Service

Workshop Manual
Jetta 2005 Bora 2006
Electrical System
Edition 05.2005
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Service Department. Technical Information

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Service
List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
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Repair Group
27 - Starter, current supply, 90 - Instruments, GCI

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92 - Windscreen wash/wipe system 94 - Lights, lamps, switches - outside 96 - Lights, lamps, switches - inside 97 - Wiring

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher. Copyright 2010 Volkswagen AG, Wolfsburg MEX5R005820

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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Contents

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1 1 1 2 4 5 5 5 6 7 10 11 14 15 15 19 27 29 29 29 31 31 32 36 37 37 38 58 76 97 98 98 98 99 99 104 108 115 122 126 133 137 142 145 145 145 146 147 148 149

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1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 4 4.1 4.2 5 5.1 5.2 6 7 7.1 7.2 7.3 7.4 8 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 10 10.1 10.2 10.3 10.4 10.5 11

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure when checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking battery with magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking low maintenance battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check no load voltage of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaluating test result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting and reconnecting batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models with a petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models with a diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing starter, automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing starter, automated shift gearboxes . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing starter, manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastening B+ wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking ribbed belt (poly V-belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 1.6 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 1.6 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 1.9 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 2,0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing ribbed belt (poly V-belt) pulley on alternator . . . . . . . . . . . . . . . . Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General torque settings for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 l injection engine and 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 l and 2.0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 11.1 1 1.1 1.2 1.3 1.4 2 2.1 1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 5 5.1 5.2 5.3 6 1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5 Activating and deactivating cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volkswage A. Renewing dash panel a insert ..................................... G.d. gen AG . . . . . . .n. oes ksw l o tg Removing and binstalling dash panel insert . . n.o. .u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yV ara d e s Description ........................... te. riof reverse side of dash panel insert . . . n. o eo h t ulamp r. Warning symbols in dash panel insert . . . . . . . . . ac. . . . . . . . . . . . . . . . . . . . . . . . . . a ss Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

150 150 151 152 152 154 154 155 155 156 160 161 162 163 165 165 166 168 169 169 170 171 171 172 173 173 173 174 174 175 176 176 176 176 178 179 179 181 182 184 188 189 190 191 192 192 192 198

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deactivating APP function of wiper motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rain and light detector sensor G397 . . . . . . . . . . . . . . . . . . . . . . Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview of windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing reservoir for windscreen and headlight washer systems . . . . . . Removing and installing washer pump V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing windscreen washer spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting front windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . Removing and installing pop-up spray jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight washer system jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding the headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wash water line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview, Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main headlights with gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - gas discharge headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 2.6 2.7 2.8 2.9 2.10 3 3.1 3.2 3.3 3.4 4 4.1 5 5.1 5.2 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 8 8.1 9 9.1 9.2 9.3 9.4 10 10.1 10.2 10.3 11 11.1 11.2 11.3 11.4 11.5 12 12.1 12.2 12.3 12.4 12.5 1 1.1 2 2.1 2.2 Removing and installing gas discharge light control unit . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight range control unit J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sideA marker in agfront . Volksw en AG bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . gen G do s a w s Removing and installing . .t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . k front side marker . . .e. no Vol gu y ara db e Mirror turn signal bulb and entry light in exterior mirror .te. . . . . . . . . . . . . . . . . . . . . . . . . . . n is r o e h t Removing a and installing turn signal bulb . . . . . . . . . . . . . o. u r a. . . . . . . . . . . . . . . . . . . . . . . . c s s Removing and installing entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light bulb carrier in side panel . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light bulb carrier in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing high level brake light bulb M25 . . . . . . . . . . . . . . . . . . . . . . . . . . Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parking aid sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear parking aid warning buzzer H15 . . . . . . . . . . . . . . . . . . . . . . Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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198 198 201 204 204 205 205 205 206 207 208 208 209 209 210 212 212 212 213 214 214 215 217 217 218 218 219 220 220 227 228 229 229 229 231 233 234 234 235 236 236 238 238 238 238 238 238 239 239 240 240 241

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96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 5 5.1 5.2 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 8 8.1 8.2 9 9.1 9.2 9.3 10 10.1 10.2 10.3 10.4 10.5 1 1.1 2 2.1 3
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97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting vehicle Diagnosis, Testing and Information System VAS 5051A . . . . . . . . . . Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuse holder on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 281 283 283 285

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Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . Removing and installing switches and instruments illumination regulator E20 . . . . . . . . . . Removing and installing front passenger side airbag deactivated warning lamp K145 . . Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing left footwell light W9 and right footwell light W10 . . . . . . . . . . . . Removing and installing key operated switch to deactivate front passenger side airbag E224 ...................................................................... Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing window regulator switch in front passenger door E107 . . . . . . . . Removing and installing switch module for driver side mirror adjustment . . . . . . . . . . . . . . Removing and installing driver side interior locking button for central locking system E308 ........................................................................ Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing switch module for driver side window lift . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear left window regulator switch, in door E52 and rear right window regulator switch, in door E54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front interior light and reading light (vehicles with no sliding sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front interior light and reading light (vehicles with sliding sunroof) ........................................................................ Rear interior and reading light (vehicles without ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear interior and reading light (vehicles with ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front passenger side illuminated vanity mirror W14 and driver side illuminated vanity mirror W20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing garage door operating unit E284 . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing TCS and ESP button E256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . Checking treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm system (ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activating and deactivating anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft alarm ultrasonic sensor G209 . . . . . . . . . . . . . . . . . . . . Removing and installing vehicle inclination sender G384 . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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242 242 243 244 244 246 248 248 248 249 250 250 252 254 254 254 256 256 257 258 258 261 265 267 269 271 272 272 274 274 274 275 275 275 275 277 277 278 278 278 279

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 3.1 3.2 4 4.1 5 5.1 5.2 5.3 5.4 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 8 8.1 8.2 Removing and installing relay carrier with safety cut-out on left of dash panel . . . . . . . . . . Removing and installing relay carrier on onboard supply control unit, on left of dash panel ........................................................................ Electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing electronics box on left in engine compartment . . . . . . . . . . . . . . Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central control unit for convenience system J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . Notes on repairs to wiring harness and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplementary notes on repair of CAN bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring harness repair set V.A.G 1978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - an aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a new aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque settings: Cables . . . . . . . . . . . . . . . A ..................................... n G. Volkswagen AG do es n wage of engine compartment s Torque settings: Electronics box in V left side k l ot g . . . . . . . . . . . . . . . . . . o y b d Torque settings trailer detector control unit J345 . . . . . . . . . . . . . .ua . r. ................ an ise
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285 286 288 288 292 292 294 295 299 302 302 302 302 303 304 305 305 305 305 307 307 307

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Contents

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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Contents

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

27
1

Starter, current supply, CC

Battery
WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !

Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery page 1 .

1.1

Fundamentals for batteries

To ensure long use of the battery, the battery must be checked, serviced and maintained as per instructions in this Manual. Apart from supplying energy for starting the engine, the battery has other tasks: it acts as a buffer and supplies electrical energy to the complete vehicle electrical system. Note

Observe Self-study programme No. 234 ; vehicle batteries .

1.2 1.2.1

Types of battery Low maintenance battery

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Lead-acid battery, electrolyte level must be checked regularly and topped-up with distilled water as required. These batteries are often equipped with a magic eye. The magic eye provides information concerning the level of the electrolyte and the charge state of the battery.

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1.2.2

Maintenance-free battery

Maintenance-free battery with liquid electrolyte (wet battery). These batteries have a cover over the cells instead of cell plugs. The cover seals the battery after initial filling during production. Caution

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Never under any circumstances remove the cover for the bat tery cells. The battery housing will be damaged and the battery is therefore unusable.
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Lead-acid battery, where electrolyte need not be topped-up with distilled water under normal conditions. This term is normally used for batteries with a predetermined amount of electrolyte.

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1. Battery

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 These batteries are often equipped with a magic eye. The magic eye provides information concerning the level of the electrolyte and the charge state of the battery.

1.2.3

Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte. Lead-acid battery where the electrolyte is contained within a mi croscopic glass mat (AGM). The battery is sealed and fitted with valves. AGM is the abbreviation for Absorbent Glass Mat. Note
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1.2.4

Gel battery

Maintenance-free battery with a contained electrolyte. Lead-acid battery where the electrolyte is contained within a gel. The battery is sealed and fitted with valves. Note

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The procedure for checking and testing gel and absorbent

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Currently gel batteries are only used in motor homes/campers

1.3 1.3.1

Warning notices and safety regulations Dangers when handling vehicle batter ies
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Recognition and avoidance of dangers

Batteries can be dangerous. These dangers can be avoided when the warnings on the battery and in the owners/instruction manual and in ELSA are observed.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 WARNING

Untrained personal e.g. apprentices, trainees etc. may only work on batteries when supervised by a vehicle me chanic/foreman or vehicle electrician/foreman. Acid is highly corrosive. There is a considerable danger of acid burns if personal do not handle batteries correctly. Therefore suitable measures must be taken to ensure that equipment/solutions etc. are available to neutralize acid burns. A suitable solution is: e.g. a soap solution. If electrolyte leaks from a battery it may cause skin burns and acid corrosion, rusting on the vehicle. This may dam age safety relevant components on the vehicle. The gas which forms when charging and the gas which may escape through vent valves is explosive. In extreme cases a battery may explode if the battery is not handled correctly. It 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

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2. - Wear eye protection before commencing work on battery. 3. - Keep children away from acid and batteries.

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4. - Disposal: old batteries are classed as hazardous waste. They may only be disposed of through a suitable collection centre and only in accordance with respective legislation. 5. - Never dispose of old batteries in household waste system! 6. - There is a danger of an explosion when working with batteries. A highly explosive gas is produced when batteries are charged. 7. - Follow instructions concerning batteries, in ELSA "electrical system" and in owner's manual. 8. - Battery acid is very caustic, therefore wear eye protection and gloves when working with batteries. Do not tilt battery. Acid can leak out of the gas vents of some batteries.
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1. Battery

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

1.4

Battery terminal connection

Caution

To prevent damage to the battery terminal 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 torque, the threaded connections should not be tightened any further.
The tightening torque for the battery terminal clamps -1- and the additional clamps-2- can be found in this table Tightening tor ques: Battery page 36 .

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Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Checking battery
WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !

Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery page 1 .

2.1
1. 2. 3. 4.

Procedure when checking the battery

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Carry out procedure in sequence as follows: Visual check page 5 .

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2.2

Visual check
WARNING

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Perform a battery load test using battery tester with printer -VAS 5097 A- page 12 .

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Danger of injury! Observe warning notices 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.
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Caution

The battery will be damaged if the battery is not secured correctly.

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Check battery is securely seated, if necessary tighten se curing bolt to specified torque setting. page 36
AG.

Whether the battery housing is damaged: Check whether the battery housing is damaged. Electrolyte can leak out if the housing is damaged. If battery acid leaks out, serious damage to the vehicle could be caused. Treat areas of the vehicle af fected by leaked battery acid immediately with acid neutraliser or a soap solution. Whether the battery terminals (battery wiring/cable connec tions) are damaged. Check whether the battery terminals (bat tery wire connections) are damaged. The necessary contact at the terminal clamps cannot be guaranteed if the terminals are damaged. When connecting clamps to the terminals, tight
2. Checking battery

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Vibrations shorten the life of the battery, there is a danger of an explosion, the cell plates may be damaged and the securing plate may damage the battery housing.
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 en the clamps to the torque specified in this workshop manual. If the clamps are not correctly seated and tightened, the wiring could burn, which could result in electrical system malfunc kswagen AG tions. Which will cause malfunctions in the electrical AG. Volsystem. d agen w s k Therefore it can no longer be guaranteed that the vehicle will oes not g l Vo y ua b function correctly. ran ed

2.3

Checking battery with magic eye

WARNING
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Danger of injury! Observe warning notices and safety regula tions page 2 !
The magic eye (condition indicator) provides information on the electrolyte level and condition (charge state) of the battery. Batteries with a magic eye are produced in two versions: Low maintenance page 1 Maintenance-free page 1 Note

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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.
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The air bubbles, which can influence the display, will dissipate when doing this. The colour display of the magic eye will therefore be more accurate. Note Air bubbles can form below the magic eye particularly when

the battery is being charged, including during normal vehicle operation. These falsify the colour display of the magic eye. tery.

The magic eye can be located at various positions on the bat Three different colour displays are possible: Green, battery is charged sufficiently. Black, Battery partly discharged, charge state < 65 % or completely discharged. Colourless or yellow, battery must be renewed. Note Charging battery with battery charger -VAS 5095 A-

page 15 . page 19 .

Charging battery with battery charger -VAS 5900-

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.4

Checking low maintenance battery

WARNING
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d notices and safety regula e nte is r o eo h ut ra a c s s

Danger of injury! Observe warning tions page 2 !

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This battery is low maintenance this means the electrolyte level must be checked and occasionally topped-up with distilled water as required.

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2.4.1

Checking electrolyte level of battery

Check electrolyte level on housing: Check electrolyte level via -min./ max.- marking on the battery 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: If fitted, remove the protective foil on the cell sealing plug. Note
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Switch off the ignition and all electrical consumers.

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The foil with the warning notices must remain on the battery.
Remove cell sealing plugs.
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Check the electrolyte level of the battery cells. The electrolyte level is OK when the fluid level -1- is the same height as the plastic peg. Note

The plastic peg corresponds to the max. marking.

If electrolyte level is OK: Check the cell sealing plugs and the O-ring seals for damage. Damaged parts must be replaced. Seal the cells with the cell sealing plugs. If the electrolyte level is under the plastic peg: Replenished with distilled water page 7 .

2.4.2

Topping up with distilled water

Special tools and workshop equipment required

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2. Checking battery

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Battery filler bottle -VAS 5045/n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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Caution

When filling up with undistilled water or electrolyte the bat tery will be damaged. Top up with distilled water only. The battery may be damaged when the cells are overfilled. When topping up use only the battery filling 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.
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If fitted, remove the protective foil on the cell sealing plug.

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Note

Remove cell sealing plugs. Replenish with distilled water using battery filling bottle -VAS 5045/- . When the max. level is reached the flow is interrupted automatically. Check the cell sealing plugs and the O-ring seals for damage. Damaged parts must be replaced. Seal the cells with the cell sealing plugs. Check no load voltage of battery page 10 . Perform battery load/discharge test page 12 .

2.4.3

Check electrolyte density

Special tools and workshop equipment required

Rep. Gr.27 - Starter, current supply, CC

AG.

The foil with the warning notices must remain on the battery.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Commercially available hydrometer

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
olks The foil with the warning notices must remain on the battery. yV
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Remove cell sealing plugs.

The electrolyte density is determined by the float position in the battery electrolyte. The value can be read from the float scale. Electrolyte density 1.28 g/cm3 1,21 1,18 1,10 g/cm3 g/cm3 g/cm3 Charge 100 % 60 % 40 % 0% Voltage 12,7 V 12,3 V 12,1 V 11,7 V

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Draw electrolyte off a cell using a hydrometer until the float swims unhindered.

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Note

Checking electrolyte density directly after topping up with distilled water will lead to erroneous results. Check electrolyte density only after charging the battery.
Check the cell sealing plugs and the O-ring seals for damage. Damaged parts must be replaced.
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Seal the cells with the cell sealing plugs.

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2. Checking battery

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.5

Check no load voltage of battery

WARNING
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Note

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The no load voltage test is used to determine the capacity of the battery.

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The battery must not be charged or discharged for at least 2 hours before making the measurements. Charging or discharging dur ing this period falsify the test result.
No load voltage 11,70 V 12,20 V Charge 0% Condition of battery

50 %

12,35 V

65 %

Discharged, no capacity. Heavily discharged. page 27 . 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. On batteries with a magic eye, the display will change from green to black. The battery should be recharged on new/vehicles which have been stored. Full capacity.
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12.70 V

100 %

Special tools and workshop equipment required Hand multimeter -V.A.G 1526 B-

Switch off ignition and all electrical consumers and pull out ignition key. Disconnect negative terminal on battery page 29 . Wait at least 2 hours. The battery must not be charged or dis charged within this period. Check battery no load voltage with hand multimeter -V.A.G 1526 B- .

10

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Measured value No load voltage 12.5 V No load voltage < 12.5 V Measure to be performed No load voltage is OK, perform a battery load test page 10 . Charge battery page 15 .

If the battery has been recharged as a result of the no load test, proceed as follows: Wait at least 2 hours. The battery must not be charged or dis charged within this period. Check battery no load voltage again with hand multimeter V.A.G 1526 B- . If after the loading process the battery no load voltage is < 12.5 V, renew battery page 31 .

2.6

Battery tester with printer -VAS 5097 AWARNING

Danger of injury! Observe warning notices and 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 according to IEC (International Engineering Consortium) ks
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tee ri ho orDIN can be 1) Batteries ut with a low-temperature test current of 520 A according to ac a s testedsusing setting for 499A according to DIN.

For test purposes the battery is loaded with a current which is similar to the starting current required to start the vehicle. The battery is assessed on this loading and the result is printed out. Note

Observe the Instruction Manual for battery tester with printer

-VAS 5097 A- or sticker Brief instructions for battery tester with printer -VAS 5097 A- stuck on the unit or table Low-tem perature current. page 13

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Observe battery manufacture's handling instructions!

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2. Checking battery

11

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.6.1

Description of battery tester with printer -VAS 5097 A-

Battery tester with printer -VAS 5097 A1 - Green LED, unit operating 2 - Red LED, unit reverse-polarity connected 3 - Red LED, battery cannot be tested, recharge battery. 4 - Start tester 5 - Low-temperature current selection switch 6 - ON/OFF and functions switch 7 - Selection switch (battery tester to pick-off point on battery/ external test point in engine compartment) AG. Volkswagen 8 - Button to advance paper 9 - Printer
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2.6.2

Battery load test using battery tester with printer -VAS 5097 A-

rrectness of i t to the co nf o r m spec atio h re n in wit

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-

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Perform battery load test:

Switch off the ignition and all electrical consumers. Check no load voltage of battery page 10 . Set low-temperature test current for battery in Ampere (A) ac cording to DIN standard. If the battery values are shown in IEC or EN/ SAE instead of DIN then convert figures using table 2.6.3 Table: low-temperature test current, page 13 or using table on unit. Select low-temperature test current via low-temperature test current selection switch page 12 . Select measuring range 80 - 379 A or 380 - 499 A with ON/ OFF and functions switch page 12 . Connect red terminal + of unit to positive terminal.

12

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Connect black terminal - of unit to negative terminal. Note

Ensure test clamps have a good contact!

Select point of connection of test terminals with selection switch page 12 . 12Connected directly to battery. Connected to external test points in engine compartment.

Check that the figures given on the battery are correct for the settings on the battery tester. Press start test button page 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

EN/ SAE 136 - 17 178 - 219 220 - 261 262 - 303 304 - 345 346 - 387 388 - 429 430 - 471 472 - 513 514 - 555 556 - 597 598 - 639 640 - 657 658 - 675 676 - 693 694 - 711 712 - 729 730 - 747 748 - 765 766 - 783 784 - 801
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95 - 124 125 - 154 155 - 184 185 - 214 215 - 244 245 - 274 275 - 304 305 - 334 335 - 364 365 - 394 395 - 424 425 - 454 455 - 464 465 - 474 475 - 484 485 - 494 495 - 504 505 - 514 515 - 524 525 - 534 535 - 544

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DIN 80 - 104 105 - 129 130 - 154 155 - 179 180 - 204 204 - 229 230 - 254 255 - 279 280 - 304 305 -329 330 - 354 355 - 379 380 - 389 390 - 399 400 - 409 410 - 419 420 - 429 430 - 439 440 - 449 450 - 459 460 - 469

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2. Checking battery

13

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Low-temperature test current in A IEC 545 - 554 555 - 564 565 - 574

EN/ SAE 802 - 819 820 - 837 838 - 855

DIN 470 - 479 480 - 489 490 - 4992)

2) Batteries with a low-temperature test current of 520 A according to DIN can be tested using setting for 499A according to DIN.

2.7

Evaluating test result

Because of the high load on the battery during this test (a high current flows) the battery voltage drops. If the battery is OK the voltage value only lowers to the mini mum voltage. If the battery is defective or has a low charge the battery 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
12345-

Comments concerning test print out

Measuring range set on tester. Diagram -arrow- indicates battery condition. Test result. Battery voltage during load test.
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Note

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The print out is required for warranty purposes. Perform test once only. Repeating the test falsifies the results.

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2.7.2

Assessing test results

Measure to be performed Battery OK Battery OK Charge battery page 15 and repeat battery load test 3)

Battery tester print out Starting power very good Start output good Starting power sufficient Starting power poor Starting power very poor Not capable of being tested

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14

Rep. Gr.27 - Starter, current supply, CC

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3) If after battery has been recharged Starting output sufficient, Starting output poor, Starting output very poor or Cannot be tested is shown, the battery should be renewed.

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WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !

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Charging battery

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, Bora 2006 - Edition 05.2005

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Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery page 1 .

3.1

Battery charger -VAS 5095 A-

This chapter describes the basic functions of the battery charger -VAS 5095 A- . For additional information refer to Operating instructions for battery charger -VAS 5095 A- .
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Note

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 peaks in amperage or volt age. This will not adversely effect the onboard electronics. The battery can remain in the vehicle while it is being charged and need not be disconnected. Battery charger -VAS 5095 A1 - ON / OFF switch (0 = charger OFF) 2 - Charging current indicator (I > 12 A) 3 - Charging current indicator, battery partially charged > 90 % 4 - Maintaining charge, lights up green when battery is fully charg ed 5 - Malfunction indicator 6 - Support mode indicator 7 - Support mode/normal mode changer-over switch 8 - Charger cable posts, red terminal +, black terminal - 9 - Battery type change-over switch (on base of charger unit)

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Observe Operating instructions for battery charger -VAS

AG.

