit of the lugs arrow Tighten threaded connections...

Page 140: ...m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 9 3 Ribbed belt routing 1 9 l TDI engine Models without air conditioning system 1 Tensioning roller 2 Ribbed belt pulley Alternator 3 Poly V belt 4 Ribbed belt pulley Crankshaft Models with air conditioning system 1 Tensioning roller 2 Ribbed belt pulley Alternator 3 Ribbed belt pulley Air conditioner compresso...

Page 141: ...d bolts M8x45 20 Nm 2 Tensioning element for poly V belt 3 Hexagon head collared bolts M8x90 20 Nm 4 Compact bracket For alternator and air conditioner compressor Tightening sequence page 148 5 Hexagon head collared bolts M10x65 40 Nm 6 Hexagon head collared bolts M10x45 40 Nm 7 Phillips screws M4x20 2 Nm 8 Protective cap 9 Voltage regulator Removing and installing voltage regulator page 142 10 Al...

Page 142: ... a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Removing Special tools and workshop equipment required Torque wrench V A G 1331 Locking pin T10060 A Disconnect the battery page 29 Pull engine cover off upwards arrows Pull vacuum hoses off arrow Jetta 2005 Bora 2006 Electrical Sy...

Page 143: ...securing bolts arrow Disconnect connector of DF wiring 1 and pull protective cap 2 off Unscrew B wiring arrow off alternator Pull fuel filter off the retainer and place to side fuel hoses re main connected Caution Mark top and direction of rotation of poly V belt before remov ing When installing observe direction of rotation marked on removal Installing opposite to the direction of rotation leads ...

Page 144: ...lt Remove alternator securing bolts arrows Unscrew wiring bracket arrow from alternator Remove alternator Installing Installation is carried out in the reverse order When installing note the following Caution When reinstalling used ribbed belts poly V belts observe the direction of rotation marked on removal Ensure before installing ribbed belt that all ancillaries al ternator air conditioner comp...

Page 145: ...nstructions on connecting battery terminals page 4 Connect the battery page 29 Start the engine and check belt running Switch off the engine 9 10 3 Ribbed belt routing 2 0 l TDI engine Models without air conditioning system 1 Tensioning roller 2 Ribbed belt pulley Alternator 3 Poly V belt 4 Ribbed belt pulley Crankshaft Models with air conditioning system 1 Tensioning roller 2 Ribbed belt pulley A...

Page 146: ...cket VAS 3310 Torque wrench V A G 1332 Removing Take off alternator page 98 Fit alternator in a vice on fitting points Use socket VAS 3310 to remove ribbed belt poly V belt pulley securing nut from alternator shaft Installing Installation is performed in the reverse order of installation when doing this note the following Tighten threaded connections to specified torque settings page 145 9 11 2 Re...

Page 147: ...e n t C o p y r i g h t b y V o l k s w a g e n A G Adapter VAS 3400 Torque wrench V A G 1332 Removing Take off alternator page 98 Fit alternator in a vice on fitting points Take protective cap off ribbed belt poly V belt pulley with freewheel Note The thread on the alternator shaft is a left hand thread i e turn to right when loosening and to left when tightening the threaded joint Fit adapter VA...

Page 148: ...taken off Installing Installation is carried out in the reverse order When installing note the following At first screw the ribbed belt poly V belt pulley with a free wheel on the drive shaft of the alternator by hand to limit stop The torque wrench V A G 1332 must be rearranged before in stalling the ribbed belt poly V belt pulley with a freewheel as follows Release socket 1 and pull off grip 2 T...

Page 149: ...a ribbed belt poly V belt pulley with freewheel manufacturer Valeo Special tools and workshop equipment required Adapter VAS 3400 Torque wrench V A G 1332 TORX key V A G 1603 1 Removing Take off alternator page 98 Fit alternator in a vice on fitting points Take protective cap off ribbed belt poly V belt pulley with freewheel Note The thread on the alternator shaft is a left hand thread i e turn to...

Page 150: ...stalling note the following At first screw the ribbed belt poly V belt pulley with a free wheel on the drive shaft of the alternator by hand to limit stop The torque wrench V A G 1332 must be rearranged before in stalling the ribbed belt poly V belt pulley with a freewheel as follows Release socket 1 and pull off grip 2 Turn the torque wrench grip 2 through 180 degrees and re insert socket drive S...

Page 151: ... r i g h t b y V o l k s w a g e n A G Torque screwdriver V A G 1624 Removing Remove alternator Remove securing bolt and nuts arrows and take protective cap off alternator Remove securing bolts for voltage regulator arrows Remove voltage regulator from alternator Installing Install in reverse order of removal Tighten threaded connections to specified torque settings page 145 9 12 2 Removing and in...

Page 152: ...e spring clips arrows and take protective cap off al ternator Remove securing bolts for voltage regulator arrows Remove voltage regulator from alternator Installing Installation is carried out in the reverse order When installing note the following Release locking lugs arrow and pull protective cap off voltage regulator Push voltage regulator carbon brushes in housing of voltage regulator and plac...

Page 153: ...s B wire to alternator M8 15 Nm Cable holder to alternator M5 3 2 Nm Voltage regulator to alternator M4 2 Nm Protective cap to alternator M5 4 5 Nm Poly V belt pulley with freewheel to alternator M10 80 Nm Poly V belt pulley without freewheel to alternator M10 65 Nm 10 2 1 6 l injection engine and 2 0 l FSI en gine Caution In order to avoid damage to cylinder block and compact brack et you must re...

Page 154: ...ew in all bolts by hand Tighten securing bolts of compact bracket in following se quence A Hexagon head collared bolt M10x45 52 Nm locating hole B Hexagon head collared bolt M10x45 52 Nm C Hexagon head collared bolt M10x45 52 Nm D Hexagon head collared bolt M10x45 52 Nm E Hexagon head collared bolt M10x45 52 Nm F Hexagon head collared bolt M10x45 52 Nm 10 3 2 0 l FSI turbo engine Caution In order ...

Page 155: ... Before tightening to specified torque setting screw in all bolts by hand Tighten securing bolts of compact bracket in following se quence A Cylinder collar screw M10x45 40 Nm locating hole B Cylinder collar screw M10x45 40 Nm C Cylinder collar screw M10x45 40 Nm D Cylinder collar screw M10x45 40 Nm E Cylinder collar screw M10x45 40 Nm F Cylinder collar screw M10x45 40 Nm 10 4 1 9 l and 2 0 l TDI ...

Page 156: ...e tightening to specified torque setting screw in all bolts by hand Tighten securing bolts of compact bracket in following se quence A Hexagon head collared bolt M10x65 40 Nm B Hexagon head collared bolt M10x45 40 Nm C Hexagon head collared bolt M10x45 40 Nm D Hexagon head collared bolt M10x45 40 Nm E Hexagon head collared bolt M10x65 40 Nm F Hexagon head collared bolt M10x65 with dowel sleeves 40...

Page 157: ...for CCS E45 turn signal switch page 224 You can activate and deactivate the cruise control system page 149 Fault detection and fault display Faults on the CCS are output via the engine control unit For fault finding use the vehicle diagnosis testing and informa tion system VAS 5051A in guided fault finding mode 11 1 Activating and deactivating cruise con trol system Connect Vehicle Diagnosis Testi...

Page 158: ...air of the dash panel insert In the event of defects the dash panel insert is renewed as a unit page 150 The data bus diagnostic interface J533 Gateway is an individ ual control unit option and not as on other vehicles part of the dash panel insert page 294 Fault detection and fault display The dash panel insert is equipped with self diagnosis which makes fault finding easier For fault finding use...

