• Author / Uploaded
• Mauricio Garcia

• Categories
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• Tecnología de vehículos
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Citation preview

Service

Workshop Manual Jetta 2005 ➤ Bora 2006 ➤ Electrical System Edition 05.2005

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Service Department. Technical Information

Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Repair Group

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27 - Starter, current supply,

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90 - Instruments, GCI

92 - Windscreen wash/wipe system

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94 - Lights, lamps, switches - outside 96 - Lights, lamps, switches - inside

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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

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

Contents

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Contents

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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 11.1

Activating and deactivating cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volkswage Renewing dash panel ainsert gen AG . . . . . . .n.A.G.d.oe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s ksw l o Removing and binstalling dash panel insert . . n.o.t g.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yV a d se reverse side of dash panel insert . .ra. n.te. . . . . . . . . . . . . . . . . . . . . . . . . . . . Descriptionoriof eo h t Warning aulamp symbols in dash panel insert . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . s s Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 1.1 1.2 1.3 1.4 2 2.1

150 150 151 152 152 154 154

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi sd o cu m en

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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

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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 155 155 156 160 161 162 163 165 165 166 168 169 169 170 171 171 172 173 173 173 174 174 175 176 176 176 176 178

94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5

ii

Contents

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 . . . . . . . . . . . . . . . . . . . . . . . . . .

179 179 181 182 184 188 189 190 191 192 192 192 198

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 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 sideAmarker agfront . Volkswin en AG bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . gen G do a w s Removing and installing k front side marker . . .e.s .no.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol gu y ar db Mirror turn signal ise bulb and entry light in exterior mirror an.te. . . . . . . . . . . . . . . . . . . . . . . . . . . r o e h Removing aand installing turn signal bulb . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . . . . . . ut c s Removings 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do c um en

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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

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

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96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 1 1.1 2 2.1 2.2

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

239 239 240 240 241

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 1 1.1 2 2.1 3

iv

Contents

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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281 281 283 283 285

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 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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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.G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . n G do es n wage Torque settings: Electronics box in Vleft ot g . . . . . . . . . . . . . . . . . . olksside of engine compartment y b d Torque settings trailer detectorisecontrol unit J345 . . . . . . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . .

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Contents

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Contents

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27 –

Starter, current supply, CC

1

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

Types of battery

1.2.1

Low maintenance battery

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Low maintenance battery with liquid electrolyte (wet battery). These batteries are recognised by the removable cell plugs.

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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.

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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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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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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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 AG. Volkswagen AG d agen oes

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Gel battery

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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

♦ The procedure for checking and testing gel and absorbent

glass mat batteries is identical.

♦ Currently gel batteries are only used in motor homes/campers

at Volkswagen.

Warning notices and safety regulations

1.3.1

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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. olkswagen AG en AG. V

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3. - Keep children away from acid and batteries. 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.

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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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2. - Wear eye protection before commencing work on battery.

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c s 1. - Fires, ssparks, naked lights and smoking are prohibited. Avoid sparks as well as electrostatic discharge when working with ca‐ bles and electrical units. Avoid short circuits. Therefore never lay a tool on a battery.

1. Battery

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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.

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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 .

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

2

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

Procedure when checking the battery

Carry out procedure in sequence as follows: AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d eye ⇒ page 6 or checking Checking battery with a magic e nte is r o eo a low maintenance battery ⇒ page 7 . h ut ra a c s s of battery ⇒ page 10 . Check no load voltage

1.

Visual check ⇒ page 5 .

2.

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Visual check

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2.2

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4.

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3.

WARNING

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.

♦ The battery will be damaged if the battery is not secured correctly. ht rig py Co t.

♦ 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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Caution

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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

5

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 wthat s k Therefore it can no longer be guaranteed the vehicle will oes not g l Vo y ua b function correctly. ran ed

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2.3

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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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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. AG.

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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.

♦ The magic eye can be located at various positions on the bat‐

tery.

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 .

♦ Charging battery with battery charger -VAS 5900-

⇒ page 19 .

6

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

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– Before performing a visual check, tap the magic eye lightly and carefully with the handle of a screwdriver.

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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 .

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

2.4

Checking low maintenance battery WARNING

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Danger of injury! Observe warning tions ⇒ page 2 !

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d noticesiseand safety regula‐ nte r o eo h ut ra a c s s

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2.4.1

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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.

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.

AG.

– Remove cell sealing plugs.

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

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Note

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– Switch off the ignition and all electrical consumers.

– 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

2. Checking battery

7

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Battery filler bottle -VAS 5045/-

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Caution

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♦ 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.

– 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.

– 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

8

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

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Note

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– If fitted, remove the protective foil on the cell sealing plug.

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– Check the electrolyte level of the battery ⇒ page 7 .

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 n AG. Volkswagen AG do es n wage ot g ua ran tee or ac

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

– Remove cell sealing plugs.

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Electrolyte density

Charge

1.28 g/cm3

100 %

1,21

g/cm3

60 %

1,18

g/cm3

40 %

1,10

g/cm3

0%

Note

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The electrolyte density is determined by the float position in the battery electrolyte. The value can be read from the float scale. Voltage 12,7 V 12,3 V 12,1 V 11,7 V

Checking electrolyte density directly after topping up with distilled water will lead to erroneous results. Check electrolyte density only after charging the battery.

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– Seal the cells with the cell sealing plugs.

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– Check the cell sealing plugs and the O-ring seals for damage. Damaged parts must be replaced.

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

2. Checking battery

9

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

2.5

Check no load voltage of battery WARNING . Volkswagen AG gen AG does not gu ara nte eo ra c

wa Danger of injury! Observe warning notices olks and safety regula‐ yV b tions ⇒ page 2 ! ed

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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.

50 %

65 %

♦ The battery should be recharged on new/vehicles which have been stored.

100 %

Full capacity. AG.

12.70 V

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.

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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12,35 V

0%

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12,20 V

Condition of battery

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11,70 V

Charge

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No load voltage

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Measured value

Measure to be performed

No load voltage ≥ 12.5 V

No load voltage is OK, perform a battery load test ⇒ page 10 . Charge battery ⇒ page 15 .

No load voltage < 12.5 V

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 AG. Vol wagen AG d agen o

es n ksw ♦ 136 - 855 A VAollow-temperature test current to EN/ otaccording gu y b arEngineers) SAE (European Norm/Standard of Automotive d a e n s 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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tee ri ho 1) Batteries ut with a low-temperature test current of 520 A according toorDIN ac can be a s testedsusing setting for 499A according to DIN.

Note

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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.

♦ 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

♦ Observe battery manufacture's handling instructions!

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2. Checking battery

11

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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

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9 - Printer

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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– 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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Perform battery load test:

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2.6.2

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8 - Button to advance paper

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 . 1-

Connected directly to battery.

2-

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.

Table: low-temperature test current . Volkswag

n AG d AG Low-temperature testecurrent agen oesin A ksw not l o V y b ⇒ guara ed IEC

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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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⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒

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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

AG.

ss

DIN

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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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EN/ SAE

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2.6.3

2. Checking battery

13

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Low-temperature test current in A IEC ⇒

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

545 - 554 555 - 564 565 - 574

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

Comments concerning test print out

1-

Measuring range set on tester.

2-

Diagram -arrow- indicates battery condition.

3-

Test result.

4-

Battery voltage during load test.

5-

es n lksw be completed by test Vehicle data and date. person‐ ot g VoMust ua by nel. d ran e s

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♦ The print out is required for warranty purposes.

2.7.2

Assessing test results

Battery tester print out

Measure to be performed

Starting power very good Start output good Starting power sufficient Starting power poor Starting power very poor Not capable of being tested

Battery OK Battery OK Charge battery ⇒ page 15 and repeat battery load test 3)

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

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14

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

♦ Perform test once only. Repeating the test falsifies the results.

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Note

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Charging battery WARNING

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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 .

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

♦ Observe ⇒ Operating instructions for battery charger -VAS

3.1.1

AG.

♦ Observe battery manufacture's handling instructions!

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5095 A- .

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Note

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3

➤ , Bora 2006 ➤ - Edition 05.2005

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Jetta 2005 AG. Volkswagen AG d agen oes ksw not Electrical System l o gu yV ara db e nte ris eo ho ut ra a c s s

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)

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

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Note

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

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

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

♦ 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. – 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 .

16

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

AG.

– Remove charger unit terminals from battery terminals.

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– Switch off charging unit ⇒ page 15 .

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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.

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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 %).

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

3.1.3

Charging totally discharged battery with battery charger -VAS 5095 AWARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! olkswagen AG en AG. V

wag olks yV b ed ris The charger unit automatically recognises totally ho discharged bat‐ t au with a low charg‐ teries and initiates a gentle charging procedure ss

♦ 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

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

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Note

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

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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.

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.

♦ A minimum load of 0.6 A (e.g. parking light) must be

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Note

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– Exchange battery ⇒ page 31 . – Switch off charging unit ⇒ page 15 .

– Remove charger unit terminals from battery terminals. – Set support mode/normal mode change-over switch to ⇒ page 15 “normal mode” again.

3.1.5

Charging battery in buffer/ maintenance mode with battery charger -VAS 5095 AWARNING

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

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

Prote cted by

Note

AG.

– Proceed as for charging battery ⇒ page 16 .

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In the buffer mode the battery charger -VAS 5095 A- is charged correctly and is maintained in a fully charged condition.

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

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 on vehicle parking light.

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

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

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- .

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Description of battery charger -VAS 5900-

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3.2.1

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♦ Observe

AG. Volkswagen AG d agen oes ksw not l o V gu ⇒ Operating instructions for battery charger -VAS y b ara d nte ise r o eo h t u ra a c battery manufacture's handlingssinstructions!

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” ↑

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WARNING

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3.2.2

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5 - INFO

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4 - START / STOP

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3 - Adjustment button “Down” ↓

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

3. Charging battery

19

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

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

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♦ Battery charger -VAS 5900-

♦ 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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– 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 . AG.

– 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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the battery is being charged.

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Note

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‐

sumers while charging is possible. The charging period will be longer.

♦ The battery charger will switch to maintenance mode after

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: 1-

Displayed battery voltage is not as per nominal voltage:

– Press respective button “Up” ↑ or “Down” ↓ until charging sequence starts. Displayed battery voltage is not as per nominal voltage – charging sequence already started: olkswagen AG en AG. V

– Press START / STOP twice.

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Display remains unchanged.

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3-

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– Press respective button “Up” ↑ or sequence starts again.

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2-

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

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

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3.2.3

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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.

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-

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Note

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♦ 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 .

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

AG.

– Connect black terminal clamp “-” to negative terminal on bat‐ tery.

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– Connect red terminal clamp “+” to positive terminal on battery.

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– Set battery capacity (Ah) of battery for charging using respec‐ tive button “Up” ↑ or “Down” ↓ .

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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.

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

Note

The success of the “service charge” depends on the severity of the sulphation of the battery. Possible faults and fault rectification: 1-

Displayed battery voltage is not as per nominal voltage:

– Press respective button “Up” ↑ or “Down” ↓ until charging sequence starts. 2-

Displayed battery voltage is not as per nominal voltage – charging sequence already started:

– Press START / STOP twice.

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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.

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– 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. AG.

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.

3.2.4

Charging totally discharged battery with battery charger -VAS 5900WARNING

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

3. Charging battery

23

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Caution

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

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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♦ 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.

♦ 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

AG.

Note

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♦ Battery charger -VAS 5900-

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Special tools and workshop equipment required

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Batteries with a voltage of less than 2 Volt will not be recognised automatically by battery charger -VAS 5900- .

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

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thoblack terminal clamp “-” of – Disconnect au s ative terminal on battery. s

oes not gu ara nte or charger unit from eneg‐ ac

– Disconnect red terminal clamp “+” of charger unit from nega‐ tive terminal on battery.

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 !

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

– Pull charger unit plug out power supply socket.