3. Charging battery

15

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

3.1.2

Charging battery with battery charger VAS 5095 AWARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !
Special tools and workshop equipment required Battery charger -VAS 5095 A-

Caution

Always set battery type 2.4 V/C This applies for all batteries.

Note

The battery must have a temperature of at least 10 C. If the battery has cell sealing plugs, do not open them while

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara (Volt/Cells) when charging! d e nte is r o eo h ut ra a c s s

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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 - of charger unit to negative terminal on battery. Switch on battery charger page 15 . The charging current indicators page 15 -2- and -3- light up yellow. When only the light emitting diode (LED) -3- lights up yel low, battery is partially discharged (approx. 90 %).
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If the LED lights up green page 15 -4- the charger has switched to "maintaining charge". The battery is fully charged. Remove charger unit terminals from battery terminals.
AG.

Switch off charging unit page 15 .

16

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

3.1.3

Charging totally discharged battery with battery charger -VAS 5095 AWARNING

Note

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ing current. The charging current is automatically adapted to suit the charge condition of the battery.

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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 AWARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !
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Battery charger -VAS 5095 A-

Caution

Always set battery type 2.4 V/C (Volt/Cells) when in sup port mode! This applies for all batteries. The battery charger -VAS 5095 A- terminal clamps must remain in contact with the battery terminal clamps whilst the battery is being exchanged.

AG.

Special tools and workshop equipment required

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When in support mode the battery charger -VAS 5095 A- replaces a defective vehicle battery whilst it is being exchanged. The on board supply remains intact. The vehicles electrical equipment (e.g. electric windows) can be used.
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3. Charging battery

17

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Switch off the ignition and all electrical consumers. Set support mode/normal mode change-over switch to page 15 support mode. Connect red terminal clamp + of charger unit to positive ter minal of vehicle. Connect black terminal clamp - of charger unit to negative terminal of vehicle. Check setting for battery type on type of battery switch page 15 . Must be set to 2.4 V/C (Volt/Cells). Switch on battery charger page 15 . The yellow LEDs page 15 -6- and -3- light up. Note A minimum load of 0.6 A (e.g. parking light) must be
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Switch on vehicle parking light. Exchange battery page 31 . Switch off charging unit page 15 .

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During the support mode the current draw is limited to 5 A.

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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/ maintenance mode with battery charger -VAS 5095 AWARNING

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Danger of injury! Observe warning notices and safety regula tions page 2 !
In the buffer mode the battery charger -VAS 5095 A- is charged correctly and is maintained in a fully charged condition. Proceed as for charging battery page 16 . Note When a battery is being charged in the buffer mode and a
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consumer draws current from the battery, the battery charger -VAS 5095 A- automatically compensates the charge.

The buffer mode can be continued for an unlimited period. The battery is always ready for use. Observe battery manufacture's maintenance instructions!

18

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

3.2

Battery charger -VAS 5900WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !
This chapter describes the basic functions of the battery charger -VAS 5900- . For additional information refer to Operating in structions for battery charger -VAS 5900- . Note Observe

5900- .

Observe

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3.2.1

Description of battery charger -VAS 5900-

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Battery charger -VAS 5900- 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). Battery charger -VAS 59001 - Display 2 - Adjustment button Up 4 - START / STOP 5 - INFO

3 - Adjustment button Down

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WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !
Special tools and workshop equipment required

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3.2.2

Charging battery with battery charger VAS 5900-

3. Charging battery

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19

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Battery charger -VAS 5900-

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Note

The battery must have a temperature of at least 10 C. If the battery has cell sealing plugs, do not open them while Switch off the ignition and all electrical consumers.
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the battery is being charged.

Connect charger unit 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 clamp + to positive terminal on battery. Connect black terminal clamp - to negative terminal on bat tery. The charger unit recognises the voltage required for the connec ted battery (6 V, 12 V or 24 V) and initiates the charging sequence. At a charge condition of approx. 80 - 85 % the charger unit switches to the final charge mode. The fourth bar appears in display -1-. The battery is ready for use.

20

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 At a charge condition of 100 % all bars appear in display. Note In the battery type standard charge the parallel use of con The battery charger will switch to maintenance mode after

sumers while charging is possible. The charging period will be longer. about 1-7 hours, depending on type of battery. To achieve a 100 % charge the battery should remain connected for this period.

Possible faults and fault rectification: 1Displayed battery voltage is not as per nominal voltage: Press respective button Up or Down until charging sequence starts. 2Displayed battery voltage is not as per nominal voltage charging sequence already started: olkswagen AG en AG. V
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Press START / STOP twice. Press respective button Up or sequence starts again. 3-

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Display remains unchanged.

pe rm itte d

Battery charger does not detect a battery, when battery volt age is less than 2 V:

rrectness of i t to the co nform spec a t i h re o n in wit thi s

The battery type and ampere hours (Ah) as set is displayed. Ending battery charging sequence: Press START / STOP .

Disconnect black terminal clamp - of charger unit from neg ative terminal on battery. Disconnect red terminal clamp + of charger unit from nega tive terminal on battery. Pull charger unit plug out power supply socket.
r te o iva r rp fo g n

3.2.3

Charging battery in service mode with battery charger -VAS 5900ht rig py Co t.

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Caution

The operating mode service charge is not permitted on VW vehicles as the voltage peaks will damage the onboard elec tronics. If there is a requirement to use service charge the battery must be disconnected from the onboard supply.

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AG.

Prote cted by

Danger of injury! Observe warning notices and safety regula tions page 2 !

c o p yri gh t. C op yi

WARNING

3. Charging battery

21

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Caution

When charging always set the battery charger to the correct type of battery Operating instructions for battery charger VAS 5900- ! Service charge must only be used for: Wet batteries, where distilled water can be replenished. Gel/absorbent glass mat batteries. Do not use operating mode service charge with maintenancefree wet batteries page 1 .
The operating mode service charge (SERV) is only used on suspect defective batteries (e.g. sulphation). The battery will be charged 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-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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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 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 service charge for wet batteries or the symbol -2- for service charge for gel/absorbent glass mat batteries will appear.
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Set battery capacity (Ah) of battery for charging using respec tive button Up or Down . Connect black terminal clamp - to negative terminal on bat tery.

The charger unit recognises the voltage required for the connec ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

22

Rep. Gr.27 - Starter, current supply, CC

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Connect red terminal clamp + to positive terminal on battery.

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At a switches to the final charge mode. The fourth bar appears in display -1-. The battery is ready for use. Note

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a charge condition of approx. 80 85 % the charger unit c s s

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

The success of the service charge depends on the severity of the sulphation of the battery.
Possible faults and fault rectification: 1Displayed battery voltage is not as per nominal voltage: Press respective button Up or Down until charging sequence starts. 2Displayed battery voltage is not as per nominal voltage charging sequence already started:

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Press START / STOP twice. Press respective button Up or Down until charging sequence starts.
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The operating mode and ampere hours (Ah) as set is displayed. Ending battery charging sequence: Press START / STOP . Disconnect black terminal clamp - of charger unit from neg ative terminal on battery. Disconnect red terminal clamp + of charger unit from nega tive terminal on battery. Pull charger unit plug out power supply socket.
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3.2.4

Charging totally discharged battery with battery charger -VAS 5900WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !

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Display remains unchanged.

Prote cted by

c o p yri gh t. C op yi

3-

Battery charger does not detect a battery, when battery volt age is less than 2 V:

3. Charging battery

23

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Caution

The terminal polarity protection in operating mode charg ing totally discharged batteries/support mode is not ac tive. Connect battery charger terminal clamps correctly to battery terminals. When charging always set the battery 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- . Battery charger -VAS 5900-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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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 supply. The last selected operating mode will appear on display page 19 .

24

Rep. Gr.27 - Starter, current supply, CC

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Special tools and workshop equipment required

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Set battery to respective operating mode with INFO . In the display the symbol -1- for service charge for wet batteries or the symbol -2- for service 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 clamp + to positive terminal on battery. Connect black terminal clamp - to negative terminal on bat tery. Press START / STOP for approx. 5 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 polarity correct". Check polarity of charger unit cables. Confirm polarity of charger unit cables with START / STOP . Charger will start charging sequence for totally discharged bat tery.
. Volkswagen AG Ending battery charging sequence: gen AG d

o yV . Press START /d b STOP

e ris

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tho Disconnect black terminal clamp - of au s ative terminal on battery. s

oes not gu ara nte or charger unit from e neg ac

ility ab y li an pt ce

Disconnect red terminal clamp + of charger unit from nega tive terminal on battery. Pull charger unit plug out power supply socket.

rrectness of i t to the co nf o r m spec atio h re n in wit

3.2.5

Charging battery in support mode with battery charger -VAS 5900WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !

thi sd o cu m en

ht rig py Co t.

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3. Charging battery

25

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Caution

The terminal polarity protection in operating mode charg ing totally discharged batteries/support mode is not ac tive. Connect battery charger terminal clamps correctly to battery terminals. When charging in support mode always set the battery charger to the correct type of battery Operating instruc tions for battery charger -VAS 5900- ! Do not press START / STOP button when charger unit cables are connected incorrectly. The charger unit may be damaged.
When in support mode the battery charger -VAS 5900- replaces Volkswagen AG a defective vehicle battery whilst it is being The n AG.exchanged. does on wage s k not l o vehicles electrical equipment board supply remains intact. The V gu by ara d (e.g. electric windows) can be used. n ise
ut Special tools and workshop equipment required sa

r ho

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Battery charger -VAS 5900un le

tee or ac
ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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 seconds. The menu charging totally discharged batteries/support mode will be activated.
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Press respective button Up or Down to set the re spective onboard supply voltage (6 V, 12 V or 24 V). Note
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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 . Connect red terminal clamp + of charger unit to positive ter minal of vehicle. Connect black terminal clamp - of charger unit to negative terminal of vehicle. Then follows the enquiry for "is charger cable terminal polarity correct". Check polarity of charger unit cables. Confirm polarity of charger unit cables with START / STOP .

26

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 The battery charger starts with support mode. Exchange battery page 31 . Press START / STOP . The support mode is terminated. Disconnect black terminal clamp - of charger unit from neg ative terminal of vehicle. Disconnect red terminal clamp + of charger unit from positive terminal of vehicle. Pull charger unit plug out power supply socket.

3.2.6

Charging battery in maintenance mode with battery charger -VAS 5900WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !
AG. Volkswagen AG d agen oes ksw not l o gu yV b ar5900d When the battery is fully charged the battery charger -VAS an e is tee r o switches to maintenance mode. h t or u ac a s s Proceed as for charging battery page 19 .

ility ab y li an pt ce

At a charge condition of 100 % all bars appear in display. Note

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

When a battery is being charged in the buffer mode and a

consumer draws current from the battery, the battery charger -VAS 5900- automatically compensates the charge. riod.

The maintenance mode can be continued for an unlimited pe The battery is always ready for use. Observe battery manufacture's maintenance instructions!

3.3

Totally discharged batteries

WARNING
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Danger of injury! Observe warning notices and safety regula tions page 2 !
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AG.

A battery is designated totally discharged when the "no load" voltage is less than 12.2 V. Caution

Totally discharged batteries freeze prematurely. Frozen batteries should no longer be used.

3. Charging battery

27

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Note Batteries that have not been used for a long time e.g. vehicles

that have been stored, will self-discharge.

In totally discharged batteries, the electrolyte is comprised al

most entirely of water because the acid content is so low. surfaces of the battery harden.

Totally discharged batteries sulphate, that is, the entire plate If a battery is recharged shortly after it has totally lost its
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte If these batteries are not recharged the plates continue to is r o eo h harden and the ability to recharge is reduced. utA reduction in ra a c s the battery output is the result. s

charge, the sulphation will dissipate.

ility ab y li an pt ce

Check no load voltage of battery page 15 . Charge battery. Charging battery with battery charger -VAS 5095 A- page 15 . Charging battery with battery charger -VAS 5900- page 19 .

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

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28

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Disconnecting and reconnecting bat teries

WARNING

Danger of injury! Observe warning notices and safety regula tions page 2 !

4.1
Note

Disconnecting battery

By disconnecting the battery earth wire (open circuit), safety

is ensured when carrying out work on the electrical system. moval of the battery.

The battery positive wire need only be disconnected for re Switch off the ignition and all electrical consumers. Release catch -arrow- and take cover off battery box. First unscrew battery earth clamp -1- from battery negative terminal.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s Then unscrew battery positive clamp -2from battery s

terminal.

positive

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rrectness of i t to the co nform spec at i h re o n wit in t his

4.2

Connecting battery
Caution

Observe instructions on connecting battery terminals page 4 .

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ht rig py Co t.

Special tools and workshop equipment required

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AG.

c o p yri gh t. C op yi

4. Disconnecting and reconnecting batteries

29

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Torque wrench -V.A.G 1331-

Note

After connecting the battery and switching the ignition on the ESP and TCS warning lamp -K155- lights up permanently. The warn ing lamp goes out automatically if a distance of 15 to 20 km/h is driven straight ahead. This activates the steering angle sender G85- again.
Caution
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a the battery as described in the ss

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 procedures as detailed in the table. Steps after connecting battery Procedures Performed

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Disconnecting and connecting Workshop Manual page 29 .

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

30

Rep. Gr.27 - Starter, current supply, CC

AG.

If necessary, table can be printed out.

ht rig py Co t.

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Switch ignition on and off again using ignition key Read fault memory: Guided fault finding using VAS 5051A . Clock: Check time on clock and change as necessary. Electric windows: Open all electric windows fully and close again. Functional check: of all electri cal consumers.

thi sd o cu m en

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 1331AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

Removing: Disconnect the battery page 29 . Pull panel of battery box out upwards in direction of arrow.

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Unscrew securing bolt -1- and remove battery holder -2-.

AG.
Prote cted by

ht rig py Co t.

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c o p yri gh t. C op yi

5. Removing and installing battery

31

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Fold handles -arrows- upwards and take battery out. Installing: Caution

A loosely 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. V clamping bracket (possi olkswagen AG gen AG subsequent does bility of acid leaking,ktherefore higher costs). swa n
db Poor crash safety ise
es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ol yV

Installation is performed in the reverse order of installation; when doing this, note the following: Tighten threaded connections to specified torque settings page 36 . After installing, check that battery is seated securely. Connect the battery page 29 . Caution

r ho ut a ss

ot g ua ran tee or ac
ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

5.2

Models with a diesel engine

Special tools and workshop equipment required Torque wrench -V.A.G 1331ht rig py Co t.

thi sd o cu m en

32

Rep. Gr.27 - Starter, current supply, CC

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AG.

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 Spring-type

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Jetta 2005 AG. Volkswagen AG d agen oes Electrical System ksw not l o gu yV ara db e nte is or clip -VAS 5024Aeo hpliers ut ra a c s s
ility ab y li an pt ce

, Bora 2006 - Edition 05.2005

rrectness of i t to the co nf o r m spec atio h re n in wit

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-.

thi sd o cu m en

Disconnect connector -1- and loosen spring type clip -2- with spring type clip pliers -VAS 5024A- .

Pull the vacuum hose -arrow- off air filter housing.

ht rig py Co t.

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5. Removing and installing battery

33

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Pull panel of battery box out upwards in direction of arrow.

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34

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

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AG.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing bolt -1- and remove battery holder -2-.

Fold handles -arrows- upwards and take battery out. Installing: Caution

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

A loosely 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

thi sd o cu m en

After installing, check that battery is seated securely. Connect the battery page 29 . Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

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Tighten threaded connections to specified torque settings page 36 .

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5. Removing and installing battery

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Installation is performed in the reverse order of installation; when doing this, note the following:
c o p yri gh t. C op yi

35

AG. Volkswagen AG d Jetta 2005 , Bora 2006 agen oes ksw not l o V Electrical System - Edition 05.2005 gu by

Threaded connections
es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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ss Torque settings: battery

ed ris o h t au

ara nte e

or ac
ility ab y li an pt ce

Torque settings 6 Nm 6 Nm 20 Nm 10 Nm

Battery clamp to battery terminal M6 Additional clamp to battery terminal M6 clamp Securing bolt of battery holder M8x35 Air filter housing to body

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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36

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 the following menu items one after the other: Body Electrical System 27 - Starter, current supply Electrical components B - Starter
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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7. Starter

37

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

7.2

Removing and installing starter, auto matic gearbox Vehicles with 1.6 l injection engine

7.2.1

Special tools and workshop equipment required Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Spring-type clip pliers -VAS 5024-

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Removing:

Disconnect the battery page 29 . 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.

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AG.

38

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull air filter housing on right side upwards off rubber mounting -arrow-. Remove air filter housing from vehicle.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte Push down protective cap in -direction of arrowfrom solenoid is r o eo h switch. ut ra a c s s

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rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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 .

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Unscrew securing nut -1- from lower starter securing bolt. Remove wiring retainer -2-.
AG.

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7. Starter

39

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove lower securing bolt

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is -arrow-. r of starter o eo h ut ra a c s s

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rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew securing nut -1- from upper starter securing bolt. Remove wiring retainer -2-.

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Unscrew earth wire securing nut -1- and place earth wire -2to 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 .

7.2.2

Vehicles with 1.6 l FSI engine

Special tools and workshop equipment required

40

Rep. Gr.27 - Starter, current supply, CC

AG.

Remove upper securing bolt of starter -arrow-.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Removing:

Disconnect the battery page 29 . Push down protective cap in -direction of arrow- from solenoid switch.

do c um en

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 .

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

7. Starter

41

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

Remove lower securing bolt of starter -arrow-.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

Unscrew securing nut -1- from upper starter securing bolt. Remove wiring retainer -2-.

thi sd o cu m en

Remove upper securing bolt of starter -arrow-.

ht rig py Co t.
Prote cted by c o p yri gh t. C op yi

42

Rep. Gr.27 - Starter, current supply, CC

agen lksw Vo by

AG.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew earth wire securing nut -1- and place earth wire -2to one side. Remove starter from vehicle upwards. Installing:
AG. Volkswagen AG d agen oes ksw not l o V Installation is carried out in the reverse order. When installing, gu y b ara d note the following: nte ise r o eo h t u ra a torque settings Tighten threaded connections to specified c s s
urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le

page 97 .

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

7.2.3

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-

r fo ng

Removing: Disconnect the battery page 29 .

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

7. Starter

43

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Disconnect connector -arrow-.

Unclip vacuum hose from its mounting -arrow-.

Pull hose -1- off air filter housing.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024- .

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Open retainer -arrow- on front side of air filter housing and take hose -1- off.

r fo ng

44

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 5024- .

pe rm itte d

Pull hose -2- off pipe union.

es, in part or in w l purpos hole ercia , is n m ot com

Carefully lift air filter housing upwards out of the vehicle taking into consideration the length of the hose.

un le

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r type clip pliers -VAS o h t or u ac a ss

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Separate connector -arrow- on rear of air filter housing.

r te o iva r rp fo g n

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

45

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

AG. Volkswagen AG d agen oes ksw not l o V gu y b Remove noise insulation General Body Repairs, Exterior; ara d nte ise r Rep. Gr. 50 ; Body front; Noise insulation . o eo h t u ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Unscrew securing nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

r te o iva r rp fo g n

do c um en

Remove lower securing bolt of starter -arrow-.

46

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing nut -1- from upper starter securing bolt. Remove wiring retainer -2-.

Remove upper securing bolt of starter -arrow-.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

Unscrew earth wire securing nut -1- and place earth wire -2to 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 .

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

47

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 5024AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

Removing: Disconnect the battery page 29 . Pull engine cover off upwards -arrows-.

48

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Unscrew nut -1- from lower starter securing bolt. Remove wiring retainer -2-.
r fo ng
ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

49

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove lower securing bolt of starter -arrow-.
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

Unscrew nut -1- from upper starter securing bolt. Remove wiring retainer -2-.

thi sd o cu m en

Remove starter from vehicle downwards.

agen lksw Vo by

Installing:

Installation is carried out in the reverse order. When installing, note the following: Tighten threaded connections to specified torque settings page 97 .
AG.

50

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

Remove upper securing bolt of starter -arrow-.

Prote cted by c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 5024AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

do c um en

Removing: Disconnect the battery page 29 . Pull engine cover upwards -arrows A- and forwards -arrow B-.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

51

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

Unscrew air filter housing securing bolt -arrow-.

Unlock lugs -arrows- and take cover off.

thi sd o cu m en

52

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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; Noise insulation .

Unscrew nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

53

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew earth wire securing nut -1- and place earth wire end -2- in direction of battery to side. Remove starter from vehicle upwards. Installation is carried out in the reverse order. When installing, note the following:
AG.
ht rig py Co t.

do c um en

Tighten threaded connections to specified torque settings page 97 .

54

Rep. Gr.27 - Starter, current supply, CC

agen lksw Vo by

Prote cted by

c o p yri gh t. C op yi

Installing:

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

7.2.6

Vehicles with 2.0 l SDI engine

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Special tools and workshop equipment required Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Spring-type clip pliers -VAS 5024-

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

Removing: Disconnect the battery page 29 . Pull engine cover upwards -arrows A- and forwards -arrow B-.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

55

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

Remove air filter housing from vehicle.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut right side upwards off rubber mounting ra Pull air filter housing on a c s s -arrow-.

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Push down protective cap in -direction of arrow- from solenoid switch.

do c um en

56

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 .

Remove wiring retainer -2-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Unscrew securing nut -1- from lower starter securing bolt.

un le

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

7. Starter

57

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 Vehicles with 1.6 l injection engine
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

7.3.1

Special tools and workshop equipment required Torque wrench -V.A.G 1331urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Torque wrench -V.A.G 1332 Spring-type clip pliers -VAS 5024-

ility ab y li an pt ce

un le

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

Removing: Disconnect the battery page 29 .

58

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 solenoid switch.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

Unscrew positive wire -1- and disconnect connector from ter minal 50 -2-.