Page 159: ...in Vehicle Diagnosis Testing and Information System VAS 5051A Using the Go to key select Function component selection and the following menu items one after the other Body Electrical System 01 On Board Diagnostic capable systems Dash panel insert Dash panel insert functions Adapting renewing dash panel insert 1 2 Removing and installing dash panel in sert Note Before removing the dash panel insert...

Page 160: ... securing bolts arrows for dash panel insert Note When pulling out dash panel insert there is no need to separate the connectors The connections comprise of one part that is fixed to the vehicle and are thus separated automatically when the dash panel insert is pulled out Pull dash panel insert out of dash panel Installing Install in reverse order of removal 1 3 Description of reverse side of dash...

Page 161: ...Bulb failure 6 Rear fog lights 7 Low coolant level 8 Brake pad wear 9 Washer fluid level 10 Fuel reserve 11 Airbag display 12 Seat belt 13 Anti locking brake system ABS 14 Electronic stabilisation programme ESP 15 Brake fault handbrake 16 Cruise control system CCS 17 Daylight 18 Tyre pressure monitor 19 Water in fuel 20 Rear seat backrest lock 21 Shift Lock Warning lamp exists only on vehicles wit...

Page 162: ...agenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Service interval display 2 1 Resetting service interval display Maintenance Booklet 20 1 Jetta 2005 Bora 2006 Electrical System Edition 05 2005 154 Rep Gr 90 Instruments G...

Page 163: ...n The wiper motor control unit J400 and the wiper motor V are joined together as one unit To remove the wiper blades the wiper arms should be placed in the service winter position The service winter position is acti vated within 10 seconds after ignition is switched off by pressing windscreen wiper lever in tip wipe Operating instructions for vehicle Fault detection and fault display The onboard s...

Page 164: ... this position is reached the APP function must be deactivated code wiper motor control unit J400 Note The APP function cannot be activated After 100 cycles of wiper movement the APP function is acti vated automatically This applies to wiper motors on which the APP function has been deactivated and also to new wiper mo tors Connect the vehicle diagnosis testing and information system VAS 5051A to ...

Page 165: ... h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Special tools and workshop equipment required Torque wrench V A G 1331 Puller T10130 Removal lever 80 200 1 2 1 Removing windscreen wiper system Deactivating APP function page 155 Allow wiper to move to park position and then switch ignition off Disconnect the battery page 29 Note To remove the wiper frame with rods and the wiper...

Page 166: ...sing a screwdriver Loosen the hexagon nut arrows without removing it com pletely Position legs of puller T10130 2 under wiper arm 4 as shown in the figure Turn thrust bolt 1 of puller T10130 clockwise until it comes into contact with the wiper shaft The hexagon nut 3 previ ously loosened on the wiper arm serves as a means of centring and guiding the thrust bolt 1 Turn thrust bolt 1 of puller T1013...

Page 167: ... Removing air cowling Remove securing screws 1 and securing nut 2 from air cowling 3 Take air cowling 3 out of vehicle 1 2 5 Removing wiper frame with linkage and wiper motor Disconnect connector 1 Unscrew securing bolts arrows and pull wiper frame 2 for wards out of vehicle 1 2 6 Removing wiper motor out of wiper frame Lever linkage arrow ball head 1 using release lever 80 200 off crank arm of mo...

Page 168: ...t 3 Tighten threaded connections to specified torque settings page 178 1 2 8 Installing the windscreen wiper system Install wiper frame in reverse order of removal Note when in stalling that securing pin 2 of wiper frame must be inserted in grommet 1 in bulkhead Tighten threaded connections to specified torque settings page 178 Fit connector to wiper motor connection and lock in position Install a...

Page 169: ... s w a g e n A G Place wiper arm in approximate park position on wiper arm shaft and tighten securing nut arrows by hand Adjust windscreen wiper blade park position page 161 1 4 Adjusting wiper blade park position Special tools and workshop equipment required Torque wrench V A G 1331 Puller T10130 Note On RHD vehicles the wiper blades are a mirror image Deactivate the APP function if not already d...

Page 170: ...uld be 10 mm If necessary adjust wiper blade park position by moving wiper arm Removing wiper arms page 158 Tighten threaded connection to specified torque setting page 178 1 5 Removing and installing aerodynamic wipers Removing Note Driver s and front passenger wiper blades should not be inter changed during installation The aerodynamic wipers are very flexible To lift the wiper blades off the wi...

Page 171: ...stop arrow A Pull wiper blade 1 off axis of wiper arm arrow B Installing Slide wiper blade onto axis of wiper arm Turn wiper blade on axis of wiper arm onto stop Carefully fold wiper arm back down onto windscreen 1 6 Removing and installing rain and light detector sensor G397 Removing Special tools and workshop equipment required Removal wedge 3409 Switch off ignition and all electrical consumers ...

Page 172: ... sensor G397 and not only the upper shell of the sensor Installing Installation is performed in the reverse order of installation when doing this note the following Note Before installing thoroughly clean the windscreen within the retainer for the rain and light detector sensor G397 The surface coupling cushions of the rain and light detector sensor G397 must not be soiled when installing If the s...

Page 173: ... windscreen spray jets 2 Spray jet for windscreen washer system right Removing and installing page 169 Adjusting page 169 3 Spray jet for windscreen washer system left Removing and installing page 169 Adjusting page 169 4 Elbow Connection to left wind screen spray jet Overview of washer wa ter line hose couplings page 174 5 Hose Hose repair page 176 6 Elbow Connection to right windscreen spray jet...

Page 174: ... one another when installing 1 Removing and installing filler pipe for windscreen and head light washer system reservoir page 166 2 Connecting pipe filler neck reservoir the connecting pipe is removed together with the reservoir for windscreen washer and headlight washer systems page 167 3 Removing and installing reservoir for windscreen and head light washer systems page 167 2 2 1 Removing and in...

Page 175: ...dscreen and headlight washer sys tem reservoir page 166 Remove front bumper cover Body Repairs exterior Rep Gr 63 Front bumper Note The connections to the pump and hose lines are colour coded in order to prevent the washer water lines being incorrectly connec ted to the front and rear washer water pump V5 The hose fittings must be inserted into the correct colour coded pump con nections during ass...

Page 176: ...all electrical consumers and pull out ignition key Remove front bumper cover Body Repairs exterior Rep Gr 63 Front bumper Note The connections to the pump and hose lines are colour coded in order to prevent the washer water lines being incorrectly connec ted to the front and rear windscreen and rear window washer pump V59 The hose fittings must be inserted into the correct colour coded pump connec...

Page 177: ...rds arrow A and pull out of bonnet from rear arrow B Pull hose 1 off spray jet and disconnect connector 2 Installing Fit connector 2 and hose 1 on spray jet Push spray jet in installation hole until it is heard to lock in place Adjust spray jets page 169 2 5 Adjusting front windscreen washer sys tem spray jets Note If the spray field is not uniform because the spray jet is soiled remove the spray ...

Page 178: ...indscreen washer system is activated the headlights are also washed if the windscreen wiper lever on the steering wheel is pulled for at least 1 5 seconds provided either dipped beam or high beam are switched on The active time of the headlight washer system can be variably adjusted to between 0 and 12 75 seconds page 294 To guarantee sound functioning the headlight washer system must be vented fo...

Page 179: ... 173 Removing and installing pop up spray jet cylin der page 172 3 Elbow Connection to left spray jet pop up cylinder Overview of washer wa ter line hose couplings page 174 4 Hose 5 Elbow Connection to right spray jet pop up cylin der Distribution of washer water to spray jets on headlight washer sys tem Overview of washer water line hose couplings page 174 6 T piece Distribution of washer water t...

