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Service

Workshop Manual
Jetta 2005
Bora 2006
Electrical System
Edition 05.2005

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Service Department. Technical Information


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

Repair Group

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90 - Instruments, GCI

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94 - Lights, lamps, switches - outside


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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
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MEX5R005820

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Contents

1
1.1
1.2
1.3
1.4

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
2
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

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

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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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


1
1.1
1.2
1.3
1.4

150
150
151
152
152

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Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154


Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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2
2.1

Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Renewing dash panel ainsert
. a. g.e.n.A.G.d.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Removing and binstalling
dash
panel
insert . . n.o.t g.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V
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Descriptionoriof
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Warning
symbols in dash panel insert . . . . . . . . .or.ac. . . . . . . . . . . . . . . . . . . . . . . . . .
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Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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

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

Contents

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

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
2.6
2.7
2.8
2.9
2.10

Removing and installing gas discharge light control unit . . . . . . . . . . . . . . . . . . . . . . . . . .


Headlight range control unit J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198
198
201
204
204

3
3.1
3.2
3.3
3.4

Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205
205
205
206
207

4
4.1

Removing and installing sideAmarker


bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
agfront
en
G. Volkswin
does
agen side marker AG
wfront
s
Removing and installing
.
. . . .no.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
k
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by

d
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Mirror turn signal
ise bulb and entry light in exterior mirror an.te. . . . . . . . . . . . . . . . . . . . . . . . . . .
or
e
h
t
Removing aand
installing turn signal bulb . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . . . . . .
u
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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

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

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239
239
240
240
241

iii

6.3
6.4
6.5
6.6
7
7.1
8
8.1
8.2
9
9.1
9.2
9.3
10
10.1
10.2
10.3
10.4
10.5

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5
5.1
5.2
6
6.1

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4.1
4.2

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3.4
3.5
3.6

242
242
243
244
244
246
248
248
248
249
250
250
252
254
254

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3
3.1
3.2
3.3

Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . .


Removing and installing switches and instruments illumination regulator E20 . . . . . . . . . .
Removing and installing front passenger side airbag deactivated warning lamp K145 . .
Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing left footwell light W9 and right footwell light W10 . . . . . . . . . . . .
Removing and installing key operated switch to deactivate front passenger side airbag E224
......................................................................
Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing window regulator switch in front passenger door E107 . . . . . . . .
Removing and installing switch module for driver side mirror adjustment . . . . . . . . . . . . . .
Removing and installing driver side interior locking button for central locking system E308
........................................................................
Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing switch module for driver side window lift . . . . . . . . . . . . . . . . . . . .
Removing and installing remote release button for fuel filler flap and rear lid E463 and key
operated switch to block release of rear lid remote E232 . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear left window regulator switch, in door E52 and rear right window
regulator switch, in door E54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front interior light and reading light (vehicles with no sliding
sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front interior light and reading light (vehicles with sliding sunroof)
........................................................................
Rear interior and reading light (vehicles without ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear interior and reading light (vehicles with ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front passenger side illuminated vanity mirror W14 and driver side
illuminated vanity mirror W20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing garage door operating unit E284 . . . . . . . . . . . . . . . . . . . . . . . .
Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing TCS and ESP button E256 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . .
Checking treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-theft alarm system (ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activating and deactivating anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing anti-theft alarm ultrasonic sensor G209 . . . . . . . . . . . . . . . . . . . .
Removing and installing vehicle inclination sender G384 . . . . . . . . . . . . . . . . . . . . . . . . . .
Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.3
2.4
2.5
2.6
2.7
2.8

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

AG. Volkswagen AG d
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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

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

Contents

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281
281
283
283
285

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
285

4
4.1

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

5
5.1
5.2
5.3
5.4

Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Central control unit for convenience system J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

292
292
294
295
299

6
6.1
6.2
6.3
6.4
6.5
7
7.1
7.2
7.3
8
8.1
8.2

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
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Torque settings: Electronics box in Vleft
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Torque settings trailer detectorisecontrol unit J345 . . . . . . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . .

302
302
302
302
303
304
305
305
305
305
307
307
307

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Contents

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286
288
288

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3.1
3.2

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

AG.

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Contents

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

27

Starter, current supply, CC

Battery
WARNING

Danger of injury! Observe warning notices and safety regula


tions page 2 !

Caution

To prevent damage to the battery and vehicle, the following


should be observed concerning types of battery page 1 .

1.1

Fundamentals for batteries

To ensure long use of the battery, the battery must be checked,


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

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

1.2

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.

AG.

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1. Battery

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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
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The procedure for checking and testing
Vol

glass mat batteries is identical.sed by


i
or

th
Always replace an absorbent
au glass mat battery with another

Gel battery

rrectness of i
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spec
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wit
thi
s

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

Dangers when handling vehicle batter


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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.

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

Downloaded from www.Manualslib.com manuals search engine

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1.3

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1.2.4

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absorbent glass mat battery.

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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

1.3.2

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SafetyVomarkings
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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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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.

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1. Battery

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Electrical System - Edition 05.2005

1.4

Battery terminal connection


Caution

To prevent damage to the battery terminal clamps and battery


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

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Downloaded from www.Manualslib.com manuals search engine

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

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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

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:


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Checking battery with a magic
e
ir s
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a low maintenance battery

page
7
.
h
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a
ss

1.

Visual check page 5 .

2.

4.

Perform a battery load test using battery tester with printer


-VAS 5097 A- page 12 .

Visual check

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t to the co
nform
spec
a
t
ion
h re
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in t
his

2.2

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.
Caution

The battery will be damaged if the battery is not secured


correctly.
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Vibrations shorten the life of the battery, there is a danger


of an explosion, the cell plates may be damaged and the
securing plate may damage the battery housing.

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Check no load voltage of battery page 10 .

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Check battery is securely seated, if necessary tighten se


curing bolt to specified torque setting. page 36
AG.

Whether the battery housing is damaged: Check whether the


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

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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
n AG. Volsystem.
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Therefore it can no longer be guaranteed
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Checking battery with magic eye

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2.3

tee
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ac

WARNING

rrectness of i
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spec
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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.

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 .

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.

do
c
um
en

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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ab
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ce

This battery is low maintenance this means the electrolyte level


must be checked and occasionally topped-up with distilled water
as required.

2.4.1

Checking electrolyte level of battery

Check electrolyte level on housing:

Check electrolyte level via -min./ max.- marking on the battery


housing.
The electrolyte level is OK when the fluid level is at the max.
marking.
If the electrolyte level is below the -max.- marking:
Replenished with distilled water page 7 .
Check electrolyte level in the cells:

Switch off the ignition and all electrical consumers.


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

AG.

Prote
cted
by

Remove cell sealing plugs.

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

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Note

rrectness of i
t to the co
nform
spec
atio
h re
n
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i
n
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en

urposes, in part or in wh
ole,
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is n
mer
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erm
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itte
ir va
du
p
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g
n

Danger of injury! Observe warning


tions page 2 !

AG. Volkswagen AG d
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noticesiseand
safety regula
nte
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c
ss

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

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Electrical System - Edition 05.2005

n AG. Volkswagen AG do
es n
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a
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rrectness of i
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atio
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wit

Caution

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Battery filler bottle -VAS 5045/-

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.
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Switch off the ignition and all electrical consumers.


ng

AG.

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

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

Downloaded from www.Manualslib.com manuals search engine

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Prote
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Note

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

thi
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m
en

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

Remove cell sealing plugs.

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th
au

un
le

The electrolyte density is determined by the float position in the


battery electrolyte. The value can be read from the float scale.
Electrolyte density

Charge

1.28

g/cm3

100 %

1,21

g/cm3

60 %

1,18

g/cm3

40 %

1,10 g/cm3

0%

Note

Voltage
12,7 V
12,3 V
12,1 V
11,7 V

AG.

Seal the cells with the cell sealing plugs.

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Prote
cted
by
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rig
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.
C
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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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Co
t.

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fo
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Checking electrolyte density directly after topping up with distilled


water will lead to erroneous results. Check electrolyte density only
after charging the battery.

rrectness of i
t to the co
nform
spec
a
t
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h re
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n in
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urposes, in part or in wh
ole,
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Draw electrolyte off a cell using a hydrometer until the float


swims unhindered.

2. Checking battery

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

2.5

Check no load voltage of battery


WARNING
. Volkswagen AG
gen AG
does
not
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nte
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c

a
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Danger of injury! Observe warning notices
and
safety regula
Vol
by
tions page 2 !
d
e

rrectness of i
t to the co
nform
spec
a
t
ion
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his

Note

urposes, in part or in wh
ole,
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The no load voltage test is used to determine the capacity of the


battery.

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ss

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 %

Full capacity.

Prote
cted
by

100 %

The battery should be recharged on new/vehicles which


have been stored.
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
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136 - 855 A VAollow-temperature
test current
to EN/
otaccording
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arEngineers)
SAE (European
Norm/Standard
of
Automotive
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s

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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.
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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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Note

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ion
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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.

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2. Checking battery

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11

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

2.6.1

Description of battery tester with printer


-VAS 5097 A-

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

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8 - Button to advance paper


9 - Printer
ss

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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AG.

Prote
cted
by
c
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rig
ht
.
C
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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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Co
t.

Perform battery load test:

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
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ole,
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Battery load test using battery tester


with printer -VAS 5097 A-

ility
ab
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an
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ce

2.6.2

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.

2.6.3

Table: low-temperature test current


. Volkswag

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by

urposes, in part or in wh
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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

rrectness of i
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spec
a
t
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wit
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do
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en

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

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

ris
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EN/ SAE

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Low-temperature
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2. Checking battery

Downloaded from www.Manualslib.com manuals search engine

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
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Vehicle data and date.
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nel.
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AG. Volkswagen AG d
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o

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.

AG.

Prote
cted

Downloaded from www.Manualslib.com manuals search engine

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

ht
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14

rrectness of i
t to the co
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f
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m
spec
atio
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wit

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

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urposes, in part or in wh
ole,
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tee
or
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ility
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Note

ri
ho
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a
ss

Charging battery
WARNING

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

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- .
c
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Observe Operating instructions for battery charger -VAS


Prote
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by

3.1.1

AG.

Observe battery manufacture's handling instructions!

agen
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5095 A- .

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Note

do
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urposes, in part or in wh
ole,
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a
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ir v
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, Bora 2006
- Edition 05.2005

ility
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Jetta 2005
AG. Volkswagen AG d
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Electrical
System
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ri
ho
or
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ac
a
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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

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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

ility
ab
y li
an
pt
ce

Note

The battery must have a temperature of at least 10 C.


If the battery has cell sealing plugs, do not open them while

the battery is being charged.

Switch off the ignition and all electrical consumers.


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 .

Remove charger unit terminals from battery terminals.

16

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Switch off charging unit page 15 .

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by

Prote
cted
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.
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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.

ht
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Co
t.

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 %).

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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his
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a
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Always set battery type 2.4 V/C


This applies for all batteries.

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(Volt/Cells) when
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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

3.1.3

Charging totally discharged battery with


battery charger -VAS 5095 AWARNING

Danger of injury! Observe warning notices and safety regula


tions page 2 !
olkswagen AG
en AG. V

does
not
gu
ara
nte
eo
ra
c

the charge condition of the battery.


Note

Observe notes in chapter page 27 .

The battery voltage must be at least 0.6 V.


Charge battery page 16 .

3.1.4

Charging battery in support mode with


battery charger -VAS 5095 AWARNING

Danger of injury! Observe warning notices and safety regula


tions page 2 !

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AG.

Prote
cted
by
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Special tools and workshop equipment required

ht
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Co
t.

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.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
cial p
is n
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ot p
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erm
o
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t
itte
ir va
du
p
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nl
f
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g
n

ility
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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
ing current. The charging current is automatically
adapted to suit

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

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17

Jetta 2005 , Bora 2006


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

un
le

ility
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ce

on, otherwise support mode is not possible.

AG. Volkswagen AG d
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Switch off charging unit page 15 .

es, in part or in w
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hole
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, is n
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com

Exchange battery page 31 .

rrectness of i
t to the co
n
f
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r
m
spec
atio
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wit

Switch on vehicle parking light.

pe
rm
itte
d

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

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 A-

Note
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

Downloaded from www.Manualslib.com manuals search engine

AG.

Proceed as for charging battery page 16 .

agen
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by

Prote
cted
by
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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.

ht
rig
py
Co
t.

ng

Danger of injury! Observe warning notices and safety regula


tions page 2 !

thi
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en

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fo

WARNING

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- .

Observe

5900- .

3.2.1

ility
ab
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Observe

AG. Volkswagen AG d
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Operating instructions for battery charger
-VAS
by
ara
d
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s
ri
o
eo
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t
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ra
a
c
battery manufacture's handlingssinstructions!
urposes, in part or in wh
ole,
cial p
is n
mer
m
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o
c
r
erm
o
e
t
a
itte
riv
du
p
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o
nl
f
e
ng

Note

Description of battery charger -VAS


5900-

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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

3 - Adjustment button Down

AG.

Prote
cted
by

WARNING

agen
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Vo
by

Charging battery with battery charger VAS 5900c


o
p
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3.2.2

do
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en

5 - INFO

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Co
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4 - START / STOP

Danger of injury! Observe warning notices and safety regula


tions page 2 !
Special tools and workshop equipment required

3. Charging battery

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19

un
le

ility
ab
y li
an
pt
ce

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
ua
by
d
ran
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s
i
tee
r 2006
Jetta 2005 , Bora
o
h
t
or
ac
au - Edition 05.2005
Electrical System
s
s

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

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

pe
rm
itte
d

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
ng

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Prote
cted
by
c
o
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rig
ht
.
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yi

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

Downloaded from www.Manualslib.com manuals search engine

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rig
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Co
t.

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.

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

Display remains unchanged.

pe
rm
itte
d

Battery charger does not detect a battery, when battery volt


age is less than 2 V:
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

3-

does
not
gu
ara
nte
eo
ra
c
ility
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an
pt
ce

Press respective button Up or


sequence starts again.

ag
ksw
Vol
y
db
ise
or
Down uthuntil
charging
a
ss
un
le

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.

ng

r
te o
iva
r
rp
fo

Danger of injury! Observe warning notices and safety regula


tions page 2 !

agen
lksw
Vo
by

c
o
p
yri
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C
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yi

WARNING

thi
sd
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m
en

Charging battery in service mode with


battery charger -VAS 5900ht
rig
py
Co
t.

3.2.3

AG.

Prote
cted
by

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

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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

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ise
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a
ss

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

Note

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

pe
rm
itte
d

ility
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an
pt
ce

un
le

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

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 .
r
te o
iva
r
rp
fo

ng

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Connect black terminal clamp - to negative terminal on bat


tery.

agen
lksw
Vo
by

Prote
cted
by
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o
py
rig
ht
.
C
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yi

Connect red terminal clamp + to positive terminal on battery.

ht
rig
py
Co
t.

Set battery capacity (Ah) of battery for charging using respec


tive button Up or Down .

thi
sd
o
cu
m
en

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
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not
l
o
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nte
ir se
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t
u
ra
a
charge
condition of approx. 80 - 85 % the charger unit
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Note

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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
te o
a
itte
ir v
du
p
or
nl
f
e
ng

ility
ab
y li
an
pt
ce

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

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.

Battery charger does not detect a battery, when battery volt


age is less than 2 V:
agen
lksw
Vo
by

Prote
cted
by
c
o
py
rig
ht.
C
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yi

Display remains unchanged.

ht
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py
Co
t.

3-

do
c
um
en

Press respective button Up or Down until charging


sequence starts.

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

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23

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

n AG. Volkswagen AG do
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Caution

rrectness of i
t to the co
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f
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m
spec
atio
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wit

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

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 .

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

Downloaded from www.Manualslib.com manuals search engine

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- .

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fo

Do not press START / STOP button when charger unit


cables are connected incorrectly. The charger unit may be
damaged.

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
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Press START /d bSTOP
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thoblack terminal clamp - of


Disconnect
au
ative terminal
on battery.
ss

oes
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or
charger unit from eneg
ac

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Disconnect red terminal clamp + of charger unit from nega


tive terminal on battery.
es, in part or in w
l purpos
hole
ercia
, is n
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com

3.2.5

Charging battery in support mode with


battery charger -VAS 5900WARNING

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Danger of injury! Observe warning notices and safety regula


tions page 2 !

rrectness of i
t to the co
n
f
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m
spec
atio
h re
n in
wit

Pull charger unit plug out power supply socket.

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Prote
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C
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3. Charging battery

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25

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Caution

The terminal polarity protection in operating mode charg


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

tee
or
ac

r
ho

ut
Special tools and workshop
equipment required
sa
s

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 .

Prote
cted
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Co
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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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AG.

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

Downloaded from www.Manualslib.com manuals search engine

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Press START / STOP for approx. 5 seconds. The menu


charging totally discharged batteries/support mode will be
activated.

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
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urposes, in part or in wh
ole,
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is n
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erm
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ir va
du
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or
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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
a
t
i
h re
o
n in
wit
thi
s

Note

do
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um
en

urposes, in part or in wh
ole,
cial p
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mer
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r5900When the battery isisefully
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

Downloaded from www.Manualslib.com manuals search engine

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

n AG. Volkswagen AG do
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If these batteries are not recharged the plates continue
to
ir se
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h reduction in
or
harden and the ability to recharge is reduced.autA
ac
s
the battery output is the result.
s

charge, the sulphation will dissipate.

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Charge battery.

rrectness of i
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n
f
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mat
spec
ion
h re
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in

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l purpos
hole
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, is n
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Check no load voltage of battery page 15 .


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

ng

AG.

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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 .

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Disconnecting and reconnecting bat


teries
WARNING

Danger of injury! Observe warning notices and safety regula


tions page 2 !

4.1

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.

un
le
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rm
itte
d

4.2

positive

rrectness of i
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spec
atio
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terminal.

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sa
unscrew battery positive clamp -2- from battery
sThen

Connecting battery
Caution

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Prote
cted
by
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Special tools and workshop equipment required

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Observe instructions on connecting battery terminals


page 4 .

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AG.

4. Disconnecting and reconnecting batteries

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29

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Torque wrench -V.A.G 1331-

Note

After connecting the battery and switching the ignition on the ESP
and TCS warning lamp -K155- lights up permanently. The warn
ing lamp goes out automatically if a distance of 15 to 20 km/h is
driven straight ahead. This activates the steering angle sender G85- again.
Caution

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Disconnecting and connecting


Workshop Manual page 29 .

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or
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a
the
battery as described in the
ss

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l purpos
hole
ercia
, is n
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ot
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rrectness of i
t to the co
n
f
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
Procedures

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AG.

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

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cted
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.
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30

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t.

If necessary, table can be printed out.

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en

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

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Removing and installing battery


WARNING

Danger of injury! Observe warning notices and safety regula


tions page 2 !

5.1

Models with a petrol engine

Special tools and workshop equipment required


Torque wrench -V.A.G 1331-

Removing:
Disconnect the battery page 29 .

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

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AG. Volkswagen AG d
agen
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ir se
o
eo
h
t
u
ra
a
c
ss

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

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Co
t.

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cted
by
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py
rig
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Unscrew securing bolt -1- and remove battery holder -2-.


AG.