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

59

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

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 .

thi sd o cu m en

60

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Special tools and workshop equipment required Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

7.3.2

Vehicles with 2,0 l FSI engine

AG. Volkswagen AG d agen oes ksw not l o V gu , Bora 2006 Jetta 2005 by ara d e is tee r Electrical System - nEdition 05.2005 o h or ut ac a s s
ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Spring-type clip pliers -VAS 5024-

do c um en

Removing: Disconnect the battery page 29 . Disconnect connector -arrow-.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

7. Starter

61

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

un le

Unclip vacuum hose from its mounting -arrow-.

pe rm itte d

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024- . Pull hose -1- off air filter housing.
r te o iva r rp fo g n

do c um en

Open retainer -arrow- on front side of air filter housing and take hose -1- off.

Unscrew air filter housing securing bolt -arrow-.

62

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o gu Pull air filter housing on right side upwards y V off rubber mounting b ara d e nte -arrow-. is r o eo h ut ra a c s s

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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.

r fo ng

Separate connector -arrow- on rear of air filter housing.

AG.

Remove air filter housing from vehicle. Push down protective cap in -direction of arrow- from solenoid switch.

ht rig py Co t.

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

7. Starter

63

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 .

Remove connectors -arrows-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

64

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

Remove lower securing bolt of starter -arrow-. Remove starter from vehicle Installing:

Tighten threaded connections to specified torque settings page 97 .

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Installation is carried out in the reverse order. When installing, note the following:
un le

n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b downwards. ed ran s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

65

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

7.3.3

Vehicles with 2.0 l FSI turbo engine

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

Special tools and workshop equipment required Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332-

rrectness of i t to the co nf o r m spec atio h re n in wit

Spring-type clip pliers -VAS 5024-

thi sd o cu m en

Removing: Disconnect the battery page 29 . Unbolt securing bolts -arrow-.

66

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Disconnect connector -arrow-.
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Loosen spring-type clips -1- using spring type clip pliers -VAS 5024- .

r te o iva r rp fo g n

do c um en

Pull engine cover off upwards -arrows-.

Push down protective cap in -direction of arrow- from solenoid switch.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

7. Starter

67

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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:

Tighten threaded connections to specified torque settings page 97 .

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Installation is carried out in the reverse order. When installing, note the following:

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

68

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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-

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

Removing: Disconnect the battery page 29 . Pull engine cover upwards -arrows A- and forwards -arrow B-.

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

69

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h housing securing bolt -arrow-. ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Unlock lugs -arrows- and take cover off.

r fo ng

70

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

n AG d AG Pull hose -arrow- off air filter housing and take hose out. agen oes ksw n
. Volkswage

Pull air filter housing

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

Vol by of d upwards out e s ri ho ut a ss

brackets and remove.

ot g ua ran tee or ac
ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Push down protective cap -direction of arrow- from solenoid switch.

r fo ng

Remove upper securing bolt of starter -arrow-.

agen lksw Vo by

Unscrew positive wire -1- and disconnect connector from ter minal 50 -2-.
AG.
Prote cted by

ht rig py Co t.

c o p yri gh t. C op yi

7. Starter

71

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 wrench -V.A.G 1332 Spring-type clip pliers -VAS 5024-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

do c um en

Removing: Disconnect the battery page 29 .

72

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Unscrew air filter housing securing bolt -arrow-.

ht rig py Co t.

Unlock lugs -arrows- and take cover off.

agen lksw Vo by
c o p yri gh t . C op yi

r fo ng

AG.

Prote cted by

7. Starter

73

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 . Volkswagen AG minal 50 -2-. gen AG does swa
k Vol by d e ris tho u a ss

not gu ara nte eo ra c

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

Unclip hose -1- from hose retainer -2-.

do c um en

74

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 torque settings page 97 .

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

r te o iva r rp fo g n

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

75

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

7.4

Removing and installing starter, manual gearbox Vehicles with 1.6 l engine

7.4.1

Special tools and workshop equipment required Torque wrench -V.A.G 1331 Torque wrench -V.A.G 1332 Spring-type clip pliers -VAS 5024-

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

76

Rep. Gr.27 - Starter, current supply, CC

AG.

Push down protective cap -direction of arrow- from solenoid switch.

Prote cted by

agen lksw Vo by

Disconnect the battery page 29 .

ht rig py Co t.

c o p yri gh t. C op yi

Removing:

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew positive wire -1- and disconnect connector from ter minal 50 -2-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

Unscrew earth wire from starter securing bolt

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s -arrow-. s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Unscrew starter securing bolt -arrow-.

Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .

r fo ng

Unscrew nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

7. Starter

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

77

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew starter securing bolt -arrow-. Remove starter. Installing:
agen AG . Volksw Installation is carried out in the reversew order. When installing, gen AG does s a k not l o note the following: gu yV

ris Tighten threaded connections to specified torque settings ho ut a page 97 . s

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le
s

b ed

ara nte e

or ac
ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

7.4.2

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-

r fo ng

78

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Disconnect the battery page 29 . Disconnect connector -arrow-.

Unclip vacuum hose from its mounting -arrow-.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

AG. Volkswagen AG d agen oes ksw not l o V by from hose -1- using spring typeguar Loosen spring-type clip -arrowd an e tee clip pliers -VAS 5024- h.oris t or u ac a ssfilter housing. Pull hose -1- off air

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

Open retainer -arrow- on front side of air filter housing and take hose -1- off.

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

7. Starter

79

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew air filter housing securing bolt -arrow-.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Pull air filter housing on right side upwards off rubber mounting -arrow-. Loosen spring-type clip -1- using spring type clip pliers -VAS 5024- .

r te o iva r rp fo g n

do c um en

Separate connector -arrow- on rear of air filter housing.

80

Rep. Gr.27 - Starter, current supply, CC

agen lksw Vo by

Carefully lift air filter housing upwards out of the vehicle taking into consideration the length of the hose.

ht rig py Co t.

Pull hose -2- off pipe union.

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Unscrew earth wire from starter securing bolt -arrow-.

r fo ng

Unscrew starter securing bolt -arrow-. Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

81

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 specified torque settings page 97 .
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

do c um en

82

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Removing:

Disconnect the battery page 29 . Unbolt securing bolts -arrow-.

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

83

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Disconnect connector -arrow-.

Loosen spring-type clips -1- using spring type clip pliers -VAS 5024 A- .

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Pull engine cover off upwards -arrows-.

r fo ng

Push down protective cap in -direction of arrow- from solenoid switch.

84

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew positive wire -1- and disconnect connector from ter AG. Volkswagen AG d agen oes minal 50 -2-. n lksw
o yV db e ris tho au

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ss

ot g ua ran tee or ac
ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew earth wire from starter securing bolt -arrow-.

do c um en

Unscrew starter securing bolt -arrow-.

Unscrew securing nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

agen lksw Vo by

AG.

Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .

ht rig py Co t.

Prote cted by c o p yri gh t. C op yi

7. Starter

85

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 wrench -V.A.G 1332
AG. Volkswagen AG d agen oes ksw not l o V gu y Spring-type clip pliers -VAS b ara d nte ise 5024r o eo h t u ra a c s s
es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

Removing: Disconnect the battery page 29 .

86

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

agen Push down protective cap -direction of arrowksw from solenoid Vol y switch. db
ss
e ris ho t au

AG. Volkswagen AG d oes not gu ara nte eo ra c

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

Unscrew positive wire -1- and disconnect connector from ter minal 50 -2-.

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

7. Starter

87

Jetta 2005 , Bora 2006 AG. Volkswagen AG d agen05.2005 oes Electrical System V -o Edition not lksw Unscrew
by ed ris from o earth wire th au ss

starter securing bolt -arrow-.

gu ara nte eo ra c
ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Unscrew starter securing bolt -arrow-. Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .

r te o iva r rp fo g n

do c um en

Unscrew nut -1- from lower starter securing bolt. Remove wiring retainer -2-.
AG.

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 .

88

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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-

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Removing:

Disconnect the battery page 29 . Pull engine cover upwards -arrows A- and forwards -arrow B-.
r te o iva r rp fo g n

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

89

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew air filter housing securing bolt -arrow-.

Unlock lugs -arrows- and take cover off.

do c um en

90

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull hose -arrow- off air filter housing and take hose out. Pull air filter housing upwards out of brackets and remove.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a Push down protective cap -direction of arrowfrom solenoid c s s

switch.

Unscrew positive wire -1- and disconnect connector from ter minal 50 -2-.

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

Unscrew earth wire from starter securing bolt -arrow-.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

91

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew starter securing bolt -arrow-. Remove starter. Installing:

do c um en

92

Rep. Gr.27 - Starter, current supply, CC

agen lksw Vo by

AG.

Prote cted by

Tighten threaded connections to specified torque settings page 97 .

ht rig py Co t.

c o p yri gh t. C op yi

Installation is carried out in the reverse order. When installing, note the following:

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 5024AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

Removing: Disconnect the battery page 29 . Pull engine cover upwards -arrows A- and forwards -arrow B-.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

7. Starter

93

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

Push down protective cap -direction of arrow- from solenoid switch.

do c um en

94

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew positive wire -1- and disconnect connector from ter minal 50 -2-.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

Unscrew earth wire from starter

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a s s securing bolt -arrow-.

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Unscrew starter securing bolt -arrow-. Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .

r fo ng

Unscrew nut -1- from lower starter securing bolt. Remove wiring retainer -2-.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

7. Starter

95

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 .

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

96

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Torque settings: starter

Torque settings M12 M10 M8 M8 M8 M8 75 Nm 60 Nm 15 Nm 15 Nm 15 Nm 10 Nm 15 Nm

Threaded connections Starters on automatic, manual gearboxes Starter on automated shift gearboxes Earthing wire to starter securing bolt Wiring retainer on starter securing bolt Positive wire to starter solenoid switch Air filter housing to body Earthing wire to automatic gearbox

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

8. Torque settings: starter

97

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Alternator
Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

9.1

Fastening B+ wire to alternator

Caution

If the B+ wire is not secured with the prescribed torque the following may occur: Battery not charge fully. Vehicle electrics/electronics fail completely (breakdown). Danger of fires from sparks. Damage to electronic components and control to excessive voltage.
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra units due a c s s

ility ab y li an pt ce

The tightening torque for the securing nut of the B+ wire -arrow- an be found in the following table Tightening torques page 145 .

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

9.2

Checking ribbed belt (poly V-belt)

Crank engine at vibration damper/belt pulley using a socket. Fit ribbed belt (poly V-belt).
ht rig py Co t.

do c um en

Fraying of cord strands Flank wear (material wear, frayed flanks, flank brittleness (glassy flanks), surface cracks) Traces of oil and grease Caution

It is essential to renew poly V-belt if faults are found. This will avoid possible break-downs or operating problems.

98

Rep. Gr.27 - Starter, current supply, CC

AG.

chassis breakout

agen lksw Vo by

Layer separation (top layer, draw strands)

Prote cted by c o p yri gh t. C op yi

Sub-surface cracks (cracks, core ruptures, cross sectional breaks)

9.3

Check alternator -C-

Select guided 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 Electrical components C - Alternator

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Connect Vehicle Diagnosis, Testing -VAS 5051A- page 281 .

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27 - Starter, current supply

9.4 9.4.1

Alternator, 1.6 l injection engine Assembly overview

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3 - Bracket 4 - Hexagon head collared nut M8 5 - Hexagon head collared bolts M8x45 52 Nm 6 - Protective cap 7 - Hexagon head collared nut M8 8 - Cross-head screw M5x21 4.5 Nm 9 - Hexagon nut, flat M8 10 - Plain washer M5 11 - Phillips screws M4x19 2 Nm 12 - Cross-head screw M4x13

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2 - Hexagon head collared bolts M8x50 23 Nm

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1 - Hexagon head collared bolt M8x108 23 Nm

9. Alternator

99

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 2 Nm 13 - Voltage regulator AG. Volkswagen AG d Removing and installing voltage regulator page 142 oes n agen ksw
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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

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15 - Poly V-belt Checking page 98 .

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9.4.2

Removing and installing alternator, 1.6 l injection engine

Caution

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Torque wrench -V.A.G 1331-

Locking pin -T10060 A-

Removing: Disconnect the battery page 29 .

100

Rep. Gr.27 - Starter, current supply, CC

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Disconnecting and connecting the battery as described in the Workshop Manual page 29 .
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull engine 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.

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Release poly V-belt by 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.

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101

 Unclip coolant hose from hose retainer -1- and remove secur ing nut -2-.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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Unbolt securing bolts -arrow-.

Take hose retainer together with tensioning element out of the vehicle.

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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 compressor) are secured tightly. Ensure ribbed belt (poly V-belt) is seated correctly in belt pulley when installing.

102

Rep. Gr.27 - Starter, current supply, CC

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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 .

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Connect the battery page 29 . Switch off the engine.

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Start the engine and check belt running.

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Models with air conditioning system: 12345Tensioning roller Ribbed belt pulley - Alternator Ribbed belt pulley - Air conditioner compressor Poly V-belt Ribbed belt pulley - Crankshaft

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Ribbed belt routing, 1.6 l injection en gine

9. Alternator

103

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.5 9.5.1

Alternator, 1.6 l FSI engine Assembly overview

1 - Hexagon bolt 40 Nm 2 - Washer 3 - 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
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16 - Hexagon head collared bolts M8x90 23 Nm 17 - Hexagon head collared bolts M8x50 25 Nm 18 - Tensioning element 19 - Bracket For tensioning element and air conditioner compressor 20 - Hexagon head collared bolt M10x50

104

Rep. Gr.27 - Starter, current supply, CC

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15 - Poly V-belt Checking ribbed belt (poly V-belt) page 98

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14 - Alternator Removing and installing alternator page 105

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 AAG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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Removing:

Disconnect the battery page 29 .

Remove upper securing bolt of alternator -arrow-. Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Noise insulation .

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9. Alternator

105

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove wiring bracket -1- and pull protective cap -2- off. AG. Volkswagen
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Disconnect connector of DF wiring -1- and pull B+ wiring -2off alternator. Caution

r te o iva r rp fo g n

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-belt by 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.
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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 compressor

Remove lower securing bolt of alternator -arrow-. Remove alternator from vehicle downwards. 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 poly V-belt, that all ancillaries (alternator, air conditioner compressor, power assisted steering vane pump) are secured tightly. Ensure ribbed belt (poly V-belt) is seated correctly in belt pulley when installing.

106

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-.

Position wiring bracket -arrow- on rear of generator at 9 olkswagen AG o'clock. en AG. V

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9.5.3
12345-

Ribbed belt routing, 1.6 l FSI engine

Models without air conditioning system: Ribbed belt (poly V-belt) pulley Coolant pump Tensioning roller Ribbed belt (poly V-belt) pulley Alternator Poly V-belt
r te o iva r rp fo g n

Ribbed belt (poly V-belt) pulley - Crankshaft

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234567-

Idler roller Ribbed belt (poly V-belt) pulley Alternator Tensioning roller Ribbed belt (poly V-belt) pulley Air conditioner compressor Poly V-belt Ribbed belt (poly V-belt) pulley - Crankshaft

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Ribbed belt (poly V-belt) pulley Coolant pump

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Models with air conditioning system:

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9. Alternator

107

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.6 9.6.1

Alternator, 2.0 l FSI engine Assembly overview

1 - Hexagon head collared 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 screws M4x19 2 Nm 13 - Cross-head screw M4x13 2 Nm
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14 - Voltage regulator Removing and installing voltage regulator page 142 15 - Alternator Removing and installing alternator page 109 16 - Poly V-belt Checking page 98 .

108

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 -VAS 5024 A-

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Removing: Disconnect the battery page 29 .

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9. Alternator

109

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull engine cover off upwards -arrows-.

Disconnect connector -arrow-.

Unclip vacuum hose from its mounting -arrow-.

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Pull hose -1- off air filter housing.

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Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024 A- .

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110

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Open retainer -arrow- on front side of air filter housing and take hose -1- off.

Unscrew air filter housing securing bolt

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Pull air filter housing on right side upwards off rubber mounting -arrow-.

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Loosen spring-type clip -1- using spring type clip pliers -VAS 5024 A- . Pull hose -2- off pipe union.

Carefully lift air filter housing upwards out of the vehicle taking into consideration the length of the hose.

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9. Alternator

111

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Separate connector -arrow- on 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.

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Unscrew B+ wiring -arrow- off alternator. Caution

pe rm itte d

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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-belt by turning the tensioning device with an open-ended spanner AF 16 in -direction of arrow-.
r te o iva r rp fo g n

do c um en

112

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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: Installation is carried out in the reverse order. When installing, note the following:

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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9. Alternator

113

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-.

Position wiring bracket -arrow- on rear of generator at 12 o'clock. Tighten threaded connections to specified torque settings page 145 . Caution

When reinstalling used ribbed belts (poly V-belts) observe n AG. Volkswagen AG do the direction of rotation marked on removal! e wage
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Ensure ribbed belt (poly V-belt) is seatedsscorrectly in belt pulley when installing.
Tighten threaded connections to specified torque settings page 145 . Caution

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Observe instructions on connecting battery terminals page 4 .

Connect the battery page 29 . Switch off the engine.

Start the engine and check belt running.

9.6.3
1234-

Ribbed belt routing, 2,0 l FSI engine

ht rig py Co t.

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Models without air conditioning system: Tensioning roller Poly V-belt Ribbed belt pulley - Crankshaft Ribbed belt pulley - Alternator

114

Rep. Gr.27 - Starter, current supply, CC

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Models with air conditioning 12345Tensioning roller

Ribbed belt pulley - Air conditioner compressor

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Poly V-belt

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Ribbed belt pulley - Alternator

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Ribbed belt pulley - Crankshaft

9.7 9.7.1

Alternator, 2.0 l FSI turbo engine Assembly overview

r te o iva r rp fo g n

3 - Compact bracket For alternator and air conditioner compressor Tightening sequence page 146 4 - Hexagon head collared bolts M10x45 45 Nm 5 - Protective cap 6 - Hexagon head collared nut M8 7 - Cross-head screw M5x21 4.5 Nm 8 - Hexagon nut, flat M8 9 - Plain washer M5 10 - Phillips screws M4x19 2 Nm 11 - Cross-head screw M4x13 2 Nm

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2 - Hexagon head collared bolts M8x90 23 Nm

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1 - Hexagon head collared bolts M8x45 23 Nm

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9. Alternator

115

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 equipment required Torque wrench -V.A.G 1331 Locking pin -T10060- or locking pin -T10060 A Spring-type clip pliers -VAS 5024 AAG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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116

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Disconnect the battery page 29 . Unbolt securing bolts -arrow-.

Disconnect connector -arrow-.

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Loosen spring-type clips -1- using spring type clip pliers -VAS 5024 A- .
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Pull engine cover off upwards -arrows-.

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9. Alternator

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117

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 quick release coupling -arrow-.

Loosen spring-type clip -arrow- using spring type clip pliers VAS 5024 A- .
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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rrectness of i t to the co nform spec at i h re o n wit in t his

Unbolt securing bolts -arrow-. Take hose out of the vehicle. Remove connecting pipe between charge air cooler and tur bocharger. 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!

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Mark direction of rotation of poly V-belt.

ht rig py Co t.

118

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Release poly V-belt by turning the tensioning element with an open jaw spanner AF 16 in -direction of arrow- and lock ten n AG. Volkswagen A G do es n wage sioning element with retaining pin -T10060 A- . o olks Remove ribbed belt.
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rrectness of i t to the co nf o r m spec atio h re n in wit

Loosen threaded connections of coolant pipe -arrows-. Note

The coolant pipe can remain installed. To take out the alternator it must be loosened.

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Disconnect connector of DF wiring -1- and pull protective cap -2- off.

9. Alternator

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Remove alternator securing bolts -arrows-.

119

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew B+ wiring -arrow- off alternator.

Unscrew wiring bracket -arrow- from Take alternator out of the vehicle. Installing:

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pe rm itte d

Installation is carried out in the reverse order. When installing, note the following: Caution

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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.
Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-.
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Position wiring bracket -arrow- on rear of generator at 9 o'clock.

120

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 to specified page 145 . Caution

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Observe instructions on connecting battery terminals page 4 .

Connect the battery page 29 . Switch off the engine.

Start the engine and check belt running.

9.7.3
1234-

Ribbed belt routing, 2.0 l turbo engine

Models without air conditioning system: Tensioning roller Ribbed belt pulley - Alternator Poly V-belt

do c um en

Ribbed belt pulley - Crankshaft

Models with air conditioning system: 12345Tensioning roller Ribbed belt pulley - Alternator Ribbed belt pulley - Air conditioner compressor Poly V-belt Ribbed belt pulley - Crankshaft

9. Alternator

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121

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.8 9.8.1

Alternator 2.5 l injection engine Assembly overview

1 - Compact bracket For alternator and air n AG. Volkswagen AG do conditioner compressor e wage
by 2 - Multi-point socket ed head bolt ris M8x60 o th au 25 Nm ss

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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 . 11 - Hexagon head collared bolts M8x90 25 Nm Qty. 2

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

9.8.2

Removing and installing alternator, 2.5l engine

Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .
Removing: Special tools and workshop equipment required

122

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Torque wrench -V.A.G 1331-

Locking pin -T10060 A-

Disconnect the battery page 29 .

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le

Take the engine cover off upwards and forwards.

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ility ab y li an pt ce

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

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Disconnect connector of DF wiring -1- and pull protective cap -2- off.

r fo ng

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9. Alternator

123

 Unscrew B+ wiring -arrow- off alternator. Caution

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ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

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!
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-.

thi sd o cu m en

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-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.
Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in direction of arrow.

124

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

lksw AG. Voat Position wiring bracket -arrow- on rear of w generator 9agen AG doe agen s no s k l o o'clock. t gu V y

risspecified torque settings Tighten threaded connections hto t o u page 145 . sa

b ed

ara nte e

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.

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or ac
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9.8.3
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Ribbed belt routing, 2.5l engine

Models with air conditioning system: Upper idler roller Lower idler roller Belt pulley - Alternator

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Belt pulley - Air conditioner compressor

AG.