Page 180: ... installing note the following Tighten threaded connections to specified torque settings page 178 Bleed the headlight washer system after completing work page 173 3 3 Removing and installing pop up spray jet cylinder Removing Switch off ignition and all electrical consumers and pull out ignition key Pull spray jets with cap 1 out of bumper cover onto stop Unclip cap 1 from mounting points arrows o...

Page 181: ...ll not seat correctly If the washer spray jet assembly is pulled in too far the cover cap and the bumper cover could be pushed out of shape Push washer spray jet assembly in pop up cylinder until it en gages Fit cover cap on washer spray jet assembly and allow pop up cylinder to retract Check the cover cap is seated correctly on the bumper cover If necessary adjust seat of cover cap by pushing was...

Page 182: ...nd or as points of separation 4 1 Windscreen and rear window washer system Pull the two coupling sections apart no securing device to loosen the connection To secure the connection push the two coupling sections to gether until you hear and feel them engage To loosen the connection rotate the lock ring 1 by 90 arrow and pull off the hose connection To secure the connection push on the hose connect...

Page 183: ...e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 2 Headlight washer system To loosen the connection 1 push the lock ring arrow and pull off the hose connection To secure the connection push and hold the lock ring arrow and push on the hose connection Check that the se curing clip has correctly engaged by depressing and trying to pu...

Page 184: ...ts 5 1 General description The replacement parts can be found in the parts catalogue ETKA Replacement parts are available for repair of both smooth and corrugated pipes 5 2 Repairing smooth pipe Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re paired with EPDM hose Cut damaged section at right angles out of smooth pipe which is to be repaired Select the appropriate EPDM hose 2 and cable t...

Page 185: ...ce of corrugated pipe must be used and the procedure described below must be performed twice Cut damaged section at right angles out of corrugated pipe which is to be repaired Select the appropriate connectors 2 and 3 as well as the appropriate heat shrink hose according to the parts catalogue ETKA Heat end of corrugated pipe 1 Push connector 2 into corrugated pipe 2 arrow A Heat end of corrugated...

Page 186: ... t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 6 Torque settings Windscreen wash wipe system Threaded connections Torque settings Wiper motor to wiper frame M6 8 Nm Motor crank arm to wiper motor shaft M8 18 Nm Wiper frame to body M6 8 Nm Windscreen wiper arms to wiper motor shaft M8 20 Nm Windscreen washer system and headlight washer system reservoir M6 8 Nm Po...

Page 187: ... the lighting system is first under stood Additional information Operating instructions In the vehicle there are fitted headlights of three different manu facturers AL Automotive Lighting Hella Removal and installation of the headlights and its attachments is the same only the removing and installing of the actuator motors are different Fault detection and fault display The onboard supply control ...

Page 188: ...ewing page 185 4 Left side light bulb M1 or right side light bulb M3 Bulb 12 V W 5 W Renewing page 187 5 Cover cap 6 Front left turn signal bulb M5 or front right turn signal bulb M7 Bulb 12 V PY 21 W Renewing page 188 7 Bulb holder with grip ele ment For front left turn signal bulb M5 or front right turn signal bulb M7 8 Body section 9 Cover cap 10 Bulb holder with grip ele ment For left headligh...

Page 189: ...ecessary to disconnect the battery earth strap The diagrams show how the left headlight is removed and in stalled If a headlight is removed it should always be adjusted Main tenance Booklet 20 1 If a headlight with gas discharge lamps is removed a basic setting must be performed to adjust the headlights Mainte nance Booklet 20 1 Switch off ignition and all electrical consumers and pull out ignitio...

Page 190: ...ion is central i e shutlines are equal around headlight If the shutlines around the headlight are uneven the installation position must be adjusted page 182 Check function of headlight Note If a headlight is removed it should always be adjusted Check headlight setting and adjust headlight as necessary Maintenance Booklet 20 1 1 3 Adjusting headlight installation position Note To adjust the headlig...

Page 191: ...adlight Unscrew securing screw arrow on lower right headlight Adjust shutlines to body by pushing in or pulling out alignment bush arrow on lower left or lower right headlight Tighten threaded connections to specified torque settings page 238 Check and if necessary readjust headlight to ensure gaps are even all round Install radiator General Body Repairs Exterior Rep Gr 66 Strips and trim Removing...

Page 192: ...eadlight bulb for the left headlight Removing Switch off ignition and all electrical consumers and pull out ignition key Turn cover cap 1 in direction of arrow and remove Turn bulb holder with dipped beam headlight bulb 1 in direction of arrow and remove from headlight Pull dipped beam headlight bulb 2 in direction of arrow out of bulb holder 1 Installing Note When installing cap ensure that it is...

Page 193: ...the pin on the dipped beam headlight bulb lies in the recess arrow of bulb holder 2 Place bulb holder with dipped beam headlight bulb 1 in head light and turn bulb holder with dipped beam headlight bulb in direction of arrow Place cover cap 1 in headlight recess and tighten in direction of arrow Check function of headlight Check headlight setting and adjust headlight as necessary Maintenance Bookl...

Page 194: ...r 2 Press spring retaining clip 2 in direction of arrow under the locking lugs 1 and fold spring retaining clip 2 upwards Take headlight main beam bulb 1 out of the headlight Installing Note When installing cap ensure that it is seated correctly The in gress of water will lead to permanent damage of the headlight Do not touch bulb glass when fitting bulbs Fingers leave traces of grease on the glas...

Page 195: ...k s w a g e n A G Place the headlight main beam bulb 1 in the recesses arrows on the headlight Check function of headlight Check headlight setting and adjust headlight as necessary Maintenance Booklet 20 1 1 4 3 Renewing side light bulb Note The diagrams show renewal of the side light bulb for the left headlight Removing Switch off ignition and all electrical consumers and pull out ignition key Pu...

Page 196: ... 20 1 1 4 4 Renewing front turn signal bulb Note The diagrams show renewal of the turn signal bulb for the left headlight Removing Switch off ignition and all electrical consumers and pull out ignition key Turn bulb holder with front turn signal bulb 1 in direction of arrow and remove from headlight Push front turn signal bulb into bulb holder turn front turn sig nal bulb anti clockwise and pull f...

Page 197: ...uthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 6 Adjusting headlights Adjusting headlights Maintenance Booklet 20 1 Jetta 2005 Bora 2006 Electrical System Edition 05 2005 1 Headlight 189 ...

Page 198: ...automatic headlight range control on headlights with gas discharge bulbs is equipped with self diagnosis When dealing with complaints it is absolutely essential that the function and operation of the lighting system is first under stood Additional information Operating instructions Current flow diagrams Electrical fault finding and Fitting loca tions Fault detection and fault display The automatic...

Page 199: ...or right headlight range control motor V49 Headlight manufactur er AL Automotive Lighting Note 3 Securing bolts For left headlight range control motor V48 or right headlight range control motor V49 4 Cover cap 5 Gas discharge light starter unit N195 6 Bulb locking For left gas discharge bulb L13 or right gas discharge bulb L14 7 Left gas discharge bulb L13 or right gas discharge bulb L14 Type D2S ...

Page 200: ... J343 or right gas discharge light control unit J344 17 Left headlight main beam bulb M30 or right headlight main beam bulb M32 Bulb H7U 12 V 55 W Renewing page 194 18 Front left turn signal bulb M5 or front right turn signal bulb M7 Bulb 12 V H2 WLL 21 W Renewing page 197 19 Left side light bulb M1 or right side light bulb M3 Bulb 12 V W 5 W Renewing page 196 20 Cover cap For front left turn sign...