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3. Charging battery

25

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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 AGThe on‐ a defective vehicle battery whilst it is being n AG.exchanged. does wage s k not l o vehicles electrical equipment board supply remains intact. The gu yV b ara d used. (e.g. electric windows) canisebe n

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– 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 .

r fo ng

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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).

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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 . – 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

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– Press START / STOP for approx. 5 seconds. The menu ““charging totally discharged batteries/support mode” will be activated.

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♦ Battery charger -VAS 5900-

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 !

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

♦ 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.

♦ The maintenance mode can be continued for an unlimited pe‐

riod.

♦ The battery is always ready for use. ♦ Observe battery manufacture's maintenance instructions!

3.3

Totally discharged batteries

WARNING

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

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

Note

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ar5900d When the battery isisefully charged the battery charger -VAS an tee r o switches to maintenance mode. h t or u ac a s s – Proceed as for charging battery ⇒ page 19 .

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

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.

♦ Totally discharged batteries sulphate, that is, the entire plate

surfaces of the battery harden.

♦ If a battery is recharged shortly after it has totally lost its

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.autA reduction in ra c s the battery output is the result. s

charge, the sulphation will dissipate.

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– Check no load voltage of battery ⇒ page 15 . – Charge battery.

Charging battery with battery charger -VAS 5095 A- ⇒ page 15 .

AG.

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

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28

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Charging battery with battery charger -VAS 5900- ⇒ page 19 .

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♦

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

4

Disconnecting and reconnecting bat‐ teries WARNING

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

4.1

Disconnecting battery Note

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

is ensured when carrying out work on the electrical system.

♦ The battery positive wire need only be disconnected for re‐

moval of the battery.

– Switch off the ignition and all electrical consumers. – Release catch -arrow- and take cover off battery box. – First unscrew battery earth clamp -1- from battery negative terminal.

4.2

positive

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

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terminal.

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–

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

Connecting battery Caution

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Special tools and workshop equipment required

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Observe instructions on connecting battery terminals ⇒ page 4 .

4. Disconnecting and reconnecting batteries

29

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AG.

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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

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Disconnecting and connecting Workshop Manual ⇒ page 29 .

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a the battery as described in the ss

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

– 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

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

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30

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If necessary, table can be printed out.

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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.

Performed

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Procedures

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

5

Removing and installing battery WARNING

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

5.1

Models with a petrol engine

Special tools and workshop equipment required

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

Removing: – Disconnect the battery ⇒ page 29 .

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

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

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♦ Torque wrench -V.A.G 1331-

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

5. Removing and installing battery

31

AG.

Prote cted by

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. Vclamping bracket (possi‐ olkswagen AG gen AG subsequent does bility of acid leaking,ktherefore higher costs). swa n ol yV

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db ♦ Poor crash safety ise

– 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 .

5.2

Models with a diesel engine

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

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c o p yri gh t. C op yi

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

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32

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

– Tighten threaded connections to specified torque settings ⇒ page 36 .

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Installation is performed in the reverse order of installation; when doing this, note the following:

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➤ , Bora 2006 ➤ - Edition 05.2005

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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-.

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♦ Spring-type

Jetta 2005 AG. Volkswagen AG d agen oes Electrical System ksw not l o gu yV ara db e nte is or clipthpliers -VAS 5024Aeo u ra a c s s

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– 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.

5. Removing and installing battery

33

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew air filter housing securing bolt -arrow-.

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

– Pull hose -arrow- off air filter housing and take hose out. – Pull air filter housing upwards out of brackets and remove.

AG.

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

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34

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

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– Unlock lugs -arrows- and take cover off.

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

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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

– Fold handles -arrows- upwards and take battery out.

Caution

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

Installing:

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).

AG.

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– After installing, check that battery is seated securely.

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– Tighten threaded connections to specified torque settings ⇒ page 36 .

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Installation is performed in the reverse order of installation; when doing this, note the following:

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♦ Poor crash safety

– Connect the battery ⇒ page 29 . Caution

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

5. Removing and installing battery

35

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

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

6 Nm 6 Nm 20 Nm 10 Nm

AG.

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

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36

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Torque settings

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Threaded connections

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ss Torque settings: battery

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6

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

7

Starter Caution

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

7.1

Checking starter -B-

– Connect the vehicle diagnosis, testing and information system -VAS 5051A- to ⇒ page 281 Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐ formation System -VAS 5051A- . – Using the “Go to” key, select “Function/component selection” and the following menu items one after the other: ♦ Body

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♦ B - Starter

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♦ Electrical components

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♦ 27 - Starter, current supply

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♦ Electrical System

7. Starter

37

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

7.2

Removing and installing starter, auto‐ matic gearbox

7.2.1

Vehicles with 1.6 l injection engine

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

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

– Disconnect the battery ⇒ page 29 . – Release spring-type clip -1- using spring type clip pliers -VAS 5024- and remove securing bolt -2-.

AG.

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

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38

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– Release hose -3- and pull it off the air filter housing.

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:

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♦ Spring-type clip pliers -VAS 5024-

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.

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

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

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

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

– Remove wiring retainer -2-.

7. Starter

39

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

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– Remove lower securing bolt

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

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

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Installing:

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– Remove starter from vehicle upwards.

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

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– Remove upper securing bolt of starter -arrow-.

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

ility ab y li an pt ce

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Removing:

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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

♦ Torque wrench -V.A.G 1332-

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

do c um en

ht rig py Co t.

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– 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 .

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-.

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

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

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

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42

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– Remove upper securing bolt of starter -arrow-.

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:

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

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-

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♦ Spring-type clip pliers -VAS 5024-

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7.2.3

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⇒ page 97 .

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Removing: – Disconnect the battery ⇒ page 29 .

7. Starter

43

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

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– Unclip vacuum hose from its mounting -arrow-.

– Pull hose -1- off air filter housing.

AG.

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

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44

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

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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

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

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-.

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– Pull hose -2- off pipe union.

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– Loosen spring-type clip -1- using spring 5024- .

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

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

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

7. Starter

45

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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-.

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

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–

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

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

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

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46

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– Remove lower securing bolt of starter -arrow-.

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– Remove wiring retainer -2-.

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-.

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

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

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

– 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:

thi sd o cu m en

– Tighten threaded connections to specified torque settings ⇒ page 97 .

7. Starter

47

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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-

ility ab y li an pt ce

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

48

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

AG.

– Pull engine cover off upwards -arrows-.

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– Disconnect the battery ⇒ page 29 .

thi sd o cu m en

Removing:

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

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

♦ Spring-type clip pliers -VAS 5024-

ht rig py Co t.

♦ Torque wrench -V.A.G 1332-

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.

– 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.

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– Remove wiring retainer -2-.

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

7. Starter

49

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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 – Remove lower securing bolt of starter -arrow-.

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-.

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– Remove starter from vehicle downwards. agen lksw Vo by

Installing:

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– Remove upper securing bolt of starter -arrow-.

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

– Tighten threaded connections to specified torque settings ⇒ page 97 .

50

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

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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 1332-

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

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

ility ab y li an pt ce

♦ Spring-type clip pliers -VAS 5024-

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

do c um en

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♦ Torque wrench -V.A.G 1331-

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AG.

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

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.

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

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– Unscrew air filter housing securing bolt -arrow-.

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

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52

thi sd o cu m en

– Unlock lugs -arrows- and take cover off.

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 .

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

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

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

– Remove wiring retainer -2-.

thi sd o cu m en

7. Starter

53

ht rig py Co t.

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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 – Remove lower securing bolt of starter -arrow-.

– Unscrew nut -1- from upper 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

ility ab y li an pt ce

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

– Remove upper securing bolt of starter -arrow-.

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.

Prote cted by

54

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

AG.

– Tighten threaded connections to specified torque settings ⇒ page 97 .

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c o p yri gh t. C op yi

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

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Installing:

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– Remove starter from vehicle upwards.

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

Vehicles with 2.0 l SDI engine

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

AG.

♦ Spring-type clip pliers -VAS 5024-

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♦ Torque wrench -V.A.G 1332-

ility ab y li an pt ce

♦ Torque wrench -V.A.G 1331-

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

Special tools and workshop equipment required

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

ht rig py Co t.

7.2.6

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

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

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-.

ility ab y li an pt ce

– Remove air filter housing from vehicle.

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.

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AG.

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

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56

do c um en

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 housings aon c s -arrow-.

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-.

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– Remove wiring retainer -2-.

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

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.

ht rig py Co t.

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

7. Starter

57

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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 – Unscrew starter securing bolt -arrow-. – Remove starter from vehicle downwards. Installing: Installation is carried out in the reverse order. When installing, note the following: – Tighten threaded connections to specified torque settings ⇒ page 97 .

7.3

Removing and installing starter, auto‐ mated shift gearboxes

7.3.1

Vehicles with 1.6 l injection engine

r fo ng

58

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

AG.

– Disconnect the battery ⇒ page 29 .

agen lksw Vo by

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

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

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

♦ Spring-type clip pliers -VAS 5024-

ility ab y li an pt ce

♦ Torque wrench -V.A.G 1332-

un le

♦ Torque wrench -V.A.G 1331-

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

ht rig py Co t.

Special tools and workshop equipment required

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.

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ility ab y li an pt ce

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

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

do c um en

7. Starter

59

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 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-.

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 .

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

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

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60

thi sd o cu m en

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Vehicles with 2,0 l FSI engine 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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7.3.2

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

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

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

♦ Spring-type clip pliers -VAS 5024-

do c um en

ht rig py Co t.

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

7. Starter

61

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

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– Unclip vacuum hose from its mounting -arrow-.

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

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

AG.

62

agen lksw Vo by

c o p yri gh t . C op yi

– Unscrew air filter housing securing bolt -arrow-.

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

do c um en

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– Pull hose -1- off air filter housing.

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

ility ab y li an pt ce

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

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

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

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

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

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-.

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– Remove connectors -arrows-.

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

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7.3.3

Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1331♦ Torque wrench -V.A.G 1332-

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– Unbolt securing bolts -arrow-.

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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-. Installing:

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– Remove starter from vehicle upwards.

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-

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

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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- .

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– Unlock lugs -arrows- and take cover off.

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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 .

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– Separate connector -1-, release spring-type clip -2- with spring type clip pliers -VAS 5024- and pull off vacuum hose -3-.

7. Starter

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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.

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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove upper securing bolt of starter -arrow-.

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– Tighten threaded connections to specified torque settings ⇒ page 97 .

7. Starter

75

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

7.4

Removing and installing starter, manual gearbox

7.4.1

Vehicles with 1.6 l engine

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

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

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– Disconnect the battery ⇒ page 29 .

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

– Unscrew starter securing bolt -arrow-.

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

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

7. Starter

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– Unclip vacuum hose from its mounting -arrow-.

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7. Starter

79

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– Unscrew air filter housing securing bolt -arrow-.

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

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80

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

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– Pull hose -2- off pipe union.

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

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove air filter housing from vehicle.

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

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 .

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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-

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83

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

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– Unscrew starter securing bolt -arrow-.

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

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-

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88

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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-

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

7. Starter

89

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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- .

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– Unlock lugs -arrows- and take cover off.

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.

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–

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switch.

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

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AG.

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– Unscrew earth wire from starter securing bolt -arrow-.

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 .

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

ility ab y li an pt ce

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

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

– Remove starter.

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

Prote cted by

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

AG.

92

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c o p yri gh t. C op yi

– Tighten threaded connections to specified torque settings ⇒ page 97 .

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Installing:

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– Unscrew starter securing bolt -arrow-.

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– Remove wiring retainer -2-.

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 1332-

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

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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♦ Spring-type clip pliers -VAS 5024-

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thi sd o cu m en

ht rig py Co t.

♦ Torque wrench -V.A.G 1331-

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AG.

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

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-.

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ility ab y li an pt ce

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

– Pull air filter housing on right side upwards off rubber mounting -arrow-. – Remove air filter housing from vehicle.

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

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

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94

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

– Unscrew starter securing bolt -arrow-.

ht rig py Co t.

r fo ng

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

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

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

ility ab y li an pt ce

– Unscrew earth wire from starter

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

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

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:

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AG.