Belt pulley - Crankshaft

Tensioning roller for air conditioner compressor poly V-belt Tensioning roller for alternator poly V-belt and coolant pump

10 - Belt pulley - Coolant pump

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Poly V-belt for air conditioner compressor

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Poly V-belt for alternator and coolant pump

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9. Alternator

125

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.9 9.9.1

Alternator, 1.9 l TDI engine Assembly overview

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

1 - Hexagon head collared 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 M4x20 2 Nm

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rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

10 - Protective cap for carbon brushes 11 - Voltage regulator Removing and installing voltage regulator page 142 12 - Alternator Removing and installing alternator page 127 13 - Poly V-belt Checking page 98 .

126

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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 An AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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rrectness of i t to the co nform spec at i h re o n wit in t his

Disconnect the battery page 29 .

Pull engine cover upwards -arrows A- and forwards -arrow B-.

do c um en

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9. Alternator

127

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 securing bolt -3-.

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Unbolt securing bolt -arrow-.

Remove noise insulation General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .
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128

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew charge air pipe securing bolt -arrow-.

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Disconnect connector of charge air pipe -arrow-. Take charge air pipe out upwards.

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Disconnect connector of DF wiring -1- and pull protective cap -2- off.
ht rig py Co t.

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 to belt damage!
Mark direction of rotation of poly V-belt.

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Prote cted by

c o p yri gh t. C op yi

9. Alternator

129

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Release poly V-belt by 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.
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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Remove alternator securing bolts -arrows-.

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Unscrew wiring bracket from alternator -arrow-. Installing:

ht rig py Co t.

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.

130

Rep. Gr.27 - Starter, current supply, CC

AG.

Installation is carried out in the reverse order. When installing, note the following:
Prote cted by

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Remove alternator.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Drive threaded sleeves -A- out of the alternator 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:
nA wage

Fit hose/tube without assistance of tools. G. Volkswage

olks -arrow-. Check for secure fit of the lugs yV

Observe instructions on connecting battery terminals page 4 .

Connect the battery page 29 . Start the engine and check belt running. Switch off the engine.

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b ed ris o th Tighten threadedau connections page 145 . ss

to specified

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Caution

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9. Alternator

131

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.9.3
1234-

Ribbed belt routing, 1.9 l TDI engine

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
un le

Models without air conditioning system: Tensioning roller Poly V-belt Ribbed belt pulley - Alternator

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Ribbed belt pulley - Crankshaft

Models with air conditioning system: 12345Tensioning roller Ribbed belt pulley - Alternator Poly V-belt

Ribbed belt pulley - Air conditioner compressor Ribbed belt pulley - Crankshaft
r fo ng

132

Rep. Gr.27 - Starter, current supply, CC

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.10 9.10.1

Alternator, 2,0 l TDI engine Assembly overview

1 - Hexagon head collared 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

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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10 - Alternator Removing and installing alternator page 133

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do c um en

11 - Poly V-belt Checking page 98 .

9.10.2

Removing and installing alternator, 2,0 l TDI engine

Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

agen lksw Vo by

AG.

9. Alternator

133

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Special tools and workshop equipment required Torque wrench -V.A.G 1331-

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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Locking pin -T10060 A-

rrectness of i t to the co nform spec at i h re o n wit in t his

Disconnect the battery page 29 . Pull engine cover off upwards -arrows-.
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Pull vacuum hoses off -arrow-.

134

Rep. Gr.27 - Starter, current supply, CC

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AG.

 Unbolt securing bolts -arrow-.

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AG agen ksw l o yV db ise r tho au s s

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 . Volkswage

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Disconnect connector of DF wiring -1- and pull protective cap -2- off.

do c um en

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 to belt damage!
Mark direction of rotation of poly V-belt. Release poly V-belt by turning the tensioning device with an open-ended spanner AF 16 in -direction of arrow-.

AG.

Prote cted by

Unscrew B+ wiring -arrow- off alternator.

ht rig py Co t.

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c o p yri gh t. C op yi

9. Alternator

135

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Lock tensioning element with retaining pin -T10060 A- . Remove ribbed belt.

Remove alternator securing bolts -arrows-.

wagen AG . Volks n AG Unscrew wiring bracket s-arrowfrom alternator. does wage

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Installing:

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Installation is carried out in the reverse order. When installing, note the following: Caution

ri tho u a ss

not gu ara nte eo ra c

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rrectness of i t to the co nform spec at i h re o n wit in t his

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.

Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-.

do c um en

136

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

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Prote cted by

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Position wiring bracket -arrow- on rear of generator at 9 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.

9.10.3
1234-

Ribbed belt routing, 2,0 l TDI engine

Models without air conditioning system: Tensioning roller Ribbed belt pulley - Alternator Poly V-belt Ribbed belt pulley n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or Crankshaft u ac a ss

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rrectness of i t to the co nform spec at i h re o n wit in t his

Models with air conditioning system: 12345Tensioning roller Ribbed belt pulley - Alternator Ribbed belt pulley - Air conditioner compressor Poly V-belt Ribbed belt pulley - Crankshaft

do c um en

9.11

Special tools and workshop equipment required

AG.

Prote cted by

9.11.1

Removing and installing a ribbed belt (poly V-belt) pulley with no freewheel

ht rig py Co t.

Removing and installing ribbed belt (poly V-belt) pulley on alternator

agen lksw Vo by
c o p yri gh t . C op yi

9. Alternator

137

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Socket -VAS 3310-

Torque wrench -V.A.G 1332-

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 .

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Removing:

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9.11.2

Special tools and workshop equipment required

138

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

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Removing and installing a ribbed belt (poly V-belt) pulley with freewheel, man ufacturer: Bosch

do c um en

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t left-hand thread, i.e. turn The thread on the alternator shaft is a u ra a c to right when loosening and to leftss when tightening the threaded

Note

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Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley with a freewheel of the alternator with a ring spanner AF 17.

pe rm itte d

joint.

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r te o iva r rp fo g n

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ht rig py Co t.

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9. Alternator

139

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Insert a socket M10 -1- in the alternator shaft. Loosen threaded joint by turning to right and counter-hold with ring spanner. Hold the ribbed belt (poly V-belt) pulley with a freewheel with the hand and turn the drive shaft of the alternator until the rib bed belt (poly V-belt) pulley with a freewheel can be 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-.

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara Turn the torque wrench grip -2- through 180 degrees and re d e nte s i r insert socket drive. o eo h ut ra a c s s of rotation on socket to left. Set torque wrench direction

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rrectness of i t to the co nf o r m spec atio h re n in wit

Insert a socket M10 -1- in the alternator shaft. Counter-hold adapter -VAS 3400- with ring spanner, AF 17. Tighten the ribbed belt (poly V-belt) pulley with a freewheel by turning the alternator drive shaft to left using torque wrench V.A.G 1332- . Tighten threaded connections to specified torque settings page 145 .

thi sd o cu m en

140

Rep. Gr.27 - Starter, current supply, CC

ht rig py Co t.

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AG.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.11.3

Removing and installing a ribbed belt (poly V-belt) pulley with freewheel, manufacturer: Valeo

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

TORX key -V.A.G 1603/1-

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n AG. Volkswagen AG do es n wage s k l ot g o Special tools and workshop yV ua b ran equipment is required ed tee r o h t or u Adapter -VAS 3400ac a ss

Torque wrench -V.A.G 1332-

ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

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 -VAS 3400- in the ribbed belt (poly V-belt) pulley with a freewheel of the alternator with a ring spanner AF 17.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

9. Alternator

141

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Fit TORX key -V.A.G 1603/1- into alternator shaft. Loosen threaded joint by turning to right and counter-hold with ring spanner. Hold the ribbed belt (poly V-belt) pulley with a freewheel with the hand and turn the drive shaft of the alternator until the rib bed belt (poly V-belt) pulley with a freewheel can be 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-. Turn the torque wrench grip -2- through 180 degrees and re insert socket drive. Set torque wrench direction of rotation on socket to left.

Counter-hold adapter -VAS 3400- with ring spanner, AF 17. Tighten the ribbed belt (poly V-belt) pulley with a freewheel by turning the alternator drive shaft to left using torque wrench V.A.G 1332- . Tighten threaded connections to specified torque settings page 145 .

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Fit TORX key -V.A.G 1603/1- into alternator shaft.

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

Special tools and workshop equipment required

142

Rep. Gr.27 - Starter, current supply, CC

AG.

Prote cted by

9.12.1

Removing and installing voltage regula tor, manufacturer: Bosch

ht rig py Co t.

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c o p yri gh t . C op yi

9.12

Voltage regulator for alternator

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Torque screwdriver -V.A.G 1624-

Removing: Remove alternator. Remove securing bolt and nuts -arrows- and take protective cap off alternator.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Install in reverse order of removal. Tighten threaded connections to specified torque settings page 145 .

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9.12.2

Removing and installing voltage regula tor, manufacturer: Valeo

Special tools and workshop equipment required Torque wrench -V.A.G 1783/-

r fo ng

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

9. Alternator

143

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Remove alternator. Remove 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:

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Tighten threaded connections to specified torque settings page 145 .

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Push protective cap into guides -arrows- until it audibly en gages.

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10
10.1

Torque settings: alternator

General torque settings for all vehicles
Torque settings M8 M5 M4 M5 M10 M10 15 Nm 3,2 Nm 2 Nm 4.5 Nm 80 Nm 65 Nm

Threaded connections B+ wire to alternator Cable holder to alternator Voltage regulator to alternator Protective cap to alternator Poly V-belt pulley with freewheel to alternator Poly V-belt pulley without freewheel to alternator

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 respect the tightening sequence for the compact bracket.

10.2.1

Torque settings
Torque settings 23 Nm 23 Nm 52 Nm
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Threaded connections Alternator to compact M8 bracket Tensioning element to com M8x50 pact bracket Compact bracket to cylin M10x45 der block

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10.2.2

Tightening sequence for compact bracket to cylinder block Procedure Place compact bracket on cylinder block. Note

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Tightening sequence for compact brack et, models with air conditioning system

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Before 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, 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 F - Hexagon head collared bolt, M10x45, 52 Nm
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E - Hexagon head collared bolt, M10x45, 52 Nm

Caution

In order to avoid damage to cylinder block and compact brack et, you must respect the tightening sequence for the compact bracket.

10.3.1

Torque settings
Torque settings M8x90 M8x90 M10x45 M8x100 23 Nm 23 Nm 40 Nm 23 Nm

Threaded connections Alternator to compact bracket Tensioning element to com pact bracket Compact bracket to cylin der block Air conditioner compressor to compact bracket

146

Rep. Gr.27 - Starter, current supply, CC

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10.3

2.0 l FSI turbo engine

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

10.3.2

Tightening sequence for compact brack et, models with air conditioning system

Tightening sequence for compact bracket to cylinder block Procedure Place compact bracket on cylinder block. Note

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 engine

10.4.1

Torque settings

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bracket.

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Threaded connections

Torque settings M8x90 M8 M10 20 Nm 20 Nm 40 Nm

Alternator to compact bracket Tensioning element to compact bracket Compact bracket to cylinder block

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10.4.2

Tightening sequence for compact brack et

Tightening sequence for compact bracket to cylinder block Procedure Place compact bracket on cylinder block. Note Observe dowel sleeve between compact bracket and cylinder

block.

Before 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 Nm

10.5 10.5.1

2.5 l injection engine Torque settings

Torque 25 Nm 23 Nm 52 Nm
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i settings tee r o h t or u ac a ss

Threaded connections Alternator to compact M8x90 bracket Tensioning element to com M8x50 pact bracket Compact bracket to cylin M10x45 der block Note

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Observe dowel sleeve between compact bracket and cylinder

block.

For the compact bracket no tightening torque must be ob

served.

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148

Rep. Gr.27 - Starter, current supply, CC

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11

Cruise control system (CCS)

General description: The functions of the cruise control system are controlled by the engine control unit. There are no additional components, apart from the switch for CCS -E45- , which is integrated into the turn signal switch. Removing and installing switch 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

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: Drive Engine code

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a Connect Vehicle Diagnosis, Testing and ss Information -VAS 5051A- page 281 .

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01 - On Board Diagnostic capable systems Engine control and/or direct diesel injection and pre-glow sys tem Function Activating and deactivating cruise control system

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90
1

Instruments, GCI
Dash panel insert

General description: Integrated in the dash panel insert are the following components: Control unit with display in dash panel insert -J285 Immobilizer control unit -J362 Speedometer Rev counter Fuel gauge Coolant temperature gauge Multi-function display Warning lamps, page 152 To provide acoustic support to some of the visual displays, the n AG. Volkswagen AG do es n wage dash panel features a warning buzzer, which is actuated by the ks l ot g o yV ua control unit. b d r
e ris

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 the vehicle diagnosis, testing and informa tion system -VAS 5051A- in guided fault finding mode.

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All warning lamps feature LEDs. No provision has been made for tho au s repair of the dashs panel insert. In the event of defects, the dash panel insert is renewed as a unit page 150 .

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1.1

Renewing dash panel insert

The work sequence Renewing dash panel insert consists of the following work: If a new dash panel insert has to be installed in the vehicle, the dash panel insert control unit has to be adapted to the dif ferent vehicle equipment and the respective country variant. To adapt the integrated immobilizer to the engine control unit, the data of the engine control unit must be stored in the ex change dash panel insert. After installing a new dash panel insert, perform adaption of all vehicle keys.
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Special tools and workshop equipment required

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Rep. Gr.90 - Instruments, GCI

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Vehicle Diagnosis, Testing and Information System -VAS 5051A-

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Diagnosis lead -VAS 5051/6A-

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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, the work procedure Re newing dash panel insert should always be carried out in order that the data stored in the control unit can be interrogated page 150 .
Removing: Switch off ignition and all electrical consumers and pull out ignition key. Remove steering wheel General body repairs, interior; Rep. Gr. 69 ; Airbag; Removing and installing steering wheel .

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Using the Go to key, select Function/component selection and the following menu items one after the other:

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1. Dash panel insert

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Connect the vehicle diagnosis, testing and information system -VAS 5051A- to page 281

151

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove the upper part of the steering column trim General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing steering column switch trim . Remove 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 pan n AG. Volkswagen AG do el insert es n wage o olks
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The dash panel insert must not be dismantled. In the event of defects, the dash panel insert is renewed as a unit.
1236-pin connector Warning buzzer

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1.4

Warning lamp symbols in dash panel in sert

Note

The warning lamps on the dash panel insert depend on the vehi cle's equipment, country and engine type.

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152

Rep. Gr.90 - Instruments, GCI

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 1 - Electric On Board Diagno sis (EOBD) 2 - Engine malfunction (EPC) Warning lamp is fitted only on vehicles with petrol engine. 3 - Immobilizer 5 - 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 with automatic gearbox 22 - Oil level 23 - Bonnet open 24 - Door open 25 - Oil pressure 26 - Main beam 27 - Steering heating 28 - Trailer turn signals 29 - Glow plug system Warning lamp is fitted only on vehicles with diesel engine. 30 - Tank filler cap 31 - Exhaust filter 32 - Electronic steering (EPS-Electronic Power Steering)
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4 - Battery charge

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2
2.1

Service interval display

Resetting service interval display

Maintenance ; Booklet 20.1

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154

Rep. Gr.90 - Instruments, GCI

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92
1

Windscreen wash/wipe system

Windscreen wiper system
Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

Note

Additional information:
Operating instructions General description: 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. Theservice/winter position is acti vated within 10 seconds after ignition is switched off by pressing windscreen wiper lever in tip wipee Operating instructions for n AG. Volkswagen AG do es n wag vehicle . o olks
ed Fault detection and fault ris display:

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For fault finding, use the vehicle diagnosis, testing and informa tion system -VAS 5051A- in guided fault finding mode.
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au control unit -J519- is equipped with The onboard supply ss agnosis, which is designed to ease fault finding.

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1.1

Deactivating APP function of wiper mo tors

Special tools and workshop equipment required Vehicle Diagnosis, Testing and Information System -VAS 5051A-

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1. Windscreen wiper system

155

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Diagnosis lead -VAS 5051/6A-

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The windscreen wiper system is equipped with an APP function (alternating park position system). With the APP function, the wiper arm is moved up slightly once it has reached the lowest position. This occurs every second time the wiper system is switched off. To fit the crank arm on the wiper motor, it is necessary for the motor to be in the lowest park position. To ensure this position is reached, the APP function must be deactivated (code wiper motor control unit -J400- ). Note

The APP function cannot be activated.

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 other: Body Electrical System 01 - On Board Diagnostic capable systems Onboard supply control unit Onboard supply control unit functions Control unit functions for wiper electronics

1.2

Removing and installing the windscreen wiper system

Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

156

Rep. Gr.92 - Windscreen wash/wipe system

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vated automatically. This applies to wiper motors on which the APP function has been deactivated and also to new wiper mo tors.
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After 100 cycles of wiper movement, the APP function is acti

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Special tools and workshop equipment required Torque wrench -V.A.G 1331 Puller -T10130 Removal lever -80-200-

1.2.1

Deactivating APP function page 155 . Allow wiper to move to park position and then switch ignition off. Disconnect the battery page 29 . Note

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Removing windscreen wiper system

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To remove the wiper frame with rods and the wiper motor, wiper arms, plenum chamber cover and air duct cover must be re moved.

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1. Windscreen wiper system

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

1.2.2

Removing wiper arm

Lever off the protective cap -arrows- using a screwdriver.

Loosen the hexagon nut -arrows-, without removing it com pletely.

Position legs of puller -T10130- -2- under wiper arm-4- as wagen AG. Volkswagen AG doe s no olks shown in the figure. t gu yV
ris it comes Turn thrust bolt -1- of puller -T10130- clockwise until ho utnut -3- previ into contact with the wiper shaft. The hexagon a ss ously loosened on the wiper arm serves as a means of centring and guiding the thrust bolt -1-.
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Turn thrust bolt -1- of puller -T10130- clockwise using 6 mm spanner until wiper arm -4- is released from the shaft.

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1.2.3

Removing plenum chamber cover

Unclip plenum chamber cover -1-, starting from side, off top of windscreen frame -arrow-.

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Rep. Gr.92 - Windscreen wash/wipe system

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1.2.4

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

s no ks Lever linkage -arrow- ball t gu Vol head -1- using release lever by ara d -80-200- off crankriarm of motor. nt se

Removing wiper motor out of wiper frame G. Volkswagen

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Remove securing nut -1-. Pull crank -2- off wiper motor shaft. Unscrew securing bolts -arrows- and remove wiper motor with control unit from wiper frame.

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1. Windscreen wiper system

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

1.2.7

Installing wiper motor in wiper frame

Insert wiper motor with control unit in wiper frame and secure it in place with the securing bolts -arrows-. Tighten threaded connections to specified torque settings page 178 .

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Tighten threaded connections to specified torque settings page 178 .

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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.
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Install air cowling, plenum chamber cover and plenum cham ber seal in reverse order of removal. Install wiper arms page 160 .
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Connect the battery page 29 .

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1.3
Removing:

Removing and installing wiper arms

Removing wiper arms page 158 . Installing: Note

Securing nuts of wiper arms are not tightened to specified torque until after wiper blade park position has been adjusted.
Deactivate the APP function if not already done page 155 . To move wiper motors to their park position, switch wind screen wipers on and off with ignition on.

160

Rep. Gr.92 - Windscreen wash/wipe system

c o p yri gh t . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-

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Puller -T10130-

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Note

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Deactivate the APP function if not already done page 155 . Allow wiper to move to park position and then switch ignition off. Now adjust windscreen wiper blade park position.
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On RHD vehicles, the wiper blades are a mirror image.

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1. Windscreen wiper system

161

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Driver's side: Distance -A- between wiper blade and upper edge of plenum chamber cover should 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 n AG. Volkswagen AG do page 178 . es wage
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Front passenger's side:

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Distance -B- between wiper blade and upper edge of plenum chamber cover should 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 .

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1.5
Removing: Note

Removing and installing aerodynamic wipers

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Driver's and front passenger wiper blades should not be inter

blades off the windscreen, touch them only in the area in which the wiper blades are attached to the wipers. in the service/winter position. Theservice/winter position is activated within 10 seconds after ignition is switched off by pressing windscreen wiper lever in tip wipe.

To remove the wiper blades, the wiper arms should be placed

Place wiper arm in service/winter position by operating the windscreen wiper lever within 10 seconds after ignition is switched off in tip wipe position. Lift up wiper arm.

162

Rep. Gr.92 - Windscreen wash/wipe system

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The aerodynamic wipers are very flexible. To lift the wiper

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Turn wiper blade -1- on wiper arm onto limit 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.
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1.6
Removing:

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Removing and installing rain and light detector sensor -G397-

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Special tools and workshop equipment required Removal wedge -3409-

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Remove interior mirror General body repairs, interior; Rep. Gr. 68 ; Removing and installing interior mirror . Pull connector -1- off rain and light detector sensor -G397-2-.
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Switch off ignition and all electrical consumers and pull out ignition key.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Using removal wedge -3409- , lever rain and light detector sensor -G397- -1- out of retainer -2-. Note

When removing, ensure to remove the complete rain and light detector sensor -G397- and not only the upper shell of the sensor.
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Before installing, thoroughly clean the windscreen, within the The surface (coupling cushions) of the rain and light detector
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retainer for the rain and light detector sensor -G397- . sensor -G397- must not be soiled when installing.

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If the surface (coupling cushions) of the rain and light detector

sensor -G397- is soiled, it can possibly be cleaned by Apply ing and Pulling off one or more tapes. must be no air bubbles between windscreen and the surface (coupling cushions).

After installing the rain and light detector sensor -G397- there

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2
Note

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Operating instructions

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2.1

Assembly overview of windscreen washer system

1 - Y-piece Distribution of wash wa ter line to 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

r fo ng

5 - Hose Hose repair page 176 6 - Elbow Connection to right windscreen spray jet Overview of washer wa ter line hose couplings page 174 7 - Filler pipe for reservoir for windscreen washer and head light washer systems Removing and installing page 166 8 - Washer pump -V5 Removing and installing page 168 9 - Windscreen washer system and headlight washer system reservoir Removing and installing page 167

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4 - Elbow Connection to left wind screen spray jet Overview of washer wa ter line hose couplings page 174

2. Windscreen washer system

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2.2

Removing and installing reservoir for windscreen and headlight washer sys tems

The reservoir for windscreen and headlight washer systems has three parts. The individual parts are connected together. To en sure a correct positioning of the individual parts, observe that the guides of the individual parts run in 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

Removing:

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2.2.1

Removing and installing filler pipe for windscreen and headlight washer sys tem reservoir

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Pull filler pipe -1- off union -3- on reservoir for windscreen and headlight washer systems. Remove securing bolt -2-. Unclip hose retainer from filler neck -3- and take it out of the vehicle. Installing: Installation is carried out in the reverse order. When installing, note the following:

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The funnel on the underside of the filler pipe should be inserted in the hole -arrow-.
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Connecting pipe -1- and filler neck -2- must be fitted together so that the guides -arrows- grip into one another.