Page 201: ...d automatically when the gas discharge bulb starter unit N195 is removed Turn gas discharge bulb starter unit N195 1 in direction of starter unit lettering OPEN and pull gas discharge bulb start er unit N195 off headlight WARNING Within the bulb glass of gas discharge bulbs pressures can range from between 7 bar cold and 100 bar hot Temperatures can reach up to 700 degrees Celsius on the glass bul...

Page 202: ...ly sensitive and is subjected to a very high pressure Avoid looking directly into the collimated beam as the UV rays from the gas discharge bulb are about 2 5 times greater than normal halogen bulbs When installing cap ensure that it is seated correctly The in gress of water will lead to permanent damage of the headlight If a headlight is removed with automatic range control the ba sic setting of ...

Page 203: ...ning clip 2 upwards Take main beam bulb 1 out of headlight Installing Note When installing cap ensure that it is seated correctly The in gress of water will lead to permanent damage of the headlight Do not touch bulb glass when fitting bulbs Fingers leave traces of grease on the glass which evaporate when the bulb is switched on and cause the glass to cloud over Installation is performed in the re...

Page 204: ...y Pull off cover cap 1 Pull depending on the cable length the bulb holder 2 with the side light bulb as far it is possible out of the reflector 1 Pull side light bulb 2 in direction of arrow out of the bulb holder 1 Installing Note When installing cap ensure that it is seated correctly The in gress of water will lead to permanent damage of the headlight Do not touch bulb glass when fitting bulbs F...

Page 205: ...ength the bulb holder 1 with the front turn signal bulb in direction of arrow and take them out of the reflector Push front turn signal bulb 2 into bulb holder 1 and turn front turn signal bulb 2 in direction of arrow Pull front turn signal bulb 2 out of the bulb holder 1 Installing Note When installing cap ensure that it is seated correctly The in gress of water will lead to permanent damage of t...

Page 206: ...ght page 181 Remove securing bolts arrows of gas discharge light control unit 1 Note When taking off the gas discharge light control unit the connectors must not be removed The connector is fitted tightly to the head light and is automatically disconnected when taking off the gas discharge light control unit Take off gas discharge light control unit 1 from headlight Installing Note When installing...

Page 207: ...e When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srew driver Removing Switch off ignition and all electrical consumers and pull out ignition key Remove lateral cover 1 out of the dash panel by inserting the removal wedge VAS 3409 or a screwdriver in the recess 2 and lever off ...

Page 208: ...tion when doing this note the following Fit the control unit for headlight range control J431 3 into the bracket 2 with the lug 2 Lock connector 1 by pressing the locking clip 2 in direction of arrow Note After installing a new control unit for headlight range control J431 it must be coded page 200 2 7 2 Coding control unit for headlight range control J431 Connect the vehicle diagnosis testing and...

Page 209: ...ng of the headlights must be performed after having coded the control unit Maintenance Booklet 20 1 2 8 Vehicle level sender There is a vehicle level sender located on the front axle front left vehicle level sender G78 and on the rear axle rear left vehicle level sender G76 Note If the vehicle level senders are replaced check the values from the sensors page 203 and carry out basic setting on head...

Page 210: ...verse order When installing note the following Tighten threaded connections to specified torque settings page 238 Check front left vehicle level sender G78 page 203 Perform basic setting of headlights Maintenance Booklet 20 1 Note If the vehicle level sensors are replaced check the sensor values page 203 and carry out basic setting on headlights Maintenance Booklet 20 1 If the values from the vehi...

Page 211: ...er The vehicle level senders transmit the longitudinal inclination an gle of the vehicle by way of signals to the headlight range control unit J431 It must then be confirmed whether the rear left vehicle level sen sor G76 and front left vehicle level sensor G78 are supplying the headlight range adjustment unit J431 with plausible signals No fault entry is stored in the headlight range control unit...

Page 212: ... r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 9 Servicing headlight securing lugs Information on servicing headlight securing lugs was not available when it was time of going to press 2 10 Adjusting headlights Adjusting headlights with gas discharge lamp Maintenance Booklet 20 1 Jetta 2005 Bora 2...

Page 213: ... supply control unit has a self diagnosis function which makes fault finding on the fog lights easier For fault finding use the vehicle diagnosis testing and informa tion system VAS 5051A in guided fault finding mode 3 1 Assembly overview fog light Torque settings page 238 1 Front bumper 2 Vent hose 3 Left fog light bulb L22 or right fog light bulb L23 Bulb H11 12 V 55 W Removing and installing pa...

Page 214: ... electrical consumers and pull out ignition key Remove bolt 2 Unclip cover cap 2 off locking device Unbolt securing bolts arrow Pull fog light housing out of front bumper and disconnect con nector arrow Installing Installation is performed in the reverse order of installation when doing this note the following Check functions of headlight Check fog light adjustment adjusting if necessary Mainte na...

Page 215: ... i g h t b y V o l k s w a g e n A G Turn bulb holder 1 in direction of arrow and take out of fog light The bulb for the fog light is permanently attached to the bulb holder and cannot be renewed separately Fog light bulb H11 12 V 55 W Installing Installation is performed in the reverse order of installation when doing this note the following Check functions of headlight Check fog light adjustment...

Page 216: ...d installing front side mark er Removing Note Removal and installation of front side marker on left and right are identical Remove noise insulation General Body Repairs Exterior Rep Gr 50 Assembly overview noise insulation Unlock side marker 1 by pressing the locking lug in direction of arrow Remove bulb holder 2 out of side marker Installing Installation is performed in the reverse order of insta...

Page 217: ... onboard supply control unit is equipped with self diagnosis which makes fault finding easier For fault finding use the vehicle diagnosis testing and informa tion system VAS 5051A in guided fault finding mode 5 1 Removing and installing turn signal bulb The driver side exterior mirror turn signal bulb L131 or the front passenger side exterior mirror turn signal bulb L132 is installed in the housin...

Page 218: ...exterior mirror W52 or the front passenger side entry light in exterior mirror W53 is installed in the housing of the left or right exterior mirror Note To remove and install the entry lights the exterior mirror must not be removed Removal and reinstallation of entry lights is carried out in the same manner on both sides and is described for one side only Removing Switch off ignition and all elect...

Page 219: ... i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull bulb carrier 2 in direction of arrow out of entry light housing 1 Renew bulb Pull bulb 1 in direction of arrow out of the carrier 2 Plug base bulb 12 V W6 W Installing Installation is performed in the reverse order of installation when doing this note the following Note After the installation perform functional c...

Page 220: ...6 1 Assembly overview tail light in side panel Torque settings page 238 1 Securing nuts 2 Left brake and tail light bulb M21 or right brake and tail light bulb M22 3 Tail light housing in side panel Removing and installing page 212 4 Bulb for left brake blinker and tail light 2 M72 or bulb for right brake blinker and tail light 2 M73 5 Bulb carrier Removing and installing page 213 6 2 Removing and...

Page 221: ... 2 on tail light in side panel Remove tail light Installing Installation is performed in the reverse order of installation when doing this note the following Tighten securing nuts 2 to specified tightening torque page 238 Note The tail light connector in the side panel must audibly engage When installation is complete check shutlines of tail light to body 6 3 Removing and installing tail light bul...

Page 222: ...b y V o l k s w a g e n A G 6 4 Assembly overview tail light in tailgate Torque settings page 238 1 Securing nuts 2 Bulb carrier Removing and installing page 215 3 Left reversing light bulb M16 or right reversing light bulb M17 12 V P 21 W 4 Tail light housing in tailgate Removing and installing page 214 5 Plain washer 6 5 Removing and installing tail light in tail gate Removing Switch off ignitio...