5. Removing and installing battery

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31

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Fold handles -arrows- upwards and take battery out.
Installing:
Caution

A loosely fitted battery creates the following dangers:


Shortened service life due to damage from vibration (dan
ger of explosion).
The cells in the battery will be damaged if the battery is
not secured correctly.
Damage to battery housing by. Vclamping
bracket (possi
olkswagen AG
gen AG subsequent
does
bility of acid leaking,ktherefore
higher
costs).
swa
n
ol
yV

ot g
ua
ran
tee
or
ac

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-

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

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

ht
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Co
t.

32

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Tighten threaded connections to specified torque settings


page 36 .

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
te
itte
iva
r
du
p
or
nl
f
e
ng

Installation is performed in the reverse order of installation; when


doing this, note the following:

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pt
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ut
a
ss

, Bora 2006
- Edition 05.2005

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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-.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
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du
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or
nl
f
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n

Spring-type

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

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t.

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AG.

Prote
cted
by

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.
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i

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

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33

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew air filter housing securing bolt -arrow-.

Unlock lugs -arrows- and take cover off.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
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erm
te o
a
itte
ir v
du
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or
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f
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db
ran
e
ir s
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.

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

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

agen
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Vo
by

AG.

Prote
cted
by
c
o
py
rig
ht
.
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Downloaded from www.Manualslib.com manuals search engine

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Co
t.

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

do
c
um
en

34

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew securing bolt -1- and remove battery holder -2-.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

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

Fold handles -arrows- upwards and take battery out.

Caution

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

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).
Poor crash safety

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.
Co
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AG.

Prote
cted
by

After installing, check that battery is seated securely.

ht
rig
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Co
t.

Tighten threaded connections to specified torque settings


page 36 .

do
c
um
en

Installation is performed in the reverse order of installation; when


doing this, note the following:

Connect the battery page 29 .


Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

5. Removing and installing battery

Downloaded from www.Manualslib.com manuals search engine

35

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

Threaded connections

Torque settings

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

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

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

20 Nm
10 Nm

ht
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Co
t.

36

or
ac

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

Torque settings: battery

ility
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an
pt
ce

ara
nte
e

ed
ris
ho
t
au
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Starter
Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

7.1

Checking starter -B-

Connect the vehicle diagnosis, testing and information system


-VAS 5051A- to page 281
Select guided fault finding in Vehicle Diagnosis, Testing and In
formation System -VAS 5051A- .
Using the Go to key, select Function/component selection
and the following menu items one after the other:
Body

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
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r
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o
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t
itte
iva
r
du
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Prote
cted
by

B - Starter

AG.

Electrical components

AG. Volkswagen AG d
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not
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27 - Starter, current supply

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Electrical System

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7. Starter

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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 Spring-type clip pliers -VAS
5024-

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l purpos
hole
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Disconnect the battery page 29 .


Release spring-type clip -1- using spring type clip pliers -VAS
5024- and remove securing bolt -2-.
Release hose -3- and pull it off the air filter housing.

AG.

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

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38

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Jetta 2005 , Bora 2006


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

ility
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an
pt
ce

rrectness of i
t to the co
n
f
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spec
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Push down protective cap
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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 .

agen
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Prote
cted
by
c
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rig
ht.
C
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Unscrew securing nut -1- from lower starter securing bolt.


AG.

Remove wiring retainer -2-.

7. Starter

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39

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

ility
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rrectness of i
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spec
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Remove lower securing bolt

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of starter
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Unscrew securing nut -1- from upper starter securing bolt.


Remove wiring retainer -2-.

Prote
cted
by

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

Downloaded from www.Manualslib.com manuals search engine

AG.

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-

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Torque wrench -V.A.G 1332-

Disconnect the battery page 29 .

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


switch.

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Prote
cted

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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

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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
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
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Unscrew securing nut -1- from upper starter securing bolt.


Remove wiring retainer -2-.

AG.

Downloaded from www.Manualslib.com manuals search engine

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

ht
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Co
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42

do
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en

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:

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note the following:
ris

tho

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-

ht
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Co
t.

r
fo
ng

Spring-type clip pliers -VAS


5024-

rrectness of i
t to the co
nform
spec
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t
i
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wit
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7.2.3

urposes, in part or in wh
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au torque
Tighten threaded connections to specified
ss
page 97 .

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Prote
cted
by
c
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rig
ht
.
C
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Removing:
Disconnect the battery page 29 .

7. Starter

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43

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Disconnect connector -arrow-.

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Unclip vacuum hose from its mounting -arrow-.

rrectness of i
t to the co
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f
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mat
spec
ion
h re
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in

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Pull hose -1- off air filter housing.

pe
rm
itte
d

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

ng

AG.

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cted
by

Downloaded from www.Manualslib.com manuals search engine

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

ht
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44

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en

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iva
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rp
fo

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

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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ab
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an
pt
ce

Pull hose -2- off pipe union.

urposes, in part or in wh
ole,
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a
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Loosen spring-type clip -1- using spring


5024- .

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i
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typethoclip pliers -VAS
eo
u
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a
c
ss

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

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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

do
c
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ht
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Co
t.

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by

AG.

Prote
cted
by

c
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p
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gh
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C
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yi

7. Starter

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45

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove air filter housing from vehicle.
Push down protective cap in -direction of arrow- from solenoid
switch.

Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

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ab
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an
pt
ce

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

Downloaded from www.Manualslib.com manuals search engine

AG.

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

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46

Prote
cted
by
c
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rig
ht.
C
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Remove lower securing bolt of starter -arrow-.

ht
rig
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Co
t.

Remove wiring retainer -2-.

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

es, in part or in w
l purpos
hole
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, is n
m
m
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erm
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t
a
itte
v
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du
p
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nl
f
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AG. Volkswagen AG d
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Remove noise insulation General Body Repairs, Exterior;
ara
d
e
nte
s
i
r
Rep. Gr. 50 ; Body front; Noise insulation .
o
eo
h
t
u
ra
a
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew securing nut -1- from upper starter securing bolt.
Remove wiring retainer -2-.

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f
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m
spec
atio
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wit

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, is n
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un
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Remove upper securing bolt of starter -arrow-.

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:

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Co
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Tighten threaded connections to specified torque settings


page 97 .

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by

AG.

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

7. Starter

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47

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

7.2.4

Vehicles with 2,5 l injection engine

Special tools and workshop


equipment required
Torque wrench -V.A.G
1331-

ility
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ce

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

Downloaded from www.Manualslib.com manuals search engine

Prote
cted
by

48

AG.

Pull engine cover off upwards -arrows-.

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.
Co
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Disconnect the battery page 29 .

do
c
um
en

Removing:

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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
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erm
o
te
a
itte
ir v
du
p
or
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.

Push down protective cap -direction of arrow- from solenoid


switch.

Unscrew nut -1- from lower starter securing bolt.


Remove wiring retainer -2-.

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

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

Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

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an
pt
ce

AG. Volkswagen AG d
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a
c
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ht
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Co
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AG.

Prote
cted
by

c
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p
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gh
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C
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yi

7. Starter

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49

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove lower securing bolt of starter -arrow-.

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

Unscrew nut -1- from upper starter securing bolt.


Remove wiring retainer -2-.

cop
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.
Co
py
i

Remove starter from vehicle downwards.


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Prote
cted
by

Installing:

ht
rig
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Co
t.

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

Downloaded from www.Manualslib.com manuals search engine

do
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um
en

urposes, in part or in wh
ole,
cial p
is n
mer
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a
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ir v
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AG. Volkswagen AG d
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h
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ra
a
c
ss

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
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
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is n
mer
m
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t
itte
ir va
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n

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Spring-type clip pliers -VAS


5024-

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ht
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Co
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Torque wrench -V.A.G


1331-

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Prote
cted
by
c
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py
rig
ht
.
C
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yi

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

7. Starter

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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
nform
spec
a
t
i
h re
o
n in
wit
thi
s

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

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pt
ce

AG. Volkswagen AG d
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V
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s
i
r
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h
t
u
ra
a
c
ss

Unscrew air filter housing securing bolt -arrow-.

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

agen
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Vo
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cop
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.
Co
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i

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

do
c
um
en

52

ht
rig
py
Co
t.

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 .

Remove wiring retainer -2-.

ht
rig
py
Co
t.

Unscrew nut -1- from lower starter securing bolt.

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

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

ility
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an
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ce

AG. Volkswagen AG d
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is
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ss

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AG.

Prote
cted
by

cop
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gh
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.
Co
py
i

7. Starter

Downloaded from www.Manualslib.com manuals search engine

53

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove lower securing bolt of starter -arrow-.

Unscrew nut -1- from upper starter securing bolt.


Remove wiring retainer -2-.

Remove upper securing bolt of starter -arrow-.

Unscrew earth wire securing nut -1- and place earth wire end
-2- in direction of battery to side.
Remove starter from vehicle upwards.

Prote
cted
by

54

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Tighten threaded connections to specified torque settings


page 97 .

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Vo
by

cop
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gh
t
.
Co
py
i

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


note the following:

ht
rig
py
Co
t.

Installing:

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
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an
pt
ce

AG. Volkswagen AG d
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not
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o
V
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by
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s
i
r
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h
t
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ra
a
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Vehicles with 2.0 l SDI engine

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
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Spring-type clip pliers -VAS


5024-

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Torque wrench -V.A.G


1332-

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Torque wrench -V.A.G


1331-

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Special tools and workshop


equipment required

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7.2.6

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

7. Starter

Downloaded from www.Manualslib.com manuals search engine

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
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an
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ce

Remove air filter housing from vehicle.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
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his

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


switch.

AG.

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

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56

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Pull air filter housings aon
ac
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 noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

ng

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Prote
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Remove wiring retainer -2-.

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

7. Starter

57

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew starter securing bolt -arrow-.
Remove starter from vehicle downwards.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
Tighten threaded connections to specified torque settings
page 97 .

7.3

Removing and installing starter, auto


mated shift gearboxes

7.3.1

Vehicles with 1.6 l injection engine

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

Downloaded from www.Manualslib.com manuals search engine

Prote
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by

58

AG.

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Disconnect the battery page 29 .

rrectness of i
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spec
at
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Removing:

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Spring-type clip pliers -VAS


5024-

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Torque wrench -V.A.G


1332-

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l purpos
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Torque wrench -V.A.G


1331-

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ht
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Co
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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.

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Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

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


switch.

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AG.

Prote
cted
by
c
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py
rig
ht.
C
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7. Starter

Downloaded from www.Manualslib.com manuals search engine

59

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew earth wire from starter securing bolt -arrow-.

Unscrew starter securing bolt -arrow-.


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

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


Remove wiring retainer -2-.

Unscrew starter securing bolt -arrow-.


Remove starter from vehicle downwards.
Installing:

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


note the following:
Tighten threaded connections to specified torque settings
page 97 .

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

agen
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c
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p
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C
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Rep. Gr.27 - Starter, current supply, CC

ht
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Co
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60

rrectness of i
t to the co
nform
spec
atio
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wit
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thi
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urposes, in part or in wh
ole,
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Vehicles with 2,0 l FSI engine

Special tools and workshop


equipment required
Torque wrench -V.A.G
1331 Torque wrench -V.A.G
1332-

Spring-type clip pliers -VAS


5024-

rrectness of i
t to the co
nform
spec
at
i
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7.3.2

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Jetta
2005
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Electrical
System
- nEdition
05.2005
o
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Prote
cted
by

cop
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gh
t
.
Co
py
i

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

7. Starter

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61

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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a
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ion
h re
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his

urposes, in part or in wh
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t
itte
iva
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du
p
or
nl
f
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ility
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an
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ce

Unclip vacuum hose from its mounting -arrow-.

Loosen spring-type clip -arrow- from hose -1- using spring type
clip pliers -VAS 5024- .
Pull hose -1- off air filter housing.

Downloaded from www.Manualslib.com manuals search engine

AG.

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

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Prote
cted
by
c
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rig
ht
.
C
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62

ht
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Co
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Unscrew air filter housing securing bolt -arrow-.

do
c
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en

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

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

ility
ab
y li
an
pt
ce

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

urposes, in part or in wh
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cial p
is n
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m
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a
itte
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f
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Pull air filter housing on right side upwards
by off rubber mounting
ara
d
e
nte
-arrow-.
s
ri
o
eo
h
t
u
ra
a
c
ss

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

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

do
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ht
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Co
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C
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yi

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


AG.

Prote
cted
by

Remove air filter housing from vehicle.


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

7. Starter

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63

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew positive wire -1- and disconnect connector from ter
minal 50 -2-.

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


Remove wiring retainer -2-.

Remove upper securing bolt of starter -arrow-.


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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
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nl
f
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pt
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AG. Volkswagen AG d
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by
ara
d
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is
r
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t
u
ra
a
c
ss

Remove connectors -arrows-.

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

agen
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Prote
cted
by

cop
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.
Co
py
i

Downloaded from www.Manualslib.com manuals search engine

ht
rig
py
Co
t.

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

thi
sd
o
cu
m
en

64

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew securing nut -1- from lower starter securing bolt.
Remove wiring retainer -2-.

Remove lower securing bolt of starter -arrow-.


Remove starter from vehicle
Installing:

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


note the following:

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Co
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en

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f
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m
spec
atio
h re
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wit

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l purpos
hole
ercia
, is n
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Tighten threaded connections to specified torque settings


page 97 .

agen
lksw
Vo
by

AG.

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

7. Starter

Downloaded from www.Manualslib.com manuals search engine

65

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

n AG. Volkswagen AG do
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b
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ise
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h
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ac
a
ss

Vehicles with 2.0 l FSI turbo engine

ility
ab
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an
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Special tools and workshop


equipment required
Torque wrench -V.A.G
1331 Torque wrench -V.A.G
1332-

Spring-type clip pliers -VAS


5024-

66

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Unbolt securing bolts -arrow-.

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Prote
cted
by
c
o
py
rig
ht
.
C
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yi

Disconnect the battery page 29 .

ht
rig
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Co
t.

Removing:

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

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l purpos
hole
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erm
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t
a
itte
v
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du
p
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nl
f
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7.3.3

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
n AG. Volkswagen AG do
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V
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b
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ise
tee
r
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h
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ss

rrectness of i
t to the co
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f
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r
m
spec
atio
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wit

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hole
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Disconnect connector -arrow-.

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Co
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Prote
cted
by
c
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py
rig
ht
.
C
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Pull engine cover off upwards -arrows-.

thi
sd
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cu
m
en

r
te o
iva
r
rp
fo

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

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


switch.

7. Starter

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67

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew positive wire -1- and disconnect connector from ter
minal 50 -2-.

Remove upper securing bolt of starter -arrow-.

Remove lower securing bolt of starter -arrow-.


Remove starter from vehicle upwards.
Installing:
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un
le

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Installation is carried out in the reverse order.


note the following:

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When
installing,

ng

AG.

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Prote
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by
c
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rig
ht.
C
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Rep. Gr.27 - Starter, current supply, CC

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Co
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68

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en

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t to the co
n
f
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m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
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, is n
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Tighten threaded connections to specified torque settings


page 97 .

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-.

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

Removing:

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
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a
itte
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du
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f
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ss

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

7. Starter

Downloaded from www.Manualslib.com manuals search engine

69

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024- .

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

ility
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y li
an
pt
ce

Unlock lugs -arrows- and take cover off.

AG.

Downloaded from www.Manualslib.com manuals search engine

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Prote
cted
by
c
o
py
rig
ht.
C
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Rep. Gr.27 - Starter, current supply, CC

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rig
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Co
t.

70

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
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t
itte
ir va
du
p
or
nl
f
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g
n

Unscrew air filter

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h
t
housing
securing
bolt
-arrow-.
u
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a
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ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
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AG
Pull hose -arrow- off air filter housing
and
agentake hose out.AG does
ksw
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b of brackets and remove.


dout
Pull air filter housing upwards
ise

Push down protective cap -direction of arrow- from solenoid


switch.

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Co
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Prote
cted
b
y
c
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gh
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.
Co
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Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

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

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l purpos
hole
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m
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t
a
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v
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f
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ss

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AG.

Remove upper securing bolt of starter -arrow-.

7. Starter

Downloaded from www.Manualslib.com manuals search engine

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 .

Vehicles with 2,0 l TDI engine

r
fo
ng

urposes, in part or in wh
ole,
cial p
is n
mer
m
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a
itte
v
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d
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Spring-type clip pliers -VAS


5024-

72

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Disconnect the battery page 29 .

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Prote
cted
by
c
o
py
rig
ht
.
C
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Removing:

rrectness of i
t to the co
nform
spec
a
t
i
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n in
wit
thi
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en

Torque wrench -V.A.G


1332-

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an
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ce

Torque wrench -V.A.G


1331-

un
le

Special tools and workshop


equipment required

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7.3.5

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull engine cover off upwards -arrows-.

Separate connector -1-, release spring-type clip -2- with spring


type clip pliers -VAS 5024- and pull off vacuum hose -3-.

Unscrew air filter housing securing bolt -arrow-.

ht
rig
py
Co
t.

Unlock lugs -arrows- and take cover off.

rrectness of i
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7. Starter

Downloaded from www.Manualslib.com manuals search engine

73

Jetta 2005 , Bora 2006


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

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


switch.

Unscrew positive wire -1- and disconnect connector from ter


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minal 50 -2-.
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Unclip hose -1- from hose retainer -2-.

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

do
c
um
en

74

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove upper securing bolt of starter -arrow-.

Remove lower securing bolt of starter -arrow-.


Remove starter from vehicle upwards.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
Tighten threaded connections to specified torque settings
page 97 .

do
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rrectness of i
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nform
spec
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s

urposes, in part or in wh
ole,
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7. Starter

75

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-

urposes, in part or in wh
ole,
cial p
is n
mer
m
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erm
o
te
a
itte
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du
p
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Downloaded from www.Manualslib.com manuals search engine

AG.

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

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76

ht
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Push down protective cap -direction of arrow- from solenoid


switch.

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

Disconnect the battery page 29 .

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Removing:

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t
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ra
a
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew positive wire -1- and disconnect connector from ter
minal 50 -2-.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
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t
a
itte
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Unscrew earth wire from starter securing bolt

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-arrow-.
ss

Unscrew starter securing bolt -arrow-.

Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

do
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Co
t.

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Unscrew nut -1- from lower starter securing bolt.


Remove wiring retainer -2-.

7. Starter

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77

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew starter securing bolt -arrow-.
Remove starter.
Installing:
AG. Volkswagen AG d
Installation is carried out in the reverseworder.
agen When installing,
oes
not
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note the following:
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Tighten threaded connections
to specified torque settings
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page 97 .
sa

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t to the co
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spec
a
t
ion
h re
wit
in t
his

7.4.2

or
ac
ility
ab
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an
pt
ce

Vehicles with 2,0 l FSI engine

Special tools and workshop


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

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AG.

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by
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ht.
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Downloaded from www.Manualslib.com manuals search engine

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

do
c
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en

78

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Removing:
Disconnect the battery page 29 .
Disconnect connector -arrow-.

Unclip vacuum hose from its mounting -arrow-.

ility
ab
y li
an
pt
ce

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
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by from hose -1- using spring typeguar
Loosen spring-type clip -arrowd
an
e
s
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clip pliers -VAS 5024- h.ori
t
or
u
ac
a
Pull hose -1- off airssfilter housing.

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7. Starter

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79

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew air filter housing securing bolt -arrow-.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
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c
r
erm
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t
a
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or
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ac
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ss

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

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

Downloaded from www.Manualslib.com manuals search engine

AG.