2.2.2

Removing and installing reservoir for windscreen and headlight washer sys tems

Removing: Switch off ignition and all electrical consumers and pull out ignition key. Remove filler pipe for windscreen and headlight washer sys tem reservoir page 166 . Remove front bumper cover Body Repairs, exterior; Rep. n AG. Volkswagen AG do e Gr. 63 ; Front bumper . g a es sw Note
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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 assembly.
To unlock, turn the securing clips hose connections -3- and -5- and pull them out of the windscreen washer pump -V5-4-. If necessary, collect washer fluid that leaks out with a suitable container. Separate the connector -6- of windscreen washer fluid level sender -7-. Take washer pump -V5- -4- upwards out of reservoir and sep arate connector -2-. Pull headlight washer system pump -V11- -9- upwards out of reservoir and separate connector and separate connector -10-.

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2. Windscreen washer system

167

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unbolt securing bolts -arrows- and take reservoir out of vehi cle. Installing: Installation is carried out in the reverse order. When installing, note the following: Tighten threaded connections to specified torque settings page 178 . Bleed the headlight washer system after completing work page 173 .
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2.3
Removing:

Removing and installing washer pump V5-

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Switch off ignition and 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 connections during assembly.
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To unlock, turn the securing clips hose connections -3- and -5- and pull them out of the windscreen washer pump -V5-4-. Pull washer pump -V5- -4- upwards out of the reservoir. Disconnect connector -2-. Installing: Installation is carried out in the reverse order. When installing, note the following: Tighten threaded connections to specified torque settings page 178 . Bleed the headlight washer system after completing work page 173 .

If necessary, collect fluid leaking out with a suitable container.

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Rep. Gr.92 - Windscreen wash/wipe system

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2.4
Removing:

Removing and installing windscreen washer spray jets

Push spray jets upwards -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.
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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 jet and clean in opposite direction of spray with water. In the following it is allowed to blow the spray jets in op posite direction of spray with compressed air. Do not use objects to clean the spray jets.
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Maintenance ; Booklet 20.1

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3
Note

Headlight washer system

Additional information:
Current flow diagrams, Electrical fault finding and Fitting loca tions Operating instructions General description: Every fifth time the front windscreen 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 following assembly work or when activated for the first time page 173 . Fault detection and fault display: The onboard supply control unit -J519- is equipped with self-di agnosis, 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.
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Rep. Gr.92 - Windscreen wash/wipe system

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3.1

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d 1 - Washer spray jet assembly e nte is r o eo with right spray jets h ut ra a c s s Removing and installing

Assembly overview - headlight washer system

spray jet assembly page 173 Adjusting spray jets page 173 Removing and installing pop-up spray jet cylin der page 172

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2 - Washer spray jet assembly with left spray jets Removing and installing spray jet assembly page 173 Adjusting spray jets page 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
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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 to spray jets on headlight washer system 7 - Elbow 8 - Headlight washer system pump -V11 Removing and installing page 171 9 - Windscreen washer system and headlight washer system reservoir Removing and installing page 166 10 - Filler pipe for reservoir for windscreen washer and headlight washer systems Removing and installing page 166

3.2

Removing and installing headlight washer system pump -V11-

The headlight washer system pump -V11- is fitted on the wind screen and headlight washer system in the right housing liner.

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3. Headlight washer system

171

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Switch off ignition and all electrical consumers and pull out ignition key. Remove front bumper cover Body Repairs, exterior; Rep. Gr. 63 ; Front bumper . Pull headlight washer system pump -V11- -9- upwards out of the reservoir. Disconnect connector -10-. To remove the connecting pipe -8- pull securing clip on con nection and pull connecting pipe -8- off headlight washer system pump -V11- . Installing: Installation is carried out in the reverse order. When 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:

Removing and installing pop-up spray jet cylinder

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Switch off ignition and all electrical consumers and pull out ignition key.
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Pull spray jets with cap -1- out of bumper cover onto stop. Unclip cap -1- from mounting points -arrows- on washer spray jet assembly. Remove front bumper cover Body Repairs, exterior; Rep. Gr. 63 ; Front bumper . Pull the securing clip -4- off hose connection. Pull hose connection off pop-up cylinder -2-. Remove securing bolt -1-. Installing: Unclip pop-up spray jet cylinder -2- from bracket -3-. Installation is carried out in the reverse order. When installing, note the following:
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Bleed the headlight washer system after completing work page 173 .

172

Rep. Gr.92 - Windscreen wash/wipe system

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Tighten threaded connections to specified torque settings page 178 .

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The pop-up spray jet cylinder hose must be attached to the securing clip on the bracket.

3.4
Removing:

Removing and installing spray jet as sembly

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, Bora 2006 Electrical System - Edition 05.2005

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Switch off ignition and all electrical consumers and pull out ignition key. Pull spray jet with cover cap -1- onto stop out of bumper cover. Unclip cap -1- from mounting points -arrows- on washer spray jet assembly.

Lever locking hooks -arrow- up slightly and pull out spray jet assembly. Installing: Note

do c um en

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 washer spray jet assembly in higher or lower position on pop-up cylinder. Bleed the headlight washer system after completing work page 173 . Check headlight washer system spray jets and adjust if nec essary page 173 .

3.5 3.6

Adjusting headlight washer system jets Bleeding the headlight washer system

Maintenance ; Booklet 18.1

To guarantee sound functioning, the headlight washer system must be bled following assembly work or when operated for the first time. Fill reservoir for windscreen and headlight washer systems. Start the engine. Switch ON the headlight. Operate headlight washer system several times (3-5 times, 3 seconds each time). Repeat this bleeding procedure until the pop-up cylinders and spray jets are functioning soundly.

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The degree to which the cover cap of the spray jet is pulled down onto the bumper cover can be adjusted using the clips on the washer spray jet assembly. If the washer spray jet assembly is not pulled in far enough, the cover cap will 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.
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3. Headlight washer system

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4
4.1

Wash water line hose couplings

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The following hose coupling types are used to connect the hoses to pumps and spray jets and/or as points of separation:

To secure the connection, push the two coupling sections to gether, until you hear and feel them engage.
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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 connection and rotate the lock ring -1- -arrow- until it engages.
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To loosen the connection, pull up the lock ring -1- by approx. 1 mm -arrow- and pull off the hose connection. To secure the connection, push on the hose connection and push in the lock ring -1- until it engages.

174

Rep. Gr.92 - Windscreen wash/wipe system

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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 pull off without the clip.

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4. Wash water line hose couplings

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Hose repair

A new repair concept has been developed for repair work on wash system hoses. Various connectors, special EPDM hoses (ethyl ene propylene diene monomer) and heat-shrink hose are availa ble as spare parts

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

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Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe can each be pushed about 10 mm into the EPDM hose -2-.

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Secure the repair joints with cable ties -1-.

Hot air gun -VAS 5179- or

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Hot air gun -V.A.G 1416/- or Hot air blower -VAS 1978/14-

176

Rep. Gr.92 - Windscreen wash/wipe system

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Special tools and workshop equipment required

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5.3

Repairing corrugated pipe

 Repair points must not be subjected to pulling or bending

forces.

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Note

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If the damaged section is longer than 20 mm, a new piece 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-. Heat end of corrugated pipe -4-. Push connector -2- into corrugated pipe -2- -arrow A-. Push connector -3- into corrugated pipe -4- -arrow B-. Cut heat-shrink hose so that ends of corrugated pipe are each covered by about 20 mm -dimension x- of heat-shrink hose.
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Push heat-shrink hose over corrugated pipe, join connectors and secure repair joints with heat-shrink hose.

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5. Hose repair

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Torque settings: Windscreen wash/wipe system

Torque settings M6 M8 M6 M8 M6 8 Nm 18 Nm 8 Nm 20 Nm 8 Nm 4.5 Nm

Threaded connections Wiper motor to wiper frame Motor crank arm to wiper motor shaft Wiper frame to body Windscreen wiper arms to wiper motor shaft Windscreen washer system and headlight washer system reservoir Pop-up spray jet cylinder front bumper cover

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178

Rep. Gr.92 - Windscreen wash/wipe system

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94
1
Note

Lights, lamps, switches - outside

Headlight

Before working on headlights, always switch off the headlights

and remove the ignition key.

When dealing with complaints, it is absolutely essential that Additional information: Operating instructions

the function and operation of the lighting system is first under stood.

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 unit has a self-diagnosis function, which makes fault finding on the headlights easier. AG. Volkswagen
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1.1
Note

a Assembly overview, Headlight ss

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In the overview there are shown the three control motors of the different headlight manufacturers because their removal and in stallation is different.

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1. Headlight

179

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 1 - Securing bolts 4 Nm
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2 - Adjustment Correcting installation position of headlight page 182

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3 - Left headlight main beam bulb -M30- or right headlight main beam bulb -M32 Bulb H7U 12 V, 55 W Renewing 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
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8 - Body section 9 - Cover cap 10 - Bulb holder with grip ele ment For left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M3111 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31 Bulb H7 12 V, 55 W Renewing page 184 12 - Headlights Removing and installing page 181 Correcting installation position of headlight page 182 Servicing headlight securing lugs page 188

180

Rep. Gr.94 - Lights, lamps, switches - outside

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7 - Bulb holder with grip ele ment For front left turn signal bulb -M5- or front right turn signal bulb -M7-

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

1.2 1.2.1
Note

Removing and installing headlights Removing headlights

It is not necessary 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 ignition key. Release multi-pin connector -arrow- and pull off multi-pin con nector. Remove front bumper General body repairs; Rep. Gr. 63 ; Front bumper
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Unscrew securing screw -arrow- on upper headlight.

Unscrew securing screw -arrow- on lower left headlight.

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1. Headlight

181

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing screw -arrow- on lower right headlight.

1.2.2

Installing headlights

Installation is performed in the reverse order of installation; when doing this, note the following:
swagen A Tighten all securing bolts to specified torque setting n AG. Volk G do es n wage s k l ot g o page 238 . V y

nte is r Check headlight installation position is central, i.e. shutlines eo tho u ra are equal around headlight. c sa
es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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If the shutlines around the headlight are uneven, the installation position must be adjusted page 182 . Check function of headlight. Note

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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 headlight installation position, the front bumper

must not be removed.

do c um en

The diagrams show the left headlight. If it transpires during checking of the installation position that the shutlines between headlight and body are uneven, the installation position must be adjusted. Switch off ignition and all electrical consumers and pull out ignition key. Remove radiator General Body Repairs, Exterior; Rep. Gr. 66 ; Strips and trim .
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182

Rep. Gr.94 - Lights, lamps, switches - outside

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 Unscrew

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AG. Volkswagen AG d Electrical agen oes ksw not l o V g ua by ran ed -arrow- on upper headlight. securing screw tee ris o h t or u ac a ss

Jetta 2005 , Bora 2006 System - Edition 05.2005

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rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew securing screw -arrow- on lower left headlight.

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Unscrew securing screw -arrow- on lower right headlight.

AG.

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 and installing radiator . Check function of headlight. Note

If a headlight is removed or adapted to the body it should always be adjusted after installing or adapting it.
Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1

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1. Headlight

183

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

1.4 1.4.1
Note

Renewing headlight bulbs Renewing dipped beam headlight bulb

. Volkswagen AG The diagrams show renewal of the dipped beam headlight bulb gen AG does swa k not l o for the left headlight. V gu by

Removing:
pe rm itte d

Switch off ignition and all electrical consumers and pull out ignition key. Turn cover cap -1- in -direction of arrow- and remove.
es, in part or in w l purpos hole ercia , is n m ot com

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ss

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ara nte e

or ac
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rrectness of i t to the co nform spec a t i h re o n in wit thi s

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Turn bulb holder with dipped beam headlight bulb -1- in -direction of arrow- and remove from headlight.

do c um en

Pull dipped beam headlight bulb -2- in -direction of arrow- out of 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. Fingers leave

traces of grease on the glass, which evaporate when the bulb is switched on and cause the glass to cloud over.

184

Rep. Gr.94 - Lights, lamps, switches - outside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Place headlight dipped beam bulb -1- in the bulb holder that 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-.

olkswagein Place cover cap -1- in headlight recess and G. Vtighten n AG d A agen oes ksw -direction of arrow-. not l o V
ise Check function of headlight. or
h ut

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a and adjust headlight as necessary Check headlight setting ss Maintenance ; Booklet 20.1

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1.4.2

Renewing main beam headlight bulb

Note

The diagrams show renewal of the main beam headlight bulb for the left headlight.
Removing:

Switch off ignition and all electrical consumers and pull out ignition key.
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AG.

1. Headlight

185

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull off cover cap -1-.
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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rrectness of i t to the co nf o r m spec atio h re n in wit

Pull off multi-pin connector -2-.

thi sd o cu m en

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 glass, which evaporate when the bulb is switched on and cause the glass to cloud over.

Installation is performed in the reverse order of installation; when doing this, note the following:

186

Rep. Gr.94 - Lights, lamps, switches - outside

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Press spring retaining clip -2- in -direction of arrow- under the locking lugs-1- and fold spring retaining clip -2- upwards.
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AG.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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
pe rm itte d

Note

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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. Pull off cover cap -1-.

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Renewing side light bulb

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Pull, depending on the cable length, the bulb holder -1- with the side light bulb as far it is possible out of the reflector.
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1. Headlight

187

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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. 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 reverse order of installation; when doing this, note the following: Check function of headlight. Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

1.4.4
Note

Renewing front turn signal bulb

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
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The diagrams show renewal of the turn signal bulb for the left headlight.
Removing:

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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 front turn signal bulb out of bulb holder. Installing: Note

Installation is performed in the reverse order of installation; when doing this, note the following: Check function of headlight. Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1

1.5

Servicing headlight securing lugs

Information on servicing headlight securing lugs was not available when it was time of going to press.

188

Rep. Gr.94 - Lights, lamps, switches - outside

AG.

traces of grease on the glass, which evaporate when the bulb is switched on and cause the glass to cloud over.

Prote cted by

Do not touch bulb glass when fitting bulbs. Fingers leave

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correctly. The ingress of water will lead to permanent damage of the headlight.

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When installing bulb holder, ensure that the seal is seated

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

1.6

Adjusting headlights

Adjusting headlights Maintenance ; Booklet 20.1 .

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1. Headlight

189

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2
Note

Main headlights with gas discharge bulbs

Before working on gas discharge headlights, always switch off

es n w The automatic headlight range otgas olks control on headlights with g yV

the headlights and remove the ignition. key. Volkswag

AG agen

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db discharge bulbs is equipped with self-diagnosis. ise

stood.

Additional information: Operating instructions Current flow diagrams, Electrical fault finding and Fitting loca tions Fault detection and fault display: The automatic headlight range adjustment (HRA) and onboard supply control unit have a self-diagnosis function, which makes fault finding on the headlights using gas discharge lamps easier. For fault finding, use the vehicle diagnosis, testing and informa tion system -VAS 5051A- in guided fault finding mode.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ua ran tee r o h or utcomplaints, it is absolutely essential that When dealing with ac a the function andss operation of the lighting system is first under

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190

Rep. Gr.94 - Lights, lamps, switches - outside

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2.1
urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
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ss

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

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Assembly overview - gas discharge headlights

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Note

After any measures which could affect the headlight setting, the headlight must be checked and if necessary adjusted Maintenance ; Booklet 20.1 .
rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

1 - Vent hose On headlight 2 - Left headlight range control motor -V48- or right headlight range control motor -V49 Headlight manufactur er: AL (Automotive Lighting) Note

5 - Gas discharge light starter unit -N1956 - Bulb locking For left gas discharge bulb -L13- or right gas discharge bulb -L147 - Left gas discharge bulb L13- or right gas discharge bulb -L14 Type D2S, 35W Renewing page 192 8 - Securing bolt 4 Nm On upper headlight 9 - Headlights Removing and installing page 181 Correcting installation position of headlight page 182 Servicing headlight securing lugs page 204 10 - Headlight range control unit -J431 Removing and installing page 198 Coding page 200 Note 11 - Front left vehicle level sender -G78 Removing and installing page 201 Checking page 203 .

AG.

4 - Cover cap

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3 - Securing bolts For left headlight range control motor -V48- or right headlight range control motor -V49Prote cted by c o py rig ht . C op yi

r fo ng

2. Main headlights with gas discharge bulbs

191

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 12 - Rear left vehicle level sender -G76 Removing and installing page 201 Checking page 203 . 13 - Adjustment bush Correcting installation position of headlight page 182 14 - Securing bolt 4 Nm On lower headlight 15 - Left gas discharge light control unit -J343- or right gas discharge light control unit -J344 Not capable of self-diagnosis Removing and installing page 198 16 - Securing bolts For left gas discharge light control unit -J343- or right gas discharge light control unit -J34417 - 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 Volkswagen AG AG. -M7does agen ksw not l Bulb 12 V, H2 WLL 21 W o gu yV b ara d e nte Renewing page 197 ris
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a bulb -M319 - Left side light bulb -M1- or right side light ss Bulb 12 V, W 5 W Renewing page 196

ho ut

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20 - Cover cap For front left turn signal bulb -M5- or front left turn signal bulb -M7- and for left side light bulb -M1- or right side light bulb -M3rrectness of i t to the co nform spec at i h re o n wit in t his

21 - Cover cap For left headlight main beam bulb -M30- or right headlight main beam bulb -M32-

2.2 2.3 2.4 2.4.1

Note

Removing and installing headlights Adjusting headlight installation position Renewing headlight bulbs Renewing gas discharge bulb
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Removing and installing headlights page 181 .

Adjusting headlight installation position page 182 .

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The diagrams show renewal of a gas discharge bulb for the left headlight.
Removing: Remove headlight page 181 .

192

Rep. Gr.94 - Lights, lamps, switches - outside

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AG.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Turn cover cap -1- in -direction of arrow- and remove.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Pull off connector -1-. Note

The connector is ejected automatically when the gas discharge bulb starter unit -N195- is removed.

thi sd o cu m en

The glass bulb may explode resulting in a risk of injury from burning. Always wear eye protection and gloves when removing and installing gas discharge bulbs!
Turn bulb retainer -1- in -direction of arrow- and remove bulb retainer.

AG.

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 bulb.

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WARNING

2. Main headlights with gas discharge bulbs

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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.
c o p yri gh t. C op yi

193

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Carefully pull gas discharge bulb -1- out of mounting. Installing: Note Do not touch bulb glass when fitting a gas discharge lamp

bulb . Fingers leave traces of grease on the glass, which when switching the gas discharge lamp bulb on, evaporate and cause the glass to cloud over. do not subject the bulb to mechanical stress. The glass bulb is extremely sensitive and is subjected to a very high pressure. from the gas discharge bulb are about 2.5 times greater than normal halogen bulbs.

Use extreme care when fitting a gas discharge lamp bulb and Avoid looking directly into the collimated beam as the UV rays When installing cap, ensure that it is seated correctly. The in

gress of water will lead to permanent damage of the headlight. sic setting of the headlight should always be checked when reinstalling Maintenance ; Booklet 20.1 .

If a headlight is removed with automatic range control, the ba

Installation is performed in the reverse order of installation; when doing this, note the following: Check function of headlight. Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1

2.4.2
Note

Renewing main beam headlight bulb

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The following diagrams show renewal of the main beam headlight bulb for the left headlight.
Removing:

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Switch off ignition and all electrical consumers and pull out ignition key. Pull off cover cap -1-.

r fo ng

194

Rep. Gr.94 - Lights, lamps, switches - outside

ht rig py Co t.

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AG.

Prote cted by c o p yri gh t. C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull connector off -arrow-.

Press spring retaining clip -2- in -direction of arrow- under the locking lugs-1- and fold spring retaining clip -2- upwards.

Take main beam bulb -1- out of headlight.

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

un le

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

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 reverse order of installation; when doing this, note the following: Place the headlight main beam bulb -1- in the recesses -arrows- on the headlight. Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1
AG.
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r te o iva r rp fo g n

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Check function of headlight.

2. Main headlights with gas discharge bulbs

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195

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.4.3
Note

Renewing side light bulb

The following diagrams show renewal of the side light bulb for the left headlight. AG. Volkswagen A
Removing: Switch off ignition and all electrical ignition key. Pull off cover cap -1-.
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pe rm itte d

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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-.
r te o iva r rp fo g n

do c um en

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. 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 reverse order of installation; when doing this, note the following: Check function of headlight. Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1

196

Rep. Gr.94 - Lights, lamps, switches - outside

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AG.

Prote cted by c o py rig ht . C op yi

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.4.4
Note

Renewing front turn signal bulb

The following 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. Pull off cover cap -1-.

Pull, depending on the cable length, the bulb holder -1- with n AG. Volkswagen AG do es n wage s k l the front turn signal bulb in -direction of arrow- and take them ot g o yV ua b d out of the reflector. ran se
es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

ri tho u a ss

tee or ac
ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

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

thi sd o cu m en

gress of water will lead to permanent damage of the headlight.

c o p yri gh t . C op yi

Check function of headlight. Check headlight setting and adjust headlight as necessary Maintenance ; Booklet 20.1

2. Main headlights with gas discharge bulbs

AG.

Prote cted by

Installation is performed in the reverse order of installation; when doing this, note the following:

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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.
agen lksw Vo by

197

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.5

Removing and installing headlight range control motor Removing and installing gas discharge light control unit AG. Volkswagen
Note
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Information was not available when it was time of going to press.