Page 223: ...on when doing this note the following Secure washer 2 with an adhesive point e g Loctite before fitting on threaded domes 1 to prevent from falling in the body Fit the washers 2 on the threaded domes 1 Tighten securing nuts 1 to specified tightening torque page 238 Fit connector 2 on bulb carrier When installation is complete check shutlines of tail light to body 6 6 Removing and installing tail l...

Page 224: ...t guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unclip the two retaining tabs in direction of arrow and take bulb carrier 1 out Installing Install in reverse order of removal Jetta 2005 Bora 2006 Electrical System Edition 05 2005 216 Rep Gr 94 Li...

Page 225: ...f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 Number plate lights 7 1 Removing and installing number plate light X Removing Switch off ignition and all electrical consumers and pull out ignition key Remove securing bolts arrows of number plate light X Take the lens off together with the number plate light X Number plate light X Soffitte 12 V C ...

Page 226: ... 1 Removing and installing high level brake light bulb M25 Note In the event of damage the complete high level brake light M25 unit must be renewed Removing Switch off ignition and all electrical consumers and pull out ignition key Remove strip roof leading edge General body repairs in terior Rep Gr 70 Removing and installing strip roof leading edge Pull connector 1 off Press high level brake ligh...

Page 227: ...ing and connecting the battery as described in the Workshop Manual page 29 Note After installing a new steering column electronics control unit J527 it must be coded page 227 In the event of faults in the steering column switch the coding of the steering column electronics control unit J527 must be checked page 227 Fault detection and fault display The steering column electronics control unit J527...

Page 228: ...if fitted with cruise control sys tem cruise control sys tem switch E45 The illustration shows the turn signal switch without cruise control system switch E45 2 Steering column switch base Removing and installing page 226 3 Windscreen wiper switch E Removing and installing page 225 4 Securing bolt 5 Steering column electronics control unit J527 Removing and installing page 221 Coding page 227 Fina...

Page 229: ...e de scribed as follows must be observed Disconnect the battery page 29 Remove steering wheel General body repairs interior Rep Gr 69 Airbag Removing and installing steering wheel Remove steering column trim General body repairs interior Rep Gr 68 Compartments covers and trim Removing and installing steering column switch trim Remove components of steering column switch in the sequence as follows ...

Page 230: ...ng tab arrow 2 Using a screwdriver press against the rear securing clip arrow of the steering column electronics control unit J527 Carefully pull the steering column electronics control unit J527 downwards off the steering column switch Unclip arrow A connector 1 and separate from steering col umn electronics control unit J527 Remove locking device 3 out of connector Unclip arrow B connector 2 and...

Page 231: ...e in the straight ahead position Lift up locking tabs arrows on coil connector 1 slightly and pull coil connector backwards off steering column and steering column switch Installing Installation is performed in the reverse order of installation when doing this note the following Note For installation of the coil connector the coil connector must be in the central position and the road wheels must ...

Page 232: ...itch arrow Installing Install in reverse order of removal 9 2 4 Removing and installing turn signal switch Note The turn signal switch comprises of the following compo nents turn signal switch E2 headlight dipper flasher switch E4 and if fitted with cruise control system cruise control sys tem switch E45 For reasons of clarity the steering column switch is shown with cruise control system switch E...

Page 233: ... c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 9 2 5 Removing and installing windscreen wiper switch E Removing Note For reasons of clarity the steering column switch is shown in the removed state Release retaining clips arrows using 1 0 mm feeler gauge 1 and take windscreen wiper switch E off backwards Installing Installation is performed in the reverse order of installation when doin...

Page 234: ...amage and or mal function Please remove the components in the specified se quence Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Removing Disconnect the battery page 29 Remove the following components in sequence Remove steering wheel General body repairs interior Rep Gr 69 Airbag Removing and installing steering wheel Remove steering column trim Gener...

Page 235: ... electronics control unit J527 Removing and installing steering column electronics control unit J527 page 221 9 3 1 Coding steering column electronics con trol unit J527 Connect the vehicle diagnosis testing and information system VAS 5051A to page 281 Select guided fault finding in Vehicle Diagnosis Testing and Information System VAS 5051A Using the Go to key select Function component selection a...

Page 236: ...ng angle sender G85 Removing and installing steering angle sender G85 page 224 9 4 1 Basic setting steering angle sender G85 Connect the vehicle diagnosis testing and information system VAS 5051A to page 281 Select guided fault finding in Vehicle Diagnosis Testing and Information System VAS 5051A Using the Go to key select Function component selection and the following menu items one after the oth...

Page 237: ...ithout lock cylinder it will block and must be renewed The steering lock must not be actuated without lock cylin der Removing Disconnect the battery page 29 Remove basic brace for steering column switch page 226 10 2 Removing and installing lock cylinder Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 The steering lock could be destroyed If the steering...

Page 238: ...own without turn signal and windscreen wiper switch There is no need to remove the switches for removal of the lock cylinder The immobilizer reader coil is secured to the lock cylinder and cannot be replaced individually Disconnect connector arrow at reader coil Insert ignition key in lock cylinder and turn to position Drive Position of key in lock cylinder 1 Position Stop 2 Position Drive 3 Posit...

Page 239: ...ce lock cylinder 1 in steering lock housing Note The connection for the immobilizer reader coil must be inserted in the steering lock housing guide Pull steel rod 2 out of lock cylinder 1 and check lock cylinder is seated correctly in the steering lock housing Fit connector to immobilizer reader coil Install all parts in reverse order of removal 10 3 Removing and installing ignition switch Caution...

Page 240: ...4 The ignition key withdrawal lock solenoid N334 is located di rectly adjacent to the ignition starter key Note To remove ignition key on vehicles with an automatic gearbox always move selector lever to position P first then switch off ig nition Otherwise the ignition key withdrawal lock solenoid N334 will inhibit the removal of the ignition key Removing Remove steering column electronics control ...

Page 241: ...g aid system or PDC Park Distance Control supports the driver during parking maneuvers by indicating the distance from the rear of the vehicle to the obstacle by way of acoustic signals The parking aid system comprises Parking aid control unit J446 Rear parking aid warning buzzer H15 Rear left centre parking aid sensor G204 Rear left inner parking aid sensor G334 Rear right inner parking aid senso...

Page 242: ...e 234 3 Rear centre right parking aid sender G205 In the rear bumper cover Removing and installing page 235 4 Rear right inner parking aid sensor G335 In the rear bumper cover Removing and installing page 235 5 Rear left inner parking aid sensor G334 In the rear bumper cover Removing and installing page 235 6 Rear centre left parking aid sender G204 In the rear bumper cover Removing and installing...

Page 243: ...e parking aid control unit 1 out of the retainer Installing Install in reverse order of removal 11 3 Removing and installing parking aid sensor Following 4 senders are located in the rear bumper cover Rear centre left parking aid sender G204 Rear left inner parking aid sensor G334 Rear right inner parking aid sensor G335 Rear centre right parking aid sender G205 Note Removal and installation of th...

Page 244: ...r parking aid warning buzzer H15 The rear parking aid warning buzzer H15 is fitted on the rear shelf plate It is accessible via the luggage compartment Removing Pull off connector 1 Release securing clips arows remove rear parking aid warn ing buzzer H15 from retainer Installing Install in reverse order of removal 11 5 Final control diagnosis Connect the vehicle diagnosis testing and information s...

Page 245: ...u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Parking aid functions Final control diagnosis Jetta 2005 Bora 2006 Electrical System Edition 05 2005 11 Parking aid 237 ...