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

ht rig py Co t.

96

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

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

ility ab y li an pt ce

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– Tighten threaded connections to specified torque settings ⇒ page 97 .

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

8

Torque settings: starter

Threaded connections

Torque settings M12 M10 M8 M8 M8

75 Nm 60 Nm 15 Nm 15 Nm 15 Nm 10 Nm 15 Nm

M8

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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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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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

8. Torque settings: starter

97

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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

9

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.

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♦ Damage to electronic components and control to excessive voltage.

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9.2

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

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

Checking ribbed belt (poly V-belt)

– Crank engine at vibration damper/belt pulley using a socket.

♦ 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.

♦ Fraying of cord strands

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♦ chassis breakout

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♦ Layer separation (top layer, draw strands)

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

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– Fit ribbed belt (poly V-belt).

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

9.3

Check alternator -C-

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

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Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐ formation System -VAS 5051A- .

♦ Body ♦ Electrical System

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

♦ 27 - Starter, current supply

9.4.1

Assembly overview

Prote cted by

2 - Hexagon head collared bolts ❑ M8x50 ❑ 23 Nm

c o p yri gh t. C op yi

1 - Hexagon head collared bolt ❑ M8x108 ❑ 23 Nm

AG.

Alternator, 1.6 l injection engine

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9.4

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♦ C - Alternator

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♦ Electrical components

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

9. Alternator

99

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b 14 - Alternator ed ris o h t ❑ Removing and installing alternator ⇒ page 100 au

ss

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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

9.4.2

Removing and installing alternator, 1.6 l injection engine

Caution

Prote cted by

♦ Locking pin -T10060 A-

Removing: – Disconnect the battery ⇒ page 29 .

100

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

AG.

♦ Torque wrench -V.A.G 1331-

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c o p yri gh t. C op yi

Special tools and workshop equipment required

ht rig py Co t.

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

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15 - Poly V-belt ❑ Checking ⇒ page 98 .

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.

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Caution

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– Unscrew B+ wiring -arrow- off alternator.

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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-. – Lock tensioning element with retaining pin -T10060 A- .

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9. Alternator

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– Remove ribbed belt.

101

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ility ab y li an pt ce

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

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

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

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

– Unbolt securing bolts -arrow-.

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

AG.

– Remove alternator.

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– Unscrew wiring bracket -arrow- from alternator.

ht rig py Co t.

– Remove alternator securing bolts -arrows-.

thi sd o cu m en

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

– Position wiring bracket -arrow- on rear of generator at 3 o'clock. – Tighten threaded connections to specified torque settings ⇒ page 145 . Caution

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–

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

c o p yri gh t . C op yi

– Connect the battery ⇒ page 29 . – Start the engine and check belt running. AG.

Prote cted by

9.4.3

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– Switch off the engine.

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Observe instructions on connecting battery terminals ⇒ page 4 .

Ribbed belt routing, 1.6 l injection en‐ gine

Models with air conditioning system: 1-

Tensioning roller

2-

Ribbed belt pulley - Alternator

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

9. Alternator

103

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

9.5

Alternator, 1.6 l FSI engine

9.5.1

Assembly overview

1 - Hexagon bolt ❑ 40 Nm 2 - Washer 3 - Idler roller 4 - Washer 5 - Valve gear casing

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

r te o iva r rp fo g n

14 - Alternator ❑ Removing and installing alternator ⇒ page 105 15 - Poly V-belt ❑ Checking ribbed belt (poly V-belt) ⇒ page 98 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

do c um en

13 - Voltage regulator ❑ Removing and installing voltage regulator ⇒ page 142

AG.

12 - Cross-head screw ❑ M4x13 ❑ 2 Nm

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11 - Phillips screws ❑ M4x19 ❑ 2 Nm

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

10 - Protective cap

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

9 - Plain washer ❑ M5

pe rm itte d

8 - Hexagon nut, flat ❑ M8

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7 - Cross-head screw ❑ M5x21 ❑ 4.5 Nm

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

ht rig py Co t.

6 - Hexagon head collared nut ❑ M8

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 A-

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

Removing:

ility ab y li an pt ce

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

– Disconnect the battery ⇒ page 29 .

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

thi sd o cu m en

ht rig py Co t.

9. Alternator

105

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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 AG do es n ot g ua ran tee or ac

– Disconnect connector of DF wiring -1- and pull B+ wiring -2off alternator. Caution

– Mark direction of rotation of poly V-belt. ht rig py Co t.

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

– Release poly V-belt by turning the tensioning device with an open-ended spanner AF 16 in -direction of arrow-. agen lksw Vo by

– Lock tensioning element with retaining pin -T10060 A- . AG.

– Remove ribbed belt.

– Remove air conditioner compressor ⇒ Heating, air condition‐ er; Rep. Gr. 87 ; Repair work on refrigerant circuit must be carried out in workshops with trained personnel only (work‐ shop service centres for air conditioning system); Removing and installing 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

do c um en

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!

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

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

pe rm itte d

ss

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– Remove wiring bracket -1- and pullAGprotective . Volkswagencap -2- off.

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 ag lksw

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9.5.3

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

pe rm itte d

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ility ab y li an pt ce

– Start the enginesand check belt running. sa

Ribbed belt routing, 1.6 l FSI engine

Models without air conditioning system: 2-

Tensioning roller

3-

Ribbed belt (poly V-belt) pulley – Alternator

4-

Poly V-belt

5-

Ribbed belt (poly V-belt) pulley - Crankshaft

agen lksw Vo by

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

Models with air conditioning system: 1-

Ribbed belt (poly V-belt) pulley – Coolant pump

2-

Idler roller

3-

Ribbed belt (poly V-belt) pulley – Alternator

4-

Tensioning roller

5-

Ribbed belt (poly V-belt) pulley – Air conditioner compressor

6-

Poly V-belt

7-

Ribbed belt (poly V-belt) pulley - Crankshaft

do c um en

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Ribbed belt (poly V-belt) pulley – Coolant pump

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1-

9. Alternator

107

AG.

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

9.6

Alternator, 2.0 l FSI engine

9.6.1

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

un le pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

13 - Cross-head screw ❑ M4x13 ❑ 2 Nm

r te o iva r rp fo g n

12 - Phillips screws ❑ M4x19 ❑ 2 Nm

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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11 - Plain washer ❑ M5

AG.

10 - Hexagon nut, flat ❑ M8

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9 - Cross-head screw ❑ M5x21 ❑ 4.5 Nm

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

8 - Hexagon head collared nut ❑ M8

ht rig py Co t.

7 - Protective cap

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

6 - Hexagon head collared bolts ❑ M10x45 ❑ 52 Nm

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

5 - Compact bracket ❑ For alternator and air conditioner compressor ❑ Tightening sequence ⇒ page 146

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 .

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

♦ Torque wrench -V.A.G 1331-

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

♦ Locking pin -T10060- or locking pin -T10060 A-

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 A-

do c um en

ht rig py Co t.

Special tools and workshop equipment required

agen lksw Vo by

AG.

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

Removing: – Disconnect the battery ⇒ page 29 .

9. Alternator

109

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

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

pe rm itte d

ility ab y li an pt ce

un le

– Disconnect connector -arrow-.

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

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

– Unclip vacuum hose from its mounting -arrow-.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

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

ht rig py Co t.

110

do c um en

– Pull hose -1- off air filter housing.

r te o iva r rp fo g n

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

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

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

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

– Unscrew air filter housing securing bolt

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 -arrow-. a c s s

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

– 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.

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.

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

pe rm itte d

ility ab y li an pt ce

un le

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

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

Caution

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

– Unscrew B+ wiring -arrow- off alternator.

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.

agen lksw Vo by

AG.

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

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

ht rig py Co t.

112

do c um en

r te o iva r rp fo g n

– Release poly V-belt by turning the tensioning device with an open-ended spanner AF 16 in -direction of arrow-.

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-.

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

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– Unscrew wiring bracket -arrow- from alternator. Installing:

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

– Take alternator out of the vehicle. Installation is carried out in the reverse order. When installing, note the following:

thi sd o cu m en

9. Alternator

113

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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 12 o'clock. – Tighten threaded connections to specified torque settings ⇒ page 145 . Caution

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♦ Ensure ribbed belt (poly V-belt) is seatedsscorrectly in belt pulley when installing.

Caution

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

– Tighten threaded connections to specified torque settings ⇒ page 145 .

Observe instructions on connecting battery terminals ⇒ page 4 . – Connect the battery ⇒ page 29 .

– Start the engine and check belt running. – Switch off the engine.

Ribbed belt routing, 2,0 l FSI engine

Models without air conditioning system:

Poly V-belt

4-

Ribbed belt pulley - Crankshaft

114

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

Prote cted by

3-

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Ribbed belt pulley - Alternator

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2-

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Tensioning roller

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1-

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9.6.3

Jetta 2005 ➤ , Bora 2006 ➤ 05.2005

2-

Ribbed belt pulley - Alternator

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

9.7

Alternator, 2.0 l FSI turbo engine

9.7.1

Assembly overview r te o iva r rp fo g n

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AG.

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

2 - Hexagon head collared bolts ❑ M8x90 ❑ 23 Nm

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1 - Hexagon head collared bolts ❑ M8x45 ❑ 23 Nm

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Tensioning roller

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1-

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Models with air conditioning

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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

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-

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

r fo ng

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

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116

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

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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♦ Spring-type clip pliers -VAS 5024 A-

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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9. Alternator

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– Pull engine cover off upwards -arrows-.

117

AG.

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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:

♦ 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- .

– 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!

– Mark direction of rotation of poly V-belt.

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

ht rig py Co t.

118

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

– Unbolt securing bolts -arrow-.

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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.

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

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ss

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– 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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– Remove alternator securing bolts -arrows-.

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

9. Alternator

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.

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ility ab y li an pt ce

Installing:

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

Caution

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

pe rm itte d

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

♦ 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.

AG.

Prote cted by

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

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c o p yri gh t. C op yi

120

ht rig py Co t.

– Position wiring bracket -arrow- on rear of generator at 9 o'clock.

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r te o iva r rp fo g n

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

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-.

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

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

Caution

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– Tighten threaded connections to specified ⇒ page 145 .

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Observe instructions on connecting battery terminals ⇒ page 4 . – Connect the battery ⇒ page 29 .

– Start the engine and check belt running. – Switch off the engine.

9.7.3

Ribbed belt routing, 2.0 l turbo engine

Models without air conditioning system:

Poly V-belt

4-

Ribbed belt pulley - Crankshaft

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3-

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Ribbed belt pulley - Alternator

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2-

ht rig py Co t.

Tensioning roller

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1-

Models with air conditioning system: 1-

Tensioning roller

2-

Ribbed belt pulley - Alternator

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

9. Alternator

121

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

9.8

Alternator 2.5 l injection engine

9.8.1

Assembly overview

1 - Compact bracket ❑ For alternator and air n AG. Volkswagen AG do conditioner compressor e wage

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by 2 - Multi-point socket ed head bolt ris M8x60 o th au ❑ 25 Nm ss

3 - Multi-point socket head bolt M8x110 ❑ 25 Nm

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

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

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

10 - Poly V-belt ❑ Checking ⇒ page 98 .

ht rig py Co t.

9 - Alternator ❑ Removing and installing alternator ⇒ page 127

thi sd o cu m en

8 - Voltage regulator ❑ Removing and installing voltage regulator ⇒ page 142

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

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

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

♦ Locking pin -T10060 A-

ility ab y li an pt ce

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– Disconnect the battery ⇒ page 29 .

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

– 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

ht rig py Co t.

r fo ng

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

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

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

– Take the engine cover off upwards and forwards.

9. Alternator

123

agen lksw Vo by

AG.

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

– Unscrew B+ wiring -arrow- off alternator.

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-.

ht rig py Co t.