80

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

ht
rig
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Co
t.

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

do
c
um
en

Pull hose -2- off pipe union.

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.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
te o
a
itte
ir v
du
p
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nl
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ra
a
c
ss

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

Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

Unscrew earth wire from starter securing bolt -arrow-.

do
c
um
en

ht
rig
py
Co
t.

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by

AG.

Prote
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by

cop
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.
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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

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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 .

agen
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by

AG.

Prote
cted
by
c
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py
rig
ht.
C
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Rep. Gr.27 - Starter, current supply, CC

do
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82

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
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nl
f
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ng

ility
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an
pt
ce

AG. Volkswagen AG d
agen
oes
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not
l
o
V
gu
by
ara
d
nte
ir se
o
eo
h
t
u
ra
a
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

7.4.3

Vehicles with 2.0 l FSI turbo engine

Special tools and workshop


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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

Disconnect the battery page 29 .


Unbolt securing bolts -arrow-.

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Removing:

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a
ss

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Co
t.

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Vo
by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
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yi

7. Starter

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83

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Disconnect connector -arrow-.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
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nl
f
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k
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ran
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tee
ris
o
h
t
or
u
ac
a
ss

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

AG.

Downloaded from www.Manualslib.com manuals search engine

agen
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by

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

ht
rig
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Co
t.

84

do
c
um
en

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


switch.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Pull engine cover off upwards -arrows-.

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
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rm
itte
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ss

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ran
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ise
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tho
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un
le

Unscrew positive wire -1- and disconnect connector from ter


AG. Volkswagen AG d
agen
oes
minal 50 -2-.
n
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ng

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by

AG.

Prote
cted
by
c
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rig
h
t
.
Co
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i

Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

ht
rig
py
Co
t.

Unscrew starter securing bolt -arrow-.

thi
sd
o
cu
m
en

r
te o
iva
r
rp
fo

Unscrew earth wire from starter securing bolt -arrow-.

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


Remove wiring retainer -2-.

7. Starter

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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-

Downloaded from www.Manualslib.com manuals search engine

AG.

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

agen
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Vo
by

Prote
cted
by
c
o
py
rig
ht
.
C
op
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86

do
c
um
en

Disconnect the battery page 29 .

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
te
itte
iva
r
du
p
or
nl
f
e
ng

ility
ab
y li
an
pt
ce

Removing:

ht
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py
Co
t.

n AG. Volkswagen AG do
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wage
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olks
V
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Spring-type clip pliers -VAS
ua
db
ran
e
ir s
5024tee
o
h
t
or
u
ac
a
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull engine cover off upwards -arrows-.

Separate connector -1-, release spring-type clip -2- with spring


type clip pliers -VAS 5024- and pull off vacuum hose -3-.

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

gen solenoid
Push down protective cap -direction of arrowwafrom
olks
V
y
switch.
db

Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

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ab
y li
an
pt
ce

e
ris
tho
u
a
ss

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Co
t.

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by

AG.

Prote
cted
by

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.
Co
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7. Starter

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87

Jetta 2005 , Bora 2006 AG. Volkswagen A


G do
agen05.2005
es n
Electrical System V- oEdition
lksw
ot
starter securing bolt -arrow-.

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

Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

ht
rig
py
Co
t.

agen
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Vo
by

Prote
cted
by

cop
yri
gh
t
.
Co
py
i

Unscrew nut -1- from lower starter securing bolt.


AG.

Remove wiring retainer -2-.

Unscrew starter securing bolt -arrow-.


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

88

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

Downloaded from www.Manualslib.com manuals search engine

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Unscrew starter securing bolt -arrow-.

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
te
itte
iva
r
du
p
or
nl
f
e
ng

Unscrew

y
db
ise
r
earth wire
tho from
au
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

7.4.5

Vehicles with 1.9 l TDI engine

Special tools and workshop


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

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

Disconnect the battery page 29 .


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

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

Removing:

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an
pt
ce

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ise
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h
t
or
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ac
a
ss

ht
rig
py
Co
t.

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Vo
by

AG.

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

7. Starter

Downloaded from www.Manualslib.com manuals search engine

89

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024- .

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

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
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ng

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an
pt
ce

n AG. Volkswagen AG do
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wage
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olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s

Unscrew air filter housing securing bolt -arrow-.

AG.

Downloaded from www.Manualslib.com manuals search engine

agen
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Vo
by

Prote
cted
by
c
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Rep. Gr.27 - Starter, current supply, CC

ht
rig
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Co
t.

90

do
c
um
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.

ility
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switch.

rrectness of i
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ion
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a down protective cap -direction of arrow- from solenoid
Push
c
ss

Unscrew positive wire -1- and disconnect connector from ter


minal 50 -2-.

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

7. Starter

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91

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew starter securing bolt -arrow-.

AG. Volkswagen AG d
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un
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Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

ng

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


note the following:

Downloaded from www.Manualslib.com manuals search engine

Prote
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by

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

AG.

92

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cop
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Co
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Tighten threaded connections to specified torque settings


page 97 .

thi
sd
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Installing:

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Remove starter.

ht
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Co
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Unscrew starter securing bolt -arrow-.

rrectness of i
t to the co
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f
o
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m
spec
atio
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wit

Remove wiring retainer -2-.

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

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
nform
spec
a
t
i
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wit
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s

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Spring-type clip pliers -VAS


5024-

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Torque wrench -V.A.G


1331-

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AG.

Prote
cted
by
c
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rig
ht.
C
op
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Removing:
Disconnect the battery page 29 .
Pull engine cover upwards -arrows A- and forwards
-arrow B-.

7. Starter

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93

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Release spring-type clip -1- using spring type clip pliers -VAS
5024- and disconnect connector -2-.
Remove securing bolt -3-.

Pull vacuum hose off -arrow-.

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

Push down protective cap -direction of arrow- from solenoid


switch.

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

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

ht
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94

rrectness of i
t to the co
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spec
a
t
i
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wit
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urposes, in part or in wh
ole,
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ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew positive wire -1- and disconnect connector from ter
minal 50 -2-.

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Unscrew earth wire from starter securing bolt -arrow-.

Unscrew starter securing bolt -arrow-.

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Co
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Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

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by

AG.

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

Unscrew nut -1- from lower starter securing bolt.


Remove wiring retainer -2-.

7. Starter

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95

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew starter securing bolt -arrow-.
Remove starter.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
Tighten threaded connections to specified torque settings
page 97 .

agen
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by

AG.

Prote
cted
by
c
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rig
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Downloaded from www.Manualslib.com manuals search engine

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

do
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en

96

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

urposes, in part or in wh
ole,
cial p
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mer
m
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AG. Volkswagen AG d
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ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Torque settings: starter

Threaded connections

Torque settings

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

M12
M10
M8
M8
M8

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

M8

rrectness of i
t to the co
nform
spec
at
i
h re
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8. Torque settings: starter

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97

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Alternator
Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

9.1

Fastening B+ wire to alternator


Caution

If the B+ wire is not secured with the prescribed torque the


following may occur:
Battery not charge fully.
Vehicle electrics/electronics fail completely (breakdown).

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Damage to electronic components and control


to excessive voltage.

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Danger of fires from sparks.

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

Checking ribbed belt (poly V-belt)

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


ng

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


breaks)

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

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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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Fit ribbed belt (poly V-belt).

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9.2

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The tightening torque for the securing nut of the B+ wire


-arrow- an be found in the following table Tightening torques
page 145 .

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

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Using the Go to key, select Function/component selection


and the following menu items one after the other:

27 - Starter, current supply

Alternator, 1.6 l injection engine

9.4.1

Assembly overview

Prote
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by
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ht
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2 - Hexagon head collared


bolts
M8x50
23 Nm

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1 - Hexagon head collared bolt


M8x108
23 Nm

AG.

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

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99

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
2 Nm
13 - Voltage regulator
AG. Volkswagen AG d
page 142 oes n
Removing and installing voltage
regulator
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14 - Alternator
ise
or
h
t
Removing and installing
alternator page 100
au

ss

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

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

Locking pin -T10060 A-

Removing:
Disconnect the battery page 29 .

100

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Torque wrench -V.A.G 1331-

agen
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Prote
cted
by
c
o
py
rig
ht.
C
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Special tools and workshop equipment required

ht
rig
py
Co
t.

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

thi
sd
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en

urposes, in part or in wh
ole,
cial p
is n
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f
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ng

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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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ab
y li
an
pt
ce

Caution

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
te o
a
itte
ir v
du
p
or
nl
f
e
ng

Unscrew B+ wiring -arrow- off alternator.

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

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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AG.

Prote
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by

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Co
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9. Alternator

Downloaded from www.Manualslib.com manuals search engine

do
c
um
en

ht
rig
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Co
t.

Remove ribbed belt.

101

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

Unbolt securing bolts -arrow-.

Take hose retainer together with tensioning element out of the


vehicle.

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

When reinstalling used ribbed belts (poly V-belts) observe


the direction of rotation marked on removal!
Ensure, before installing ribbed belt, that all ancillaries (al
ternator, air conditioner compressor) are secured tightly.
Ensure ribbed belt (poly V-belt) is seated correctly in belt
pulley when installing.

102

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

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AG.

Remove alternator.

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Prote
cted
by
c
o
py
rig
ht.
C
op
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Unscrew wiring bracket -arrow- from alternator.

ht
rig
py
Co
t.

Remove alternator securing bolts -arrows-.

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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um
en

urposes, in part or in wh
ole,
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is n
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t
itte
ir va
du
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f
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n

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

AG. Volkswagen AG d
agen
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d
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ir se
o
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h
t
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ra
a
c
ss

Position wiring bracket -arrow- on rear of generator at 3


o'clock.
Tighten threaded connections to specified torque settings
page 145 .

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Caution

ng

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Start the engine and check belt running.


AG.

Prote
cted
by

9.4.3

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Switch off the engine.

ht
rig
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Co
t.

Connect the battery page 29 .

thi
sd
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cu
m
en

Observe instructions on connecting battery terminals


page 4 .

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

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l purpos
hole
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AG. Volkswagen AG d
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Drive threadedbysleeves
-A- out of the alternator
housing
for
gu
ara
d in -direction of arrow-.
e
approx. 4 mm
nte
is
r
eo
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ra
au
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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

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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

13 - Voltage regulator
Removing and installing
voltage regulator
page 142

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
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g
n

12 - Cross-head screw
M4x13
2 Nm

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

Downloaded from www.Manualslib.com manuals search engine

AG.

11 - Phillips screws
M4x19
2 Nm

agen
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by

10 - Protective cap

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

9 - Plain washer
M5

Prote
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by
c
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rig
ht.
C
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8 - Hexagon nut, flat


M8

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7 - Cross-head screw
M5x21
4.5 Nm

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s

ht
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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-

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

Disconnect the battery page 29 .

Remove upper securing bolt of alternator -arrow-.

ht
rig
py
Co
t.

r
fo
ng

Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Noise insulation .

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
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cu
m
en

Removing:

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s

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un
le

Locking pin -T10060 A-

agen
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Vo
by

AG.

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

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

105

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove wiring bracket -1- and pullAGprotective
. Volkswagencap -2- off.

AG do
es n
ot g
ua
ran
tee
or
ac

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.
ht
rig
py
Co
t.

Prote
cted
by
c
o
py
rig
h
t
.
Co
py
i

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

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rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

ility
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y li
an
pt
ce

ss

n
wage
olks
V
by
ed
ris
o
th
au

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

does
n

o
Tighten threaded connections
to specified torque settingsot gua
yV
db
ran
e
s
page 145 .
i
te
or

eo
ra
c

h
ut

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

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

cop
yri
gh
t
.
Co
py
i

Models with air conditioning system:

agen
lksw
Vo
by

Ribbed belt (poly V-belt) pulley Coolant pump

Prote
cted
by

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

ht
rig
py
Co
t.

1-

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

9.5.3

ility
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pt
ce

Start the enginesand


check belt running.
sa

AG.

9. Alternator

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107

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

ng

r
te o
iva
r
rp
fo

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

Downloaded from www.Manualslib.com manuals search engine

thi
sd
o
cu
m
en

11 - Plain washer
M5

AG.

10 - Hexagon nut, flat


M8

agen
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Vo
by

9 - Cross-head screw
M5x21
4.5 Nm

Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i

8 - Hexagon head collared nut


M8

ht
rig
py
Co
t.

7 - Protective cap

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

6 - Hexagon head collared


bolts
M10x45
52 Nm

n AG. Volkswagen AG do
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ise
tee
r
o
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t
or
u
ac
a
ss

ility
ab
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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

Locking pin -T10060- or


locking pin -T10060 A-

Spring-type clip pliers -VAS


5024 A-

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

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

Torque wrench -V.A.G


1331-

n AG. Volkswagen AG do
es n
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ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s

ht
rig
py
Co
t.

Special tools and workshop


equipment required

agen
lksw
Vo
by

AG.

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

Removing:
Disconnect the battery page 29 .

9. Alternator

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109

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull engine cover off upwards -arrows-.

Disconnect connector -arrow-.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

ility
ab
y li
an
pt
ce

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
s
ri
o
eo
h
t
u
ra
a
c
ss

Unclip vacuum hose from its mounting -arrow-.

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

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

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
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.

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
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
itte
iva
r
du
p
or
nl
f
e
ng

Unscrew air filter housing securing bolt

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
y
ua
db
ran
e
ir s
tee
o
h
t
or
u
-arrow-.
ac
a
ss

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
py
rig
ht
.
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

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111

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Separate connector -arrow- on rear of air filter housing.
Remove air filter housing from vehicle.
Remove upper intake manifold.

Disconnect connector of DF wiring -1- and pull protective cap


-2- off.

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-.

AG.

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
by

Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i

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

ht
rig
py
Co
t.

112

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
ab
y li
an
pt
ce

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
y
ua
b
d
ran
ise
tee
r
o
h
t
or
u
ac
a
ss

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-.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

ility
ab
y li
an
pt
ce

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

Unscrew wiring bracket -arrow- from alternator.


Installing:

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

Take alternator out of the vehicle.


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

do
c
um
en

ht
rig
py
Co
t.

agen
lksw
Vo
by

AG.

Prote
cted
by

cop
yri
gh
t
.
Co
py
i

9. Alternator

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113

Jetta 2005 , Bora 2006


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

Position wiring bracket -arrow- on rear of generator at 12


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

When reinstalling used ribbed belts (poly V-belts) observe


n AG. Volkswagen AG do
the direction of rotation marked on removal!
e
wage

s no
t gu
ara
nte
eo
ra
c

ks
Vol

by
Ensure, before installing ribbed belt, that all ancillaries
(al
ed
ris tightly.
ternator, air conditioner compressor) are secured
o
th
au

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.

9.6.3

Ribbed belt routing, 2,0 l FSI engine

Models without air conditioning system:

3-

Poly V-belt

4-

Ribbed belt pulley - Crankshaft

114

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Ribbed belt pulley - Alternator

agen
lksw
Vo
by

2-

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

Tensioning roller

ht
rig
py
Co
t.

1-

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
ab
y li
an
pt
ce

Ensure ribbed belt (poly V-belt) is seatedsscorrectly in belt


pulley when installing.

Jetta 2005 , Bora 2006


05.2005

Ribbed belt pulley - Alternator

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

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

2-

9.7.1

Assembly overview

Prote
cted
by

2 - Hexagon head collared


bolts
M8x90
23 Nm

cop
yri
gh
t
.
Co
py
i

1 - Hexagon head collared


bolts
M8x45
23 Nm

AG.

Alternator, 2.0 l FSI turbo engine

agen
lksw
Vo
by

9.7

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

Tensioning roller

ility
ab
y li
an
pt
ce

1-

ht
rig
py
Co
t.

Models with air conditioning

n AG d
AG. VolkswageElectrical
System - Edition
agen
oes
ksw
not
l
o
V
gu
y
ara
system: rised b
nte
o
eo
h
t
u
ra
a
c
ss

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

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115

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
12 - Voltage regulator
Removing and installing voltage regulator page 142
13 - Alternator
Removing and installing alternator page 116
14 - Poly V-belt
Checking page 98 .
15 - Tensioning element for poly V-belt

9.7.2

Removing and installing alternator, 2.0 l


turbo FSI engine
Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

Special tools and workshop


equipment required
Torque wrench -V.A.G
1331 Locking pin -T10060- or
locking pin -T10060 A Spring-type clip pliers -VAS
5024 A-

agen
lksw
Vo
by

AG.

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

Downloaded from www.Manualslib.com manuals search engine

ht
rig
py
Co
t.

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

do
c
um
en

116

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

ility
ab
y li
an
pt
ce

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
nte
ir se
o
eo
h
t
u
ra
a
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Removing:
Disconnect the battery page 29 .
Unbolt securing bolts -arrow-.

Disconnect connector -arrow-.

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
y
ua
db
ran
e
is
tee
r
o
h
t
or
u
ac
a
ss

ht
rig
py
Co
t.

un
le

r
fo
ng

Pull engine cover off upwards -arrows-.

agen
lksw
Vo
by

AG.

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

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

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

ility
ab
y li
an
pt
ce

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

117

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Note
All hoses of the charge air system are secured with hose clips

or with quick release couplings. When using quick release


couplings the following points must be observed:

Unlock connection by pulling the securing clamp -arrow-.


Pull hose/tube off without assistance of tools.

Disconnect quick release coupling -arrow-.

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

Unbolt securing bolts -arrow-.


Take hose out of the vehicle.
Remove connecting pipe between charge air cooler and tur
bocharger.
Caution

Mark top and direction of rotation of poly V-belt before remov


ing. When installing observe direction of rotation marked on
removal. Installing opposite to the direction of rotation leads to
belt damage!

Mark direction of rotation of poly V-belt.

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
by

cop
yri
gh
t
.
Co
py
i

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
d
o
cu
m
en

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

ility
ab
y li
an
pt
ce

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
s
i
r
o
eo
h
t
u
ra
a
c
ss

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.

Loosen threaded connections of coolant pipe -arrows-.


Note

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

ht
rig
py
Co
t.

agen
lksw
Vo
by

AG.

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

Remove alternator securing bolts -arrows-.

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
ab
y li
an
pt
ce

ss

t gu
ara
nte
eo
ra
c

yV
db
ise
r
tho
au

Disconnect connector of DF wiring -1- and pull protective cap


-2- off.

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

119

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew B+ wiring -arrow- off alternator.

Unscrew wiring bracket -arrow- from

ility
ab
y li
an
pt
ce

Installing:

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

Take alternator out of the vehicle.

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

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


note the following:

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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-.

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
by

cop
yri
gh
t
.
Co
py
i

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

ht
rig
py
Co
t.

120

do
c
um
en

Position wiring bracket -arrow- on rear of generator at 9


o'clock.

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-.

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rm
itte
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Tighten threaded connections to specified


page 145 .

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torque
s
s

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

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

Caution

Observe instructions on connecting battery terminals


page 4 .
Connect the battery page 29 .

Start the engine and check belt running.


Switch off the engine.

9.7.3

Ribbed belt routing, 2.0 l turbo engine

4-

Ribbed belt pulley - Crankshaft

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Poly V-belt

AG.

3-

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Ribbed belt pulley - Alternator

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

2-

ht
rig
py
Co
t.