2.6

Removing:

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

The left gas discharge light control unit -J343- or the right gas discharge light control unit -J344- are not capable of self-diagno sis.

n wage olks V by ed ris o th au ss

AG do es n ot g ua ran tee or ac
ility ab y li an pt ce

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Remove headlight 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.
r fo ng

Installing: Note

When installing the gas discharge light control unit secure correct seat of the seal. The ingress of water will lead to permanent dam age of the headlight.
Installation is performed in the reverse order of installation; when doing this, note the following: Check function of headlight. Perform basic setting of headlights Maintenance ; Booklet 20.1 .
AG.
Prote cted by

2.7 2.7.1

Headlight range control unit -J431Removing and installing headlight range control motor -J431-

Special tools and workshop equipment required

198

Rep. Gr.94 - Lights, lamps, switches - outside

ht rig py Co t.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removal wedge -VAS 3409-

pe rm itte d

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Note

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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 cover-1- in -direction of arrow-.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

r te o iva r rp fo g n

do c um en

Unlock the locking clip -1- in -direction of arrow- and pull off connector -2- from control unit for headlight range control J431- .

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AG.

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2. Main headlights with gas discharge bulbs

199

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing bolt -arrow- and take control unit for head light range control -J431- -1- of bracket -2-. Installing: Installation is performed in the reverse order of installation; when doing this, note the following:

Fit the control unit for headlight range control -J431- -3- into the bracket -2- with the lug -2-.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Lock -direction of arrow-. Note

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u connector -1by pressing the locking clip -2in ac a ss

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rrectness of i t to the co nform spec at i h re o n wit in t his

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 information system -VAS 5051A- to page 281 Select guided fault finding in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .
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Using the Go to key, select Function/component selection and the following menu items one after the other: Electrical System
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Body

01 - On Board Diagnostic capable systems

200

Rep. Gr.94 - Lights, lamps, switches - outside

AG.

Prote cted by

c o p yri gh t . C op yi

 Automatic headlight range

Coding automatic headlight range control Note

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Automatic headlight range control functions

Jetta 2005 , Bora 2006 AG. Volkswagen AG does agen ksw not l Electrical System - Edition 05.2005 o V gu y b ara d e nte s ri eo control utho ra a c s s
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rrectness of i t to the co nf o r m spec atio h re n in wit

If the control unit for headlight range control -J431- has been co ded, the basic setting 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

thi sd o cu m en

If the vehicle level senders are replaced, check the values from If the values from the vehicle level sensors are outside the
Prote cted by

2.8.1
Removing:

Removing and installing front left vehicle level sender -G78-

Switch off ignition and all electrical consumers and pull out ignition key. Pull off connector -arrow-.

2. Main headlights with gas discharge bulbs

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specified tolerance, basic headlight setting cannot be carried out.

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the sensors page 203 and carry out basic setting on head lights Maintenance ; Booklet 20.1 .
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove securing nut -1-. Unscrew securing bolt -2- and remove front left vehicle level sender -G78- -3-. Installing: Installation is carried out in the reverse 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 . specified tolerance, basic headlight setting cannot be carried out.

If the values from the vehicle level sensors are outside the

2.8.2
Removing:

Removing and installing rear left vehicle level sender -G76-

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew the five securing bolts -1- and remove rear left vehi cle sender -G76- -2-. Installing: Installation is carried out in the reverse order. When installing, note the following: Tighten threaded connections to specified torque settings AG. Volkswagen AG d agen oes page 238 . ksw not l o V Check front left vehicle level sender -G76ise page 203 . or
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If the vehicle level sensors are replaced, check the sensor

values page 203 and carry out basic setting on headlights Maintenance ; Booklet 20.1 . specified tolerance, basic headlight setting cannot be carried out.

If the values from the vehicle level sensors are outside the

2.8.3

Checking vehicle level sender

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 -J431in the following instances:
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Vehicle level senders installed are not of type specified in this workshop manual Vehicle level senders have mechanical fault Vehicle suspension has been modified (e.g. lowered) Note

If the values of the vehicle level senders are outside the specified tolerance, basic headlight setting cannot be carried out.
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 other: Body Electrical System 01 - On Board Diagnostic capable systems Automatic headlight range control Automatic headlight range control functions Checking vehicle level sender
2. Main headlights with gas discharge bulbs

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2.9 2.10

Servicing headlight securing lugs Adjusting headlights

Information on servicing headlight securing lugs was not available when it was time of going to press.

Adjusting headlights with gas discharge lamp Maintenance ; Booklet 20.1 .

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Fog lights

Fault detection and fault display: The onboard 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 page 206 4 - Fog light housing Removing and installing page 205 5 - Cover cap 6 - Securing bolts 7 - Spreader nuts
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3.2
Note

Removing and installing fog lights

The diagrams show how the left fog light is removed and installed.

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3. Fog lights

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Switch off ignition and all 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 nance ; Booklet 20.1 .

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3.3
Note

Removing and installing fog light bulb

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The diagram shows how the left fog light is removed and installed.
Removing: Remove fog light page 205 .

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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, adjusting if necessary Mainte nance ; Booklet 20.1 .

3.4

Adjusting fog lights

Adjusting fog lights Maintenance ; Booklet 20.1 .

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3. Fog lights

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Removing and installing side marker in front bumper

Removing and installing front side mark er

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4.1
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
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Unlock side marker -1- by pressing the locking lug -in direction of arrow-. Remove bulb holder -2- out of side marker. Installing

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Installation is performed in the reverse order of installation; when doing this, note the following: Note

After the installation perform functional check.

4.1.1

Renewing side marker bulb

Pull side marker bulb -1- in direction of arrow out of the bulb holder -2-.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

5
Note

Mirror turn signal bulb and entry light in exterior mirror

Additional information:
Current flow diagrams, Electrical fault finding and Fitting loca tions General description: The exterior mirror turn signal bulbs are located in the housing of the exterior mirror. Furthermore there is located an entry light on each side in the housing, which illuminates the entry area around the driver and front passenger side. 1 - Driver side exterior mirror turn signal bulb -L131- or front pas senger side exterior mirror turn signal bulb -L1322 - Driver side entry light in exterior mirror -W52- or front passen ger side entry light in exterior mirror -W53Fault detection and fault display: The onboard supply control unit is equipped with self-diagnosis AG. Volkswagen AG d agen oes which makes fault finding easier. n lksw
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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 housing of the left or right exterior mirror. Note

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The complete driver side exterior mirror turn signal bulb -L131- or the complete front passenger side exterior mirror turn signal bulb -L132- must be replaced if damaged.
Removing:

Switch off ignition and all electrical consumers and pull out ignition key. Remove driver side exterior mirror turn signal bulb -L131- or the front passenger side exterior mirror turn signal bulb -L132 General Body Repairs, Exterior; Rep. Gr. 66 ; Exterior rear view mirror; Removing and installing side mounted turn sig nals . Installing: Install driver side exterior mirror turn signal bulb -L131- or the front passenger side exterior mirror turn signal bulb -L132- General Body Repairs, Exterior; Rep. Gr. 66 ; Exterior rear view mirror; Removing and installing side mounted turn sig nals .
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5. Mirror turn signal bulb and entry light in exterior mirror

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5.2

The driver side entry light in 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

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Removing and installing entry light in ex terior mirror

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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 Removing:

same manner on both sides and is described for one side only.

Switch off ignition and all electrical consumers and pull out ignition key. Fold exterior mirror -1- in -direction of arrow- forwards.

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Unbolt securing bolt -1-.

Unclip entry light in -direction of arrow- out of the exterior mirror and pull it out as far as possible.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull bulb carrier -2- in -direction of arrow- out of entry light housing -1-. Renew bulb:

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Pull bulb -1- in -direction of arrow- out of the carrier -2-. Plug base bulb: 12 V, W6 W Installing:

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Installation is performed in the reverse order of installation; when doing this, note the following: Note

After the installation perform functional check of the exterior mir ror.

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5. Mirror turn signal bulb and entry light in exterior mirror

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6
6.1

Tail lights
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 -M223 - 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 -M735 - Bulb carrier Removing and installing page 213

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6.2
Removing:

Removing and installing tail light in side panel

Switch off ignition and all electrical consumers and pull out ignition key. Press side trim to side.
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull connector -1- off. Remove securing nuts -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:
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Tighten securing nuts -2- to specified tightening torque page 238 . Note

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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:

Removing and installing tail light bulb carrier in side panel

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Pull connector -1- off.

Unclip retaining tabs -1- -in direction of arrow- and take bulb carrier out of tail light housing -2-. Installing: Install in reverse order of removal.

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6. Tail lights

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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
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6.5
Removing:

Removing and installing tail light in tail gate

Switch off ignition and all electrical consumers and pull out ignition key. Unclip service cover out of trim in tailgate

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 Pull connector -2- off. Remove securing nuts -1- on tail light in tailgate. Remove tail light. Installing:

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2005 , Bora 2006 Electrical System - Edition 05.2005

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Installation is performed in the reverse order of installation; 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-.
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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:

Removing and installing tail light bulb carrier in tailgate

Switch off ignition and all electrical consumers and pull out ignition key. Unclip service cover out of trim in tailgate Pull connector -2- off. Note

The lower tail light trim must not be removed. For reasons of clarity the lower tailgate trim is not shown in the following figure.

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6. Tail lights

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unclip the two retaining tabs -in direction of arrow- and take bulb carrier -1- out. Installing: Install in reverse order of removal.

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7
7.1
Removing:

Number plate lights

Removing and installing number plate light -X-

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 5 W Installing: Install in reverse order of removal.
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7. Number plate lights

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8
8.1

Additional brake light

Removing and installing high level brake light bulb -M25Note

ks In the event of damage, the complete high level brake light -M25Vol by d unit must be renewed. ise
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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 light bulb -M25- to rear window -in direction of arrowInstalling:

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Installation is performed in the reverse order of installation; when doing this, note the following:

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Steering column switch

Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

Fault detection and fault display: The steering column electronics control unit -J527- 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.

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In the event of faults in the steering column switch, the coding

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of the steering column electronics control unit -J527- must be checked page 227 .

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9. Steering column switch

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9.1

Assembly overview - steering column switch

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

1 - Turn signal switch Removing and installing page 224 The turn signal switch comprises of the follow ing components turn signal switch -E2- , headlight dipper/flasher switch -E4- and, 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 -E452 - Steering column switch base Removing and installing page 226 3 - Windscreen wiper switch E Removing and installing page 225 4 - Securing bolt

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6 - Airbag coil connector and return ring with slip ring -F138 Removing and installing page 223 7 - Steering angle sender -G85 Removing and installing page 224 Basic settings page 228

9.2

Removing and installing steering col umn switch

Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

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5 - Steering column electronics control unit -J527 Removing and installing page 221 Coding page 227 Final control diagnosis page 227

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Note

When removing the steering column switch, observe that no metal shavings/swarf enter the steering column switch when drilling out the shear head bolts.
Removing: For removal of the complete steering column switch, inc. base module, the switch is dismantled and the steering lock housing is also removed. For assembly of the steering lock housing, new shear head bolts are required. Even if just one component of the steering column switch is removed or renewed, the sequence 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 .
n AG d gen A repairs, interior; abody Remove steering column trim General oes ksw not l o V and trim; Removing and gu Rep. Gr. 68 ; Compartments, covers by ara d e nte installing steering column switch ris trim .

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Steering column electronics control unit -J527- page 221 Airbag coil connector and return ring with slip ring -F138 page 223 Steering angle sender -G85- page 224 Turn signal switch page 224 Windscreen wiper switch -E- page 225 Steering column switch base page 226 Installing: Install in reverse order of removal.

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9.2.1

Removing and installing steering col umn electronics control unit -J527r fo ng

Note

After new control unit has been installed, it must be coded In the event of faults in the steering column switch, the coding
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9. Steering column switch

221

 Unscrew bolt -1-.

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Insert a thin rod, e.g. of 2.5 mm -2- approx. 45 mm in the hole -arrow 1- in steering column electronics control unit J527- to release the locking tab -arrow 2-.

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Removing:

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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 separate from steering col umn electronics control unit -J527- . Installing: Installation is performed in the reverse order of installation; when doing this, note the following: Note

Ensure when fitting the connector that none of the pins become bent and that the connector can be heard to engage.

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Carefully pull the steering column electronics control unit J527- downwards off the steering column switch.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.2.2

Removing and installing coil connector for airbag and reset ring with slip ring F138-

Removing: Note

The coil connector should not be moved out of the central position during removal and the road wheels should be 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

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The coloured strip (black rectangles) -arrow- must be in view -1-. The coloured strip (yellow) -arrow- must be in view -1-.
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If a new steering angle sensor -G85- is installed, this procedure must be followed by a basic setting page 228 .
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Note

9. Steering column switch

223

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.2.3
Removing:

Removing and installing steering angle sensor -G85-

Pull the steering angle sender -G85- -1- backwards and away from the steering column switch -arrow-. Installing: Install in reverse order of removal.

9.2.4

Removing and installing turn signal switch

Note

nents turn signal switch -E2- , headlight dipper/flasher switch -E4- and, if fitted with cruise control system cruise control sys tem switch -E45cruise control system switch -E45- .

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The turn signal switch comprises of the following compo

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For reasons of clarity, the steering column switch is shown with Removing:

Release retaining clips -arrows- using a 1.0 mm feeler gauge -1- and take turn signal switch off backwards. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: Note

The turn signal switch should be heard to engage.

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Rep. Gr.94 - Lights, lamps, switches - outside

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9.2.5
Removing: Note

Removing and installing windscreen wiper switch -Ees, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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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 doing this, note the following: Note

The windscreen wiper switch -E- should be heard to engage.

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9. Steering column switch

225

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.2.6

Removing and installing base module of steering column switch

Note

To remove the base module of the steering column switch -2- -, the shear head bolts of the steering lock housing must be drilled out. To reinstall, new shear head bolts -1- are required Parts catalogue (ETKA) .
Caution

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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 General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing steering column switch trim .
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Remove steering column electronics control unit -J527 page 221 .

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Remove coil spring for airbag/coil connector with slip ring F138- page 223 . Remove steering angle sender -G85- page 224 . Remove the turn signal light switch -E2- page 224 . Remove windscreen wiper switch -E- page 225 . Disconnect connector -arrow- at reader coil -3-. The basic brace can be removed once all the components moun ted on it have been dismantled: Drill out securing bolts -1- of steering lock housing -3-. Note

Bolts M8 -1-, core diameter 6.8 mm.

226

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull steering lock housing and base module of steering column switch -2- to rear off steering column. Take steering lock housing off base module of steering column switch. Installing: Place the steering lock housing into the basic for the steering column switch. Push base module of steering column switch -2- as far as possible onto steering column. Fit connector -arrow- at reader coil -3-. Tighten the new shear head bolts -1- to steering column. Tighten the new shear head bolts -1- until bolt heads shear off. Install all parts in reverse order of removal.

9.3

Steering column electronics control unit -J527Coding steering column electronics con trol unit -J527G. Volkswage
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Removing and installing steering column electronics control unit -J527- page 221

9.3.1

s no olks and information system Connect the vehicle diagnosis, testing t gu yV b ara d -VAS 5051A- to page 281 e n s i

Using the Go to key, select Function/component selection and the following menu items one after the other: Body Electrical System

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t Select guided fault finding in Vehicle Diagnosis, Testing and au ss Information System -VAS 5051A- .

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01 - On Board Diagnostic capable systems Steering wheel electronics Steering wheel electronics functions Coding control unit for steering wheel electronics

9.3.2

Steering column electronics control unit -J527- final control diagnosis

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- .
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Using the Go to key, select Function/component selection and the following menu items one after the other:
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01 - On Board Diagnostic capable systems Steering wheel electronics functions

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9. Steering column switch

227

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Steering wheel electronics final control diagnosis

9.4 9.4.1

Steering angle sender -G85Basic setting steering angle sender G85-

Removing and installing steering angle sender -G85 page 224

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 other: Running gear Brake system 01 - Mark 60/Mark 70 systems, capable of self-diagnosis Anti-lock braking system ABS/EDL/TCS/ESP Mark 60 Function Basic setting steering angle sensor (00778-3132) -G85-

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Ignition switch and lock cylinder

Removing and installing steering lock housing

Caution

Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

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Note

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To remove steering lock housing it is necessary to remove the steering column switch base first.
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The steering lock could be destroyed.

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If the steering lock is actuated without 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

Disconnecting and connecting the battery as described in the Workshop Manual page 29 . The steering lock could be destroyed. If the steering lock is actuated without 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 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 steering column electronics control unit -J527 page 221 .

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Removing and installing lock cylinder

Caution

10. Ignition switch and lock cylinder

229

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove coil spring for airbag/coil connector with slip ring F138- page 223 . Remove steering angle sender -G85- page 224 . Note For reasons of clarity, the diagram is shown without turn signal

and windscreen wiper switch. There is no need to remove the switches for removal of the lock cylinder. cannot be replaced individually.

The immobilizer reader coil is secured to the lock cylinder and 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 - Position Start

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Note

For reasons of clarity, the diagram shows a removed lock cylinder without ignition key.
Insert steel rod (approx. 1.2 mm) in drilling -arrow- adjacent to ignition key. Using steel rod -2- disengage -arrow- safety bar -3- of lock cylinder -1-. Pull lock cylinder -1- out of steering lock housing.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Installing: Note

For reasons of clarity, the ignition key is not shown in the following diagram.
Insert ignition key in lock cylinder -1- and turn to position Drive. Using steel rod -2- disengage -arrow- safety bar -3- of lock cylinder -1-. Place 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

Removing:

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Disconnecting and connecting the Workshop Manual page 29 .

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Disconnect the battery page 29 . Pull connector -2- off ignition switch -1-. Release ignition switch using small screwdriver -arrows-. Pull ignition switch -1- out of steering lock housing. Installing: Insert ignition switch in steering lock housing until it can be heard to engage.

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231

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Insert ignition key in lock cylinder and turn to position Drive. Note

Insert ignition key in lock cylinder and turn to position Drive.

Position of key in lock cylinder: 1 - Position Stop 2 - Position Drive 3 - Position Start Install all parts in reverse order of removal.

10.3.1

Removing and installing ignition key withdrawal lock solenoid -N334-

The ignition key withdrawal lock solenoid -N334- is located di rectly adjacent to the ignition starter key.
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Note

Removing:

Remove steering column electronics control unit -J527 page 221 . Release locking device -2- using a screwdriver. Pull ignition key withdrawal lock solenoid -N334- -1- in direc tion of arrow and out of its mounting. The electrical connection will be disconnected automatically. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: Note

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will inhibit the removal of the ignition key.

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232

Rep. Gr.94 - Lights, lamps, switches - outside

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After reconnecting the battery, carry out final control diagnosis to activate ignition key withdrawal lock solenoid -N334 page 227 .
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

11
Note

Parking aid

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General description:

The parking 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 sensor -G335 Rear centre right parking aid sender -G205Fault detection and fault display: The parking aid system is equipped with self-diagnosis, which is designed to simplify fault finding.

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To check the entire parking aid system, perform final control di agnosis page 236 .
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For fault finding, use the vehicle diagnosis, testing and informa tion system -VAS 5051A- in guided fault finding mode.
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11. Parking aid

233

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

11.1

Assembly overview - parking aid

1 - Parking aid system warning buzzer -H15 Below the rear shelf Removing and installing page 236 2 - Parking aid control unit J446 Behind right luggage compartment trim panel Removing and installing page 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 gen AG. Volkswagen AG does wa sensor -G334not olks gu yV b ara d cover e In the rear bumper nte is r o eo h ut Removing a and installing ra c s s page 235 6 - Rear centre left parking aid sender -G204 In the rear bumper cover Removing and installing page 235
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11.2

Removing and installing parking aid control unit -J446-

The parking aid control unit is located behind the right luggage compartment panel trim. Removing: Switch off ignition and all electrical consumers and pull out ignition key. Remove right side panel trim in luggage compartment Gen eral body repairs, interior; Rep. Gr. 70 ; Load and luggage area trims .
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234

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove connectors -1- by pressing the locking tabs -arrows- inwards.

Press locking tabs -arrows- of the retainer outwards and take parking aid control unit -1- out of the retainer. Installing: Install in reverse order of removal.

11.3

olks rear bumper cover. Following 4 senders are located in the yV

is Rear centre left parking th aid or sender -G204b ed

Removing and installing parking aid sensor G. Volkswagen

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Rear right inner parking aid sensor -G335 Rear centre right parking aid sender -G205Note

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ss aid sensor -G334 Rear left inner parking

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Removal and installation of the rear parking aid sensor is carried out in the same way for all sensors and is described below for just one sensor.
Removing:

Switch off ignition and all electrical consumers and pull out ignition key. Remove rear bumper cover General body repairs, exterior; Rep. Gr. 63 ; Rear bumper .

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11. Parking aid

235

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Disconnect connector -arrow-.

Release locking lugs -arrows- and pull sender out of bumper cover. Installing: Install in reverse order of removal.

11.4

Removing: Pull off connector -1-.

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a The rear parking aid warning buzzer -H15- is ss fitted on the shelf plate. It is accessible via the luggage compartment.

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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

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Connect the vehicle diagnosis, testing and information system -VAS 5051A- to page 281
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Select guided fault finding in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .
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Using the Go to key, select Function/component selection and the following menu items one after the other: Body General Body Repairs 01 - On Board Diagnostic capable systems Parking aid
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236

Rep. Gr.94 - Lights, lamps, switches - outside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Parking aid functions Final control diagnosis

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11. Parking aid

237

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

12

Torque settings: lights, bulbs, switches - exterior

Torque settings: headlight
Torque settings 4 Nm 4 Nm 4 Nm

12.1

Threaded connections Upper headlight Lower left headlight Lower right headlight

12.2

Torque settings: fog lights

Torque settings 1,5 Nm

Threaded connections Headlight securing screws

12.3

Torque settings - tail light in side panel

Torque settings 3.5 Nm 0.5 Nm

Threaded connections Securing nuts

12.4

Torque settings - tail light in tailgate

Torque settings 3.5 Nm 0.5 Nm
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Threaded connections Securing nuts

12.5

Torque settings: vehicle level sender

M6 M5

Threaded connections Front left vehicle level sender -G78Rear left vehicle level sender -G76un le

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238

Rep. Gr.94 - Lights, lamps, switches - outside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

96
1
Note

Lights, lamps, switches - inside

Lights and switches in engine com partment

The Jetta or the Bora have no lights in the engine compartment.