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Prote cted by

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– 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

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

Caution

thi sd o cu m en

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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 lksw AG. Voat – Position wiring bracket -arrow- on rear of wgenerator 9agen AG doe agen s no s k l o o'clock. t gu V y b ed

ara nte e

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

or ac

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s

Caution

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

Observe instructions on connecting battery terminals ⇒ page 4 . – Connect the battery ⇒ page 29 . – Start the engine and check belt running. – Switch off the engine.

9.8.3

Ribbed belt routing, 2.5l engine

Models with air conditioning system: 2-

Belt pulley - Alternator

3-

Lower idler roller

4-

Poly V-belt for alternator and coolant pump

5-

Belt pulley - Air conditioner compressor

6-

Poly V-belt for air conditioner compressor

7-

Belt pulley - Crankshaft

8-

Tensioning roller for air conditioner compressor poly V-belt

9-

Tensioning roller for alternator poly V-belt and coolant pump

ht rig py Co t.

Upper idler roller

thi sd o cu m en

1-

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Prote cted by

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10 - Belt pulley - Coolant pump

9. Alternator

125

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

r fo ng

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

6 - Hexagon head collared bolts ❑ M10x45 ❑ 40 Nm

Prote cted by

5 - Hexagon head collared bolts ❑ M10x65 ❑ 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 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

AG.

4 - Compact bracket ❑ For alternator and air conditioner compressor ❑ Tightening sequence ⇒ page 148

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3 - Hexagon head collared bolts ❑ M8x90 ❑ 20 Nm

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

2 - Tensioning element for poly V-belt

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1 - Hexagon head collared bolts ❑ M8x45 ❑ 20 Nm

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Assembly overview

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c o p yri gh t. C op yi

9.9.1

Alternator, 1.9 l TDI engine

ht rig py Co t.

9.9

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 A-

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

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

ility ab y li an pt ce

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

– Disconnect the battery ⇒ page 29 .

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

do c um en

ht rig py Co t.

9. Alternator

127

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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 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.

– Remove securing bolt -3-.

– Unbolt securing bolt -arrow-.

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

– Disconnect connector -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

– Pull vacuum hose -1- off.

ility ab y li an pt ce

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

ht rig py Co t.

128

do c um en

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

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

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

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

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

thi sd o cu m en

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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ht rig py Co t.

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– 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.

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- . 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

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

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pe rm itte d

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– Remove ribbed belt.

– Unscrew wiring bracket from alternator -arrow-.

Prote cted by

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:

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Installing:

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– Remove alternator.

do c um en

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– Remove alternator securing bolts -arrows-.

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:

♦ Fit hose/tube without assistance of tools. G. Volkswage nA wage

olks -arrow-. ♦ Check for secure fit of they Vlugs

to specified

Caution

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

Observe instructions on connecting battery terminals ⇒ page 4 .

ility ab y li an pt ce

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

do c um en

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

–

b ed ris o th Tighten threadedauconnections ⇒ page 145 . ss

n AG d oes not gu ara nte eo torque settings ra c

9. Alternator

131

ht rig py Co t.

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

9.9.3

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

Ribbed belt routing, 1.9 l TDI engine un le

2-

Ribbed belt pulley - Alternator

3-

Poly V-belt

4-

Ribbed belt pulley - Crankshaft

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

Tensioning roller

Models with air conditioning system: 2-

Ribbed belt pulley - Alternator

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

agen lksw Vo by

AG.

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

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

132

r fo ng

Tensioning roller

ht rig py Co t.

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-

ility ab y li an pt ce

Models without air conditioning system:

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

9.10

Alternator, 2,0 l TDI engine

9.10.1

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

7 - Phillips screws ❑ M4x20 ❑ 2 Nm 8 - Protective cap 9 - Voltage regulator ❑ Removing and installing voltage regulator ⇒ page 142

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

6 - Hexagon head collared bolts ❑ M10x45 ❑ 40 Nm

ility ab y li an pt ce

5 - Hexagon head collared bolts ❑ M10x65 ❑ 40 Nm

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

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

4 - Compact bracket ❑ For alternator and air conditioner compressor ❑ Tightening sequence ⇒ page 148

AG.

Removing and installing alternator, 2,0 l TDI engine

agen lksw Vo by

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9.10.2

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11 - Poly V-belt ❑ Checking ⇒ page 98 .

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10 - Alternator ❑ Removing and installing alternator ⇒ page 133

Caution

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

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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♦ Locking pin -T10060 A-

– Disconnect the battery ⇒ page 29 .

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134

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– Pull vacuum hoses off -arrow-.

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– Pull engine cover off upwards -arrows-.

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– Unbolt securing bolts -arrow-.

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

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– Pull fuel filter off the retainer and place to side (fuel hoses re‐ main connected).

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– Unscrew B+ wiring -arrow- off alternator.

Caution

Mark top and direction of rotation of poly V-belt before remov‐ ing. When installing observe direction of rotation marked on removal. Installing opposite to the direction of rotation leads to belt damage! – Mark direction of rotation of poly V-belt. – Release poly V-belt by turning the tensioning device with an open-ended spanner AF 16 in -direction of arrow-.

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-.

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y – Remove alternator. db se

Installing:

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

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Caution

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

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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

Ribbed belt routing, 2,0 l TDI engine

Models without air conditioning system: 1-

Tensioning roller

2-

Ribbed belt pulley - Alternator

3-

Poly V-belt

4-

Ribbed belt pulley -

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Models with air conditioning system: 2-

Ribbed belt pulley - Alternator

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

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

9.11.1

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

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9.11

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Tensioning roller

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Special tools and workshop equipment required

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 .

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Removing:

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– Fit alternator in a vice on fitting points.

Installing:

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– Use socket -VAS 3310- to remove ribbed belt (poly V-belt) pulley securing nut from alternator shaft. Installation is performed in the reverse order of installation; when doing this, note the following: – Tighten threaded connections to specified torque settings ⇒ page 145 .

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Special tools and workshop equipment required

AG.

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

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138

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

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9.11.2

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 The thread on the alternator shaft isauat left-hand thread, i.e. turn ra c to right when loosening and to leftsswhen tightening the threaded

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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.

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joint.

9. Alternator

139

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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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–

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– 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 .

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

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–

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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

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♦ TORX key -V.A.G 1603/1-

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♦ Torque wrench -V.A.G 1332-

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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.

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.

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– 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 .

Removing and installing voltage regula‐ tor, manufacturer: Bosch Prote cted by

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

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Special tools and workshop equipment required

142

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9.12.1

Voltage regulator for alternator

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

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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.

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– Tighten threaded connections to specified torque settings ⇒ page 145 .

9.12.2

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Install in reverse order of removal.

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n AG. Volkswagen AG do es n wage s k l ot g o – Remove securingy Vbolts for voltage regulator -arrows-. ua b ran ed s i tee r – Remove voltage regulator from alternator. o h t or u ac a Installing: ss

Removing and installing voltage regula‐ tor, manufacturer: Valeo

Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1783/-

9. Alternator

143

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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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h ut – Push voltage regulator acarbon brushes in housing of voltage s s regulator and place voltage regulator in alternator.

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

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

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

10

Torque settings: alternator

10.1

General torque settings for all vehicles

Threaded connections

Torque settings

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

M8 M5 M4 M5 M10 M10

15 Nm 3,2 Nm 2 Nm 4.5 Nm 80 Nm 65 Nm

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.

Torque settings

Threaded connections

Torque settings

Alternator to compact M8 bracket Tensioning element to com‐ M8x50 pact bracket Compact bracket to cylin‐ M10x45 der block

23 Nm 23 Nm

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52 Nm

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10. Torque settings: alternator

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10.2.1

145

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10.2.2

Tightening sequence for compact bracket to cylinder block Procedure

Note

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– Place compact bracket on 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, M10x45, 52 Nm, locating hole B - Hexagon head collared bolt, M10x45, 52 Nm C - Hexagon head collared bolt, M10x45, 52 Nm

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F - 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

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

Torque settings M8x90

23 Nm

M8x90

23 Nm

M10x45

40 Nm

M8x100

23 Nm

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

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2.0 l FSI turbo engine

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10.3

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E - Hexagon head collared bolt, M10x45, 52 Nm

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D - Hexagon head collared bolt, M10x45, 52 Nm

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

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

Torque settings

Torque settings M8x90 M8 M10

20 Nm 20 Nm 40 Nm

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

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Threaded connections

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10. Torque settings: alternator

147

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

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

2.5 l injection engine

10.5.1

Torque settings

Alternator to compact M8x90 bracket Tensioning element to com‐ M8x50 pact bracket Compact bracket to cylin‐ M10x45 der block

25 Nm 23 Nm 52 Nm

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Note

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Torque

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♦ Observe dowel sleeve between compact bracket and cylinder

block.

♦ For the compact bracket no tightening torque must be ob‐

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

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

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

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a – Connect Vehicle Diagnosis, Testing and ss Information -VAS 5051A- ⇒ 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: ♦ Drive ♦ Engine code

♦ 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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11. Cruise control system (CCS)

149

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

90 –

Instruments, GCI

1

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 somen AofG.the the swagendisplays, Volkvisual AG do es nby the wage dash panel features a warning which is actuated ksbuzzer, l o o t gu yV control unit. ar db

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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.

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.

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♦ After installing a new dash panel insert, perform adaption of all vehicle keys.

Rep. Gr.90 - Instruments, GCI

AG.

150

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Fault detection and fault display:

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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 .

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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 .

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ 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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– Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

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

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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 .

1. Dash panel insert

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 ss

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Warning buzzer

1.4

Warning lamp symbols in dash panel in‐ sert Note

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

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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.

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

12 - Seat belt 13 - Anti-locking brake system (ABS) 14 - Electronic stabilisation programme (ESP) 16 - Cruise control system (CCS) 17 - Daylight 18 - Tyre pressure monitor 19 - Water in fuel

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15 - Brake fault/handbrake

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11 - Airbag display

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10 - Fuel reserve

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9 - Washer fluid level

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7 - Low coolant level

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6 - Rear fog lights

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5 - Bulb failure

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4 - Battery charge

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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)

1. Dash panel insert

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2

Service interval display

2.1

Resetting service interval display

⇒ Maintenance ; Booklet 20.1

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

92 –

Windscreen wash/wipe system

1

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”. The“service/winter position” is acti‐ vated within 10 seconds after ignition is switched off by pressing windscreen wiper lever in “tip wipe”e⇒ Operating instructions for n AG. Volkswagen AG do es n wag vehicle . o olks V by

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Deactivating APP function of wiper mo‐ tors

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♦ Vehicle Diagnosis, Testing and Information System -VAS 5051A-

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1.1

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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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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

♦ After 100 cycles of wiper movement, the APP function is acti‐

vated automatically. This applies to wiper motors on which the APP function has been deactivated and also to new wiper mo‐ tors.

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– 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 .

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Rep. Gr.92 - Windscreen wash/wipe system

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♦ The APP function cannot be activated.

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♦ Diagnosis lead -VAS 5051/6A-

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-

Removing windscreen wiper system

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

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

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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 b ed

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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.

1.2.3

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ris it comes – Turn thrust bolt -1- of puller -T10130- clockwisethountil u nut -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-.

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

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– Remove securing nut -1-. – Pull crank -2- off wiper motor shaft.

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– Unscrew securing bolts -arrows- and remove wiper motor with control unit from wiper frame.

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159

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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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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.

– Connect the battery ⇒ page 29 . Prote cted by

Removing and installing wiper arms AG.

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– Install wiper arms ⇒ page 160 .

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– Install air cowling, plenum chamber cover and plenum cham‐ ber seal in reverse order of removal.

Removing: – 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.

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Rep. Gr.92 - Windscreen wash/wipe system

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– Tighten threaded connections to specified torque settings ⇒ page 178 .

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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

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– Deactivate the APP function if not already done ⇒ page 155 . agen lksw Vo by

– Allow wiper to move to park position and then switch ignition off. AG.

– Now adjust windscreen wiper blade park position.