Tensioning roller

thi
sd
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en

1-

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iva
r
rp
fo

Models without air conditioning system:

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

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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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Vol

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ole,
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is n
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erm
o
te
a
itte
ir v
du
p
or
nl
f
e
ng

ility
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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
nform
spec
a
t
i
h re
o
n in
wit
thi
s

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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AG.

Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i

10 - Poly V-belt
Checking page 98 .

ht
rig
py
Co
t.

9 - Alternator
Removing and installing
alternator page 127

do
c
um
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

Downloaded from www.Manualslib.com manuals search engine

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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

Disconnect the battery page 29 .

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db
ran
e
is
tee
r
o
h
t
or
u
ac
a
ss

Take the engine cover off upwards and forwards.

Bring lock carrier into service position General body repairs,


exterior; Rep. Gr. 50 ; Lock carrier service position

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

Take off poly V-belt Rep. Gr. 13

Disconnect connector of DF wiring -1- and pull protective cap


-2- off.

do
c
um
en

ht
rig
py
Co
t.

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by

AG.

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

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

123

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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Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t.
C
op
yi

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

Downloaded from www.Manualslib.com manuals search engine

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Caution

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng

ility
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pt
ce

AG. Volkswagen AG d
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s
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Jetta 2005tho , Bora 2006
u
ra
a
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Electrical
ss System - Edition 05.2005

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
ks
l
o
o'clock.
t gu
yV
b
ed

ara
nte
e

risspecified torque settings


Tighten threaded connections hto
t o
u
page 145 .
sa

or
ac

Caution

Observe instructions on connecting battery terminals


page 4 .
Connect the battery page 29 .
Start the engine and check belt running.
Switch off the engine.

9.8.3

Ribbed belt routing, 2.5l engine

Models with air conditioning system:


Upper idler roller

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.

1-

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

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

ility
ab
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an
pt
ce

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by

AG.

Prote
cted
by

cop
yri
gh
t
.
Co
py
i

10 - Belt pulley - Coolant pump

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

125

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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

ng

r
te o
iva
r
rp
fo

6 - Hexagon head collared


bolts
M10x45
40 Nm
7 - Hexagon bolt with washer
and threaded piece
M4x20, M4x15
2 Nm
8 - Protective cap for alternator
9 - Phillips screws
M4x20
2 Nm
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

Downloaded from www.Manualslib.com manuals search engine

thi
sd
o
cu
m
en

5 - Hexagon head collared


bolts
M10x65
40 Nm

AG.

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

agen
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Vo
by

3 - Hexagon head collared


bolts
M8x90
20 Nm

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

2 - Tensioning element for poly


V-belt

ility
ab
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an
pt
ce

1 - Hexagon head collared


bolts
M8x45
20 Nm

un
le

Assembly overview

AG. Volkswagen AG d
agen
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not
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by
ara
d
nte
ir se
o
eo
h
t
u
ra
a
c
ss

Prote
cted
by
c
o
py
rig
ht.
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
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
itte
iva
r
du
p
or
nl
f
e
ng

ility
ab
y li
an
pt
ce

AG. Volkswagen AG d
agen
oes
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not
l
o
V
gu
by
ara
d
e
nte
s
i
r
o
eo
h
t
u
ra
a
c
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.

agen
lksw
Vo
by

AG.

Prote
cted
by

cop
yri
gh
t
.
Co
py
i

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

127

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Note
All hoses of the charge air system are secured with hose clips

or with quick release couplings. When using quick release


couplings the following points must be observed:

Unlock connection by pulling the securing clamp -arrow-.


Pull hose/tube off without assistance of tools.

Disconnect connectors -1-.


Unclip fuel hoses -2- and take charge air hose out.

Remove securing bolt -3-.

Unbolt securing bolt -arrow-.

Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Body front; Noise insulation .

AG.

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
by

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

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

ht
rig
py
Co
t.

128

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Disconnect connector -2-.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

Pull vacuum hose -1- off.

ility
ab
y li
an
pt
ce

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db
ran
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is
tee
r
o
h
t
or
u
ac
a
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

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

pe
rm
itte
d

ility
ab
y li
an
pt
ce

un
le

Unscrew charge air pipe securing bolt -arrow-.

Disconnect connector of charge air pipe -arrow-.

ht
rig
py
Co
t.

ng

Disconnect connector of DF wiring -1- and pull protective cap


-2- off.

thi
sd
o
cu
m
en

r
te o
iva
r
rp
fo

Take charge air pipe out upwards.

agen
lksw
Vo
by

AG.

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

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

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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- .

ility
ab
y li
an
pt
ce

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
te
itte
iva
r
du
p
or
nl
f
e
ng

Remove ribbed belt.

Remove alternator securing bolts -arrows-.

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

Downloaded from www.Manualslib.com manuals search engine

AG.

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


note the following:

agen
lksw
Vo
by

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

Installing:

ht
rig
py
Co
t.

Remove alternator.

do
c
um
en

Unscrew wiring bracket from alternator -arrow-.

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

pe
rm
itte
d

Caution

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

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

Observe instructions on connecting battery terminals


page 4 .

ility
ab
y li
an
pt
ce

un
le

b
ed
ris
o
th
Tighten threadedauconnections
page 145 . ss

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

Connect the battery page 29 .


Start the engine and check belt running.

ng

ht
rig
py
Co
t.

agen
lksw
Vo
by

AG.

Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i

Downloaded from www.Manualslib.com manuals search engine

thi
sd
o
cu
m
en

r
te o
iva
r
rp
fo

Switch off the engine.

9. Alternator

131

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

9.9.3

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
s
i
r
o
eo
h
t
u
ra
a
c
ss

Ribbed belt routing, 1.9 l TDI engine

1-

Tensioning roller

2-

Ribbed belt pulley - Alternator

3-

Poly V-belt

4-

Ribbed belt pulley - Crankshaft

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

ility
ab
y li
an
pt
ce

Models without air conditioning system:

Models with air conditioning system:

3-

Ribbed belt pulley - Air conditioner compressor

4-

Poly V-belt

5-

Ribbed belt pulley - Crankshaft

Downloaded from www.Manualslib.com manuals search engine

Prote
cted
by

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

cop
yri
gh
t
.
Co
py
i

132

AG.

Ribbed belt pulley - Alternator

agen
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Vo
by

2-

ht
rig
py
Co
t.

Tensioning roller

do
c
um
en

1-

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

9 - Voltage regulator
Removing and installing
voltage regulator
page 142

pe
rm
itte
d

AG.

Removing and installing alternator, 2,0 l


TDI engine

agen
lksw
Vo
by

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

9.10.2

ht
rig
py
Co
t.

11 - Poly V-belt
Checking page 98 .

ng

10 - Alternator
Removing and installing alternator page 133

thi
sd
o
cu
m
en

r
te o
iva
r
rp
fo

8 - Protective cap

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

7 - Phillips screws
M4x20
2 Nm

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

6 - Hexagon head collared


bolts
M10x45
40 Nm

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
nte
ir se
o
eo
h
t
u
ra
a
c
ss

ility
ab
y li
an
pt
ce

5 - Hexagon head collared


bolts
M10x65
40 Nm

un
le

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

Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

9. Alternator

Downloaded from www.Manualslib.com manuals search engine

133

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Removing:
Special tools and workshop equipment required

AG. Volkswagen AG d
agen
oes
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not
l
o
V
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by
ara
d
e
nte
s
i
r
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ho
t
u
ra
a
c
ss

pe
rm
itte
d

ility
ab
y li
an
pt
ce

un
le

Torque wrench -V.A.G 1331-

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

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

Locking pin -T10060 A-

r
te o
iva
r
rp
fo

AG.

Prote
cted
by

134

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

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
by

c
o
p
yri
gh
t.
C
op
yi

Pull vacuum hoses off -arrow-.

ht
rig
py
Co
t.

ng

Pull engine cover off upwards -arrows-.

thi
sd
o
cu
m
en

Disconnect the battery page 29 .

Jetta 2005 , Bora 2006


Electrical
System - Edition 05.2005
. Volkswage

Unbolt securing bolts -arrow-.

n AG d
oes
not
gu
ara
nte
eo
ra
c

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

ility
ab
y li
an
pt
ce

ss

n AG
wage
olks
V
by
ed
ris
o
th
au

Disconnect connector of DF wiring -1- and pull protective cap


-2- off.

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

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

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

do
c
um
en

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

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135

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Lock tensioning element with retaining pin -T10060 A- .
Remove ribbed belt.

Remove alternator securing bolts -arrows-.

wagen AG
. Volksalternator.
n AGfrom
Unscrew wiring bracket s-arrowdoes
wage

y
Remove alternator.
db
se

Installing:

k
Vol

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-.

AG.

Downloaded from www.Manualslib.com manuals search engine

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

ht
rig
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Co
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136

rrectness of i
t to the co
nform
spec
at
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itte
v
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Installation is carried out in the reverse order. When installing,


note the following:

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not
gu
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c

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 -

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his

urposes, in part or in wh
ole,
cial p
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Crankshaft
u
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a
ss

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

do
c
um
en

9.11

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Tensioning roller

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1-

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cted
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Special tools and workshop equipment required

9. Alternator

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137

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Socket -VAS 3310-

Torque wrench -V.A.G 1332-

Take off alternator page 98 .

Fit alternator in a vice on fitting points.

Use socket -VAS 3310- to remove ribbed belt (poly V-belt)


pulley securing nut from alternator shaft.
Installing:

Installation is performed in the reverse order of installation; when


doing this, note the following:
Tighten threaded connections to specified torque settings
page 145 .

Removing and installing a ribbed belt


(poly V-belt) pulley with freewheel, man
ufacturer: Bosch

Prote
cted
by
c
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py
rig
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.
C
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Special tools and workshop equipment required

Downloaded from www.Manualslib.com manuals search engine

AG.

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

agen
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by

138

ht
rig
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Co
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9.11.2

rrectness of i
t to the co
nform
spec
atio
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urposes, in part or in wh
ole,
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Removing:

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o
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or
ac
au
s
s

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.
n AG. Volkswagen AG do
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The thread on the alternator shaft isauath left-hand thread, i.e. turn
ac
to right when loosening and to leftsswhen tightening the threaded

Note

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Downloaded from www.Manualslib.com manuals search engine

ht
rig
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Co
t.

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

rrectness of i
t to the co
nform
spec
at
i
h re
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his
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l purpos
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joint.

9. Alternator

139

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Insert a socket M10 -1- in the alternator shaft.
Loosen threaded joint by turning to right and counter-hold with
ring spanner.
Hold the ribbed belt (poly V-belt) pulley with a freewheel with
the hand and turn the drive shaft of the alternator until the rib
bed belt (poly V-belt) pulley with a freewheel can be taken off.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
At first screw the ribbed belt (poly V-belt) pulley with a free
wheel on the drive shaft of the alternator by hand to limit stop.
The torque wrench -V.A.G 1332- must be rearranged before in
stalling the ribbed belt (poly V-belt) pulley with a freewheel as
follows:

Release socket -1- and pull off grip -2-.

ility
ab
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an
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rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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 .

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

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

ht
rig
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Co
t.

140

do
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en

urposes, in part or in wh
ole,
cial p
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Turn the torque wrench grip -2- through
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insert socket drive.
o
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s
s
Set torque wrench direction of rotation on socket to left.

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
n AG. Volkswagen AG do
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Special tools and
Volworkshop
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ed

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Adapter
-VAS
sa
s

urposes, in part or in wh
ole,
cial p
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Torque wrench -V.A.G


1332 TORX key -V.A.G 1603/1-

rrectness of i
t to the co
nform
spec
a
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ion
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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

Downloaded from www.Manualslib.com manuals search engine

141

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Fit TORX key -V.A.G 1603/1- into alternator shaft.
Loosen threaded joint by turning to right and counter-hold with
ring spanner.
Hold the ribbed belt (poly V-belt) pulley with a freewheel with
the hand and turn the drive shaft of the alternator until the rib
bed belt (poly V-belt) pulley with a freewheel can be taken off.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
At first screw the ribbed belt (poly V-belt) pulley with a free
wheel on the drive shaft of the alternator by hand to limit stop.
The torque wrench -V.A.G 1332- must be rearranged before in
stalling the ribbed belt (poly V-belt) pulley with a freewheel as
follows:

Release socket -1- and pull off grip -2-.


Turn the torque wrench grip -2- through 180 degrees and re
insert socket drive.
Set torque wrench direction of rotation on socket to left.

Counter-hold adapter -VAS 3400- with ring spanner, AF 17.


Tighten the ribbed belt (poly V-belt) pulley with a freewheel by
turning the alternator drive shaft to left using torque wrench V.A.G 1332- .
Tighten threaded connections to specified torque settings
page 145 .

Removing and installing voltage regula


tor, manufacturer: Bosch
Prote
cted
by

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Special tools and workshop equipment required

142

agen
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9.12.1

Voltage regulator for alternator

ht
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9.12

rrectness of i
t to the co
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urposes, in part or in wh
ole,
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Fit TORX key -V.A.G 1603/1- into alternator shaft.

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a
c
ss

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.

n AG. Volkswagen AG do
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s no
olks for voltage regulator -arrows-.
Remove securingy Vbolts
t gu

b
ed

or
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Install in reverse order of removal.


Tighten threaded connections to specified torque settings
page 145 .

9.12.2

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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in t
his
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es, in part or in w
l purpos
hole
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, is n
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erm
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t
a
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v
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ara
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ris
Remove voltage
regulator from alternator.
ho
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a
Installing: ss

Removing and installing voltage regula


tor, manufacturer: Valeo

Special tools and workshop equipment required


Torque wrench -V.A.G 1783/-

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AG.

Prote
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9. Alternator

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143

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Removing:
Remove alternator.
Remove spring clips -arrows- and take protective cap off al
ternator.

Remove securing bolts for voltage regulator -arrows-.


Remove voltage regulator from alternator.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:

AG. Volkswagen AG d
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Release locking lugs -arrow- andVpull
olks protective cap off voltage
gu
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regulator.
d
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s
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or

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


gages.

AG.

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

ht
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Co
t.

144

rrectness of i
t to the co
nform
spec
at
i
h re
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l purpos
hole
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a
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v
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f
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Tighten threaded connections to specified torque settings


page 145 .

tee
or
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ility
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an
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ce

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

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.

10.2.1

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
un
le

ng

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10. Torque settings: alternator

Downloaded from www.Manualslib.com manuals search engine

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rrectness of i
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52 Nm

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145

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

ility
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Tightening sequence for compact brack


et, models with air conditioning system
un
le

10.2.2

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Tightening sequence for compact bracket to cylinder block


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

Procedure

Note

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

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
r
te o
iva
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D - Hexagon head collared bolt, M10x45, 52 Nm


ng

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F - Hexagon head collared bolt, M10x45, 52 Nm

Prote
cted
by

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

Downloaded from www.Manualslib.com manuals search engine

AG.

2.0 l FSI turbo engine

agen
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10.3

ht
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E - Hexagon head collared bolt, M10x45, 52 Nm

thi
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en

C - 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

Torque settings

20 Nm
20 Nm
40 Nm

do
c
um
en

AG.

M8x90
M8
M10

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Prote
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by

Alternator to compact bracket


Tensioning element to compact bracket
Compact bracket to cylinder block

Torque settings

ht
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Co
t.

Threaded connections

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his

10.4.1

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
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erm
o
e
t
a
itte
iv
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f
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ng

bracket.

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Caution
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ara
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s
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h
t
In order to avoid damage to cylinder block
and
compact
brack
u
ra
a
c
s
s
et, you must respect the tightening sequence for the compact

cop
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.
Co
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10. Torque settings: alternator

Downloaded from www.Manualslib.com manuals search engine

147

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
pe
rm
itte
d

23 Nm

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

52 Nm

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

Note

un
le

Torque

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Threaded connections

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settings
tee
o
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t
or
u
ac
a
ss

Observe dowel sleeve between compact bracket and cylinder

block.

For the compact bracket no tightening torque must be ob

ng

AG.

Downloaded from www.Manualslib.com manuals search engine

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

ht
rig
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Co
t.

148

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served.

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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Activating and deactivating cruise
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Connect Vehicle Diagnosis, Testing and
ss Information
-VAS 5051A- page 281 .

Select guided fault finding in Vehicle Diagnosis, Testing and


Information System -VAS 5051A- .

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

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)

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149

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

90

Instruments, GCI

Dash panel insert

General description:
Integrated in the dash panel insert are the following components:
Control unit with display in dash panel insert -J285 Immobilizer control unit -J362 Speedometer
Rev counter
Fuel gauge
Coolant temperature gauge
Multi-function display
Warning lamps, page 152
To provide acoustic support to somen AofG.the
the
swagendisplays,
Volkvisual
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dash panel features a warning
which is actuated
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control unit.
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com

Fault detection and fault display:


The dash panel insert is equipped with self-diagnosis which
makes fault finding easier.
For fault finding, use the vehicle diagnosis, testing and informa
tion system -VAS 5051A- in guided fault finding mode.

1.1

Renewing dash panel insert

The work sequence Renewing dash panel insert consists of the


following work:
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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.
Prote
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by

Rep. Gr.90 - Instruments, GCI

Downloaded from www.Manualslib.com manuals search engine

AG.

150

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Special tools and workshop equipment required

thi
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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.

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

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
repair of the dashsspanel
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-

urposes, in part or in wh
ole,
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is n
mer
m
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erm
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ir va
du
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AG.

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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rig
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Co
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Connect the vehicle diagnosis, testing and information system


-VAS 5051A- to page 281

rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
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Diagnosis lead -VAS 5051/6A-

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Prote
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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

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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.

Description of reverse side of dash pan


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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.
1-

36-pin connector

2-

Warning buzzer

1.4

Warning lamp symbols in dash panel in


sert
Note

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

AG.

Prote
cted

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Rep. Gr.90 - Instruments, GCI

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152

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spec
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urposes, in part or in wh
ole,
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1.3

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
1 - Electric On Board Diagno
sis (EOBD)

10 - Fuel reserve
11 - Airbag display
12 - Seat belt
13 - Anti-locking brake system
(ABS)
14 - Electronic stabilisation
programme (ESP)
15 - Brake fault/handbrake
16 - Cruise control system
(CCS)
17 - Daylight
18 - Tyre pressure monitor

urposes, in part or in wh
ole,
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9 - Washer fluid level

19 - Water in fuel

Prote
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by

8 - Brake pad wear

AG.

7 - Low coolant level

rrectness of i
t to the co
nform
spec
atio
h re
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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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3 - Immobilizer

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2 - Engine malfunction (EPC)


Warning lamp is fitted
only on vehicles with
petrol engine.

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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153

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Service interval display

2.1

Resetting service interval display

Maintenance ; Booklet 20.1

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Rep. Gr.90 - Instruments, GCI

do
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154

rrectness of i
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nform
spec
a
t
i
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n in
wit
thi
s

urposes, in part or in wh
ole,
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a
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ir v
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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

92

Windscreen wash/wipe system

Windscreen wiper system


Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

Note

Additional information:
Operating instructions
General description:
The wiper motor control unit -J400- and the wiper motor -V- are
joined together as one unit.
To remove the wiper blades, the wiper arms should be placed in
the service/winter position. Theservice/winter position is acti
vated within 10 seconds after ignition is switched off by pressing
windscreen wiper lever in tip wipee
Operating instructions for
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Fault detection and fault
ris display:

tho

1.1

Deactivating APP function of wiper mo


tors

Special tools and workshop equipment required


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

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

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l purpos
hole
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, is n
m
m
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erm
o
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a
itte
v
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f
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ng

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

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au control unit -J519- is equipped with


The onboard supply
ss
agnosis, which is designed to ease fault finding.