1.1

Removing and installing bonnet contact switch -F266urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Note

The bonnet contact switch -F266- is integrated into the bonnet

lock and cannot be replaced individually.

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If the bonnet contact switch -F266- is found to be defective,

the entire bonnet lock must always be replaced.

Remove front bonnet lock General Body Repairs, Exterior; Rep. Gr. 55 ; Bonnet; Removing and installing coupling lock; Removing .

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239

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2
2.1

Lights and switches in dash panel

Removing and installing light switch E1-

The following components are integrated into the light switch E1- : Fog light switch -E7 Rear fog light switch -E18 Light switch illumination bulb -L9Removing:
n AG. Volkswagen AG do es n wage s k l ot g Switch off the ignition and all electrical consumers. y Vo ua b ran ed s i tee r Turn grip of light switch to position 0. o h t or u ac a s Push in grip of light switch -1- and turn it to sthe right slightly
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-2-.

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Hold rotary part in this position and pull lighting switch (using rotary part) out of dash panel -3-.

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Disconnect connector -arrow-. Installing: Fit connector to light switch.

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Hold light switch and press rotary position indicator of light switch firmly inwards -1- and turn slightly to right -2-. Hold grip in this position and insert light switch in dash panel -3-. Turn rotary knob to 0 release and engage switch.

240

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2.2

Removing and installing glove compart ment light -W6-

Special tools and workshop equipment required Removal wedge -VAS 3409-

Note
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Switch off the ignition and all electrical consumers. Lever lens carefully out using removal wedge -VAS 3409- or a screwdriver.

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Removing:

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Disconnect connector -arrow-. Renew bulb:

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2. Lights and switches in dash panel

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241

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unlock locking tabs -1- and take thermal protection plate -2off the lens or the light.

Lever bulb carefully out of the holder. Renew glas base bulb (12 V, 5 W). Installing:
pe rm itte d

Installation is carried out in the reverse order. When installing, note the following:
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Check functions of glove box switch. The lamp must not light when the lid is closed.

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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 compartment .
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Unlock locking lug -1- and slide the switch out of the guide -arrow-. Installing: Install in reverse order of removal.

2.4
Removing:

Removing and installing switches and instruments illumination regulator -E20-

Switch off the ignition and all electrical consumers. Remove light switch page 240 . Remove stowage compartment on driver side General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

242

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Disconnect connector -arrow-.

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Unlock locking lugs -arrows- and take adjuster and regulator out. Installing: Install in reverse order of removal.

thi sd o cu m en

2.5

Switch off the ignition and all electrical consumers.

AG.

Remove centre vent Heating, air conditioning system; Rep. Gr. 80 ; Servicing heating system; remove vent; Remove cen tre vent . Remove connectors -arrows-.

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Removing:

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Removing and installing front passenger side airbag deactivated warning lamp K145c o p yri gh t . C op yi

2. Lights and switches in dash panel

243

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unlock locking lugs -arrows- and take warning lamp out. Installing: Install in reverse order of removal.

2.6
Removing:

Removing and installing hazard warning olkswagen AG does light switch -E3- olkswagen AG. V no
es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Switch off the ignition

Remove centre vent Heating, air conditioning system; Rep. Gr. 80 ; Servicing heating system; remove vent; Remove cen tre vent . Remove connectors -arrows-.

yV db ise r tho au all electrical and s s

consumers.

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Release locking lugs -arrows- and remove hazard warning light switch. Installing:
c o p yri gh t. C op yi

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Install in reverse order of removal.

2.7

Removing and installing left footwell light -W9- and right footwell light -W10-

Special tools and workshop equipment required

244

Rep. Gr.96 - Lights, lamps, switches - inside

ht rig py Co t.

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Prote cted by

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removal wedge -VAS 3409-

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). so that only one light is described.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Note

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The removal and installation of both footwell lights is the same Removing:

Switch off the ignition and all electrical consumers. Lever footwell light out of the trim under the dash panel using removal wedge -VAS 3409- or a screwdriver.

r fo ng

Disconnect connector -arrow-. Renew bulb:

2. Lights and switches in dash panel

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245

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unlock locking tabs -1- and take thermal protection plate -2off 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 -E224WARNING

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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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 and all electrical consumers. Remove glove compartment General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing glove compartment . Disconnect connector -arrow-.

thi sd o cu m en

246

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Release locking lugs -arrows- and remove key switch. Installing: Install in reverse order of removal.
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

r fo ng

2. Lights and switches in dash panel

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247

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

3
3.1

Lights and switches in front doors

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
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Removing and installing window regula tor switch in front passenger door E107Note

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

The window regulator switch in front passenger door -E107- fea tures a button illumination bulb -L76- , which must not be replaced individually.
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 .
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Release locking lugs -arrows- and remove switch from the in stallation frame. Installing: Install in reverse order of removal.

3.2

Removing and installing switch module for driver side mirror adjustment

The following components (depending on equipment) are inte grated into the switch module for the driver side mirror adjustment: Mirror adjustment switch -E43 Mirror adjustment reversing switch -E48 Exterior mirror heater button -E231 Mirror fold-in feature system switch -E263 Mirror adjustment switch illumination bulb -L78-

248

Rep. Gr.96 - Lights, lamps, switches - inside

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Disconnect connector -arrow-.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Note

In the event of repair, the complete component must be renewed.

Removing: Remove switch module window lifter, driver side page 250 . Unclip installation frame for switch from trim. Release locking lugs -arrows- and remove switch from the in stallation frame. Installing: Install in reverse order of removal.
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rrectness of i t to the co nform spec a t i h re o n in wit thi s

3.3

Removing and installing driver side in terior locking button for central locking system -E308Note

The driver side interior locking button for central locking system E308- features a button illumination bulb -L76- , which must not be replaced individually.
r te o iva r rp fo g n

Removing:

Switch off the ignition and all electrical consumers.

ht rig py Co t.

do c um en

Remove door trim General body repairs, interior; Rep. Gr. 70 ; Removing and installing front door trim, driver side . Disconnect connector -1- and tighten securing bolts -2-. Take door opener with switch out of the door trim.
AG.

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3. Lights and switches in front doors

249

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Release locking lugs -arrows- and remove interior locking switch from the installation frame. Installing: Install in reverse order of removal.

3.4

Components - front door locks

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

The following components (depending on equipment) are inte grated into the driver side door lock: Driver door contact switch -F2 Driver side central locking lock unit -F220 Driver door central locking motor -V56 Driver door central locking deadlock function motor -V161The 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-

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Front passenger door central locking deadlock function motor -V162Note

do c um en

3.5

Removing and installing switch module for driver side window lift

Special tools and workshop equipment required Removal wedge -VAS 3409-

250

Rep. Gr.96 - Lights, lamps, switches - inside

AG.

Replace relevant door lock General Body Repairs, Exterior; Rep. Gr. 57 ; Front door; Removing and installing door lock .

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In the event of component defects - front door locks:

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In the event of repair, the complete component must be renewed.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

AG. Volkswagen AG d agen oes ksw not l o V gu Note y b ara d nte ise r o eo h t u ra When removing and installing components in visual area (con a c s s a commercial adhesive tape nectors, covers, trims etc.) apply

ility ab y li an pt ce

where a lever tool is applied ( removal wedge -VAS 3409- , srew driver).
The following components (in models with 4 doors) are integrated into the switch module for the driver 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 -L76Note

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

In the event of repair, the complete component must be renewed.

ht rig py Co t.

do c um en

The following components (in models with 2 doors) are integrated into the switch module for the driver side window lift: Front right window regulator switch in driver door -E81 Button illumination bulb -L76Note
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Front left window regulator switch -E40-

In the event of repair, the complete component must be renewed.

Removing: Switch off the ignition and all electrical consumers. Carefully lever installation frame out of door trim using removal wedge -VAS 3409- or screwdriver -arrow-.

AG.

c o p yri gh t. C op yi

3. Lights and switches in front doors

251

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove connectors -arrows-.

Release locking lugs -arrows- and remove switch from the in stallation frame. Installing: Install in reverse order of removal.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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3.6

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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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-

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Note

The remote release button for fuel filler flap and rear lid -E463features a button illumination bulb -L76- , which must not be replaced individually.
Removing:

Switch off the ignition and all electrical consumers.

r fo ng

Disconnect connector -arrow-.

252

Rep. Gr.96 - Lights, lamps, switches - inside

ht rig py Co t.

Remove door trim General body repairs, interior; Rep. Gr. 70 ; Door trim; Removing and installing front door trim, driver side .
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AG.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Release locking lugs -arrows- and remove switch from the door trim. Installing: Install in reverse order of removal.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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3. Lights and switches in front doors

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253

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

4
4.1

Lights and switches in rear doors

Components - front door locks

The following components (depending on equipment) are inte grated into the rear left door lock: Rear left door contact switch -F10 Rear left central locking lock unit -F222. Volkswagen AG gen AG does swa k not l o Rear left door central locking motor, lock -V214V gu y ara db e nte s i r Rear left door central locking deadlock function motor -V163o eo h ut ra a c s s are inte The following components (depending on equipment)

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Rear right door contact switch -F11-

Rear right central locking lock unit -F223-

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

grated into the rear right door lock:

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rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

Rear right door central locking motor, lock -V215 Rear right door central deadlock function locking motor -V164Note

In the event of repair, the complete component must be renewed.

In the event of component defects - rear door locks: Replace relevant door lock General Body Repairs, Exterior; Rep. Gr. 58 ; Rear door; Removing and installing door lock .

4.2

Removing:

Remove lever shell, upper part out of the closing lever Gen eral body repairs, interior; Rep. Gr. 70 ; Removing and instal ling door trim; Rear door trim . Disconnect connector -arrow-.

254

Rep. Gr.96 - Lights, lamps, switches - inside

AG.

Switch off the ignition and all electrical consumers.

ht rig py Co t.

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Removing and installing rear left window regulator switch, in door -E52- and rear right window regulator switch, in door E54r fo ng

Installing:

Install in reverse order of removal.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Release locking lugs -arrows- and remove switch from the in stallation frame.
un le

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4. Lights and switches in rear doors

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255

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Lights and switches in luggage com partment

Removing and installing luggage com partment light -W3wa olks
e ris tho u a ss

5.1

kswagen AG . Vol Special tools and workshop equipment required gen AG d

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rrectness of i t to the co nform spec at i h re o n wit in t his

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 3409- , srewdriver).
ht rig py Co t.

do c um en

Lever light out of the luggage compartment trim using removal wedge -VAS 3409- or a screwdriver.
AG.

256

Rep. Gr.96 - Lights, lamps, switches - inside

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Switch off the ignition and all electrical consumers.

Prote cted by

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Removing:

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Disconnect connector -arrow-. 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

ua db r The rear lid lock unit -F256is integrated into the tailgate lock and an ise tee r o cannot be replaced individually. h t o
es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Removing and installing rear lid lock unit AG. Volkswagen AG d -F256agen oes ksw n
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s unit -F256- is found to be defective, the entire If the rear lid lock tailgate lock must always be replaced.

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Renew tailgate lock General Body Repairs, Exterior; Rep. Gr. 55 ; Tailgate; Removing and installing coupling lock; Re moving .

rrectness of i t to the co nf o r m spec atio h re n in wit

thi sd o cu m en

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5. Lights and switches in luggage compartment

257

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

6
6.1

Lights and switches in roof trim

Removing and installing front interior light and reading light (vehicles with no sliding 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 -W40Note

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

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss

Special tools and workshop equipment required Removal wedge -VAS 3409-

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

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:

thi sd o cu m en

Switch off the ignition and all electrical consumers.

258

Rep. Gr.96 - Lights, lamps, switches - inside

ht rig py Co t.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Carefully lever trim out of interior light using removal wedge VAS 3409- or screwdriver -arrow-.
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Unbolt securing bolts -arrow-. Take the interior light out of the headliner console.

Remove connectors -arrows-. Installing:

r te o iva r rp fo g n

do c um en

Install in reverse order of removal.

6.1.2

Replace front interior light -W1-

Special tools and workshop equipment required Removal wedge -VAS 3409-

6. Lights and switches in roof trim

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259

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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:
n AG. Volkswagen AG do Switch off the ignition and all electrical consumers. e wage
by Carefully lever lens for interior light edout using removal wedge ris -VAS 3409- or screwdriver -arrow-. o th

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Press contact -1- of light to side -arrow- and remove festoon bulb -2- with the contact from the interior light.

do c um en

Fit the contact to the new festoon bulb (12 V, 10 W). Installing: Install in reverse order of removal.

6.1.3
Removing:

Left centre reading light -W39- and right centre reading light -W40-

Remove interior light page 258 .

260

Rep. Gr.96 - Lights, lamps, switches - inside

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Pull contact -arrow- off defective festoon bulb.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.

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Installing: Install in
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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 -E8Note
ht rig py Co t.
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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.

do c um en

6.2.1

Removing and installing front interior light and reading light

Special tools and workshop equipment required

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AG.

6. Lights and switches in roof trim

261

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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).
r fo ng

Removing:

Switch off the ignition and all electrical consumers.

agen lksw Vo by

Carefully lever trim out of interior light using removal wedge VAS 3409- or screwdriver -arrow-.
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Unbolt securing bolts -arrow-. Take the interior light out of the headliner console.

262

Rep. Gr.96 - Lights, lamps, switches - inside

ht rig py Co t.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove connectors -arrows-. Installing: Install in reverse order of removal.

6.2.2
Removing:

Removing and installing sunroof switch -E8es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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Remove interior light page 261 . Disconnect connector -arrow-.

rrectness of i t to the co nform spec at i h re o n wit in t his

Release locking lugs -arrows- and remove switch from the in stallation frame. Installing: Install in reverse order of removal.

do c um en

6.2.3

Replace front interior light -W1-

Special tools and workshop equipment required

6. Lights and switches in roof trim

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AG.

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263

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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 removal wedge swausing olk gen AG en AG. V does -VAS 3409- or screwdriver ag-arrow-. w s k n
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Press contact -1- of light to side -arrow- and remove festoon bulb -2- with the contact from the interior light.

r te o iva r rp fo g n

do c um en

264

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Pull contact -arrow- off defective festoon bulb. Fit the contact to the new festoon bulb (12 V, 10 W). Installing: Install in reverse order of removal.
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6.2.4

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Left centre reading light -W39- and right centre reading light -W40-

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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.

Install in reverse order of removal.

6.3

Rear interior and reading light (vehicles without 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-

AG.

Installing:

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Renew glas base bulb (12 V, 5 W).

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Pull glas base bulb carefully out of the holder.

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6. Lights and switches in roof trim

265

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Note

The interior light and reading light as well as the switches for the lkswagen A interior light and reading light are connected together and AG. Vo G docan not agen es n be separated. When repairing, renew ksw the complete component. l ot o V

6.3.1

Removing:

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Removing and installing rear interior ss and reading light (vehicles without ATAS)

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rrectness of i t to the co nform spec at i h re o n wit in t his

Switch off the ignition and all electrical consumers. Release locking lugs -arrows- and take trim with lens off inte rior light and reading light.

do c um en

Disconnect connector -arrow-. Installing: Install in reverse order of removal.

266

Rep. Gr.96 - Lights, lamps, switches - inside

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Release locking lugs -arrows- and remove interior light and reading light from the headliner.
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AG.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

6.3.2
Removing:

Renewing rear interior and reading light bulbs (vehicles without ATAS)

Release locking lugs -arrows- and take trim with lens off inte rior light and reading light.

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

Pull glas base bulb carefully out of the holder -arrows-. Renew defective glas base bulb (12 V, 5 W). Installing: Install in reverse order of removal.

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6.4

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Rear interior and reading light (vehicles with ATAS)

The following components are integrated in the rear interior light and reading light: Rear left reading light -W11AG.
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Rear left footwell light -W45 Rear right reading light -W12agen lksw Vo by
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Anti-theft alarm ultrasonic sensor -G209Note

The switches -1- of the reading lights are integrated in the rear

interior and reading light and cannot be renewed separately. renewed separately.

The anti-theft alarm ultrasonic sensor -G209- -2- cannot be 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.

6. Lights and switches in roof trim

267

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

6.4.1

Removing and installing rear interior and reading light (vehicles with ATAS)

Note If a rear interior and reading light is removed, the ATAS must

be deactivated page 277 .

The switches -1- of the reading lights are integrated in the rear

interior and reading light and cannot be renewed separately. renewed separately.

The anti-theft alarm ultrasonic sensor -G209- -2- cannot be 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) -arrows- vertically downwards and out from the interior and reading light.
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Press both locking tabs -2- in -direction of arrow A- and take the complete interior and reading light -1- in -direction of arrow B- off the headliner.

Install in reverse order of removal.

268

Rep. Gr.96 - Lights, lamps, switches - inside

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Installing:

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Unlock connectors -1- and -2- and pull both connectors off.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

6.4.2

Renewing rear interior and reading light bulbs (vehicles with ATAS)

Note If a rear interior and reading light bulb is renewed, the ATAS

must be deactivated 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:

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pe rm itte d

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AG. Volkswagen AG d agen oes ksw not l o V gu Switch off the ignition and all electrical consumers. by ara d e nte is r o eo h utlens and reflectors) ra a Pull the entire complete trim -1- (including c s s

vertically downwards and out from the interior and reading light.

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Pull the glass base bulb to be removed (12 V, 5 W) -1- from the holder. Installing: Install in reverse order of removal.

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6.5

Removing and installing front passenger side illuminated vanity mirror -W14- and driver side illuminated vanity mirror W20-

Special tools and workshop equipment required

6. Lights and switches in roof trim

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269

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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). only one light is described.

The removal and installation of both lights is the same so that Removing: Switch off the ignition and all electrical consumers. Lever light carefully out of the roof trim using removal wedge . Volkswagen AG -VAS 3409- or a screwdriver. gen AG does swa
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Disconnect connector -arrow-. Renew bulb:

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270

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Press contact -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.

Note

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

6.6

Removing and installing garage door operating unit -E284-

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ility ab y li an pt ce

rrectness of i t to the co nf o r m spec atio h re n in wit

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 the sun visor on the driver side with garage door op erating unit -E284- -1- General body repairs, interior; Rep. Gr. 68 ; Removing and installing sun visor

thi sd o cu m en

6. Lights and switches in roof trim

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271

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

7
7.1
Removing:

Lights and switches in centre console

Removing and installing TCS and ESP button -E256-

Switch off the ignition and all electrical consumers. Take bellow carefully off centre console -arrows-.

Unbolt securing bolts

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Take mounting frame with ashtray out of the centre console.

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Remove connectors -arrows-.

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272

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Release locking lugs -arrows- and remove switch from the in stallation frame. Installing: Install in reverse order of removal.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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7. Lights and switches in centre console

273

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

8
8.1

Horn
Removing and installing treble tone horn -H2- and bass tone horn -H7Note

The treble tone horn -H2- and the bass tone horn -H7- are

controlled in parallel from the onboard supply control unit J519- . -H2- and bass tone horn -H7- is the same and is therefore described for just one horn. dinal members.
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The procedure for removal and installation of treble tone horn The horns are installed to the left and the right of the longitu AG. Volkswagen Removing: Switch off the ignition and all

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Remove front bumper General body repairs; Rep. Gr. 63 ; Front bumper Disconnect connector -arrow-.

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rrectness of i t to the co nform spec at i h re o n wit in t his

Unscrew securing bolt -arrow- and remove horn. Installing: Install in reverse order of removal.

do c um en

8.2

Checking treble tone horn -H2- and bass tone horn -H7-

The horns ( treble tone horn -H2- and bass tone horn -H7- ) can be checked using final control diagnosis from the onboard supply control unit -J519- .

274

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Immobilizer

General description: The vehicle is equipped with an immobilizer of the 4th generation. Modifications by comparison with the immobilizer of the 3rd gen eration: An adaptation of components of other group marks to Volks wagen vehicles is no longer possible. Vehicle keys are preprogrammed with a base code by the manufacturer. This base code includes a specific manufactur ers code. It is only possible to learn a key of a vehicle if they are programmed with the right manufacturers code. Fault detection and fault display:
olkswamakes gen AG fault AG. V The immobilizer is equipped with self-diagnosis which does agen ksw not l o finding easier. gu yV
b ed

ris For fault finding, use the vehicle diagnosis, testing and informa tho uin tion system -VAS 5051Aguided fault finding mode. a s
urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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9.1

Immobilizer control unit -J362un le

or ac
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The immobilizer control unit -J362- is integrated 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 .

rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

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 radio re mote control General Body Repairs, Exterior; Rep. Gr. 57 ; Central locking; Removing and installing battery for the (fold ing) main key with radio remote control .
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It is not possible to replace the change code transponder in the ignition key. The entire key must always be replaced if the change code trans ponder is found to be defective. Note If an ignition key is replaced or an additional ignition key is

required, the new ignition key must always be adapted to the immobilzer page 276 . central locking) of the ignition key is also replaced, it must be adapted to the comfort system page 276 .

If the radio container (transmission unit for radio-controlled

AG.

9.3.1

Ignition key - change code transponder

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Removing and installing the radio container (transmission unit for radio-controlled central locking) for the ignition key Gen eral Body Repairs, Exterior; Rep. Gr. 57 ; Central locking; Removing and installing battery for the (folding) main key with radio remote control .
Prote cted by c o p yri gh t. C op yi

r fo ng

9. Immobilizer

275

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

9.3.2

Adapting ignition keys to the immobilizer

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 Electrical System 01 - On Board Diagnostic capable systems Immobilizer Immobilizer functions Adapting ignition keys
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9.3.3

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 Repairs Comfort system

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Adapting ignition keys to the comfort system

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01 - On Board Diagnostic capable systems

Comfort system central control unit functions

J393 - Adapting / testing keys with radio remote control

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276

Rep. Gr.96 - Lights, lamps, switches - inside

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

10
Note

Anti-theft alarm system (ATAS)

Additional information:
Operating instructions General description: The functions of the ATAS are integrated into the central control unit for comfort system -J393- . Fault detection and fault display: The anti-theft alarm system 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. olkswagen AG en AG. V Note
es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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 .