1. Windscreen wiper system

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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

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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Removing and installing aerodynamic wipers

♦ Driver's and front passenger wiper blades should not be inter‐ Prote cted by

blades off the windscreen, touch them only in the area in which the wiper blades are attached to the wipers.

♦ To remove the wiper blades, the wiper arms should be placed

in the “service/winter position”. The“service/winter position” is activated within 10 seconds after ignition is switched off by pressing windscreen wiper lever in “tip wipe”.

– 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.

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Rep. Gr.92 - Windscreen wash/wipe system

AG.

♦ The aerodynamic wipers are very flexible. To lift the wiper

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Front passenger's side:

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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. Volkswa

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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 .

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– Switch off ignition and all electrical consumers and pull out ignition key. AG.

– Pull connector -1- off rain and light detector sensor -G397-2-.

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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. Installing:

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retainer for the rain and light detector sensor -G397- .

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♦ The surface (coupling cushions) of the rain and light detector

sensor -G397- must not be soiled when installing.

♦ 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.

♦ After installing the rain and light detector sensor -G397- there

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Rep. Gr.92 - Windscreen wash/wipe system

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must be no air bubbles between windscreen and the surface (coupling cushions).

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

2

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⇒ Operating instructions

2.1

Assembly overview of windscreen washer system

1 - Y-piece ❑ Distribution of wash wa‐ ter line to windscreen spray jets

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4 - Elbow ❑ Connection to left wind‐ screen spray jet ❑ Overview of washer wa‐ ter line hose couplings ⇒ page 174

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3 - Spray jet for windscreen washer system, left ❑ Removing and installing ⇒ page 169 ❑ Adjusting ⇒ page 169

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2 - Spray jet for windscreen washer system, right ❑ Removing and installing ⇒ page 169 ❑ Adjusting ⇒ page 169

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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

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

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2.2.1

– 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-.

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

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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-. – 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-.

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– Pull headlight washer system pump -V11- -9- upwards out of reservoir and separate connector and separate connector -10-.

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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.

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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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Removing and installing washer pump V5-

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2.3

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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

– 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 .

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AG.

– Pull washer pump -V5- -4- upwards out of the reservoir.

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– If necessary, collect fluid leaking out with a suitable container.

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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-.

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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 windscreen and rear window washer pump -V59- . The hose fittings must be inserted into the correct colour-coded pump connections during assembly.

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

2.4

Removing and installing windscreen washer spray jets

Removing: – 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. . Volkswagen AG gen AG d

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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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2. Windscreen washer system

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

3

Headlight washer system Note

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

3.1

Assembly overview - headlight washer system

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spray jet assembly ⇒ page 173 ❑ Adjusting spray jets ⇒ page 173 ❑ Removing and installing pop-up spray jet cylin‐ der ⇒ page 172

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

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4 - Hose

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3 - Elbow ❑ Connection to left spray jet pop-up cylinder ❑ Overview of washer wa‐ ter line hose couplings ⇒ page 174

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.

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

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Removing and installing pop-up spray jet cylinder un le

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Removing:

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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:

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

172

Rep. Gr.92 - Windscreen wash/wipe system

AG.

– Bleed the headlight washer system after completing work ⇒ page 173 .

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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.

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– Unclip pop-up spray jet cylinder -2- from bracket -3-.

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Removing:

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Removing and installing spray jet as‐ sembly

– 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.

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Note

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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3.4

➤ , Bora 2006 ➤ Electrical System - Edition 05.2005

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– 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

Adjusting headlight washer system jets

⇒ Maintenance ; Booklet 18.1

3.6

Bleeding the headlight washer system

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.

3. Headlight washer system

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

4

Wash water line hose couplings

The following hose coupling types are used to connect the hoses to pumps and spray jets and/or as points of separation:

4.1

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– To secure the connection, push the two coupling sections to‐ gether, until you hear and feel them engage.

– To loosen the connection, rotate the lock ring -1- by 90° -arrow- and pull off the hose connection.

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Rep. Gr.92 - Windscreen wash/wipe system

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– To secure the connection, push on the hose connection and push in the lock ring -1- 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.

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– To secure the connection, push on the hose connection and rotate the lock ring -1- -arrow- until it engages.

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

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

175

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

5

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

Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re‐ paired with EPDM hose. . Volkswage n AG wage

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♦ Hot air gun -VAS 5179- or AG.

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♦ Hot air blower -VAS 1978/14-

176

Rep. Gr.92 - Windscreen wash/wipe system

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♦ Hot air gun -V.A.G 1416/- or

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– Secure the repair joints with cable ties -1-.

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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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t or – Select thes auappropriate EPDM hose -2- and cable ties accord‐ ac s ing to the parts catalogue (ETKA).

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♦ Repair points must not be subjected to pulling or bending

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forces.

♦ 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-.

– Push connector -2- into corrugated pipe -2- -arrow A-. – Heat end of corrugated pipe -4-.

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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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– 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 connector -3- into corrugated pipe -4- -arrow B-.

5. Hose repair

177

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

Torque settings: Windscreen wash/wipe system

Threaded connections

Torque settings M6 M8 M6 M8

8 Nm 18 Nm 8 Nm 20 Nm

M6

8 Nm 4.5 Nm

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Rep. Gr.92 - Windscreen wash/wipe system

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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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6

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

94 –

Lights, lamps, switches - outside

1

Headlight Note

♦ Before working on headlights, always switch off the headlights

and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system is first under‐ stood.

♦ Additional information: ⇒ Operating instructions 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 gen swa

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k For fault finding, use the vehicle diagnosis, Vol testing and informa‐ by d e fault finding” mode. tion system -VAS 5051A- in “guided ris

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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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1.1

1. Headlight

179

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1 - Securing bolts ❑ 4 Nm 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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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

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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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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

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Rep. Gr.94 - Lights, lamps, switches - outside

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

1.2

Removing and installing headlights

1.2.1

Removing headlights

Note ♦ 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

– Unscrew securing screw -arrow- on upper headlight.

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– Unscrew securing screw -arrow- on lower left headlight.

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1. Headlight

181

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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 setting n AG. Volktorque G do es n wage s k l ot g o ⇒ page 238 . V y

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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.

♦ The diagrams show the left headlight. ht rig py Co t.

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– Switch off ignition and all electrical consumers and pull out ignition key. – Remove radiator ⇒ General Body Repairs, Exterior; Rep. Gr. 66 ; Strips and trim .

182

Rep. Gr.94 - Lights, lamps, switches - outside

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Note

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– Check function of headlight.

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If the shutlines around the headlight are uneven, the installation position must be adjusted ⇒ page 182 .

Jetta 2005 ➤ , Bora 2006 ➤ System - Edition 05.2005

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– Unscrew securing screw -arrow- on lower left headlight.

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– Unscrew

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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

1. Headlight

183

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

1.4

Renewing headlight bulbs

1.4.1

Renewing dipped beam headlight bulb

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Removing:

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– Switch off ignition and all electrical consumers and pull out ignition key.

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– Turn cover cap -1- in -direction of arrow- and remove.

♦ 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

AG.

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Installing:

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– Pull dipped beam headlight bulb -2- in -direction of arrow- out of bulb holder -1-.

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– Turn bulb holder with dipped beam headlight bulb -1- in -direction of arrow- and remove from headlight.

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-.

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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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1.4.2

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a and adjust headlight as necessary – Check headlight setting ss ⇒ Maintenance ; Booklet 20.1

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1. Headlight

185

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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull off cover cap -1-.

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– Pull off multi-pin connector -2-.

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♦ 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

AG.

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– Take headlight main beam bulb -1- out of the headlight.

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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.

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

Renewing side light bulb

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Removing: – Switch off ignition and all electrical consumers and pull out ignition key.

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– Pull off cover cap -1-.

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The diagrams show renewal of the side light bulb for the left headlight.

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1.4.3

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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.

1. Headlight

187

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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

Renewing front turn signal bulb

The diagrams show renewal of the turn signal bulb for the left headlight. Removing:

– Switch off ignition and all electrical consumers and pull out ignition key. – Turn bulb holder with front turn signal bulb -1- in direction of arrow and remove from headlight. – Push front turn signal bulb into bulb holder, turn front turn sig‐ nal bulb anti-clockwise and pull front turn signal bulb out of bulb holder.

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Note

♦ When installing bulb holder, ensure that the seal is seated

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

Prote cted by

traces of grease on the glass, which evaporate when the bulb is switched on and cause the glass to cloud over.

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♦ Do not touch bulb glass when fitting bulbs. Fingers leave

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1.4.4

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

2

Main headlights with gas discharge bulbs Note

♦ Before working on gas discharge headlights, always switch off

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stood.

♦ Additional information:

⇒ 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.

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⇒ Operating instructions

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Assembly overview - gas discharge headlights

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Note

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

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4 - Cover cap

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3 - Securing bolts ❑ For left headlight range control motor -V48- or right headlight range control motor -V49-

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After any measures which could affect the headlight setting, the headlight must be checked and if necessary adjusted ⇒ Maintenance ; Booklet 20.1 .

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 .

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 ho ut

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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

21 - Cover cap ❑ For left headlight main beam bulb -M30- or right headlight main beam bulb -M32-

2.2

Removing and installing headlights

Removing and installing headlights ⇒ page 181 .

2.3

Adjusting headlight installation position

Adjusting headlight installation position ⇒ page 182 .

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Note

The diagrams show renewal of a gas discharge bulb for the left headlight. Removing: – Remove headlight ⇒ page 181 .

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Renewing gas discharge bulb

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Renewing headlight bulbs

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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 -M3-

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Turn cover cap -1- in -direction of arrow- and remove.

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– Pull off connector -1-. Note

The connector is ejected automatically when the gas discharge bulb starter unit -N195- is removed.

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♦ 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

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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.

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♦ 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.

2. Main headlights with gas discharge bulbs

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.

♦ Use extreme care when fitting a gas discharge lamp bulb and

do not subject the bulb to mechanical stress. The glass bulb is extremely sensitive and is subjected to a very high pressure.

♦ Avoid looking directly into the collimated beam as the UV rays

from the gas discharge bulb are about 2.5 times greater than normal halogen bulbs.

♦ When installing cap, ensure that it is seated correctly. The in‐

gress of water will lead to permanent damage of the headlight.

♦ If a headlight is removed with automatic range control, the ba‐

sic setting of the headlight should always be checked when reinstalling ⇒ Maintenance ; Booklet 20.1 .

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

Renewing main beam headlight bulb

Removing:

– Switch off ignition and all electrical consumers and pull out ignition key.

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– Pull off cover cap -1-.

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The following diagrams show renewal of the main beam headlight bulb for the left headlight.

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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull connector off -arrow-.

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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.

Note

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Installing:

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– Take main beam bulb -1- out of headlight.

♦ 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.

– Place the headlight main beam bulb -1- in the recesses -arrows- on the headlight.

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– Check headlight setting and adjust headlight as necessary ⇒ Maintenance ; Booklet 20.1

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– Check function of headlight.

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Installation is performed in the reverse order of installation; when doing this, note the following:

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2. Main headlights with gas discharge bulbs

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2.4.3

Renewing side light bulb

Note

The following diagrams show renewal of the side light bulb for the left headlight. AG. Volkswagen A

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– Pull off cover cap -1-.

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– Switch off ignition and all electrical ignition key.

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Removing:

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♦ 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

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Note

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Installing:

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– Pull side light bulb -2- in -direction of arrow- out of the bulb holder -1-.

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– 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-.

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

2.4.4

Renewing front turn signal bulb

Note

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-.

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– 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

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Installation is performed in the reverse order of installation; when doing this, note the following:

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– Check function of headlight. – Check headlight setting and adjust headlight as necessary ⇒ Maintenance ; Booklet 20.1

2. Main headlights with gas discharge bulbs

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2.5

Removing and installing headlight range control motor

Information was not available when it was time of going to press.

2.6

Removing and installing gas discharge light control unit AG. Volkswagen Note

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– 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 .

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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. AG.

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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 .