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1. Windscreen wiper system

Downloaded from www.Manualslib.com manuals search engine

155

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Diagnosis lead -VAS 5051/6A-

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

The windscreen wiper system is equipped with an APP function


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

The APP function cannot be activated.

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 .

156

Rep. Gr.92 - Windscreen wash/wipe system

Downloaded from www.Manualslib.com manuals search engine

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

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ole,
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ss

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

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.

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

es, in part or in w
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hole
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a
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1.2.1

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1. Windscreen wiper system

Downloaded from www.Manualslib.com manuals search engine

157

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.
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ir va
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f
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Removing plenum chamber cover

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

AG.

Downloaded from www.Manualslib.com manuals search engine

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Rep. Gr.92 - Windscreen wash/wipe system

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158

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
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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

or
ac
ility
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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-.

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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

Removing wiper motor out of wiper


frame
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Lever linkage -arrow- ball
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-80-200- off crankriarm
of
motor.
nt
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ee
or
ac

Pull crank -2- off wiper motor shaft.


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

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

Remove securing nut -1-.

do
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um
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urposes, in part or in wh
ole,
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is n
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C
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1. Windscreen wiper system

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159

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 .

n AG. Volkswagen AG

does Distance
wage
Place crank arm of motor
not
olks-1- on shaft of wiper motor.
V
gu
y
-a- to limit stop -2- dshould
be 3 1 mm.
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le

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 .
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fo

Connect the battery page 29 .

Removing and installing wiper arms


AG.

1.3

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Prote
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Install wiper arms page 160 .

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ng

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.

160

Rep. Gr.92 - Windscreen wash/wipe system

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en

Fit connector to wiper motor connection and lock in position.

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

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

pe
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itte
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Tighten threaded connections to specified torque settings


page 178 .

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tho of motor on shaft of wiper motor using se e or


Place crank arm
ac
au
s
curing nut -3-.
s

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Place wiper arm in approximate park position on wiper arm
shaft and tighten securing nut -arrows- by hand.
Adjust windscreen wiper blade park position page 161 .

1.4

Adjusting wiper blade park position

Special tools and workshop equipment required


Torque wrench -V.A.G 1331-

Puller -T10130-

Note

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Co
t.

On RHD vehicles, the wiper blades are a mirror image.

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

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
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t
a
itte
v
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AG. Volkswagen AG d
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Deactivate the APP function if not already done page 155 .


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Allow wiper to move to park position and then switch ignition


off.
AG.

Prote
cted
by

Now adjust windscreen wiper blade park position.

1. Windscreen wiper system

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161

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Driver's side:
Distance -A- between wiper blade and upper edge of plenum
chamber cover should be 10 mm.
If necessary, adjust wiper blade park position by moving wiper
arm.
Removing wiper arms page 158 .
Tighten threaded connection to specified torque setting
n AG. Volkswagen AG do
page 178 .
es
wage

not
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c

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 .

Removing and installing aerodynamic


wipers

Note

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Removing:

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

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

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

in the service/winter position. Theservice/winter position is


activated within 10 seconds after ignition is switched off by
pressing windscreen wiper lever in tip wipe.

Place wiper arm in service/winter position by operating the


windscreen wiper lever within 10 seconds after ignition is
switched off in tip wipe position.
Lift up wiper arm.

162

Rep. Gr.92 - Windscreen wash/wipe system

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AG.

The aerodynamic wipers are very flexible. To lift the wiper

agen
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changed during installation.

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1.5

rrectness of i
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Front passenger's side:

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a
ss

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

gen AG
G.
gen Awindscreen.
Carefully fold wiper arm back down
onto
does
swa

Removing and installing rain and light


detector sensor -G397-

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Removing:

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ole,
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1.6

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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 .

do
c
um
en

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

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

1. Windscreen wiper system

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163

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

Before installing, thoroughly clean the windscreen, within the

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

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

sensor -G397- must not be soiled when installing.

If the 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

must be no air bubbles between windscreen and the surface


(coupling cushions).

AG.

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Rep. Gr.92 - Windscreen wash/wipe system

ht
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164

rrectness of i
t to the co
nform
spec
at
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his
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Note

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ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
olkswagen AG
en AG. V
does
not
gu
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nte
eo
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wag
Windscreen washer system
olks
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Note

Additional information:

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ss

2.1

rrectness of i
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nform
spec
a
t
ion
h re
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in t
his

Operating instructions

Assembly overview of windscreen washer system

1 - Y-piece
Distribution of wash wa
ter line to windscreen
spray jets
2 - Spray jet for windscreen
washer system, right
Removing and installing
page 169
Adjusting page 169

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AG.

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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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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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165

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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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Removing and installing filler pipe for


windscreen and headlight washer sys
tem reservoir
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
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erm
o
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itte
ir va
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p
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ng

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

Removing:

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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:

AG.

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Rep. Gr.92 - Windscreen wash/wipe system

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166

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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.
. Volkswagen AG
Gr. 63 ; Front bumper .
gen AG
does
swa

not
gu
ara
nte
eo
ra
c

To unlock, turn the securing clips hose connections -3- and


-5- and pull them out of the windscreen washer pump -V5-4-.
If necessary, collect washer fluid that leaks out with a suitable
container.
Separate the connector -6- of windscreen washer fluid level
sender -7-.
Take washer pump -V5- -4- upwards out of reservoir and sep
arate connector -2-.
Pull headlight washer system pump -V11- -9- upwards out of
reservoir and separate connector and separate connector
-10-.

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

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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ole,
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ir va
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n

Note

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2. Windscreen washer system

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167

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unbolt securing bolts -arrows- and take reservoir out of vehi
cle.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
Tighten threaded connections to specified torque settings
page 178 .

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un
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Bleed the headlight washer system after completing work


page 173 .

Removing:

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

Removing and installing washer pump V5-

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

2.3

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

ng

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iva
r
rp
fo

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 .

168

Rep. Gr.92 - Windscreen wash/wipe system

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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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t.

To unlock, turn the securing clips hose connections -3- and


-5- and pull them out of the windscreen washer pump -V5-4-.

thi
sd
o
cu
m
en

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

a
es n
ksw
Push spray jet in
installation
hole until it isoheard
ot g to lock in
Vol
ua
by
place.
d
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nte
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is
or

h
Adjust aspray
jets page 169 .
ut

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ole,
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erm
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itte
ir v
du
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nl
f
e
ng

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.
Maintenance ; Booklet 20.1

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

2.5

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2. Windscreen washer system

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169

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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.

AG.

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Rep. Gr.92 - Windscreen wash/wipe system

ht
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170

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
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um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
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itte
ir va
du
p
or
nl
f
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n

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

3.1

Assembly overview - headlight washer system

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b
d spray jet assembly
ran
1 - Washer
e
tee
ris
o
with right
spray
jets
h
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ac
a
ss Removing and installing

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

ng

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4 - Hose

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

thi
sd
o
cu
m
en

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

r
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iva
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fo

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hole
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com

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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

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

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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 .

Removing and installing pop-up spray


jet cylinder

ility
ab
y li
an
pt
ce

Removing:

urposes, in part or in wh
ole,
cial p
is n
mer
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itte
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3.3

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ac
a
ss

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

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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-.

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


Installing:

172

Rep. Gr.92 - Windscreen wash/wipe system

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AG.

Bleed the headlight washer system after completing work


page 173 .

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ht
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Tighten threaded connections to specified torque settings


page 178 .

ht
rig
py
Co
t.

The pop-up spray jet cylinder hose must be attached to the


securing clip on the bracket.

do
c
um
en

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


note the following:

AG. Volkswagen AG d
agen
oes
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Jetta e2005
ut
ac
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ss

Removing:

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

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.

cop
yri
gh
t
.
Co
py
i

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.

ht
rig
py
Co
t.

Installing:

do
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um
en

urposes, in part or in wh
ole,
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ir v
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3.4

, Bora 2006
Electrical System - Edition 05.2005

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by

AG.

Prote
cted
by

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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173

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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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gen AG
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securing device) to

wa
Windscreen and reary Vwindow
washer
olks
b
d
e
system
is
or

h
ut

To secure the connection, push the two coupling sections to


gether, until you hear and feel them engage.

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

To loosen the connection, rotate the lock ring -1- by 90


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

AG.

Prote
cted
by

174

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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Co
t.

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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Pull the two coupling sections
ss apart (no
loosen the connection.

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.

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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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AG.

Prote
cted
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4. Wash water line hose couplings

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175

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Hose repair

A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl
ene propylene diene monomer) and heat-shrink hose are availa
ble as spare parts

5.1

General description

The replacement parts can be found in the parts catalogue


(ETKA).
Replacement parts are available for repair of both smooth and
corrugated pipes.

5.2

Repairing smooth pipe

Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re


paired with EPDM hose.
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Cut damaged section
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a
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ion
h re
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in t
his

Secure the repair joints with cable ties -1-.

Repairing corrugated pipe

Special tools and workshop equipment required


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Hot air gun -VAS 5179- or


AG.

Prote
cted
by

Hot air blower -VAS 1978/14-

176

Rep. Gr.92 - Windscreen wash/wipe system

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agen
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Hot air gun -V.A.G 1416/- or

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5.3

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ole,
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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-.

ility
ab
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an
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t
or
Select thes auappropriate
EPDM hose -2- and cable ties accord
ac
ing to thes parts catalogue (ETKA).

Repair points must not be subjected to pulling or bending

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-.

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

agen
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Prote
cted
by
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rig
ht
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C
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AG.

Push heat-shrink hose over corrugated pipe, join connectors


and secure repair joints with heat-shrink hose.

ht
rig
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Co
t.

Cut heat-shrink hose so that ends of corrugated pipe are each


covered by about 20 mm -dimension x- of heat-shrink hose.

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
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thi
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urposes, in part or in wh
ole,
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mer
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itte
ir va
du
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Note

n AG. Volkswagen AG do
es n , Bora 2006
wage
Jetta 2005
ot
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V
y
Electrical System g-uaEdition
05.2005
db
ran
e
ir s
tee
ho
t
o
ra
au
c
ss

5. Hose repair

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177

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Torque settings: Windscreen wash/wipe system

Threaded connections

Torque settings

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

M6
M8
M6
M8

8 Nm
18 Nm
8 Nm
20 Nm

M6

8 Nm
4.5 Nm

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AG.

Prote
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by
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Downloaded from www.Manualslib.com manuals search engine

ht
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Rep. Gr.92 - Windscreen wash/wipe system

do
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en

178

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

urposes, in part or in wh
ole,
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mer
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a
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s
s

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

94

Lights, lamps, switches - outside

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

AG do
es n
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ran
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or
ac

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

In the overview there are shown the three control motors of the
different headlight manufacturers because their removal and in
stallation is different.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
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l purpos
hole
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, is n
m
m
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erm
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t
a
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v
i
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p
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f
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ng

Note

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Assembly overview,
Headlight
ss

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1.1

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AG.

Prote
cted

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1. Headlight

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179

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
AG. Volkswagen AG d
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bushes
c
ss

1 - Securing bolts
4 Nm

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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rig
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Co
t.

6 - Front left turn signal bulb M5- or front right turn signal
bulb -M7 Bulb 12 V, PY 21 W
Renewing page 188

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
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en

urposes, in part or in wh
ole,
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t
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ir va
du
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2 - Adjustment
Correcting installation
position of headlight
page 182

Prote
cted
by

8 - Body section
9 - Cover cap
10 - Bulb holder with grip ele
ment
For left headlight dipped
beam bulb -M29- or right headlight dipped beam bulb -M3111 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31 Bulb H7 12 V, 55 W
Renewing page 184
12 - Headlights
Removing and installing page 181
Correcting installation position of headlight page 182
Servicing headlight securing lugs page 188

180

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

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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.
AG. Volkswagen AG d
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a
c
ss

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

Unscrew securing screw -arrow- on upper headlight.

thi
sd
o
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en

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te o
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r
rp
fo

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

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Remove front bumper General body repairs; Rep. Gr. 63 ;


Front bumper

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Unscrew securing screw -arrow- on lower left headlight.

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AG.

Prote
cted
by

cop
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.
Co
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i

1. Headlight

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181

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unscrew securing screw -arrow- on lower right headlight.

1.2.2

Installing headlights

Installation is performed in the reverse order of installation; when


doing this, note the following:
swagen A
. Volktorque
Tighten all securing bolts to
setting
G do
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aspecified
es n
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o
page 238 .
yV

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ra

b
ed

nte
is
Check headlighthorinstallation
position is central, i.e. shutlines
eo
t
u
ra
are equal around
headlight.
c
sa

Note

If a headlight is removed, it should always be adjusted.


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

1.3

Adjusting headlight installation position

Note

To adjust the headlight installation position, the front bumper

must not be removed.

The diagrams show the left headlight.


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Co
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cop
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.
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If it transpires during checking of the installation position that the


shutlines between headlight and body are uneven, the installation
position must be adjusted.
agen
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by

AG.

Prote
cted
by

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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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

Check function of headlight.

ility
ab
y li
an
pt
ce

If the shutlines around the headlight are uneven, the installation


position must be adjusted page 182 .

Jetta 2005 , Bora 2006


System - Edition 05.2005

ility
ab
y li
an
pt
ce

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

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

pe
rm
itte
d

un
le

Unscrew

AG. Volkswagen AG d
Electrical
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ua
b
ran
ed -arrow- on upper headlight.
securing screw
tee
ris
o
h
t
or
u
ac
a
ss

ht
rig
py
Co
t.

ng

thi
sd
o
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m
en

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Unscrew securing screw -arrow- on lower left headlight.

agen
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by

Prote
cted
by

cop
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.
Co
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i

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

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183

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

1.4

Renewing headlight bulbs

1.4.1

Renewing dipped beam headlight bulb

Note
n AG. Volkswagen AG do
The diagrams show renewal of the dipped beam headlight bulb
es n
wage
s
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l
ot g
for the left headlight.
Vo
u
by

Removing:

ara
nte
e

ed
ris
tho
u
a
ss

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

Turn bulb holder with dipped beam headlight bulb -1- in


-direction of arrow- and remove from headlight.

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

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

Do not touch bulb glass when fitting bulbs. Fingers leave

traces of grease on the glass, which evaporate when the bulb


is switched on and cause the glass to cloud over.

184

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

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AG.

Note

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Prote
cted
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.
Co
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Installing:

ht
rig
py
Co
t.

Pull dipped beam headlight bulb -2- in -direction of arrow- out


of bulb holder -1-.

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

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
o
e
t
a
itte
v
i
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nl
f
e
ng

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an
pt
ce

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

or
ac

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Place headlight dipped beam bulb -1- in the bulb holder that
the pin on the dipped beam headlight bulb lies in the recess
-arrow- of bulb holder -2-.

Place bulb holder with dipped beam headlight bulb -1- in head
light and turn bulb holder with dipped beam headlight bulb in
-direction of arrow-.

olkswagein
Place cover cap -1- in headlight recess
and
G. Vtighten
n AG d
A
agen
oes
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-direction of arrow-.
not
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y
db

ise
Check function of headlight.
or
h
ut

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

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.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

1.4.2

ility
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pt
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a and adjust headlight as necessary


Check headlight setting
ss
Maintenance ; Booklet 20.1

gu
ara
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eo
ra
c

ht
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Co
t.

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AG.

Prote
cted
by

cop
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gh
t
.
Co
py
i

1. Headlight

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185

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull off cover cap -1-.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

ility
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an
pt
ce

AG. Volkswagen AG d
agen
oes
ksw
not
l
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V
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by
ara
d
nte
ir se
o
eo
h
t
u
ra
a
c
ss

Pull off multi-pin connector -2-.

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

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

Do not touch bulb glass when fitting bulbs. Fingers leave

traces of grease on the glass, which evaporate when the bulb


is switched on and cause the glass to cloud over.

Installation is performed in the reverse order of installation; when


doing this, note the following:

186

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

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AG.

Note

agen
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by

Prote
cted
by
c
o
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rig
ht.
C
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Installing:

ht
rig
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Co
t.

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

do
c
um
en

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

Note

Removing:

Switch off ignition and all electrical consumers and pull out
ignition key.
Pull off cover cap -1-.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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

ility
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y li
an
pt
ce

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
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erm
o
e
t
a
itte
riv
du
p
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nl
f
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ng

1.4.3

AG. Volkswagen AG d
agen
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o
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t
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ra
a
c
ss

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Co
t.

Prote
cted
by
c
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py
rig
ht.
C
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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.
agen
lksw
Vo
by

AG.

1. Headlight

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187

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull side light bulb -2- in -direction of arrow- out of the bulb
holder -1-.
Installing:
Note
When installing cap, ensure that it is seated correctly. The in

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

Do not touch bulb glass when fitting bulbs. Fingers leave

traces of grease on the glass, which evaporate when the bulb


is switched on and cause the glass to cloud over.

Installation is performed in the reverse order of installation; when


doing this, note the following:
Check function of headlight.
Check headlight setting and adjust headlight as necessary
Maintenance ; Booklet 20.1

Renewing front turn signal bulb

ility
ab
y li
an
pt
ce

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
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erm
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t
a
itte
riv
du
p
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nl
f
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ng

1.4.4

AG. Volkswagen AG d
agen
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Note

Removing:

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his

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

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.

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

Downloaded from www.Manualslib.com manuals search engine

Prote
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by

traces of grease on the glass, which evaporate when the bulb


is switched on and cause the glass to cloud over.

AG.

Do not touch bulb glass when fitting bulbs. Fingers leave

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correctly. The ingress of water will lead to permanent damage


of the headlight.

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Note

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Installing:

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

1.6

Adjusting headlights

Adjusting headlights Maintenance ; Booklet 20.1 .

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his

urposes, in part or in wh
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1. Headlight

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189

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Main headlights with gas discharge


bulbs
Note

Before working on gas discharge headlights, always switch off

the headlights and remove the ignition. key.


Volkswag
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s
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db
discharge bulbs is equipped
with self-diagnosis.
ise

Operating instructions
Current flow diagrams, Electrical fault finding and Fitting loca
tions
Fault detection and fault display:
The automatic headlight range adjustment (HRA) and onboard
supply control unit have a self-diagnosis function, which makes
fault finding on the headlights using gas discharge lamps easier.

ng

AG.

Downloaded from www.Manualslib.com manuals search engine

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

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190

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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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ion
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Additional information:

Assembly overview - gas discharge headlights


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2.1

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

AG. Volkswagen AG d
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wit

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

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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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Note

5 - Gas discharge light starter


unit -N1956 - Bulb locking
For left gas discharge
bulb -L13- or right gas
discharge bulb -L147 - Left gas discharge bulb L13- or right gas discharge
bulb -L14 Type D2S, 35W
Renewing page 192
8 - Securing bolt
4 Nm
On upper headlight
9 - Headlights
Removing and installing page 181
Correcting installation position of headlight page 182
Servicing headlight securing lugs page 204
10 - Headlight range control unit -J431 Removing and installing page 198
Coding page 200
Note
11 - Front left vehicle level sender -G78 Removing and installing page 201
Checking page 203 .