Page 246: ...light Threaded connections Torque settings Upper headlight 4 Nm Lower left headlight 4 Nm Lower right headlight 4 Nm 12 2 Torque settings fog lights Threaded connections Torque settings Headlight securing screws 1 5 Nm 12 3 Torque settings tail light in side panel Threaded connections Torque settings Securing nuts 3 5 Nm 0 5 Nm 12 4 Torque settings tail light in tailgate Threaded connections Torqu...

Page 247: ...Lights lamps switches inside 1 Lights and switches in engine com partment Note The Jetta or the Bora have no lights in the engine compartment 1 1 Removing and installing bonnet contact switch F266 Note The bonnet contact switch F266 is integrated into the bonnet lock and cannot be replaced individually If the bonnet contact switch F266 is found to be defective the entire bonnet lock must always be...

Page 248: ...light switch E1 Fog light switch E7 Rear fog light switch E18 Light switch illumination bulb L9 Removing Switch off the ignition and all electrical consumers Turn grip of light switch to position 0 Push in grip of light switch 1 and turn it to the right slightly 2 Hold rotary part in this position and pull lighting switch using rotary part out of dash panel 3 Disconnect connector arrow Installing ...

Page 249: ...y V o l k s w a g e n A G 2 2 Removing and installing glove compart ment light W6 Special tools and workshop equipment required Removal wedge VAS 3409 Note When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srew driver Removing Switch off the ignition and all electrical consumers ...

Page 250: ...ve box switch The lamp must not light when the lid is closed 2 3 Removing and installing glove compart ment light switch E26 The glove compartment light switch can be found on the rear of the glove compartment Removing Switch off the ignition and all electrical consumers Remove glove compartment General body repairs interior Rep Gr 68 Compartments covers and trim Removing and installing glove comp...

Page 251: ... e n t C o p y r i g h t b y V o l k s w a g e n A G Disconnect connector arrow Unlock locking lugs arrows and take adjuster and regulator out Installing Install in reverse order of removal 2 5 Removing and installing front passenger side airbag deactivated warning lamp K145 Removing Switch off the ignition and all electrical consumers Remove centre vent Heating air conditioning system Rep Gr 80 S...

Page 252: ...warning lamp out Installing Install in reverse order of removal 2 6 Removing and installing hazard warning light switch E3 Removing Switch off the ignition and all electrical consumers Remove centre vent Heating air conditioning system Rep Gr 80 Servicing heating system remove vent Remove cen tre vent Remove connectors arrows Release locking lugs arrows and remove hazard warning light switch Insta...

Page 253: ...g e n A G Removal wedge VAS 3409 Note When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srewdriver The removal and installation of both footwell lights is the same so that only one light is described Removing Switch off the ignition and all electrical consumers Lever footwell lig...

Page 254: ...the lens or the light Lever bulb carefully out of the holder Renew glas base bulb 12 V 5 W Installing Install in reverse order of removal 2 8 Removing and installing key operated switch to deactivate front passenger side airbag E224 WARNING Observe safety measures when working on airbag General body repairs interior Rep Gr 69 Safety measures when working on airbags Removing Switch off the ignition...

Page 255: ...olkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release locking lugs arrows and remove key switch Installing Install in reverse order of removal Jetta 2005 Bora 2006 Electrical System Edition 05 2005 2 Lights and switches in dash...

Page 256: ...dividually Removing Switch off the ignition and all electrical consumers Remove lever shell upper part out of the closing lever Gen eral body repairs interior Rep Gr 70 Removing and instal ling door trim Front door trim front passenger side Disconnect connector arrow Release locking lugs arrows and remove switch from the in stallation frame Installing Install in reverse order of removal 3 2 Removi...

Page 257: ...tion frame for switch from trim Release locking lugs arrows and remove switch from the in stallation frame Installing Install in reverse order of removal 3 3 Removing and installing driver side in terior locking button for central locking system E308 Note The driver side interior locking button for central locking system E308 features a button illumination bulb L76 which must not be replaced indiv...

Page 258: ...witch F2 Driver side central locking lock unit F220 Driver door central locking motor V56 Driver door central locking deadlock function motor V161 The following components depending on equipment are inte grated into the passenger side door lock Front passenger door contact switch F3 Front passenger side central locking lock unit F221 Front passenger seat central locking motor V57 Front passenger d...

Page 259: ...ver side window lift Front left window regulator switch E40 Rear left window regulator switch in driver door E53 Rear right window regulator switch in driver door E55 Front right window regulator switch in driver door E81 Childproof lock button E318 Button illumination bulb L76 Note In the event of repair the complete component must be renewed The following components in models with 2 doors are in...

Page 260: ...switch from the in stallation frame Installing Install in reverse order of removal 3 6 Removing and installing remote release button for fuel filler flap and rear lid E463 and key operated switch to block release of rear lid remote E232 Note The remote release button for fuel filler flap and rear lid E463 features a button illumination bulb L76 which must not be replaced individually Removing Swit...

Page 261: ...nAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release locking lugs arrows and remove switch from the door trim Installing Install in reverse order of removal Jetta 2005 Bora 2006 Electrical System Edition 05 2005 3 Lights and switches ...

Page 262: ...63 The following components depending on equipment are inte grated into the rear right door lock Rear right door contact switch F11 Rear right central locking lock unit F223 Rear right door central locking motor lock V215 Rear right door central deadlock function locking motor V164 Note In the event of repair the complete component must be renewed In the event of component defects rear door locks ...

Page 263: ...esnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release locking lugs arrows and remove switch from the in stallation frame Installing Install in reverse order of removal Jetta 2005 Bora 2006 Electrical System Edition 05 2005 4 Lights and swit...

Page 264: ...artment 5 1 Removing and installing luggage com partment light W3 Special tools and workshop equipment required Removal wedge VAS 3409 Note The luggage compartment light can be found on the right side in the luggage compartment trim When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 34...

Page 265: ...w Renew bulb Press contact plate 1 of the light outwards and take festoon bulb 2 out of the socket Renew festoon bulb 12 V 10 W Installing Install in reverse order of removal 5 2 Removing and installing rear lid lock unit F256 The rear lid lock unit F256 is integrated into the tailgate lock and cannot be replaced individually If the rear lid lock unit F256 is found to be defective the entire tailg...

Page 266: ... the interior light and reading light Front interior light W1 Left centre reading light W39 Left centre reading light W40 Note The interior light and reading light as well as the switches for the interior light and reading light are connected together and can not be separated When repairing renew the complete component 6 1 1 Removing and installing front interior light and reading light Special to...

Page 267: ... o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Carefully lever trim out of interior light using removal wedge VAS 3409 or screwdriver arrow Unbolt securing bolts arrow Take the interior light out of the headliner console Remove connectors arrows Installing Install in reverse order of removal 6 1 2 Replace front interior light W1 Special tools and worksho...

Page 268: ...tc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srew driver Removing Switch off the ignition and all electrical consumers Carefully lever lens for interior light out using removal wedge VAS 3409 or screwdriver arrow Press contact 1 of light to side arrow and remove festoon bulb 2 with the contact from the interior light Pull contact arrow off defective fest...

Page 269: ...ly out of the holder Renew glas base bulb 12 V 5 W Installing Install in reverse order of removal 6 2 Removing and installing front interior light and reading light vehicles with slid ing sunroof The following components are integrated in the interior light and reading light Front interior light W1 Left centre reading light W39 Left centre reading light W40 Sunroof switch E8 Note The interior ligh...

Page 270: ... p y r i g h t b y V o l k s w a g e n A G Removal wedge VAS 3409 Note When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srew driver Removing Switch off the ignition and all electrical consumers Carefully lever trim out of interior light using removal wedge VAS 3409 or screwdrive...