2.7

Headlight range control unit -J431-

2.7.1

Removing and installing headlight range control motor -J431-

Special tools and workshop equipment required

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– Take off gas discharge light control unit -1- from headlight.

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Removing:

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The left gas discharge light control unit -J343- or the right gas discharge light control unit -J344- are not capable of self-diagno‐ sis.

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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: – Switch off ignition and all electrical consumers and pull out ignition key.

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– 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-.

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♦ Removal wedge -VAS 3409-

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– Unlock the locking clip -1- in -direction of arrow- and pull off connector -2- from control unit for headlight range control J431- .

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-.

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Note

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- . – Using the “Go to” key, select “Function/component selection” and the following menu items one after the other: Prote cted by

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♦ 01 - On Board Diagnostic capable systems

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♦ Electrical System

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After installing a new control unit for headlight range control J431- , it must be coded ⇒ page 200 .

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– Lock -direction of arrow-.

♦ Automatic headlight range

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♦ Automatic headlight range control functions ♦ Coding automatic headlight range control

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Note

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

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♦ If the values from the vehicle level sensors are outside the

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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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♦ If the vehicle level senders are replaced, check the values from

Removing and installing front left vehicle level sender -G78-

Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Pull off connector -arrow-.

2. Main headlights with gas discharge bulbs

201

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 .

♦ If the values from the vehicle level sensors are outside the

specified tolerance, basic headlight setting cannot be carried out.

2.8.2

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 y db

– Check front left vehicle level sender -G76ise⇒ page 203 . or h ut

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Note

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a – Perform basic setting of headlights ⇒ ss Maintenance ; Booklet 20.1 .

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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 .

♦ If the values from the vehicle level sensors are outside the

specified tolerance, basic headlight setting cannot be carried out.

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- .

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♦ Vehicle level senders installed are not of type specified in this workshop manual

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No fault entry is stored in the headlight range control unit -J431in the following instances:

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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.

♦ 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

203

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

2.9

Servicing headlight securing lugs

Information on servicing headlight securing lugs was not available when it was time of going to press.

2.10

Adjusting headlights

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Rep. Gr.94 - Lights, lamps, switches - outside

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204

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Adjusting headlights with gas discharge lamp ⇒ Maintenance ; Booklet 20.1 .

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

3

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

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3 - Left fog light bulb -L22- or right fog light bulb -L23❑ Bulb H11 12 V, 55 W ❑ Removing and installing ⇒ page 206

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4 - Fog light housing ❑ Removing and installing ⇒ page 205

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7 - Spreader nuts

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6 - Securing bolts

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5 - Cover cap

Removing and installing fog lights Note

The diagrams show how the left fog light is removed and installed.

3. Fog lights

205

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-.

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Installing:

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– Pull fog light housing out of front bumper and disconnect con‐ nector -arrow-. 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 .

Removing and installing fog light bulb

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The diagram shows how the left fog light is removed and installed.

Rep. Gr.94 - Lights, lamps, switches - outside

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– Remove fog light ⇒ page 205 .

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Removing:

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3.3

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

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3. Fog lights

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Adjusting fog lights ⇒ Maintenance ; Booklet 20.1 .

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4

Removing and installing side marker in front bumper

4.1

Removing and installing front side mark‐ er

Removing Note

Removal and installation of front side marker on left and right are identical.

– Unlock side marker -1- by pressing the locking lug -in direction of arrow-.

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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Installing

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– Remove bulb holder -2- out of side marker.

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– Remove noise insulation ⇒ General Body Repairs, Exterior; Rep. Gr. 50 ; Assembly overview - noise insulation

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

5

Mirror turn signal bulb and entry light in exterior mirror Note

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

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Removing and installing turn signal bulb

Note

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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.

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.

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– 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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– 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 .

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Removing and installing entry light in ex‐ terior mirror

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.

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Note

♦ To remove and install the entry lights the exterior mirror must

not be removed.

♦ Removal and reinstallation of entry lights is carried out in the

same manner on both sides and is described for one side only.

Removing:

– Switch off ignition and all electrical consumers and pull out ignition key. – Fold exterior mirror -1- in -direction of arrow- forwards.

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– Unclip entry light in -direction of arrow- out of the exterior mirror and pull it out as far as possible.

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– Unbolt securing bolt -1-.

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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-.

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Renew bulb:

Plug base bulb: 12 V, W6 W

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Installing:

Installation is performed in the reverse order of installation; when doing this, note the following: Note

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– Pull bulb -1- in -direction of arrow- out of the carrier -2-.

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6

Tail lights

6.1

Assembly overview - tail light in side panel

Torque settings ⇒ page 238 1 - Securing nuts 2 - Left brake and tail light bulb -M21- or right brake and tail light bulb -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 -M73-

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Removing and installing tail light in side panel

Removing:

– Switch off ignition and all electrical consumers and pull out ignition key. r fo ng

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– Press side trim to side.

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6.2

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5 - Bulb carrier ❑ Removing and installing ⇒ page 213

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:

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Installation is performed in the reverse order of installation; when doing this, note the following:

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.

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Note

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– Tighten securing nuts -2- to specified tightening torque ⇒ page 238 .

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– 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.

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

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Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Unclip service cover out of trim in tailgate

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Removing and installing tail light in tail‐ gate

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6.5

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5 - Plain washer

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4 - Tail light housing in tailgate ❑ Removing and installing ⇒ page 214

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3 - Left reversing light bulb M16- or right reversing light bulb -M17❑ 12 V, P 21 W

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– Pull connector -2- off. – Remove securing nuts -1- on tail light in tailgate.

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– Remove tail light. Installing:

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 and installing tail light bulb carrier in tailgate

Removing: – 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.

6. Tail lights

215

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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Rep. Gr.94 - Lights, lamps, switches - outside

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

7

Number plate lights

7.1

Removing and installing number plate light -X-

Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Remove securing bolts -arrows- of number plate light -X- . – Take the lens off together with the number plate light -X- . Number plate light -X- : Soffitte 12 V, C 5 W Installing:

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Install in reverse order of removal.

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7. Number plate lights

217

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8

Additional brake light

8.1

Removing and installing high level brake light bulb -M25Note n AG. Volkswagen AG do es n wage ot g ua ran tee or ac

ks In the event of damage, the complete high level brake light -M25Vol by d unit must be renewed. ise 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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Removing:

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– Switch off ignition and all electrical consumers and pull out ignition key.

– Pull connector -1- off.

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– Remove strip roof leading edge ⇒ General body repairs, in‐ terior; Rep. Gr. 70 ; Removing and installing strip roof leading edge . – Press high level brake light bulb -M25- to rear window -in direction of arrowInstalling:

Installation is performed in the reverse order of installation; when doing this, note the following:

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Rep. Gr.94 - Lights, lamps, switches - outside

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9

Steering column switch Caution

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

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Note

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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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of the steering column electronics control unit -J527- must be checked ⇒ page 227 .

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♦ In the event of faults in the steering column switch, the coding

9. Steering column switch

219

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9.1

Assembly overview - steering column switch

2 - Steering column switch base ❑ Removing and installing ⇒ page 226 3 - Windscreen wiper switch E❑ Removing and installing ⇒ page 225

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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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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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7 - Steering angle sender -G85❑ Removing and installing ⇒ page 224 ❑ Basic settings ⇒ page 228

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6 - Airbag coil connector and return ring with slip ring -F138❑ Removing and installing ⇒ page 223

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4 - Securing bolt

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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 -E45-

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 . G. Volkswage

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♦ 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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Note

Removing and installing steering col‐ umn electronics control unit -J527-

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⇒ “9.3 Steering column electronics control unit J527 ”, page 227 .

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9.2.1

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♦ Steering column electronics control unit -J527- ⇒ page 221

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a Remove components of steering column switch in the sequence ss as follows:

♦ In the event of faults in the steering column switch, the coding AG.

of the control unit must be checked ⇒ page 227 .

9. Steering column switch

221

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– Unscrew bolt -1-.

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– Carefully pull the steering column electronics control unit J527- downwards off the steering column switch.

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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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– Using a screwdriver, press against the rear securing clip -arrow- of the steering column electronics control unit -J527- .

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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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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 (depending on manufacturer) of nector is shown in the following diagram:

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♦ The coloured strip (black rectangles) -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 .

9. Steering column switch

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9.2.3

Removing and installing steering angle sensor -G85-

Removing: – 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

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♦ The “turn signal switch” comprises of the following compo‐

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nents turn signal switch -E2- , headlight dipper/flasher switch -E4- and, if fitted with cruise control system cruise control sys‐ tem switch -E45-

♦ For reasons of clarity, the steering column switch is shown with

cruise control system switch -E45- .

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

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Rep. Gr.94 - Lights, lamps, switches - outside

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224

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The “turn signal switch” should be heard to engage.

Jetta 2005 ➤ , Bora 2006 ➤ - Edition 05.2005

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Removing:

Removing and installing windscreen wiper switch -E-

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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9.2.5

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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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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 . r fo ng

– 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.

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– Remove coil spring for airbag/coil connector with slip ring F138- ⇒ page 223 .

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– Remove steering column electronics control unit -J527⇒ page 221 .

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– 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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♦ Please remove the components in the specified se‐ quence.

Caution

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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 -J527-

Removing and installing steering column electronics control unit -J527- ⇒ page 221

9.3.1

Coding steering column electronics con‐ trol unit -J527G. Volkswage nA wage

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♦ Body

♦ Electrical System

♦ 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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– 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 ♦ Steering wheel electronics functions

9. Steering column switch

227

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Steering wheel electronics final control diagnosis

9.4

Steering angle sender -G85-

Removing and installing steering angle sender -G85⇒ page 224

9.4.1

Basic setting steering angle sender G85-

– Connect the vehicle diagnosis, testing and information system -VAS 5051A- to ⇒ page 281 – Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- . – Using the “Go to” key, select “Function/component selection” and the following menu items one after the 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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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 .

Note

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♦ The steering lock could be destroyed.

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To remove steering lock housing it is necessary to remove the steering column switch base first.

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10.1

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

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♦ If the steering lock is actuated without lock cylinder, it will block and must be renewed. agen lksw Vo by

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♦ The steering lock must not be actuated without lock cylin‐ der. Removing: – Disconnect the battery ⇒ page 29 . – Remove basic brace for steering column switch ⇒ page 226

10.2

Removing and installing lock cylinder Caution

♦ Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 . ♦ The steering lock could be destroyed. ♦ If the steering 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 .

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.

♦ The immobilizer reader coil is secured to the lock cylinder and

cannot be replaced individually.

– Disconnect connector -arrow- at reader coil.

– Insert ignition key in lock cylinder and turn to position “Drive”. Position of key in lock cylinder: 1 - Position “Stop” 2 - Position “Drive”

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

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-.

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Rep. Gr.94 - Lights, lamps, switches - outside

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230

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– Pull lock cylinder -1- out of steering lock housing.

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3 - Position “Start”

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:

– 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:

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– Insert ignition switch in steering lock housing until it can be heard to engage.

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Disconnecting and connecting the Workshop Manual ⇒ page 29 .

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10. Ignition switch and lock cylinder

231

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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. Note

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Removing:

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– 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:

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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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Note

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

11

Parking aid Note . Volkswagen AG gen AG d

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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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General description:

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11. Parking aid

233

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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

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 . agen lksw Vo by

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Rep. Gr.94 - Lights, lamps, switches - outside

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234

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6 - Rear centre left parking aid sender -G204❑ In the rear bumper cover ❑ Removing and installing ⇒ page 235

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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

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olks rear bumper cover. Following 4 senders are located iny Vthe b ed

is ♦ Rear centre left parking thaid or sender -G204au

♦ Rear right inner parking aid sensor -G335♦ Rear centre right parking aid sender -G205-

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Note

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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ss aid sensor -G334♦ Rear left inner parking

11. Parking aid

235

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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

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– Pull off connector -1-.

– Release securing clips -arows- remove rear parking aid warn‐ ing buzzer -H15- from retainer. Installing:

Install in reverse order of removal.