2. Main headlights with gas discharge bulbs

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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
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Bulb 12 V, H2 WLL 21 W
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Renewing page 197
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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

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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

2.4.1

Renewing gas discharge bulb

ng

Renewing headlight bulbs

Prote
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by

Removing:
Remove headlight page 181 .

192

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

Downloaded from www.Manualslib.com manuals search engine

AG.

The diagrams show renewal of a gas discharge bulb for the left
headlight.

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Adjusting headlight installation position page 182 .

rrectness of i
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f
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m
spec
atio
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wit

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.

Pull off connector -1-.


Note

The connector is ejected automatically when the gas discharge


bulb starter unit -N195- is removed.

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.

rrectness of i
t to the co
nform
spec
at
i
h re
o
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in t
his
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AG.

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

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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

2.4.2

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Renewing main beam headlight bulb

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

Removing:

Switch off ignition and all electrical consumers and pull out
ignition key.
Pull off cover cap -1-.

AG.

Downloaded from www.Manualslib.com manuals search engine

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

ht
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194

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urposes, in part or in wh
ole,
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ir va
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ng

The following diagrams show renewal of the main beam headlight


bulb for the left headlight.

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Note

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull connector off -arrow-.

Press spring retaining clip -2- in -direction of arrow- under the


locking lugs-1- and fold spring retaining clip -2- upwards.

Take main beam bulb -1- out of headlight.


Installing:
Note

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

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

Do not touch bulb glass when fitting bulbs. Fingers leave

traces of grease on the glass, which evaporate when the bulb


is switched on and cause the glass to cloud over.

Installation is performed in the reverse order of installation; when


doing this, note the following:
Place the headlight main beam bulb -1- in the recesses
-arrows- on the headlight.

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ht
.
C
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Check headlight setting and adjust headlight as necessary


Maintenance ; Booklet 20.1

ht
rig
py
Co
t.

Check function of headlight.

rrectness of i
t to the co
nform
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
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ir va
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ss

AG.

2. Main headlights with gas discharge bulbs

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195

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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
Removing:

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-.

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

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

Do not touch bulb glass when fitting bulbs. Fingers leave

traces of grease on the glass, which evaporate when the bulb


is switched on and cause the glass to cloud over.

Installation is performed in the reverse order of installation; when


doing this, note the following:
Check function of headlight.
Check headlight setting and adjust headlight as necessary
Maintenance ; Booklet 20.1

196

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Note

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cted
by
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Installing:

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rig
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Co
t.

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

rrectness of i
t to the co
nform
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
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erm
o
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t
itte
ir va
du
p
or
nl
f
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g
n

Pull off cover cap -1-.

G do
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or
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Switch off ignition and all electrical


ignition key.

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consumers
and pull out
au
ss

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-.

Pull, depending on the cable length, the bulb holder -1- with
n AG. Volkswagen AG do
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the front turn signal bulb in -direction of arrow- and take them
ot g
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V
ua
by
d
out of the reflector.
ran
se
ri
tho
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a
ss

tee
or
ac

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
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erm
o
e
t
a
itte
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f
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ng

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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

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

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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AG.

Prote
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by
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Installation is performed in the reverse order of installation; when


doing this, note the following:

ht
rig
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Co
t.

Do not touch bulb glass when fitting bulbs. Fingers leave

do
c
um
en

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

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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197

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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

AG do
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ran
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or
ac

rrectness of i
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spec
a
t
ion
h re
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in t
his

Removing:

Remove headlight page 181 .


Remove securing bolts -arrows- of gas discharge light control
unit -1-.
Note

When taking off the gas discharge light control unit the connectors
must not be removed. The connector is fitted tightly to the head
light and is automatically disconnected when taking off the gas
discharge light control unit .
Take off gas discharge light control unit -1- from headlight.

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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.

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

198

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

Downloaded from www.Manualslib.com manuals search engine

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t.

Installing:

do
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en

urposes, in part or in wh
ole,
cial p
is n
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ot p
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a
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f
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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
Removal wedge -VAS 3409-

urposes, in part or in wh
ole,
cial p
is n
mer
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ot p
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erm
o
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itte
ir va
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AG. Volkswagen AG d
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Note

Removing:

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

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 ignition and all electrical consumers and pull out
ignition key.

Remove lateral cover -1- out of the dash panel, by inserting


the removal wedge -VAS 3409- or a screwdriver in the recess
-2- and lever off cover-1- in -direction of arrow-.

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Co
t.

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Prote
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by

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i

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

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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

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

2.7.2

Coding control unit for headlight range


control -J431-

Connect the vehicle diagnosis, testing and information system


-VAS 5051A- to page 281
Select guided fault finding in Vehicle Diagnosis, Testing and
Information System -VAS 5051A- .
Using the Go to key, select Function/component selection
and the following menu items one after the other:
Prote
cted
by

200

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

Downloaded from www.Manualslib.com manuals search engine

AG.

01 - On Board Diagnostic capable systems

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Electrical System

ht
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Co
t.

Body

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

AG. Volkswagen AG d
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s
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Lock connector
-1- by pressing the locking clip -2- in
c
sa
s
-direction of arrow-.

Automatic headlight range

2005 , Bora 2006


n AG. Volkswagen AGJetta
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Electrical eSystem
- Edition 05.2005
olks
V
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control utho
ra
a
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ss

urposes, in part or in wh
ole,
cial p
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te
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iva
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du
p
or
nl
f
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ng

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Automatic headlight range control functions


Coding automatic headlight range control

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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

AG.

2.8.1

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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

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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-

Removing:
G. Volkswagenand
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Switch off ignition and all electrical
gen Aconsumers
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Pull off connectorth-arrow-.
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Rep. Gr.94 - Lights, lamps, switches - outside

do
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202

or
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au
ss

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
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page 238 .
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Check front left vehicle level sender -G76ise page 203 .


or
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his

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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

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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

Adjusting headlights with gas discharge lamp Maintenance ;


Booklet 20.1 .

AG.

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

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204

rrectness of i
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spec
at
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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Fog lights

Fault detection and fault display:


The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the fog lights easier.
For fault finding, use the vehicle diagnosis, testing and informa
tion system -VAS 5051A- in guided fault finding mode.

3.1

Assembly overview - fog light

Torque settings page 238


1 - Front bumper
2 - Vent hose

4 - Fog light housing


Removing and installing
page 205

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3.2

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7 - Spreader nuts

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5 - Cover cap

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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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Removing and installing fog lights


Note

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

3. Fog lights

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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.

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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 .

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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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Prote
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206

AG.

Remove fog light page 205 .

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Removing:

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Removing and installing fog light bulb

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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

Adjusting fog lights Maintenance ; Booklet 20.1 .

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his

urposes, in part or in wh
ole,
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do
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3. Fog lights

207

urposes, in part or in wh
ole,
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a
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ng

Removing and installing side marker


in front bumper

4.1

Removing and installing front side mark


er

Note

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his

Removing

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Jetta 2005 , Bora 2006
o
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Electrical System - Edition 05.2005
s
s

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

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-.

208

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

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AG.

Installing

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Remove bulb holder -2- out of side marker.

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Unlock side marker -1- by pressing the locking lug


-in direction of arrow-.

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Remove noise insulation General Body Repairs, Exterior;


Rep. Gr. 50 ; Assembly overview - noise insulation

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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
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Removing and installing turn signal bulb


pe
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5.1

a
ss

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d
For fault finding, use the vehicle diagnosis, testing andriinforma
se
ho
tion system -VAS 5051A- in guided fault finding mode.
t
u

rrectness of i
t to the co
n
f
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spec
atio
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wit

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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Installing:

5. Mirror turn signal bulb and entry light in exterior mirror

Downloaded from www.Manualslib.com manuals search engine

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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 .

209

Jetta 2005 , Bora 2006


n AG. Volkswagen AG do
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Electrical System - Edition 05.2005
o
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rrectness of i
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spec
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wit

Note

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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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Removing and installing entry light in ex


ss
terior mirror
un
le

5.2

t gu
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To remove and install the entry lights the exterior mirror must

not be removed.

Removal and reinstallation of entry lights is carried out in the

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.

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Prote
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Unclip entry light in -direction of arrow- out of the exterior mirror


and pull it out as far as possible.

210

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

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Unbolt securing bolt -1-.

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Fold exterior mirror -1- in -direction of arrow- forwards.

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull bulb carrier -2- in -direction of arrow- out of entry light
housing -1-.
Renew bulb:

urposes, in part or in wh
ole,
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Pull bulb -1- in -direction of arrow- out of the carrier -2-.


Installing:

rrectness of i
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nform
spec
atio
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Plug base bulb: 12 V, W6 W

Installation is performed in the reverse order of installation; when


doing this, note the following:
Note

After the installation perform functional check of the exterior mir


ror.

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5. Mirror turn signal bulb and entry light in exterior mirror

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211

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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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6.2

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5 - Bulb carrier
Removing and installing
page 213

Removing and installing tail light in side


panel

Removing:

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AG.

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

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212

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Press side trim to side.

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

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull connector -1- off.
Remove securing nuts -2- on tail light in side panel.
Remove tail light.
Installing:
Installation is performed in the reverse order of installation; when
doing this, note the following:

Tighten securing nuts -2- to specified tightening torque


page 238 .
Note

The tail light connector in the side panel must audibly engage.
When installation is complete, check shutlines of tail light to
body.

6.3
Removing:

Removing and installing tail light bulb


carrier in side panel

Pull connector -1- off.

rrectness of i
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nform
spec
a
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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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213

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

6.4

Assembly overview - tail light in tailgate

Torque settings page 238


1 - Securing nuts
2 - Bulb carrier
Removing and installing
page 215

urposes, in part or in wh
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Switch off ignition and all electrical consumers and pull out
ignition key.
Unclip service cover out of trim in tailgate

214

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

Downloaded from www.Manualslib.com manuals search engine

AG.

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Removing:

rrectness of i
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nform
spec
a
t
i
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wit
thi
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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.
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-.

rrectness of i
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spec
a
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2005 , Bora 2006


Electrical System - Edition 05.2005

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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

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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

do
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216

rrectness of i
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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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:

rrectness of i
t to the co
nform
spec
a
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ion
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Install in reverse order of removal.

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7. Number plate lights

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217

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Additional brake light

8.1

Removing and installing high level brake


light bulb -M25Note
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In the event of damage, the complete high level brake light -M25Vol
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unit must be renewed.
ise

Switch off ignition and all electrical consumers and pull out
ignition key.
Remove strip roof leading edge General body repairs, in
terior; Rep. Gr. 70 ; Removing and installing strip roof leading
edge .
Pull connector -1- off.

Press high level brake light bulb -M25- to rear window


-in direction of arrowInstalling:

Installation is performed in the reverse order of installation; when


doing this, note the following:

AG.

Downloaded from www.Manualslib.com manuals search engine

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

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218

rrectness of i
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Removing:

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Steering column switch


Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

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After installing a new tsteering
column
electronics
control
unit
eo
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-J527- , it must be coded
page 227 .
a
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Note

rrectness of i
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Fault detection and fault display:


The steering column electronics control unit -J527- is equipped
with self-diagnosis, which is designed to ease fault finding.
For fault finding, use the vehicle diagnosis, testing and informa
tion system -VAS 5051A- in guided fault finding mode.

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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

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9. Steering column switch

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219

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

9.1

Assembly overview - steering column switch

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2 - Steering column switch


base
Removing and installing
page 226
3 - Windscreen wiper switch E Removing and installing
page 225

Prote
cted
by

7 - Steering angle sender -G85 Removing and installing page 224


Basic settings page 228

9.2

Removing and installing steering col


umn switch
Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

220

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

Downloaded from www.Manualslib.com manuals search engine

AG.

6 - Airbag coil connector and


return ring with slip ring -F138 Removing and installing page 223

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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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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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Remove steering column trim General
oes
swabody repairs, interior;
n
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V
Rep. Gr. 68 ; Compartments, covers
trim;
Removing
and ot gua
y
b
d
ran
e
installing steering column switch
te
ris trim .
ho
ut

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.

Note

Removing and installing steering col


umn electronics control unit -J527-

After new control unit has been installed, it must be coded


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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

Downloaded from www.Manualslib.com manuals search engine

221

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-.

Using a screwdriver, press against the rear securing clip


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

AG.

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.

222

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

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rrectness of i
t to the co
nform
spec
atio
h re
n
wit
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n
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ole,
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ir va
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Unscrew bolt -1-.

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Jetta 2005 , Bora 2006ise
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Electrical System - Edition
05.2005
t
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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

For installation of the coil connector,


must be
agencoil
AG. Volkswthe
AG dconnector
agen
o s in the straight
in the central positionoland
ksw the road wheels mustebe
not
gu
ahead position.ed by V
ara

Note

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The coloured strip (yellow) -arrow- must be in view -1-.

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The coloured strip (black rectangles) -arrow- must be in view


-1-.

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

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

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

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ris
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central
ss position

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If a new steering angle sensor -G85- is installed, this procedure


must be followed by a basic setting page 228 .
agen
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by

AG.

Prote
cted
by

9. Steering column switch

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223

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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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un
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The turn signal switch comprises of the following compo

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

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

pe
rm
itte
d

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:

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AG.

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

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by
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224

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The turn signal switch should be heard to engage.

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m
en

Note

r
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iva
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rp
fo

Installation is performed in the reverse order of installation; when


doing this, note the following:

Jetta 2005 , Bora 2006


- Edition 05.2005

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

un
le
pe
rm
itte
d

Note

ility
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Removing:

Removing and installing windscreen


wiper switch -E-

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

9.2.5

Electrical System
n AG. Volkswagen AG do
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tee
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s
s

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:

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ng

The windscreen wiper switch -E- should be heard to engage.

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Note

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Prote
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9. Steering column switch

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225

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

9.2.6

Removing and installing base module of


steering column switch

Note

To remove the base module of the steering column switch -2- -,


the shear head bolts of the steering lock housing must be drilled
out. To reinstall, new shear head bolts -1- are required Parts
catalogue (ETKA) .
Caution

Ensure that the components mounted on the basic


brace
AG. Volkswagen AG d
agen
oes
not
lksw bolts.
have been removed before boring the shearVohead
g
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urposes, in part or in wh
ole,
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is n
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erm
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a
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ir v
du
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f
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ng

Please remove the components in the specified se


quence.

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

Caution

or
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ise
The boring operation can cause borehorchips
to penetrate
ut damage and/or mal
the adjacent components resultingain
ss
function!

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 .

Prote
cted
by

Remove the turn signal light switch -E2- page 224 .


Remove windscreen wiper switch -E- page 225 .
Disconnect connector -arrow- at reader coil -3-.
The basic brace can be removed once all the components moun
ted on it have been dismantled:
Drill out securing bolts -1- of steering lock housing -3-.
Note

Bolts M8 -1-, core diameter 6.8 mm.

226

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Remove steering angle sender -G85- page 224 .

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

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Co
t.

Remove steering column electronics control unit -J527 page 221 .

do
c
um
en

Remove steering column trim General body repairs, interior;


Rep. Gr. 68 ; Compartments, covers and trim; Removing and
installing steering column switch trim .

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
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olks and information systems not g


Connect the vehicle diagnosis, testing
yV
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-VAS 5051A- to page 281ised b

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ho

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- .

agen
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by

AG.

Electrical System

Prote
cted
by
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Body

ht
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Using the Go to key, select Function/component selection


and the following menu items one after the other:

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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en

urposes, in part or in wh
ole,
cial p
is n
mer
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ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

Using the Go to key, select Function/component selection


and the following menu items one after the other:

tee
or
ac
ility
ab
y li
an
pt
ce

ut
Select guided fault finding
in Vehicle Diagnosis, Testing and
sa
s
Information System -VAS 5051A- .

01 - On Board Diagnostic capable systems


Steering wheel electronics
Steering wheel electronics functions

9. Steering column switch

Downloaded from www.Manualslib.com manuals search engine

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

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ng

AG.

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

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Co
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228

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en

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t to the co
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f
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r
m
spec
atio
h re
n in
wit

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

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itte
d

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un
le

Basic setting steering angle sensor (00778-3132) -G85-

Removing and installing steering lock


housing
Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

Note

To remove steering lock housing it is necessary to remove the


steering column switch base first.

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Co
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Prote
cted
by
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The steering lock could be destroyed.

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en

Caution

rrectness of i
t to the co
nform
spec
a
t
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wit
thi
s

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ole,
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10.1

Ignition switch and lock cylinder

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10

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.
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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

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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
3 - Position Start

urposes, in part or in wh
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Note

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For reasons of clarity, the diagram shows a removed lock cylinder


without ignition key.
Insert steel rod (approx. 1.2 mm) in drilling -arrow- adjacent
to ignition key.
Using steel rod -2- disengage -arrow- safety bar -3- of lock
cylinder -1-.
Pull lock cylinder -1- out of steering lock housing.

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

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230

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

rrectness of i
t to the co
n
f
o
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m
spec
atio
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n in
wit

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l purpos
hole
ercia
, is n
m
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com

Removing:

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Disconnecting and connecting the


Workshop Manual page 29 .

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battery
as
described
in
the
s
s

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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10. Ignition switch and lock cylinder

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231

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Insert ignition key in lock cylinder and turn to position Drive.
Note

Insert ignition key in lock cylinder and turn to position Drive.


Position of key in lock cylinder:
1 - Position Stop
2 - Position Drive
3 - Position Start
Install all parts in reverse order of removal.

10.3.1

Removing and installing ignition key


withdrawal lock solenoid -N334-

The ignition key withdrawal lock solenoid -N334- is located di


rectly adjacent to the ignition starter key.
Note

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d b automatic gearbox,
To remove ignition key on vehicles withisean
ran
tee
r P first then switch off ig
o
always move selector lever to position
h
t
or
ac
au
nition. Otherwise the ignition key withdrawal
lock
solenoid
-N334s
s
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Removing:

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will inhibit the removal of the ignition key.

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

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:

Downloaded from www.Manualslib.com manuals search engine

AG.

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

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232

do
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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

oes es
wa system it is absolutely
For complaints with the parking
ksaid
not
Vol

y
sential to understand theefunction
and operation of the system.guara
db

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is
or

th
Additional information
au Operating instructions

rrectness of i
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nform
spec
a
t
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wit
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s

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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en

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ole,
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General description:

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ss

AG.

Prote
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by

11. Parking aid

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233

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

11.1

Assembly overview - parking aid

1 - Parking aid system warning


buzzer -H15 Below the rear shelf
Removing and installing
page 236
2 - Parking aid control unit J446 Behind right luggage
compartment trim panel
Removing and installing
page 234
3 - Rear centre right parking
aid sender -G205 In the rear bumper cover
Removing and installing
page 235
4 - Rear right inner parking aid
sensor -G335 In the rear bumper cover
Removing and installing
page 235

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 .

AG.

Prote
cted
by

Downloaded from www.Manualslib.com manuals search engine

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

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t.

234

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

6 - Rear centre left parking aid


sender -G204 In the rear bumper cover
Removing and installing
page 235

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um
en

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ole,
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5 - Rear left inner parking aid gen AG. Volkswagen AG


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In the rear bumper
nte
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ut
Removing aand
installing
ra
c
s
s
page 235

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

Removing and installing parking aid


sensor
G. Volkswagen
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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 -G205Note

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 .