Page 271: ... t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove connectors arrows Installing Install in reverse order of removal 6 2 2 Removing and installing sunroof switch E8 Removing Remove interior light page 261 Disconnect connector arrow Release locking lugs arrows and remove switch from the in stallation frame Installing Install in reverse order of removal 6 2 3 Replace front ...

Page 272: ...t b y V o l k s w a g e n A G Removal wedge VAS 3409 Note When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srew driver Removing Switch off the ignition and all electrical consumers Carefully lever lens for interior light out using removal wedge VAS 3409 or screwdriver arrow Pres...

Page 273: ...lling Install in reverse order of removal 6 2 4 Left centre reading light W39 and right centre reading light W40 Removing Remove interior light page 261 Turn bulb holder arrows of the defective reading light for 90 to the left Take the holder with the bulb out of the reading light Pull glas base bulb carefully out of the holder Renew glas base bulb 12 V 5 W Installing Install in reverse order of r...

Page 274: ...g light as well as the switches for the interior light and reading light are connected together and can not be separated When repairing renew the complete component 6 3 1 Removing and installing rear interior and reading light vehicles without ATAS Removing Switch off the ignition and all electrical consumers Release locking lugs arrows and take trim with lens off inte rior light and reading light...

Page 275: ...ws Renew defective glas base bulb 12 V 5 W Installing Install in reverse order of removal 6 4 Rear interior and reading light vehicles with ATAS The following components are integrated in the rear interior light and reading light Rear left footwell light W45 Rear left reading light W11 Rear right reading light W12 Anti theft alarm ultrasonic sensor G209 Note The switches 1 of the reading lights ar...

Page 276: ...ior and reading light and cannot be renewed separately The anti theft alarm ultrasonic sensor G209 2 cannot be renewed separately The anti theft alarm ultrasonic sensor G209 comprising four individual sensors 2 leads and a control element on the back of the interior and reading light must not be moved from its predefined position Removing Switch off the ignition and all electrical consumers Pull t...

Page 277: ...ated page 277 The anti theft alarm ultrasonic sensor G209 comprising four individual sensors 2 leads and a control element on the back of the interior and reading light must not be moved from its predefined position Removing Switch off the ignition and all electrical consumers Pull the entire complete trim 1 including lens and reflectors vertically downwards and out from the interior and reading l...

Page 278: ... l k s w a g e n A G Removal wedge VAS 3409 Note When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srewdriver The removal and installation of both lights is the same so that only one light is described Removing Switch off the ignition and all electrical consumers Lever light care...

Page 279: ...tact 1 of the light in direction of arrow and take festoon bulb 2 out of the socket Renew festoon bulb 12 V 5 W Installing Install in reverse order of removal 6 6 Removing and installing garage door operating unit E284 Note The garage door operating unit E284 is located in the sun visor on the driver side The sun visor and the garage door operating unit E284 may only be replaced together Remove th...

Page 280: ... n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 Lights and switches in centre console 7 1 Removing and installing TCS and ESP button E256 Removing Switch off the ignition and all electrical consumers Take bellow carefully off centre console arrows Unbolt securing bolts arrow Take mounting frame with ashtray out of the centre console Re...

Page 281: ...not guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release locking lugs arrows and remove switch from the in stallation frame Installing Install in reverse order of removal Jetta 2005 Bora 2006 Electrical System Edition 05 2005 7 Lights and switch...

Page 282: ...e onboard supply control unit J519 The procedure for removal and installation of treble tone horn H2 and bass tone horn H7 is the same and is therefore described for just one horn The horns are installed to the left and the right of the longitu dinal members Removing Switch off the ignition and all electrical consumers Remove front bumper General body repairs Rep Gr 63 Front bumper Disconnect conn...

Page 283: ...tegrated in the dash panel insert If the control unit is defective the complete dash panel in sert must be renewed Renewing dash panel insert page 150 9 2 Immobilizer reader coil D2 The immobilizer reader coil D2 is joined to the ignition switch and cannot be renewed individually Removing and installing ignition switch page 231 9 3 Ignition key Removing and installing the ignition key battery with...

Page 284: ...VAS 5051A Using the Go to key select Function component selection and the following menu items one after the other Body Electrical System 01 On Board Diagnostic capable systems Immobilizer Immobilizer functions Adapting ignition keys 9 3 3 Adapting ignition keys to the comfort system Connect Vehicle Diagnosis Testing and Information System VAS 5051A page 281 Select guided fault finding in Vehicle ...

Page 285: ...inding mode Note Once the anti theft alarm system has been triggered the alarm source that has been stored in the convenience system central control unit J393 can be interrogated page 298 10 1 Activating and deactivating anti theft alarm system Activating anti theft alarm system The anti theft alarm system is switched on automatically when the vehicle is locked The system is then immediately armed...

Page 286: ... interior and reading light must be replaced Removing and installing rear interior and reading light vehi cles with ATAS page 268 10 3 Removing and installing vehicle inclina tion sender G384 The vehicle inclination sender G384 arrow is located under the dash panel right behind the front passenger airbag Note The anti theft alarm system must be deactivated before the send er is removed page 277 Re...

Page 287: ...i theft alarm system aerial J393 to the A pillar driver side in the main wiring loom Note The antenna cannot be repaired as this would adversely affect the reception quality In the event of damage it is necessary to replace the central locking and anti theft alarm system aerial R47 10 5 Alarm horn H12 The alarm horn H12 is located on the right of the A pillar in the wing 10 5 1 Removing and instal...

Page 288: ...ousing liner Removing Drill out both pop rivets arrows using drill VAS 5134 and 6 mm twist drill Pull alarm horn H12 1 in direction of arrow out of the aperture in the bodywork Pull connector off 2 Installing Note Remove all metal particles caused during the drilling Perform measures for corrosion protection General Infor mation Body Repairs General Body Repairs Fit connector to the alarm horn H12...

Page 289: ... system from one of the rear seats Note All working instructions described such as modifications cod ing etc can be carried out using the vehicle diagnosis testing and information system VAS 5051A and the vehicle diagno sis and service information system VAS 5052 All working instructions can be found in guided fault finding and guided functions Additional information Self study programme No 202 Ve...

Page 290: ...re the only ones fitted with CAN lines and therefore allowing CAN diagnosis and or CAN communication Connecting Vehicle Diagnosis Testing and Information System VAS 5051A Apply handbrake On vehicles with automatic gearbox move selector lever to position P or N On vehicles with manual gearbox move gear stick to neutral position With the ignition switched off connect vehicle diagnosis test ing and i...

Page 291: ...der 2 1 Removing and installing fuse holder on left of dash panel Special tools and workshop equipment required Removal wedge VAS 3409 Note When removing and installing components in visual area con nectors covers trims etc apply a commercial adhesive tape where a lever tool is applied removal wedge VAS 3409 srew driver Caution Disconnecting and connecting the battery as described in the Workshop ...

Page 292: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove lateral cover 1 out of the dash panel by inserting the removal wedge VAS 3409 or a screwdriver in the recess 2 and lever off cover 1 in direction of arrow Take fuse assignment card 1 out of fuse holder 2 Remove securing bolts arrows and take fuse holder 1 out as far it is possible depending on ca...

Page 293: ...er 3 1 Removing and installing relay carrier with safety cut out on left of dash panel Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Removing Disconnect the battery page 29 Remove storage compartment on driver side General body repairs interior Rep Gr 68 Compartments covers and trim Unscrew bolts arrows of the bracket Pull relays arrows out of the rel...