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10.1

Activating and deactivating anti-theft alarm system

rrectness of i t to the co nform spec at i h re o n wit in t his

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. Note

Completely close all windows and doors before locking the vehi cle to prevent the anti-theft alarm system triggering an unneces sary alarm.
Deactivating anti-theft alarm system:
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The system is deactivated when the vehicle is unlocked using the radio remote control key or Unlock the car mechanically (emergency open) Unlock the driver door.
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when the ignition is switched on.

The anti-theft alarm system remains active, although no alarm is triggered. Switch ignition on within 15 seconds. Note

If you do not switch on the ignition, the alarm will trigger after 15 seconds.

AG.

Prote cted by c o p yri gh t. C op yi

10. Anti-theft alarm system (ATAS)

277

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 When the ignition is switched on, the electronic immobilizer de tects a valid vehicle key and deactivates the anti-theft alarm system.

10.2

Removing and installing anti-theft alarm ultrasonic sensor -G209-

The anti-theft alarm ultrasonic sensor -G209- , comprising 4 indi vidual sensors -2-, leads and a control element on the back of the interior and reading light, cannot be replaced individually, the en tire rear 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.
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r The anti-theft alarm system must be deactivated before the send o eo h ut ra er is removed page 277 . a c s s

Note

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Switch off ignition and all electrical consumers and pull out ignition key. Remove glove compartment General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing glove compartment; Removing . Unscrew the securing bolts -1- and remove vehicle inclination sender -G384- from the bracket. Release the connector -2- and pull it away from the vehicle inclination sender -G384- . Installing: Install in reverse order of removal.

pe rm itte d

Removing:

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Note

Additional information:

278

Rep. Gr.96 - Lights, lamps, switches - inside

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10.4

AG.

Central locking and anti-theft alarm sys tem aerial -R47-

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Current flow diagrams, Electrical fault finding and Fitting loca tions The central locking and anti-theft alarm system aerial -R47- is laid from the central locking and anti-theft alarm system aerial -J393to 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 10.5.1

Alarm horn -H12Removing and installing the alarm horn -H12AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

The alarm horn -H12- is located on the right of the A-pillar in the wing.

Special tools and workshop equipment required Drill -VAS 5134-

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pe rm itte d

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Twist drill 6 mm Pop rivet pliers -VAS 5072-

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Note

The anti-theft alarm system must be deactivated before the alarm horn is removed page 277 .
Removing: Switch off ignition and all electrical consumers and pull out ignition key.
10. Anti-theft alarm system (ATAS)

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279

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove front right wheel housing liner General body re pairs, interior; Rep. Gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner; Removing . olkswagen AG en AG. V
Vol Drill out both pop rivets -arrows- using drill by -VAS 5134- and d e 6 mm twist drill. ris

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Pull alarm horn -H12- -1- in -direction of arrow- out of the aperture in the bodywork. Pull connector off -2-. Installing: Note

Insert clip -2- of alarm horn -H12- -3- into the aperture in the bodywork -1-. Secure alarm horn -H12- with pop rivet pliers -VAS 5072- .

10.5.2

Checking alarm horn -H12-

The alarm horn -H12- can be tested using final control diagnosis from convenience system central control unit -J393- .

280

Rep. Gr.96 - Lights, lamps, switches - inside

AG.

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Fit connector to the alarm horn -H12- .

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Perform measures for corrosion protection General Infor mation; Body Repairs, General Body Repairs .
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c o p yri gh t . C op yi

r fo ng

Remove all metal particles caused during the drilling.

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

97
1

Wiring
Vehicle Diagnosis, Testing and Infor mation Systems
WARNING

During testing or measuring operations using a vehicle di agnosis information system, there is a risk of serious or even fatal injury! If the vehicle diagnosis information system is lodged in the activity area of an airbag during a testing or measuring operation, a triggered airbag can result in serious or even . Volkswagen AG fatal injury! gen AG d
o y V operations, work with a sec During testing and measuring db e ond person who can operate the vehicle diagnosis infor ris tho mation system from au one of the rear seats!
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Note

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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- . and guided functions.

All working instructions can be found in guided fault finding Additional information: Self-study programme No. 202 ; Vehicle Diagnosis, Testing and Information System VAS 5051 Self-study programme No. 256 ; VAS 5052 Self-study programme No. 294 ; Online connection of the VAS 5051
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Connecting Vehicle Diagnosis, Testing and Information Sys tem -VAS 5051A- page 281 .
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Connecting vehicle Diagnosis, Testing and Information Sys tem -VAS 5052- page 282 .
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1.1

Connecting vehicle Diagnosis, Testing and Information System -VAS 5051ANote

Observe the latest operating instructions for vehicle diagnosis, testing and information system -VAS 5051A- , which are dis played after selecting the Administration and Operating Man ual buttons.
Special tools and workshop equipment required

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1. Vehicle Diagnosis, Testing and Information Systems

281

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Vehicle Diagnosis, Testing and Information System -VAS 5051A-

Diagnosis lead -VAS 5051/6A- (5 m)

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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Diagnosis lead -VAS 5051/5A- (3 m) Note

r fo ng

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 information system -VAS 5051A- using diagnostic lead -VAS 5051/6A- to diagnostic interface -arrow- in vehicle. Switch ignition on. Switch off all electrical consumers. Note

Any additional vehicle diagnosis, measuring and information sys tems and/or vehicle diagnosis and service information systems are connected in the sequence described above.

282

Rep. Gr.97 - Wiring

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Only these leads are to be used for diagnosis, as they are the only ones fitted with CAN lines and therefore allowing CAN diagnosis and/or CAN communication.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

2
2.1

Removing and installing fuse holder

Removing and installing fuse holder on left of dash panel

Special tools and workshop equipment required Removal wedge -VAS 3409-

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Caution

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o h t installing components in visual area (con e or When removing and u ac a nectors, covers,sstrims etc.) apply a commercial adhesive tape

Note

where a lever tool is applied ( removal wedge -VAS 3409- , srew driver).

ility ab y li an pt ce

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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 .

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2. Removing and installing fuse holder

283

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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-.

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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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 cable length). Installing: Install in reverse order of removal.

thi sd o cu m en

284

Rep. Gr.97 - Wiring

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

3
3.1

Removing and installing relay carrier

Removing and installing relay carrier n AG. Volkswagen AG do es n wage ks l oof o with safety cut-out on left t gu dash panel V by
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Disconnecting and connecting the battery as described in the Workshop Manual page 29 .

rrectness of i t to the co nform spec at i h re o n wit in t his

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.

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Pull relays -arrows- out of the relay carrier. Note

AG.

The relay number depends on vehicle equipment.

Clip locking lugs in -direction of arrow- outwards and then press the connector -1- through the relay carrier.

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3. Removing and installing relay carrier

285

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unlock locking lug -1- of relay carrier in -direction of arrow- and take relay carrier off. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: Clip connectors into the relay carrier first.

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
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The onboard supply control unit -J519-

If the onboard supply control unit -J519- is to be replaced, first

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carry out the procedure 5.1.2 Coding onboard supply control unit J519 , page 293 to read out the stored codes.

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attached to the onboard supply control unit, on left of dash panel form one unit and cannot be separated.
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Removing:

Switch off ignition and all electrical consumers and pull out ignition key. Remove cover, footwell, on driver side General body re pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim . Remove storage compartment on driver side General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Move locking bar -1- of the relay carrier connectors on onboard supply control unit, on left of dash panel in -direction of arrow A-. Move locking bar -2- of the connectors of the on onboard sup ply control unit -J519- in -direction of arrow B-. Note

The connectors of the onboard supply unit -J519- and the swagen control AG. Volk AG do agen es relay carrier on onboard supply control unit, on ksw notleft of dash panel l o gu y V off if the locking bar is set to position may only be pulled OPEN. ar db
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Remove all connectors of the onboard supply ss J519- and the relay carrier on onboard supply control unit, on left of dash panel. Note

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The connector number depends on vehicle equipment.

Unclip onboard supply control unit -J519- and relay carrier on onboard supply control unit, on left of dash panel out of the locking device -arrows C-. Pull onboard supply control unit -J519- and relay carrier on onboard supply control unit, on left of dash panel downwards and in opposite direction of travel out of the bracket. Installing:

Installation is performed in the reverse order of installation; when doing this, note the following: Note
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The locking bars may only be set to CLOSE when all connectors are fitted correctly.
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3. Removing and installing relay carrier

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4
4.1

Electronics boxes

Caution

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Removing and installing electronics box on left in engine compartment

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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.

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Remove hexagon nuts -1-. Open -arrows- covers -2- of cable guides on electronics box. Remove wiring from stud connections. Unclip wiring from cable guides.

288

Rep. Gr.97 - Wiring

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Remove central securing screw -arrow- from electronics box -1-. Note

When the central securing screw -arrow-, the electronics box -1is 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 air filter housing, if necessary. Remove battery page 29 .
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Remove securing bolts -arrows- of battery console -1-. Take battery console -1- out of vehicle.

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4. Electronics boxes

289

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Press tabs apart on bracket of electronics box -arrows B- and slide flat contact housing -1- sidewards -arrow A- out of brack et of electronics 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
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Whether the additional vehicle equipment.

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Pull bracket of electronics box -1-, upwards off studs as far as relay carrier cables allow. Unclip relay carrier -1- sideways out of bracket of electronics box -2-. Take bracket of electronics box -2- out of vehicle. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: Tighten threaded connections to specified torque settings page 307 .

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 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.

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5
5.1
Note

Control units
Onboard supply control unit -J519un le

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The onboard supply control unit -J519- and the relay carrier

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Additional information:

Current flow diagrams, Electrical fault 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 following functions can be adapted: Deleting learning values and setting standard adaptation val ues Adjusting period for coming home function (depending on equipment) Adjusting period for leaving home function (depending on equipment) Adjusting rear window heating On time Switching on and off footwell lighting Switching on and off motorway signaling Adjusting load management Adjusting activation time for headlight cleaning system page 294

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with certain equipment configurations.

The Motorway signaling, comfort signaling, or tap signal

ing means that one touch of the turn signal lever will activate the turn signals (1-5 times) (turn signal cycles). 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.

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The above adaptations can only be carried out in conjunction

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

If the onboard supply control unit -J519- is to be replaced, first

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Fault detection and fault display:

The onboard supply control unit -J519- is equipped with self-di agnosis, 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.

5.1.1
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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 supply control unit -J519- corre sponds to the removal of the relay carrier on onboard supply control unit, on left of dash panel page 286 . Installing: The installation of the onboard supply control unit -J519- corre sponds to the installation of the relay carrier on onboard supply control unit, on left of dash panel page 286 .
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5.1.2

Coding onboard supply control unit J519-

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 Electrical System 01 - On Board Diagnostic capable systems Onboard supply control unit Onboard supply control unit functions Code control unit

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5. Control units

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

5.1.3

Modifying headlight cleaning system

The active time of the headlight cleaning system can be variably adjusted to between 0 and 12.75 seconds. 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 other: Body Electrical System
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Data bus diagnostic interface -J533-

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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:
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Responsible for exchange of data between CAN data bus sys tems drive train CAN data bus, convenience CAN data bus and Infotainment CAN data bus
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Converts diagnostic data from CAN data bus systems to COM wire and vice versa. In this way, data can also be used by the the vehicle diagnosis, testing and information system -VAS 5051ANote
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If the data bus diagnostic interface -J533- is to be removed, first carry out the procedure 5.2.1 Renewing data bus diagnostic interface J533 , page 295 , so that access can be gained to the codes stored within.
Fault detection and fault display: The data bus diagnostic interface -J533- is equipped with selfdiagnosis, 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.

294

Rep. Gr.97 - Wiring

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

5.2.1

Renewing data bus diagnostic interface -J533-

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 Electrical System 01 - On Board Diagnostic capable systems Data bus diagnostic interface Data bus diagnostic interface functions Renewing data bus diagnostic interface

5.2.2
Removing:

Removing and installing data bus diag nostic interface -J533-

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e Before removing data bus diagnostic interface -J533nte , it is es is r o eo h sentialutthat the following work procedure ra a Renewing dash panel insert, page 150 is carried c out, so 1.1 s s

Note

that access can be gained to the codes stored within.

Switch off ignition and all electrical consumers and pull out ignition key.

Remove cover, footwell, on driver side General body re pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim . Release connector -1- and pull connector off data bus diag nostic interface -J533- -2-. Installing: Install in reverse order of removal.

Push securing pins -3- together -arrows- and pull out of holes.

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Note

Additional information:
Current flow diagrams, Electrical fault finding and Fitting loca tions

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5.3

Central control unit for convenience sys tem -J393-

5. Control units

295

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Operating instructions General description: The convenience system central control unit -J393- is responsible for the following in the vehicle: Sliding/tilting sunroof control (release instruction) Power window control (release instruction) Central locking control Anti-theft alarm system control Radio-wave receiver Comfort operation Fault detection and fault display:
urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Rear lid lock

Some of the above functions can be adapted page 298 . The convenience 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.

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5.3.1
Removing:

Removing and installing convenience system central control unit -J393-

Switch off ignition and all electrical consumers and pull out ignition key. Remove glove compartment General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing glove compartment .
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Note

The connectors may only be unlocked and pulled off if the re cesses -arrows- of the connectors and the bracket align exactly.
Unlock connectors and pull them off convenience system cen tral control unit -J393- . Note

The connector number depends on vehicle equipment.

296

Rep. Gr.97 - Wiring

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Pull locking lug -1- off convenience system central control unit -J393- bracket in -direction of arrow- and move the conven ience system central control unit -J393- until the recesses -2- align with the recesses -3-.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Unscrew securing nuts -arrows-. Take bracket off with convenience system central control unit -J393- .

Pull locking lug -1- in -direction of arrow B- and push conven swagen AG. k Vol ience system central control unit -J393- -2- out of the bracket by d e in -direction of arrow A-. ris Installing: Installation is performed in the reverse order of installation; when doing this, note the following:
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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.

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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 Repairs 01 - On Board Diagnostic capable systems Comfort system Comfort system central control unit functions J393 - Coding convenience system central control unit

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5.3.2

Coding convenience system central control unit -J393-

5. Control units

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

5.3.3

Adapting convenience system central control unit -J393-

The following functions can be adapted: Activating and deactivating single door opening Activating and deactivating automatic locking above >15 Km/ h Activating and deactivating automatic unlocking when ignition key is removed Activating and deactivating country settings for intelligent alarm horn Activating and deactivating battery monitoring system (soun der) Activating and deactivating mote control unit
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Activating and deactivating delay when driver's door is opened Sensitivity of tilt angle sensor

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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 Repairs Comfort system

01 - On Board Diagnostic capable systems

Comfort system central control unit functions

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 Repairs 01 - On Board Diagnostic capable systems Comfort system Comfort system central control unit functions J393 - Read alarm sources of anti-theft alarm system

298

Rep. Gr.97 - Wiring

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5.3.4

Convenience system central control unit -J393- - Read alarm sources of anti-theft alarm system

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J393 - Adapting convenience system central control unit

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

5.4

Trailer detector control unit -J345-

The trailer detector control unit -J345- -arrow- is located behind the left side trim in the luggage compartment. Note

Additional information:
Current flow diagrams, Electrical fault finding and Fitting loca tions Operating instructions General description: Note The Golf currently features only control units manufactured by

Westfalia.

To check the control unit use plug socket tester -V.A.G 1537/

wa Aolks yV 5.4.3 Final control diagnosis trailer detector controleunit db ris J345 , page 301 . tho

The trailer detector control unit -J345- is supplied with information (light control) from the onboard supply control unit -J519- and convenience system central control unit -J393- via the CAN.
4) At least the turn signal and brake light must be switched on, in order to detect trailer operation.

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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.

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Fault detection and fault display:

The trailer detector control unit -J345- is equipped with self-diag nosis, 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.

5.4.1

Removing and installing trailer detector control unit -J345ht rig py Co t.

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Special tools and workshop equipment required Torque wrench -V.A.G 1783-

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5. Control units

299

Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Removing: Switch off ignition and all electrical consumers and pull out ignition key. Remove left side panel trim in luggage compartment Gen eral body repairs, interior; Rep. Gr. 70 ; Removing and instal ling load and luggage compartment trim; Trim, luggage compartment, sidewards . Release connectors -2- and pull off trailer detector control unit -J345- . Note

The connector number on the trailer detector control unit -J345shown 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: . Volkswag
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After installing a new trailer detector control unit -J345- it must be coded page 300 .

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Note

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5.4.2

Coding trailer detector control unit J345-

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 Repairs Trailer detector Function

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01 - On Board Diagnostic capable systems

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5.4.3

Final control diagnosis trailer detector control unit -J345-

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, Bora 2006 - Edition 05.2005

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The trailer detector control unit -J345- detects from a power

draw of minimum 5 W 4) the trailer operation.

To check use plug socket tester -V.A.G 1537/A- . Special tools and workshop equipment required Plug socket tester -V.A.G 1537/A- 5)

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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- 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 Repairs 01 - On Board Diagnostic capable systems Trailer detector Function Trailer detector control unit - Final control diagnosis

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5. Control units

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005

Wiring harness and connector re pairs

Safety instructions
Caution

6.1

For repair work on airbag and seat belt tensioner wiring har nesses, only contacts, connectors and wiring designed specif ically for this purpose may be used Parts catalogue (ETKA)!
Observe country-specific regulations. Observe vehicle stickers indicating high voltage components. Before carrying out repairs, discharge residual voltage. Wires from airbag and belt tensioner wiring harness must only AG. Volkswagen AG d be repaired using wiring harness repair set -V.A.Gw1978agen . oe
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6.2

General notes concerning repairs to ve hicle electrical system

Caution

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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 1978 Before beginning repairs to a wiring harness, first rectify the cause of the damage, e.g. sharp edges on a body part, de fective electrical consumer, corrosion.
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6.3

Notes on repairs to wiring harness and connectors

Supplementary notes on repair of CAN bus wiring page 303 Soldering is not permitted for repairs to vehicle wiring. Never repair any heat-shrink connections. If necessary, lay wiring parallel to the defective wiring. Onboard supply wiring harnesses and connectors may only be repaired using wiring harness repair set -V.A.G 1978- .

302

Rep. Gr.97 - Wiring

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If possible, do not loosen any earth wires from the body (dan ger of corrosion).

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Disconnecting the battery earth strap (open circuit) provides a safe working environment for repairs to the electrical system. The battery positive wire need only be disconnected for re moval of the battery.
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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 Operating instructions wiring harness repair set -V.A.G 1978a oes ksw not Perform wiring harness repairs Vol only with yellow wires. Mark gu y b tape. ara repair locations with yellow d e n
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th Shielded wires must au not be repaired. In case of damage, they s s must be entirely replaced.

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6.4

Supplementary notes on repair of CAN bus wiring

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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 Convenience CAN, high Infotainment CAN, high CAN Low wire (all) orange/black orange/green orange/violet orange/brown

Perform wiring harness repairs only with yellow wires. Mark repair locations with yellow tape. When repairs are performed, both bus wires must have the same length. When wires -1- and -2- are twisted together, the twist spacing should be A=20 mm.
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No section of wiring greater than B=50 mm, e.g. in the vicinity of heat-shrink sleeves -arrow-, should not be twisted.
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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. - Further information, e.g. re moval and installation of parts and components, appears in the relevant workshop manual.

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7
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nte ris A new repair concept has been developed for repair work on aer eo ho ut Now connecting wires in different lengths and r a various ial wires. a c s s adapter cables are available as replacement parts instead of a complete aerial wire.
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7.1

General description

Aerial wires must not be repaired, but if repair is required, they must be replaced only by connecting wires and adapter cables offered as genuine parts. Replacement parts can be found in the electronic parts cata logue: Special catalogue; Electrical connections; Genuine ac cessories; Subgroup 35 from illustration No. 035-20. These genuine parts are suitable for all aerial wires 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.
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7.2
123-

Assembly overview - an aerial wire

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Example: Aerial wire between radio and aerial is defective. The following wires are required for the repair: Adapter cable, to radio connection. Length approx. 30 cm. Connecting wire, available in different lengths. Adapter cable, to aerial connection. Length approx. 30 cm.

7.3
Note

Installing a new aerial wire

Note that the total length of an aerial wire, depending on vehicle equipment level, can be divided into sections by aerial diversity control unit, traffic information control unit or aerial amplifier. Only the defective section of aerial wire must be replaced.
Pull defective aerial wire connections off units. Determine the routing of the defective aerial wire in vehicle and measure the total length of the aerial connecting wire to be replaced.

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Jetta 2005 , Bora 2006 Electrical System - Edition 05.2005 The total length of aerial connecting wire is the sum of the length of adapter cables required -1- and -3- and the connecting wire -2-. To determine the length of connecting wire required, subtract 60 cm from the measured total length of aerial connecting wire -2-. n AG. Volkswagen A
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The remainder of the defective aerial wire remains in the vehicle. Connect adapter cables -1- and -3- to equipment in vehicle. Route and secure connecting wire -2- parallel to the old aerial wire. Note

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Do not kink or excessively bend aerial wires! The bending radius must not be below 50 mm.
Connect connecting wire to adapter cables. Perform a functional check.

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8
8.1

Torque settings: Cables

Torque settings: Electronics box in left side of engine compartment

Threaded connections Securing nuts -1Securing nuts -1M5 (AF 8) M6 (AF 10)

Torque settings 4 Nm 6 Nm

8.2

Torque settings trailer detector control unit -J345Torque settings 2 Nm 2 Nm

Threaded connections Securing bolts bracket to body Securing bolts control unit to bracket

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