11.5

Final control diagnosis

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

♦ 01 - On Board Diagnostic capable systems ♦ Parking aid

236

Rep. Gr.94 - Lights, lamps, switches - outside

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♦ General Body Repairs

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♦ Body

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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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– Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

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Removing:

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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.

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Parking aid functions ♦ Final control diagnosis

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237

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

12

Torque settings: lights, bulbs, switches - exterior

12.1

Torque settings: headlight

Threaded connections

Torque settings

Upper headlight Lower left headlight Lower right headlight

4 Nm 4 Nm 4 Nm

Torque settings: fog lights

Threaded connections

Torque settings

Headlight securing screws

1,5 Nm

12.3

Torque settings - tail light in side panel

Threaded connections

Torque settings

Securing nuts

3.5 Nm ± 0.5 Nm

12.4

Torque settings - tail light in tailgate

Threaded connections

Torque settings

Securing nuts

3.5 Nm ± 0.5 Nm

12.5

Torque settings: vehicle level sender

Threaded connections

5 Nm

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Rep. Gr.94 - Lights, lamps, switches - outside

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238

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Front left vehicle level sender -G78Rear left vehicle level sender -G76-

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12.2

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

96 –

Lights, lamps, switches - inside

1

Lights and switches in engine com‐ partment Note

The Jetta or the Bora have no lights in the engine compartment.

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Removing and installing bonnet contact switch -F266-

♦ The bonnet contact switch -F266- is integrated into the bonnet

lock and cannot be replaced individually.

♦ If the bonnet contact switch -F266- is found to be defective,

the entire bonnet lock must always be replaced.

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– Remove front bonnet lock ⇒ General Body Repairs, Exterior; Rep. Gr. 55 ; Bonnet; Removing and installing coupling lock; Removing .

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1. Lights and switches in engine compartment

239

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

2

Lights and switches in dash panel

2.1

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:

-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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– 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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– Hold light switch and press rotary position indicator of light switch firmly inwards -1- and turn slightly to right -2-.

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– Fit connector to light switch.

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– Disconnect connector -arrow-.

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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-

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Removing:

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– Switch off the ignition and all electrical consumers.

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– Lever lens carefully out using removal wedge -VAS 3409- or a screwdriver.

– Disconnect connector -arrow-.

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Renew bulb:

2. Lights and switches in dash panel

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:

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

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2.3

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– Check functions of glove box switch. The lamp must not light when the lid is closed.

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:

– Remove glove compartment ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing glove compartment .

Removing and installing switches and instruments illumination regulator -E20-

Removing: – 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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2.4

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Install in reverse order of removal.

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Installing:

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– Unlock locking lug -1- and slide the switch out of the guide -arrow-.

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– Switch off the ignition and all electrical consumers.

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.

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Removing:

Removing and installing front passenger side airbag deactivated warning lamp K145-

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2.5

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– 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-.

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:

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consumers.

– Remove centre vent ⇒ Heating, air conditioning system; Rep. Gr. 80 ; Servicing heating system; remove vent; Remove cen‐ tre vent .

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– Remove connectors -arrows-.

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– Release locking lugs -arrows- and remove hazard warning light switch. Install in reverse order of removal.

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Removing and installing left footwell light -W9- and right footwell light -W10-

Special tools and workshop equipment required

244

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2.7

Rep. Gr.96 - Lights, lamps, switches - inside

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Installing:

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– Switch off the ignition

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

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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- , srewdriver).

♦ The removal and installation of both footwell lights is the same

so that only one light is described.

Removing:

– Switch off the ignition and all electrical consumers.

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– Lever footwell light out of the trim under the dash panel using removal wedge -VAS 3409- or a screwdriver.

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– Disconnect connector -arrow-. Renew bulb:

2. Lights and switches in dash panel

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.

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2.8

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WARNING

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Removing and installing key operated switch to deactivate front passenger side airbag -E224-

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.

– Disconnect connector -arrow-.

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Rep. Gr.96 - Lights, lamps, switches - inside

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246

thi sd o cu m en

– Remove glove compartment ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing glove compartment .

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove key switch.

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2. Lights and switches in dash panel

247

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

3.1

Removing and installing window regula‐ tor switch in front passenger door E107-

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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Lights and switches in front doors

Note

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.

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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Install in reverse order of removal.

AG.

Installing:

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– Release locking lugs -arrows- and remove switch from the in‐ stallation frame.

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– Disconnect connector -arrow-.

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– 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 .

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

3

ility ab y li an pt ce

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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: 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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3.3

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Install in reverse order of removal.

Removing and installing driver side in‐ terior locking button for central locking system -E308Note

Removing:

– Switch off the ignition and all electrical consumers. Prote cted by c o p yri gh t. C op yi

– Disconnect connector -1- and tighten securing bolts -2-. agen lksw Vo by

– Take door opener with switch out of the door trim.

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– Remove door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Removing and installing front door trim, driver side .

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The driver side interior locking button for central locking system E308- features a button illumination bulb -L76- , which must not be replaced individually.

3. Lights and switches in front doors

249

AG.

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.

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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

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The following components (depending on equipment) are inte‐ grated into the driver side door lock: ♦ Driver door contact switch -F2-

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

♦ 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♦ Front passenger door central locking deadlock function motor -V162-

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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Note

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

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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where a lever tool is applied ( removal wedge -VAS 3409- , srew‐ driver).

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

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

AG.

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♦ Front right window regulator switch in driver door -E81-

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♦ Front left window regulator switch -E40-

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The following components (in models with 2 doors) are integrated into the switch module for the driver side window lift:

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In the event of repair, the complete component must be renewed.

♦ Button illumination bulb -L76Note

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-.

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:

3.6

Removing and installing remote release button for fuel filler flap and rear lid E463- and key operated switch to block release of rear lid remote -E232-

Note

The remote release button for fuel filler flap and rear lid -E463features a button illumination bulb -L76- , which must not be replaced individually. Removing:

– Switch off the ignition and all electrical consumers.

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– Disconnect connector -arrow-.

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Rep. Gr.96 - Lights, lamps, switches - inside

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252

ht rig py Co t.

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– Remove door trim ⇒ General body repairs, interior; Rep. Gr. 70 ; Door trim; Removing and installing front door trim, driver side .

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

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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Install in reverse order of removal.

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.

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

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

253

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

4

Lights and switches in rear doors

4.1

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-

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♦ Rear right door contact switch -F11-

♦ Rear right central locking lock unit -F223-

♦ Rear right door central locking motor, lock -V215♦ Rear right door central deadlock function locking motor -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 .

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Removing and installing rear left window regulator switch, in door -E52- and rear right window regulator switch, in door E54-

– 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.

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Removing:

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4.2

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grated into the rear right door lock:

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Install in reverse order of removal.

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Installing:

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– Release locking lugs -arrows- and remove switch from the in‐ stallation frame.

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4. Lights and switches in rear doors

255

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

5

Lights and switches in luggage com‐ partment

5.1

Removing and installing luggage com‐ partment light -W3-

kswagen AG . Volrequired Special tools and workshop equipment gen AG d wa olks

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yV ♦ Removal wedge -VAS d b 3409-

♦ 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). c o p yri gh t. C op yi

– Switch off the ignition and all electrical consumers.

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Removing:

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– Lever light out of the luggage compartment trim using removal wedge -VAS 3409- or a screwdriver.

Rep. Gr.96 - Lights, lamps, switches - inside

AG.

256

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Note

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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

Removing and installing rear lid lock unit AG. Volkswagen AG d -F256agen oes ksw n ol yV

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ua db rand The rear lid lock unit -F256is integrated into the tailgate lock an ise tee r cannot be replacedthoindividually. o

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– Renew tailgate lock ⇒ General Body Repairs, Exterior; Rep. Gr. 55 ; Tailgate; Removing and installing coupling lock; Re‐ moving .

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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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5. Lights and switches in luggage compartment

257

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

6

Lights and switches in roof trim

6.1

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

Special tools and workshop equipment required

ility ab y li an pt ce

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Note

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♦ 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- , srew‐ driver).

– Switch off the ignition and all electrical consumers.

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Rep. Gr.96 - Lights, lamps, switches - inside

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258

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Removing:

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

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– Carefully lever trim out of interior light using removal wedge VAS 3409- or screwdriver -arrow-.

– Unbolt securing bolts -arrow-.

– Remove connectors -arrows-.

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6.1.2

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Install in reverse order of removal.

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Installing:

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– Take the interior light out of the headliner console.

Replace front interior light -W1-

Special tools and workshop equipment required ♦ Removal wedge -VAS 3409-

6. Lights and switches in roof trim

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 ks Vol

by using removal wedge – Carefully lever lens for interior lightedout 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.

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Install in reverse order of removal.

6.1.3

Left centre reading light -W39- and right centre reading light -W40-

Removing: – Remove interior light ⇒ page 258 .

260

Rep. Gr.96 - Lights, lamps, switches - inside

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Installing:

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– Fit the contact to the new festoon bulb (12 V, 10 W).

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– Pull contact -arrow- off defective festoon bulb.

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. ksW). wagen AG – Renew glas base bulben(12 Vol5 AG.V,

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Installing:

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♦ Sunroof switch -E8ht rig py Co t.

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Note

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♦ Left centre reading light -W40-

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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. agen lksw Vo by

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6.2.1

Removing and installing front interior light and reading light

Special tools and workshop equipment required

6. Lights and switches in roof trim

261

Jetta 2005 ➤ , Bora 2006 ➤ n AG. Volkswagen AG do es n wage Electrical System - Edition 05.2005 o olks

ility ab y li an pt ce

c o p yri gh t. C op yi

– Switch off the ignition and all electrical consumers. – Carefully lever trim out of interior light using removal wedge VAS 3409- or screwdriver -arrow-. Prote cted by

262

Rep. Gr.96 - Lights, lamps, switches - inside

AG.

– Take the interior light out of the headliner console.

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– Unbolt securing bolts -arrow-.

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Removing:

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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).

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

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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♦ Removal wedge -VAS

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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove connectors -arrows-. Installing: Install in reverse order of removal.

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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

6.2.2

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– Remove interior light ⇒ page 261 . – Disconnect connector -arrow-.

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– Release locking lugs -arrows- and remove switch from the in‐ stallation frame.

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6.2.3

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Install in reverse order of removal.

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Installing:

Replace front interior light -W1-

Special tools and workshop equipment required

6. Lights and switches in roof trim

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.

ot g ua ran tee or ac

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Rep. Gr.96 - Lights, lamps, switches - inside

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264

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– Press contact -1- of light to side -arrow- and remove festoon bulb -2- with the contact from the interior light.

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– Carefully lever lens for interior light removal wedge swausing olkout gen AG en AG. V does -VAS 3409- or screwdriver ag-arrow-. w s k n

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:

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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Left centre reading light -W39- and right centre reading light -W40-

Removing: – Remove interior light ⇒ page 261 .

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

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6.2.4

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Install in reverse order of removal.

– Turn bulb holder -arrows- of the defective reading light for 90° to the left.

– Pull glas base bulb carefully out of the holder.

Install in reverse order of removal.

6.3

AG.

Installing:

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– Renew glas base bulb (12 V, 5 W).

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– Take the holder with the bulb out of the reading light.

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-

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,Vorenew lksw the complete component. ot y db ise r tho au

Removing:

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Removing and installing rear interior ss and reading light (vehicles without ATAS)

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– Switch off the ignition and all electrical consumers. – Release locking lugs -arrows- and take trim with lens off inte‐ rior light and reading light.

Install in reverse order of removal.

266

Rep. Gr.96 - Lights, lamps, switches - inside

AG.

Installing:

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– Disconnect connector -arrow-.

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– Release locking lugs -arrows- and remove interior light and reading light from the headliner.

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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

6.3.1

gu ara nte eo ra c

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

6.3.2

Renewing rear interior and reading light bulbs (vehicles without ATAS)

Removing:

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– Pull glas base bulb carefully out of the holder -arrows-.

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Installing: Install in reverse order of removal.