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
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is n
mer
m
ot p
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erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

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ss aid sensor -G334 Rear left inner parking

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11. Parking aid

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235

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Disconnect connector -arrow-.

Release locking lugs -arrows- and pull sender out of bumper


cover.
Installing:
Install in reverse order of removal.

11.4

. Volkswagen AG
gen AG
does
not
gu
ara
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c
rear

a
ksw aid
Removing and installing rear parking
Vol
by
d
e
warning buzzer -H15ris
ho
ut

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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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Prote
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General Body Repairs

AG.

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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ole,
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is n
mer
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iva
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ng

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

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

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Co
t.

es, in part or in w
l purpos
hole
ercia
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m
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erm
o
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t
a
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v
i
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n

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11. Parking aid

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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

12.2

Torque settings: fog lights

Threaded connections

Torque settings

Headlight securing screws

1,5 Nm

12.3

Torque settings - tail light in side panel

Threaded connections

Torque settings

Securing nuts

3.5 Nm 0.5 Nm

12.4

Torque settings - tail light in tailgate

Threaded connections

Torque settings

Securing nuts

3.5 Nm 0.5 Nm

12.5

Torque settings: vehicle level sender

Threaded connections

5 Nm

ng

AG.

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by

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

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Co
t.

238

thi
sd
o
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m
en

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iva
r
rp
fo

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

es, in part or in w
l purpos
hole
ercia
, is n
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ot
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M6
M5

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

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Torque
settings
nte
s
i
r
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ho
t
u
ra
a
9 Nm
c
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

96

Lights, lamps, switches - inside

Lights and switches in engine com


partment
Note

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

ility
ab
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pt
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Note

un
le

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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t.

r
fo
ng

Remove front bonnet lock General Body Repairs, Exterior;


Rep. Gr. 55 ; Bonnet; Removing and installing coupling lock;
Removing .

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

urposes, in part or in wh
ole,
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is n
mer
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ot p
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erm
o
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a
itte
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i
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d
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1.1

AG. Volkswagen AG d
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AG.

Prote
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by

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1. Lights and switches in engine compartment

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239

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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:

n AG. Volkswagen AG do
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or
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slightly

Switch off the ignition and all electrical consumers. y Volks


b
ed
ris
Turn grip of light switch to position 0.
o
h

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Hold light switch and press rotary position indicator of light


switch firmly inwards -1- and turn slightly to right -2-.
Hold grip in this position and insert light switch in dash panel
-3-.
Turn rotary knob to 0 release and engage switch.

240

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Fit connector to light switch.

agen
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by

Installing:

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Disconnect connector -arrow-.

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um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
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erm
o
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a
itte
iv
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pr
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f
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ng

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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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au

s
Push in grip of light switch -1- and turn it to sthe
right
-2-.

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

2.2

Removing and installing glove compart


ment light -W6-

Special tools and workshop equipment required


Removal wedge -VAS 3409-

Note
. Volkswagen AG
When removing and installing components in visual area (con
gen AG
does
swa
ktape
not
l
nectors, covers, trims etc.) apply a commercial adhesive
o
V
gu
y
b
ara
d3409where a lever tool is applied ( removal wedge -VAS
, srew
nte
ir se
o
driver).
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Removing:

au
ss

Switch off the ignition and all electrical consumers.

ng

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te o
iva
r
rp
fo

thi
sd
o
cu
m
en

Renew bulb:

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rig
py
Co
t.

Disconnect connector -arrow-.

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

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

Lever lens carefully out using removal wedge -VAS 3409- or


a screwdriver.

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by

AG.

Prote
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by
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rig
ht.
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2. Lights and switches in dash panel

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241

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unlock locking tabs -1- and take thermal protection plate -2off the lens or the light.

Lever bulb carefully out of the holder.


Renew glas base bulb (12 V, 5 W).
Installing:

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es n
wage
ot g
olks
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or
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ac
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ss

urposes, in part or in wh
ole,
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is n
mer
m
ot p
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erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

ility
ab
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an
pt
ce

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


note the following:

2.3

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

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:

Switch off the ignition and all electrical consumers.

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

Downloaded from www.Manualslib.com manuals search engine

AG.

2.4

agen
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by

Install in reverse order of removal.

Prote
cted
by
c
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rig
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.
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Installing:

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rig
py
Co
t.

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

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c
um
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
Disconnect connector -arrow-.

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

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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ole,
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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

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243

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unlock locking lugs -arrows- and take warning lamp out.
Installing:
Install in reverse order of removal.

2.6
Removing:

Removing and installing hazard warning


olkswagen AG
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consumers.

Remove centre vent Heating, air conditioning system; Rep.


Gr. 80 ; Servicing heating system; remove vent; Remove cen
tre vent .

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

Remove connectors -arrows-.

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Release locking lugs -arrows- and remove hazard warning


light switch.
Install in reverse order of removal.

AG.

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

Downloaded from www.Manualslib.com manuals search engine

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Installing:

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ole,
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Switch off the ignition

V
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ed
ris
o
th
au all electrical
and
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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Note

un
le

Removal wedge -VAS 3409-

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

When removing and installing components in visual area (con

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

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

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245

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Unlock locking tabs -1- and take thermal protection plate -2off the lens or the light.

Lever bulb carefully out of the holder.


Renew glas base bulb (12 V, 5 W).
Installing:
Install in reverse order of removal.

urposes, in part or in wh
ole,
cial p
is n
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m
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2.8

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WARNING

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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.


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

AG.

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

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246

do
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Disconnect connector -arrow-.

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Release locking lugs -arrows- and remove key switch.

ility
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rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
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urposes, in part or in wh
ole,
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Install in reverse order of removal.

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Installing:

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2. Lights and switches in dash panel

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247

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Lights and switches in front doors

3.1

Removing and installing window regula


tor switch in front passenger door E107-

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

Note

urposes, in part or in wh
ole,
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s

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.

Install in reverse order of removal.

3.2

Removing and installing switch module


for driver side mirror adjustment

The following components (depending on equipment) are inte


grated into the switch module for the driver side mirror adjustment:
Mirror adjustment switch -E43 Mirror adjustment reversing switch -E48 Exterior mirror heater button -E231 Mirror fold-in feature system switch -E263 Mirror adjustment switch illumination bulb -L78-

248

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

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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-.

do
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en

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 .

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
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rrectness of i
t to the co
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f
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mat
spec
ion
h re
wit
in

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.


ng

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Disconnect connector -1- and tighten securing bolts -2-.


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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.

AG.

Prote
cted
by

3. Lights and switches in front doors

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249

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Release locking lugs -arrows- and remove interior locking
switch from the installation frame.
Installing:
Install in reverse order of removal.

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3.4

Components - front door locks


urposes, in part or in wh
ole,
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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
a
t
i
h re
o
n in
wit
thi
s

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

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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

urposes, in part or in wh
ole,
cial p
is n
mer
m
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erm
o
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t
a
itte
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du
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o
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AG. Volkswagen AG d
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When removing and installing components
in
visual
area
(con
a
c
s
s
nectors, covers, trims etc.) apply a commercial adhesive tape

where a lever tool is applied ( removal wedge -VAS 3409- , srew


driver).

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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.

Prote
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by

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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en

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

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251

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove connectors -arrows-.

Release locking lugs -arrows- and remove switch from the in


stallation frame.
Installing:
Install in reverse order of removal.

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.


Remove door trim General body repairs, interior; Rep. Gr.
70 ; Door trim; Removing and installing front door trim, driver
side .
Prote
cted
b
y
c
op
yri
gh
t
.
Co
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i

Downloaded from www.Manualslib.com manuals search engine

AG.

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

agen
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252

ht
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Co
t.

Disconnect connector -arrow-.

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

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

3.6

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ss

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
a
t
i
h re
o
n in
wit
thi
s

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
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erm
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itte
ir va
du
p
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f
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Prote
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by
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rig
ht
.
C
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3. Lights and switches in front doors

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253

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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-

n AG. Volkswagen AG do
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s
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tee
r -V163 Rear left door central locking deadlock function motor
o
h
t
or
ac
au
s
s are inte
The following components (depending on equipment)

Rear left door central locking motor, lock -V214-

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 .

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

Downloaded from www.Manualslib.com manuals search engine

AG.

Switch off the ignition and all electrical consumers.

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by
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ht.
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Removing:

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4.2

rrectness of i
t to the co
nform
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
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erm
o
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t
itte
ir va
du
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grated into the rear right door lock:

AG. Volkswagen AG d
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Jetta
2005
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2006
b
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r
Electrical
System
Edition
o
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ss

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urposes, in part or in wh
ole,
cial p
is n
mer
m
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t
a
itte
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ng

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

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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AG.

Prote
cted
by

cop
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gh
t
.
Co
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i

4. Lights and switches in rear doors

Downloaded from www.Manualslib.com manuals search engine

255

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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
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olks

oes
not
gu
ara
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c

yV
Removal wedge -VAS
d b 3409-

Note

The luggage compartment light can be found on the right side

in the luggage compartment trim.

When removing and installing components in visual area (con

nectors, covers, trims etc.) apply a commercial adhesive tape


where a lever tool is applied ( removal wedge -VAS 3409- ,
srewdriver).
Prote
cted
by
c
o
py
rig
ht.
C
op
yi

Switch off the ignition and all electrical consumers.

ht
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Co
t.

Removing:

agen
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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

Downloaded from www.Manualslib.com manuals search engine

AG.

256

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

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

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ce

e
ris
tho
u
a
ss

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
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The rear lid lock unit -F256is integrated into the tailgate lock
an
ed
tee
ris
cannot be replacedthoindividually.
o

u
sa

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

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

Renew tailgate lock General Body Repairs, Exterior; Rep.


Gr. 55 ; Tailgate; Removing and installing coupling lock; Re
moving .

ra
c
ility
ab
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an
pt
ce

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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Prote
cted
by
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ht
.
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5. Lights and switches in luggage compartment

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257

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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
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an
pt
ce

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.

AG.

Downloaded from www.Manualslib.com manuals search engine

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

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258

rrectness of i
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en

Note

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ole,
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itte
ir va
du
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nl
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n

Removal wedge -VAS 3409-

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Carefully lever trim out of interior light using removal wedge VAS 3409- or screwdriver -arrow-.

Unbolt securing bolts -arrow-.

Take the interior light out of the headliner console.

Remove connectors -arrows-.

agen
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AG.

Prote
cted
by

6.1.2

cop
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.
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Install in reverse order of removal.

ht
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Installing:

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

urposes, in part or in wh
ole,
cial p
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erm
o
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t
itte
ir va
du
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n

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AG. Volkswagen AG d
agen
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b
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a
c
ss

Replace front interior light -W1-

Special tools and workshop equipment required


Removal wedge -VAS 3409-

6. Lights and switches in roof trim

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259

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Note

When removing and installing components in visual area (con


nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew
driver).
Removing:
n AG. Volkswagen AG do
Switch off the ignition and all electrical consumers.
e
wage
ks
Vol

by using removal wedge


Carefully lever lens for interior lightedout
ris
-VAS 3409- or screwdriver -arrow-.
o
th

Press contact -1- of light to side -arrow- and remove festoon


bulb -2- with the contact from the interior light.

AG.

Installing:
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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agen
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Prote
cted
by
c
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t
.
Co
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i

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

ht
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Co
t.

Pull contact -arrow- off defective festoon bulb.

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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
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nl
f
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n

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au
ss

s no
t gu
ara
nte
eo
ra
c

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,

ag
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b
ed
ris
in reverse
order of removal.
ho
t
au
ss

Installing:

Removing and installing front interior


light and reading light (vehicles with slid
ing sunroof)

The following components are integrated in the interior light and


reading light:
Front interior light -W1 Left centre reading light -W39 Left centre reading light -W40-

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Note

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um
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Sunroof switch -E8-

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

6.2

ility
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urposes, in part or in wh
ole,
cial p
is n
mer
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ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

Install

does
not
gu
ara
nte
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ra
c

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

AG.

Prote
cted
by

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

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261

Jetta 2005 , Bora 2006


n AG. Volkswagen AG do
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wage
Electrical System - Edition 05.2005
o
olks

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

Note

When removing and installing components in visual area (con


nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew
driver).

Prote
cted
by
c
o
py
rig
ht
.
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-.

262

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

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AG.

Take the interior light out of the headliner console.

agen
lksw
Vo
by

Unbolt securing bolts -arrow-.

ht
rig
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Co
t.

Removing:

thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng

Removal wedge -VAS

t gu
ara
nte
eo
ra
c

V
by
ed
s
i
3409-hor
t
au
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove connectors -arrows-.
Installing:
Install in reverse order of removal.

6.2.2

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ss

Removing and installing sunroof switch


-E8un
le
pe
rm
itte
d

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Removing:

Remove interior light page 261 .

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

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

Disconnect connector -arrow-.

r
te o
iva
r
rp
fo

ng

Install in reverse order of removal.

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AG.

Prote
cted
by
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.
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6.2.3

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Installing:

thi
sd
o
cu
m
en

Release locking lugs -arrows- and remove switch from the in


stallation frame.

Replace front interior light -W1-

Special tools and workshop equipment required

6. Lights and switches in roof trim

Downloaded from www.Manualslib.com manuals search engine

263

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Removal wedge -VAS 3409-

Note

When removing and installing components in visual area (con


nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew
driver).
Removing:
Switch off the ignition and all electrical consumers.
Carefully lever lens for interior light
removal wedge
swausing
olkout
gen AG
en AG. V
does
-VAS 3409- or screwdriver
ag-arrow-.
ksw
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e
ris
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ut
a
ss

ot g
ua
ran
tee
or
ac

AG.

Prote
cted

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agen
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y
c
op
yri
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t
.
Co
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Rep. Gr.96 - Lights, lamps, switches - inside

ht
rig
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Co
t.

264

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
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n

ility
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an
pt
ce

Press contact -1- of light to side -arrow- and remove festoon


bulb -2- with the contact from the interior light.

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Pull contact -arrow- off defective festoon bulb.
Fit the contact to the new festoon bulb (12 V, 10 W).
Installing:
Install in reverse order of removal.

Left centre reading light -W39- and right


centre reading light -W40-

Removing:

Remove interior light page 261 .

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

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

6.2.4

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or
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ac
a
ss

Turn bulb holder -arrows- of the defective reading light for 90


to the left.
Take the holder with the bulb out of the reading light.

Install in reverse order of removal.

6.3

AG.

Installing:

agen
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Prote
cted
by
c
o
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rig
ht
.
C
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Renew glas base bulb (12 V, 5 W).

ht
rig
py
Co
t.

Pull glas base bulb carefully out of the holder.

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

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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

Removing and installing rear interior


and reading light (vehicles without
ATAS)

Removing:

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

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

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AG.

Installing:

agen
lksw
Vo
by

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

Disconnect connector -arrow-.

ht
rig
py
Co
t.

Release locking lugs -arrows- and remove interior light and


reading light from the headliner.

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
te o
a
itte
ir v
du
p
or
nl
f
e
ng

6.3.1

gu
ara
nte
eo
ra
c
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y li
an
pt
ce

by
ed
ris
o
th
au
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

6.3.2

Renewing rear interior and reading light


bulbs (vehicles without ATAS)

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

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


Installing:
Install in reverse order of removal.

6.4

Rear interior and reading light (vehicles


with ATAS)

AG.

Rear right reading light -W12-

agen
lksw
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by

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

Rear left reading light -W11-

ht
rig
py
Co
t.

Rear left footwell light -W45-

do
c
um
en

The following components are integrated in the rear interior light


and reading light:

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

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

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

ility
ab
y li
an
pt
ce

n AG. Volkswagen AG do
es n
wage
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olks
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by
d
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ir se
tee
o
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t
or
ac
au
s
s

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

Downloaded from www.Manualslib.com manuals search engine

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.

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s

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

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

pe
rm
itte
d

ility
ab
y li
an
pt
ce

un
le

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

Downloaded from www.Manualslib.com manuals search engine

AG.

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

agen
lksw
Vo
by

268

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

Install in reverse order of removal.

ht
rig
py
Co
t.

Installing:

ng

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

thi
sd
o
cu
m
en

r
te o
iva
r
rp
fo

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.

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:

ility
ab
y li
an
pt
ce

vertically downwards and out from the interior and reading


light.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
Switch off the ignition and all electrical consumers.
b
ara
d
e
nte
is
r
o
eo
h
t
u
ra
a lens and reflectors)
Pull the entire complete trim -1- (including
c
ss

Pull the glass base bulb to be removed (12 V, 5 W) -1- from


the holder.
Installing:

Install in reverse order of removal.

ht
rig
py
Co
t.

agen
lksw
Vo
by

AG.

Prote
cted
by

cop
yri
gh
t
.
Co
py
i

Removing and installing front passenger


side illuminated vanity mirror -W14- and
driver side illuminated vanity mirror W20-

do
c
um
en

6.5

Special tools and workshop equipment required

6. Lights and switches in roof trim

Downloaded from www.Manualslib.com manuals search engine

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.

Removing:
Switch off the ignition and all electrical consumers.
Lever light carefully out of the roof trim using removal
wedge
. Volkswagen AG
-VAS 3409- or a screwdriver.
gen AG
does
swa

not
gu
ara
nte
eo
ra
c

Disconnect connector -arrow-.

Downloaded from www.Manualslib.com manuals search engine

AG.

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

agen
lksw
Vo
by

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

270

ht
rig
py
Co
t.

Renew bulb:

rrectness of i
t to the co
nform
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
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
ab
y li
an
pt
ce

olk
yV
db
ir se
tho
au
s
s

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.

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s

Removing and installing garage door


operating unit -E284urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
ng

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Note

ility
ab
y li
an
pt
ce

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

ht
rig
py
Co
t.

agen
lksw
Vo
by

AG.

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

Downloaded from www.Manualslib.com manuals search engine

do
c
um
en

6. Lights and switches in roof trim

271

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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

Remove connectors -arrows-.

AG.

Downloaded from www.Manualslib.com manuals search engine

agen
lksw
Vo
by

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

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

ht
rig
py
Co
t.

272

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

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

Take mounting frame with ashtray out of the centre console.

ility
ab
y li
an
pt
ce

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
y
ua
db
ran
e
is
tee
r
o
h
-arrow-.
t
or
u
ac
a
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Release locking lugs -arrows- and remove switch from the in
stallation frame.
Installing:
Install in reverse order of removal.

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

ht
rig
py
Co
t.

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
du
p
or
nl
f
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7. Lights and switches in centre console

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273

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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.

Removing:

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ole,
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Switch off the ignition and all

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ss
electrical
consumers.

Remove front bumper General body repairs; Rep. Gr. 63 ;


Front bumper

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

Disconnect connector -arrow-.

Unscrew securing bolt -arrow- and remove horn.


Install in reverse order of removal.

Prote
cted
by

274

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

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AG.

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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Co
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8.2

do
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um
en

Installing:

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Immobilizer

General description:
The vehicle is equipped with an immobilizer of the 4th generation.
Modifications by comparison with the immobilizer of the 3rd gen
eration:
An adaptation of components of other group marks to Volks
wagen vehicles is no longer possible.
Vehicle keys are preprogrammed with a base code by the
manufacturer. This base code includes a specific manufactur
ers code. It is only possible to learn a key of a vehicle if they
are programmed with the right manufacturers code.
Fault detection and fault display:
olkswamakes
gen AG fault
AG. V
The immobilizer is equipped with self-diagnosis
which
does
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finding easier.
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For fault finding, use the vehicle
diagnosis, testing and informa
tho
u
tion system -VAS 5051Ain
guided fault finding mode.
sa
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un
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Immobilizer control unit -J362es, in part or in w


l purpos
hole
ercia
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rrectness of i
t to the co
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f
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m
spec
atio
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wit

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.

or
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ility
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9.1

ara
nte
e

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

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Ignition key - change code transponder


AG.