Page 294: ...Fit relay carrier 2 into guide 1 and engage relay carrier 3 2 Removing and installing relay carrier on onboard supply control unit on left of dash panel Note The onboard supply control unit J519 and the relay carrier attached to the onboard supply control unit on left of dash panel form one unit and cannot be separated If the onboard supply control unit J519 is to be replaced first carry out the p...

Page 295: ... carrier on onboard supply control unit on left of dash panel may only be pulled off if the locking bar is set to position OPEN Remove all connectors of the onboard supply control unit J519 and the relay carrier on onboard supply control unit on left of dash panel Note The connector number depends on vehicle equipment Unclip onboard supply control unit J519 and relay carrier on onboard supply cont...

Page 296: ... C o p y r i g h t b y V o l k s w a g e n A G 4 Electronics boxes 4 1 Removing and installing electronics box on left in engine compartment Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Removing Disconnect the battery page 29 Release clips 1 in direction of arrow and take cover of elec tronics box 2 off upwards Remove hexagon nuts 1 Open arrows cover...

Page 297: ... n A G Remove central securing screw arrow from electronics box 1 Note When the central securing screw arrow the electronics box 1 is pushed upwards off the electronics box mounting Pull electronics box 1 upwards off electronics box mounting Note For removal of the flat contact housing 1 the air filter on vehi cles with diesel engine only the battery and the battery console must be removed Remove ...

Page 298: ...ronics box Press tabs apart on bracket of electronics box arrows C and slide flat contact housing 2 forwards arrow D out of bracket of electronics box Unscrew securing nuts arrows of bracket from electronics box 1 Note Whether the additional relay carrier is installed depends on the vehicle equipment Pull bracket of electronics box 1 upwards off studs as far as relay carrier cables allow Unclip re...

Page 299: ... a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Mount the cover 2 on the electronics box and push the safety clip 1 in direction of arrow until cover 2 engages Note Then check whether the cover 2 of the electronics box is en gaged correctly Jetta 2005 Bora 2006 Electri...

Page 300: ... finding and Fitting loca tions Operating instructions General description The onboard supply control unit J519 is responsible for the fol lowing in the vehicle Electrical load management Exterior light control Turn signal control Rear window wiper Heated rear window Terminal control Surround lighting Terminal control Dimmers instrument lighting Fuel pump presupply Alternator stand by Horn The fol...

Page 301: ... use the vehicle diagnosis testing and informa tion system VAS 5051A in guided fault finding mode 5 1 1 Removing and installing onboard supply control unit J519 Note If the onboard supply control unit J519 is to be replaced first carry out the procedure 5 1 2 Coding onboard supply control unit J519 page 293 so that access can be gained to the codes stored within Removing The removal of the onboard...

Page 302: ...light cleaning system 5 2 Data bus diagnostic interface J533 Note Additional information Current flow diagrams Electrical fault finding and Fitting loca tions Operating instructions General description The diagnosis interface for data bus J533 gateway is a sepa rate control unit It has the following functions in the vehicle Responsible for exchange of data between CAN data bus sys tems drive train...

Page 303: ...ystems Data bus diagnostic interface Data bus diagnostic interface functions Renewing data bus diagnostic interface 5 2 2 Removing and installing data bus diag nostic interface J533 Removing Note Before removing data bus diagnostic interface J533 it is es sential that the following work procedure 1 1 Renewing dash panel insert page 150 is carried out so that access can be gained to the codes store...

Page 304: ...ience system central control unit J393 is equipped with self diagnosis which is designed to ease fault finding For fault finding use the vehicle diagnosis testing and informa tion system VAS 5051A in guided fault finding mode 5 3 1 Removing and installing convenience system central control unit J393 Removing Switch off ignition and all electrical consumers and pull out ignition key Remove glove co...

Page 305: ...llation is performed in the reverse order of installation when doing this note the following Note After installing a new convenience system central control unit it must be coded page 297 The connectors may only be placed and locked if the recesses arrows of the connectors and the bracket align exactly 5 3 2 Coding convenience system central control unit J393 Connect Vehicle Diagnosis Testing and I...

Page 306: ... delay when driver s door is opened Sensitivity of tilt angle sensor Sensitivity of interior monitoring system Connect Vehicle Diagnosis Testing and Information System VAS 5051A page 281 Select guided fault finding in Vehicle Diagnosis Testing and Information System VAS 5051A Using the Go to key select Function component selection and the following menu items one after the other Body General Body ...

Page 307: ...ket tester V A G 1537 A 5 4 3 Final control diagnosis trailer detector control unit J345 page 301 The trailer detector control unit J345 etects from a power draw of minimum 5 W4 the trailer operation and transfers this infor mation to various control units via the CAN databus The trailer detector control unit J345 is supplied with information light control from the onboard supply control unit J519...

Page 308: ...own in the figure depends on vehicle equipment and may vary Remove securing bolts 1 and take trailer detector control unit J345 with the bracket out of the vehicle Remove securing bolts arrows and take trailer detector con trol unit J345 off bracket Installing Installation is performed in the reverse order of installation when doing this note the following Tighten threaded connections to specified...

Page 309: ...ocket tester V A G 1537 A Special tools and workshop equipment required Plug socket tester V A G 1537 A 5 5 After a few minutes the plug socket tester V A G 1537 A gets to hot and switches off automatically After a cooling period the plug socket tester V A G 1537 A works again perfectly Connect the plug socket tester V A G 1537 A Connect Vehicle Diagnosis Testing and Information System VAS 5051A p...

Page 310: ...le electrical system Caution Disconnecting and connecting the battery as described in the Workshop Manual page 29 Observe current notes also notes concerning removing and installing components in workshop manuals and in the Tech nical Service Handbook Yellow wiring and sections of wiring harness wrapped in yellow tape indicate a prior repair Operating instructions wiring harness repair set V A G 1...

Page 311: ...st be entirely replaced 6 4 Supplementary notes on repair of CAN bus wiring An unshielded two wire line 1 and 2 with a cross section of 0 35 mm2 or 0 5 mm2 is used for CAN bus wiring The colour codes of the CAN bus wiring can be gleaned from the following table Drivetrain CAN high orange black Convenience CAN high orange green Infotainment CAN high orange violet CAN Low wire all orange brown Perfo...

Page 312: ...p y r i g h t b y V o l k s w a g e n A G 6 5 Wiring harness repair set V A G 1978 Repairs to wiring harnesses and connectors of the onboard electrical supply system should only be carried out us ing wiring harness repair set V A G 1978 Included with the wiring har ness repair set V A G 1978 is a set of operating instructions which provides comprehen sive information on how to con duct repairs Fur...

Page 313: ... and wire diameters which may need to be replaced No provision has been made for replacement of individual aerial connectors in the event of repair The wires can be used retroactively for all VW models with all installed aerial wire diameters All adapter and connection wires are suitable for all transmitter and receiver signals This repair method can also be used for testing or retrofitting 7 2 As...

Page 314: ...ting wire 2 To determine the length of connecting wire required subtract 60 cm from the measured total length of aerial connecting wire 2 Procure the required adapter cables 1 and 3 and connect ing wire 2 at the calculated length as genuine parts from the parts catalogue ETKA Cut off connectors of defective aerial wire The remainder of the defective aerial wire remains in the vehicle Connect adapt...

Page 315: ... o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 Torque settings Cables 8 1 Torque settings Electronics box in left side of engine compartment Threaded connections Torque settings Securing nuts 1 M5 AF 8 4 Nm Securing nuts 1 M6 AF 10 6 Nm 8 2 Torque settings trailer detector control unit J345 Threaded connections Torque settings Securing bolts bracket to...

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Volkswagen Bora 2006, Workshop Manual

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Summary of Contents for Bora 2006

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