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6.4

Rear interior and reading light (vehicles with ATAS)

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♦ Rear right reading light -W12-

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♦ Rear left reading light -W11-

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♦ Rear left footwell light -W45-

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The following components are integrated in the rear interior light and reading light:

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– Renew defective glas base bulb (12 V, 5 W).

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– Release locking lugs -arrows- and take trim with lens off inte‐ rior light and reading light.

♦ 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.

♦ The anti-theft alarm ultrasonic sensor -G209- -2- cannot be

renewed separately.

♦ The anti-theft alarm ultrasonic sensor -G209- , comprising four

individual sensors -2-, leads and a control element on the back of the interior and reading light, must not be moved from its predefined position.

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.

♦ The anti-theft alarm ultrasonic sensor -G209- -2- cannot be

renewed separately.

♦ The anti-theft alarm ultrasonic sensor -G209- , comprising four

individual sensors -2-, leads and a control element on the back of the interior and reading light, must not be moved from its predefined position.

Removing: – Switch off the ignition and all electrical consumers.

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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.

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Install in reverse order of removal.

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– Unlock connectors -1- and -2- and pull both connectors off.

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– Pull the entire complete trim -1- (including lens and reflectors) -arrows- vertically downwards and out from the interior and reading light.

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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– Pull the glass base bulb to be removed (12 V, 5 W) -1- from the holder. Installing:

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Removing and installing front passenger side illuminated vanity mirror -W14- and driver side illuminated vanity mirror W20-

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Install in reverse order of removal.

Special tools and workshop equipment required

6. Lights and switches in roof trim

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).

♦ The removal and installation of both lights is the same so that

only one light is described.

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– Lever light carefully out of the roof trim using removal wedge . Volkswagen AG -VAS 3409- or a screwdriver. gen AG does swa

– Disconnect connector -arrow-.

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Rep. Gr.96 - Lights, lamps, switches - inside

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Renew bulb:

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.

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Removing and installing garage door operating unit -E284es, 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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Note

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6.6

♦ 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

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6. Lights and switches in roof trim

271

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

7

Lights and switches in centre console

7.1

Removing and installing TCS and ESP button -E256-

Removing: – Switch off the ignition and all electrical consumers. – Take bellow carefully off centre console -arrows-.

– Unbolt securing bolts

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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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Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove switch from the in‐ stallation frame. Installing:

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Install in reverse order of removal.

7. Lights and switches in centre console

273

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

8

Horn

8.1

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- .

♦ The procedure for removal and installation of treble tone horn

-H2- and bass tone horn -H7- is the same and is therefore described for just one horn.

♦ The horns are installed to the left and the right of theAGlongitu‐ . Volkswagen

dinal members.

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– Switch off the ignition and all

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– Remove front bumper ⇒ General body repairs; Rep. Gr. 63 ; Front bumper

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– Disconnect connector -arrow-.

– Unscrew securing bolt -arrow- and remove horn. Install in reverse order of removal.

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Rep. Gr.96 - Lights, lamps, switches - inside

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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- .

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Checking treble tone horn -H2- and bass tone horn -H7-

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Installing:

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

9

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

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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 .

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 . r fo ng

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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 .

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Immobilizer control unit -J362-

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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 .

♦ If the radio container (transmission unit for radio-controlled

central locking) of the ignition key is also replaced, it must be adapted to the comfort system ⇒ page 276 .

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

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– Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A- ⇒ page 281 .

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– 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 - Adapting / testing keys with radio remote control

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Rep. Gr.96 - Lights, lamps, switches - inside

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

10

Anti-theft alarm system (ATAS) Note

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

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Activating and deactivating anti-theft alarm system

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10.1

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:

– Unlock the driver door.

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Unlock the car mechanically (emergency open)

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♦ when the ignition is switched on.

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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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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.

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

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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:

Additional information:

278

Rep. Gr.96 - Lights, lamps, switches - inside

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Note

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Central locking and anti-theft alarm sys‐ tem aerial -R47-

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10.4

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Install in reverse order of removal.

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

Alarm horn -H12-

The alarm horn -H12- is located on the right of the A-pillar in the wing.

10.5.1

Removing and installing the alarm horn -H12-

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♦ Drill -VAS 5134-

♦ Twist drill ∅ 6 mm

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Note

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♦ Pop rivet pliers -VAS 5072-

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)

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 ag ksw

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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

– Perform measures for corrosion protection ⇒ General Infor‐ mation; Body Repairs, General Body Repairs . Prote cted by

– 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

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– Insert clip -2- of alarm horn -H12- -3- into the aperture in the bodywork -1-.

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– Fit connector to the alarm horn -H12- .

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

97 –

Wiring

1

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 a lksw

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Note

♦ All working instructions described, such as modifications, cod‐

ing etc. can be carried out using the vehicle diagnosis, testing and information system -VAS 5051A- and the vehicle diagno‐ sis and service information system -VAS 5052- .

♦ All working instructions can be found in “guided fault finding”

and “guided functions”.

♦ Additional information: ⇒ Self-study programme No. 202 ; 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 r fo ng

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– Connecting vehicle Diagnosis, Testing and Information Sys‐ tem -VAS 5052- ⇒ page 282 .

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Connecting vehicle Diagnosis, Testing and Information System -VAS 5051AAG.

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– Connecting Vehicle Diagnosis, Testing and Information Sys‐ tem -VAS 5051A- ⇒ page 281 .

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Note

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

1. Vehicle Diagnosis, Testing and Information Systems

281

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

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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.

– 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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Connecting Vehicle Diagnosis, Testing and Information System VAS 5051A- :

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♦ Diagnosis lead -VAS 5051/5A- (3 m)

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♦ Diagnosis lead -VAS 5051/6A- (5 m)

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♦ Vehicle Diagnosis, Testing and Information System -VAS 5051A-

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

2

Removing and installing fuse holder

2.1

Removing and installing fuse holder on left of dash panel

Special tools and workshop equipment required ♦ Removal wedge -VAS 3409-

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Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 . Removing: – Disconnect the battery ⇒ page 29 .

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– Remove storage compartment on driver side ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

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where a lever tool is applied ( removal wedge -VAS 3409- , srew‐ driver).

2. Removing and installing fuse holder

283

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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-.

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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).

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Rep. Gr.97 - Wiring

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284

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Install in reverse order of removal.

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Installing:

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

3

Removing and installing relay carrier

3.1

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

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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. AG.

Note

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.

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

♦ The onboard supply control unit -J519-

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attached to the onboard supply control unit, on left of dash panel form one unit and cannot be separated.

♦ If the onboard supply control unit -J519- is to be replaced, first

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Removing:

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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.

– 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 .

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Rep. Gr.97 - Wiring

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286

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– Remove storage compartment on driver side ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

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 unit -J519- and the swagen control AG. Volksupply G do agensupply controlAunit, eson relay carrier on onboard 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 an tee o controlr aunit c

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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.

– 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:

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The locking bars may only be set to “CLOSE” when all connectors are fitted “correctly”.

3. Removing and installing relay carrier

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

Electronics boxes

4.1

Removing and installing electronics box on left in engine compartment Caution

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

– Disconnect the battery ⇒ page 29 .

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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.

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Rep. Gr.97 - Wiring

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– Release clips -1- in -direction of arrow- and take cover of elec‐ tronics box -2- off upwards.

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4

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.

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– Remove battery ⇒ page 29 .

– Remove securing bolts -arrows- of battery console -1-.

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– Take battery console -1- out of vehicle.

4. Electronics boxes

289

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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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– 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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Whether the additional vehicle equipment.

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

5

Control units

5.1

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Onboard supply control unit -J519un le

♦ The onboard supply control unit -J519- and the relay carrier

attached to the onboard supply control unit, on left of dash panel form one unit and cannot be separated.

♦ Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating instructions General description:

♦ 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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♦ Rear window wiper

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♦ Exterior light control

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The onboard supply control unit -J519- is responsible for the fol‐ lowing in the vehicle:

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

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♦ The above adaptations can only be carried out in conjunction 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

with certain equipment configurations.

♦ The “Motorway signaling”, “comfort signaling”, or “tap signal‐

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ing” means that one touch of the turn signal lever will activate the turn signals (1-5 times) (turn signal cycles).

♦ 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.

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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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. AG.

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 .

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

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 AG. Volkswagen

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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: r te o iva r rp fo g n

♦ 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 5051A-

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Note

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.

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Rep. Gr.97 - Wiring

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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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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 and installing data bus diag‐ nostic interface -J533-

Removing: Note

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that access can be gained to the codes stored within.

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– 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-.

– Push securing pins -3- together -arrows- and pull out of holes. Installing: Install in reverse order of removal.

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5.3

Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions

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

Some of the above functions can be adapted ⇒ page 298 . Fault detection and fault display:

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.

5.3.1

Removing and installing convenience system central control unit -J393-

Removing:

– Switch off ignition and all electrical consumers and pull out ignition key. r fo ng

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

AG.

Note

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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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– Remove glove compartment ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing glove compartment .

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♦ Comfort operation

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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

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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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Coding convenience system central control unit -J393-

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5.3.2

– 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

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”

♦ “Sensitivity of interior monitoring system”

– Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A- ⇒ page 281 . – Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- . – Using the “Go to” key, select “Function/component selection” and the following menu items one after the other: ♦ Body ♦ General Body Repairs

♦ 01 - On Board Diagnostic capable systems ♦ Comfort system

♦ Comfort system central control unit functions

– 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

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Rep. Gr.97 - Wiring

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– Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A- ⇒ page 281 .

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♦ J393 - Adapting convenience system central control unit

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♦ “Sensitivity of tilt angle sensor”

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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/

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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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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”.

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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♦ Torque wrench -V.A.G 1783-

5. Control units

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Special tools and workshop equipment required

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 AG agen

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After installing a new trailer detector control unit -J345- it must be coded ⇒ page 300 .

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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

♦ 01 - On Board Diagnostic capable systems

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Rep. Gr.97 - Wiring

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♦ Coding trailer detector control unit

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♦ Function

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♦ Trailer detector

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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

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♦ Plug socket tester -V.A.G 1537/A- 5)

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Note

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5.4.3

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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

5. Control units

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

6

Wiring harness and connector re‐ pairs

6.1

Safety instructions Caution

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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Caution

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6.2

ss

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-

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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6.3

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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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♦ 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.

Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ⇒ Operating instructions wiring harness repair set -V.A.G 1978. Volkswagen AG gen AG d

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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. ht rig py Co t.

♦ 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. Wiring harness and connector repairs

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

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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Rep. Gr.97 - Wiring

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General description

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♦ 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. thi sd o cu m en

♦ All adapter and connection wires are suitable for all transmitter and receiver signals. ♦ This repair method can also be used for testing or retrofitting. ht rig py Co t.

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Assembly overview - an aerial wire agen lksw Vo by

7.2

Example: Aerial wire between radio and aerial is defective. The following wires are required for the repair: AG.

1-

Adapter cable, to radio connection. Length approx. 30 cm.

2-

Connecting wire, available in different lengths.

3-

Adapter cable, to aerial connection. Length approx. 30 cm.

7.3

Installing a new aerial wire Note

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.

7. Renewal of aerial wiring

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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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– Cut off connectors of defective aerial wire. – Connect adapter cables -1- and -3- to equipment in vehicle. – Route and secure connecting wire -2- parallel to the old aerial wire. Note

Do not kink or excessively bend aerial wires! The bending radius must not be below 50 mm. – Connect connecting wire to adapter cables.

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– Perform a functional check.

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The remainder of the defective aerial wire remains in the vehicle.

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

8

Torque settings: Cables

8.1

Torque settings: Electronics box in left side of engine compartment

Threaded connections

Torque settings

Securing nuts -1Securing nuts -1-

8.2

M5 (AF 8) M6 (AF 10)

4 Nm 6 Nm

Torque settings trailer detector control unit -J345Torque settings

Securing bolts bracket to body Securing bolts control unit to bracket

2 Nm 2 Nm

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Threaded connections

8. Torque settings: Cables

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