9.3.1

ht
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Co
t.

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 .

thi
sd
o
cu
m
en

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 .

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

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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

ility
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an
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Adapting ignition keys to the comfort


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

J393 - Adapting / testing keys with radio remote control

AG.

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by

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

ht
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Co
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276

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

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
o
e
t
a
itte
v
i
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du
p
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f
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ng

9.3.3

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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

does
not
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Activating and deactivating anti-theft


alarm system

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

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.

AG.

Unlock the car mechanically (emergency open)

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when the ignition is switched on.

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The system is deactivated when the vehicle is unlocked using


the radio remote control key or

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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)

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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.
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The anti-theft alarm system must be deactivated before
the send
o
h
t
or
u
er is removed page 277 .
ac
a
ss

Note

urposes, in part or in wh
ole,
cial p
is n
mer
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erm
o
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ir va
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Removing:

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

Switch off ignition and all electrical consumers and pull out
ignition key.
Remove glove compartment General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trim; Removing and
installing glove compartment; Removing .
Unscrew the securing bolts -1- and remove vehicle inclination
sender -G384- from the bracket.
Release the connector -2- and pull it away from the vehicle
inclination sender -G384- .
Installing:

Install in reverse order of removal.

278

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

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AG.

Additional information:

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Note

ht
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Central locking and anti-theft alarm sys


tem aerial -R47-

do
c
um
en

10.4

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-

Special tools and workshop equipment required

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or
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ac
a
ss

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng

Drill -VAS 5134-

Twist drill 6 mm

Pop rivet pliers -VAS 5072-

do
c
um
en

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Co
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AG.

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Note

The anti-theft alarm system must be deactivated before the alarm


horn is removed page 277 .
Removing:
Switch off ignition and all electrical consumers and pull out
ignition key.
10. Anti-theft alarm system (ATAS)

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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

Vol
Drill out both pop rivets -arrows- using drill
by -VAS 5134- and
d
e
6 mm twist drill.
ris

Pull alarm horn -H12- -1- in -direction of arrow- out of the


aperture in the bodywork.
Pull connector off -2-.
Installing:
Note

Remove all metal particles caused during the drilling.

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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AG.

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

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Prote
cted
by
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rig
ht
.
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Fit connector to the alarm horn -H12- .

ht
rig
py
Co
t.

Perform measures for corrosion protection General Infor


mation; Body Repairs, General Body Repairs .

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
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an
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ce

tho
au
s
s

does
not
gu
ara
nte
eo
ra
c

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

97

Wiring

Vehicle Diagnosis, Testing and Infor


mation Systems
WARNING

During testing or measuring operations using a vehicle di


agnosis information system, there is a risk of serious or
even fatal injury!
If the vehicle diagnosis information system is lodged in the
activity area of an airbag during a testing or measuring
operation, a triggered airbag can result in serious or even
. Volkswagen AG
fatal injury!
gen AG
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rrectness of i
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f
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spec
atio
h re
n in
wit

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rm
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d

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

Note

ss

ility
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un
le

o
y V operations, work with a sec
During testing and measuring
db
e
s
i
ond person who can operate
the vehicle diagnosis infor
r
ho of the rear seats!
mation system fromautone

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
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Prote
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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.

1.1

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t.

Connecting Vehicle Diagnosis, Testing and Information Sys


tem -VAS 5051A- page 281 .

thi
sd
o
cu
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en

Self-study programme No. 294 ; Online connection of the VAS


5051

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

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Vehicle Diagnosis, Testing and Information System -VAS
5051A-

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng

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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AG.

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

agen
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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.

do
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um
en

Note

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Diagnosis lead -VAS 5051/5A- (3 m)

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Diagnosis lead -VAS 5051/6A- (5 m)

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u
ac
a
ss

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

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-

n AG. Volkswagen AG do
es n
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b
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ise
te
r
o
h installing components in visual area (con e o
t
When removing and
u
ra
a
c
nectors, covers,sstrims etc.) apply a commercial adhesive tape

Note

un
le

pe
rm
itte
d

Caution

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .
Removing:
Disconnect the battery page 29 .

ht
rig
py
Co
t.

ng

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sd
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en

r
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iva
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rp
fo

Remove storage compartment on driver side General body


repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

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

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

ility
ab
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an
pt
ce

where a lever tool is applied ( removal wedge -VAS 3409- , srew


driver).

agen
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Vo
by

AG.

Prote
cted
by
c
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py
rig
ht
.
C
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2. Removing and installing fuse holder

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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

n AG. Volkswagen AG do
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b
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o
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t
or
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ac
a
ss

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

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

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itte
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pt
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un
le

Remove lateral cover -1- out of the dash panel, by inserting


the removal wedge -VAS 3409- or a screwdriver in the recess
-2- and lever off cover -1- in -direction of arrow-.

Take fuse assignment card -1- out of fuse holder -2-.

ng

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AG.

Rep. Gr.97 - Wiring

agen
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Co
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284

ht
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t.

Install in reverse order of removal.

thi
sd
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cu
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en

Installing:

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iva
r
rp
fo

Remove securing bolts -arrows- and take fuse holder -1- out
as far it is possible (depending on cable length).

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Removing and installing relay carrier

3.1

Removing
and installing relay carrier
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with
cut-out on left
t gu dash panel
V
by
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ed
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au
Caution
ss

or
ac
ility
ab
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an
pt
ce

un
le

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

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.

ng

ht
rig
py
Co
t.

agen
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o
p
yri
gh
t.
C
op
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Pull relays -arrows- out of the relay carrier.

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sd
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cu
m
en

r
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iva
r
rp
fo

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

pe
rm
itte
d

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .

AG.

Prote
cted
by

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

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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

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ab
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an
pt
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AG. Volkswagen AG d
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ut relay carrier
ra
The onboard supply control unit -J519- and the
a
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s
attached to the onboard supply control unit,s on left of dash
urposes, in part or in wh
ole,
cial p
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a
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ir v
du
p
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nl
f
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ng

Removing and installing relay carrier on


onboard supply control unit, on left of
dash panel

panel form one unit and cannot be separated.

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

Removing:

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

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

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Rep. Gr.97 - Wiring

do
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um
en

286

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
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eson
relay carrier on onboard
ksw
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l
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may only be pulled
OPEN.
ar
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ce

connectors of the onboard supply


J519- and the relay carrier on onboard supply control unit, on
left of dash panel.
Note

The connector number depends on vehicle equipment.

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

urposes, in part or in wh
ole,
cial p
is n
mer
m
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erm
te o
a
itte
ir v
du
p
or
nl
f
e
ng

an
tee
o
controlr aunit
c

e
ris
tho
u
a
Remove
all
ss

Unclip onboard supply control unit -J519- and relay carrier on


onboard supply control unit, on left of dash panel out of the
locking device -arrows C-.
Pull onboard supply control unit -J519- and relay carrier on
onboard supply control unit, on left of dash panel downwards
and in opposite direction of travel out of the bracket.
Installing:

Installation is performed in the reverse order of installation; when


doing this, note the following:
do
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um
en

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The locking bars may only be set to CLOSE when all connectors
are fitted correctly.
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AG.

Prote
cted
by

3. Removing and installing relay carrier

Downloaded from www.Manualslib.com manuals search engine

287

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Electronics boxes

4.1

Removing and installing electronics box


on left in engine compartment

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

Disconnecting and connecting the battery as described in the


Workshop Manual page 29 .
Removing:

Disconnect the battery page 29 .


Release clips -1- in -direction of arrow- and take cover of elec
tronics box -2- off upwards.

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AG.

Prote
cted
by
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Open -arrows- covers -2- of cable guides on electronics box.


Remove wiring from stud connections.
Unclip wiring from cable guides.

288

Rep. Gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

ht
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Remove hexagon nuts -1-.

thi
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en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
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nl
f
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ng

Caution

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or
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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Remove central securing screw -arrow- from electronics box
-1-.
Note

When the central securing screw -arrow-, the electronics box -1is pushed upwards off the electronics box mounting.
Pull electronics box -1- upwards off electronics box mounting.

Note

For removal of the flat contact housing -1-, the air filter (on vehi
cles with diesel engine only), the battery and the battery console
must be removed.
Remove air filter housing, if necessary.
Remove battery page 29 .

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Remove securing bolts -arrows- of battery console -1-.


Take battery console -1- out of vehicle.

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
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o
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f
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ng

ility
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i

4. Electronics boxes

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289

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Press tabs apart on bracket of electronics box -arrows B- and
slide flat contact housing -1- sidewards -arrow A- out of brack
et of electronics box.
Press tabs apart on bracket of electronics box -arrows C- and
slide flat contact housing -2- forwards -arrow D- out of bracket
of electronics box.

Unscrew securing nuts -arrows- of bracket from electronics


box -1-.
Note

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

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

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rm
itte
d

un
le

ility
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Whether the additional


vehicle equipment.

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ara
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s
i
r
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ho
t
u
ra
relay
carrier
is
installed
depends
on
the
a
c
ss

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:

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agen
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Rep. Gr.97 - Wiring

ht
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290

thi
sd
o
cu
m
en

Tighten threaded connections to specified torque settings


page 307 .

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.

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

ht
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py
Co
t.

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n

ility
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an
pt
ce

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a
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ss

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by

cop
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.
Co
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i

4. Electronics boxes

Downloaded from www.Manualslib.com manuals search engine

291

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Control units

5.1

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Onboard supply control unit -J519un


le
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Note

The onboard supply control unit -J519- and the relay carrier

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

Additional information:

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

attached to the onboard supply control unit, on left of dash


panel form one unit and cannot be separated.

Current flow diagrams, Electrical fault finding and Fitting loca


tions
Operating instructions
General description:

ng

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

292

Rep. Gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

AG.

Heated rear window

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Rear window wiper

Prote
cted
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Turn signal control

thi
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en

Exterior light control

ht
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Co
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Electrical load management

r
te o
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rp
fo

The onboard supply control unit -J519- is responsible for the fol
lowing in the vehicle:

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

n AG. Volkswagen AG do
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
Note tho
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s
s

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The above adaptations can only be carried out in conjunction


pe
rm
itte
d

with certain equipment configurations.

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.

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

Note

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ng

Removing and installing onboard supply


control unit -J519ht
rig
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Co
t.

5.1.1

thi
sd
o
cu
m
en

r
te o
iva
r
rp
fo

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

rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in

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

The Motorway signaling, comfort signaling, or tap signal

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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293

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

agen
01 - On Board Diagnostic
capable
systems AG does n
lksw

Onboard

ot g
ua
ran
tee
or
ac

unit
unit functions

Modifying headlight cleaning system

5.2

Data bus diagnostic interface -J533-

ility
ab
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an
pt
ce

Additional information:
Current flow diagrams, Electrical fault finding and Fitting loca
tions
Operating instructions
General description:
The diagnosis interface for data bus -J533- (gateway) is a sepa
rate control unit. It has the following functions in the vehicle:
Responsible for exchange of data between CAN data bus sys
tems drive train CAN data bus, convenience CAN data bus
and Infotainment CAN data bus
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-

ht
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Prote
cted
by
c
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rig
ht
.
C
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yi

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.

294

Rep. Gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

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

Note

do
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

Onboard

Vo
by
ed
supplyriscontrol
tho
au
supply
control
s
s

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

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

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

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:

Prote
cted
by

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Note

AG.

ng

Central control unit for convenience sys


tem -J393agen
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5.3

thi
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en

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fo

Install in reverse order of removal.

ht
rig
py
Co
t.

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

pe
rm
itte
d

un
le

that access can be gained to the codes stored within.

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AG. Volkswagen AG d
agen
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e
Before removing
data
bus
diagnostic
interface
-J533nte , it is es
is
r
eo
ho the following work procedure
sentialutthat
ra
a
1.1
ss Renewing dash panel insert, page 150 is carriedc out, so

Additional information:
Current flow diagrams, Electrical fault finding and Fitting loca
tions

5. Control units

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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

Comfort operation

ility
ab
y li
an
pt
ce

Rear lid lock

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng

Radio-wave receiver

n AG. Volkswagen AG do
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olks
V
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ise
tee
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t
or
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ac
a
ss

Fault detection and fault display:

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Some of the above functions can be adapted page 298 .


The convenience system central control unit -J393- is equipped
with self-diagnosis, which is designed to ease fault finding.
For fault finding, use the vehicle diagnosis, testing and informa
tion system -VAS 5051A- in guided fault finding mode.

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.

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

Downloaded from www.Manualslib.com manuals search engine

AG.

The connectors may only be unlocked and pulled off if the re


cesses -arrows- of the connectors and the bracket align exactly.

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by

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cted
by
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i

Note

ht
rig
py
Co
t.

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-.

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

Note

After installing a new convenience system central control unit

it must be coded page 297 .

The connectors may only be placed and locked if the recesses

-arrows- of the connectors and the bracket align exactly.

agen
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Vo
by

AG.

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

Coding convenience system central


control unit -J393-

ht
rig
py
Co
t.

5.3.2

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

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

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tho
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s
s

Installing:

Volkswagen AG
does
not
gu
ara
nte
eo
ra
c

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

Downloaded from www.Manualslib.com manuals search engine

297

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)

Sensitivity of tilt angle sensor

ility
ab
y li
an
pt
ce

Activating and deactivating


delay when driver's door is opened

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng

Activating and deactivating


mote control unit

AG. Volkswagen AG d
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not
l
o
gu
comfort operation via radio reby V
ara
d
e
nte
s
i
r
o
eo
h
t
u
ra
a
anti-theft alarm system
c
ss - alarm

Sensitivity of interior monitoring system

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

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

J393 - Adapting convenience system central control unit

Prote
cted
by

Select guided fault finding in Vehicle Diagnosis, Testing and


Information System -VAS 5051A- .
Using the Go to key, select Function/component selection
and the following menu items one after the other:
Body
General Body Repairs
01 - On Board Diagnostic capable systems
Comfort system
Comfort system central control unit functions
J393 - Read alarm sources of anti-theft alarm system

298

Rep. Gr.97 - Wiring

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AG.

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Connect Vehicle Diagnosis, Testing and Information System


-VAS 5051A- page 281 .

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Convenience system central control unit


-J393- - Read alarm sources of anti-theft
alarm system

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5.3.4

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Comfort system central control unit functions

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/

. Volkswagen AG
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5.4.3 Final control diagnosis trailer detector controleunit
db
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J345 , page 301 .
tho

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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.

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Torque wrench -V.A.G 1783-

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Special tools and workshop equipment required

5. Control units

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Removing and installing trailer detector


control unit -J345r
te o
iva
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5.4.1

299

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
Removing:
Switch off ignition and all electrical consumers and pull out
ignition key.
Remove left side panel trim in luggage compartment Gen
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal
ling load and luggage compartment trim; Trim, luggage
compartment, sidewards .
Release connectors -2- and pull off trailer detector control unit
-J345- .
Note

The connector number on the trailer detector control unit -J345shown in the figure depends on vehicle equipment and may vary.
Remove securing bolts -1- and take trailer detector control unit
-J345- with the bracket out of the vehicle.

Remove securing bolts -arrows- and take trailer detector con


trol unit -J345- off bracket.
Installing:
Installation is performed in the reverse order of installation; when
doing this, note the following:
. Volkswag
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Tighten threaded connections to specified
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page 307 .
ise

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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

Rep. Gr.97 - Wiring

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Prote
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300

AG.

Coding trailer detector control unit

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Function

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Trailer detector

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General Body Repairs

The trailer detector control unit -J345- detects from a power

draw of minimum 5 W 4) the trailer operation.

To check use plug socket tester -V.A.G 1537/A- .


Special tools and workshop equipment required
Plug socket tester -V.A.G 1537/A- 5)

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Final control diagnosis trailer detector


control unit -J345-

, Bora 2006
- Edition 05.2005

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5.4.3

AG. Volkswagen AG d
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Jetta 2005
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Electrical
System
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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

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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Operating instructions wiring harness repair
ed
is
or

th
General body repairs interior; Rep. Gr.
au 69
ss

General notes concerning repairs to ve


hicle electrical system
urposes, in part or in wh
ole,
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Caution

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6.2

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.

do
c
um
en

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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Perform wiring harness repairs
Vol only with yellow wires. Mark
gu
bytape.
ara
repair locations with yellow
d
e
n
is
or

Supplementary notes on repair of CAN


bus wiring

rrectness of i
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nform
spec
a
t
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h re
o
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wit
thi
s

An unshielded two-wire line -1- and -2- with a cross section of


0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
The colour codes of the CAN bus wiring can be gleaned from
the following table:
Drivetrain CAN, high
Convenience CAN, high
Infotainment CAN, high
CAN Low wire (all)

orange/black
orange/green
orange/violet
orange/brown

Perform wiring harness repairs only with yellow wires. Mark


repair locations with yellow tape.
When repairs are performed, both bus wires must have the
same length. When wires -1- and -2- are twisted together, the
twist spacing should be A=20 mm.
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No section of wiring greater than B=50 mm, e.g. in the vicinity


of heat-shrink sleeves -arrow-, should not be twisted.

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6.4

tee
or
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Shielded wires mustautnot
be repaired. In case of damage, they
s
s
must be entirely replaced.

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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.

AG.

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Rep. Gr.97 - Wiring

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304

rrectness of i
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nform
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ole,
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Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005
olkswagen AG
en AG. V

does
wag
not
Renewal
of aerial wiring
olks
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7.1

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A new repair
concept has been developed for repair
work
on aer
eo
tho
u
r a various
ial wires.
Now
connecting
wires
in
different
lengths
and
a
c
s
s
adapter
cables are available as replacement parts instead of a
complete aerial wire.

General description

rrectness of i
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nform
spec
a
t
i
h re
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wit
thi
s

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.
do
c
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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.


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Assembly overview - an aerial wire


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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-.
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Procure the required adapter cables -1- and -3- band
y V connect
d
e
ing wire -2- at the calculated length as genuine
ris parts from the
ho
parts catalogue (ETKA).
ut
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ss

urposes, in part or in wh
ole,
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Cut off connectors of defective aerial wire.


The remainder of the defective aerial wire remains in the vehicle.
Connect adapter cables -1- and -3- to equipment in vehicle.

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

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.
Perform a functional check.

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Rep. Gr.97 - Wiring

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306

Jetta 2005 , Bora 2006


Electrical System - Edition 05.2005

Torque settings: Cables

8.1

Torque settings: Electronics box in left


side of engine compartment

Threaded connections
Securing nuts -1Securing nuts -1-

8.2

Torque settings
M5 (AF 8)
M6 (AF 10)

4 Nm
6 Nm

Torque settings trailer detector control unit -J345-

Threaded connections

Torque settings

Securing bolts bracket to body


Securing bolts control unit to bracket

2 Nm
2 Nm

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
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es, in part or in w
l purpos
hole
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, is n
m
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erm
o
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a
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8. Torque settings: Cables

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307