Volkswagen Jetta Workshop Manual

Service
Workshop Manual
Jetta 2005 ➤
Bora 2006 ➤
Electrical System
Edition 05.2005
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Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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94 - Lights, lamps, switches - outside
96 - Lights, lamps, switches - inside
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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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i
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
s
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
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Removing and binstalling
dash
panel
insert . . n.o.t g.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V
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se reverse side of dash panel insert . .ra. n.te. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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Vo
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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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6
6.1
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4.1
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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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2.4
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. . . . . . . . . . . . . . . . . . . . . . . . . . .
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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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288
288
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3.1
3.2
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
27 –
Starter, current supply, CC
1
Battery
WARNING
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
Caution
To prevent damage to the battery and vehicle, the following
should be observed concerning types of battery ⇒ page 1 .
1.1
Fundamentals for batteries
To ensure long use of the battery, the battery must be checked,
serviced and maintained as per instructions in this Manual.
Apart from supplying energy for starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
to the complete vehicle electrical system.
Note
Observe ⇒ Self-study programme No. 234 ; vehicle batteries .
1.2
Types of battery
1.2.1
Low maintenance battery
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Low maintenance battery with liquid electrolyte (wet battery).
These batteries are recognised by the removable cell plugs.
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Lead-acid battery, electrolyte level must be checked regularly and
topped-up with distilled water as required.
These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.
1.2.2
Maintenance-free battery
Maintenance-free battery with liquid electrolyte (wet battery).
These batteries have a cover over the cells instead of cell plugs.
The cover seals the battery after initial filling during production.
Caution
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Lead-acid battery, where electrolyte need not be topped-up with
distilled water under normal conditions. This term is normally used
for batteries with a predetermined amount of electrolyte.
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Never under any circumstances remove the cover for the bat‐
tery cells. The battery housing will be damaged and the battery
is therefore unusable.
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1. Battery
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1
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.
1.2.3
Absorbent glass mat (AGM) battery
Maintenance-free battery with a contained electrolyte.
Lead-acid battery where the electrolyte is contained within a mi‐
croscopic glass mat (AGM). The battery is sealed and fitted with
valves.
AGM is the abbreviation for Absorbent Glass Mat.
Note
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♦ The procedure for checking and testing
Vol
glass mat batteries is identical.sed by
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♦ Always replace an absorbent
au glass mat battery with another
Gel battery
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Maintenance-free battery with a contained electrolyte.
Lead-acid battery where the electrolyte is contained within a gel.
The battery is sealed and fitted with valves.
Note
♦ The procedure for checking and testing gel and absorbent
glass mat batteries is identical.
♦ Currently gel batteries are only used in motor homes/campers
at Volkswagen.
Warning notices and safety regulations
1.3.1
Dangers when handling vehicle batter‐
ies
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Recognition and avoidance of dangers
Batteries can be dangerous. These dangers can be avoided when
the warnings on the battery and in the owners/instruction manual
and in ELSA are observed.
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
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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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3
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
1.4
Battery terminal connection
Caution
To prevent damage to the battery terminal clamps and battery
terminals, the following should be observed:
♦ The battery terminal clamps should only be fitted by hand
and without using force.
♦ Battery terminals should not be coated with grease.
♦ The battery terminal clamps should be fitted so that the
battery terminal is either flush with the clamp or protruding
from it.
♦ Once the battery terminal clamps have been tightened to
the specified torque, the threaded connections should not
be tightened any further.
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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
2
Checking battery
WARNING
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
Caution
To prevent damage to the battery and vehicle, the following
should be observed concerning types of battery ⇒ page 1 .
2.1
Procedure when checking the battery
Carry out procedure in sequence as follows:
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Checking battery with a magic
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a low maintenance battery
⇒
page
7
.
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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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spec
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t
ion
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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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urposes, in part or in wh
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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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5
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
en the clamps to the torque specified in this workshop manual.
If the clamps are not correctly seated and tightened, the wiring
could burn, which could result in electrical system malfunc‐
kswagen AG
tions. Which will cause malfunctions in the electrical
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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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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 .
6
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
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– Before performing a visual check, tap the magic eye lightly and
carefully with the handle of a screwdriver.
do
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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
ility
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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
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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
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urposes, in part or in wh
ole,
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n
Danger of injury! Observe warning
tions ⇒ page 2 !
AG. Volkswagen AG d
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– Check the electrolyte level of the battery cells.
The electrolyte level is OK when the fluid level -1- is the same
height as the plastic peg.
Note
The plastic peg corresponds to the max. marking.
If electrolyte level is OK:
– Check the cell sealing plugs and the O-ring seals for damage.
Damaged parts must be replaced.
– Seal the cells with the cell sealing plugs.
If the electrolyte level is under the plastic peg:
– Replenished with distilled water ⇒ page 7 .
2.4.2
Topping up with distilled water
Special tools and workshop equipment required
2. Checking battery
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
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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
8
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
agen
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– If fitted, remove the protective foil on the cell sealing plug.
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– Check the electrolyte level of the battery ⇒ page 7 .
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
♦ Commercially available hydrometer
– Check the electrolyte level of the battery ⇒ page 7 .
– Switch off the ignition and all electrical consumers.
– If fitted, remove the protective foil on the cell sealing plug.
Note
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The foil with the warning notices must remain on the battery.
yV
– Remove cell sealing plugs.
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The electrolyte density is determined by the float position in the
battery electrolyte. The value can be read from the float scale.
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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– Check the cell sealing plugs and the O-ring seals for damage.
Damaged parts must be replaced.
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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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– Draw electrolyte off a cell using a hydrometer until the float
swims unhindered.
2. Checking battery
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9
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
2.5
Check no load voltage of battery
WARNING
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Danger of injury! Observe warning notices
and
safety regula‐
Vol
by
tions ⇒ page 2 !
d
e
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t to the co
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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.
ility
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a
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)
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♦ 136 - 855 A VAollow-temperature
test current
to EN/
otaccording
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SAE (European
Norm/Standard
of
Automotive
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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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au
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-
agen
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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
Downloaded from www.Manualslib.com manuals search engine
ht
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Perform battery load test:
rrectness of i
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Battery load test using battery tester
with printer -VAS 5097 A-
ility
ab
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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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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
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wit
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⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
do
c
um
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
nte
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136 - 17
178 - 219
220 - 261
262 - 303
304 - 345
346 - 387
388 - 429
430 - 471
472 - 513
514 - 555
556 - 597
598 - 639
640 - 657
658 - 675
676 - 693
694 - 711
712 - 729
730 - 747
748 - 765
766 - 783
784 - 801
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EN/ SAE
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2. Checking battery
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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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♦ 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.
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Rep. Gr.27 - Starter, current supply, CC
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14
rrectness of i
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♦ Perform test once only. Repeating the test falsifies the results.
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Note
ri
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Charging battery
WARNING
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spec
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wit
thi
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Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
Caution
To prevent damage to the battery and vehicle, the following
should be observed concerning types of battery ⇒ page 1 .
3.1
Battery charger -VAS 5095 A-
This chapter describes the basic functions of the battery charger
-VAS 5095 A- . For additional information refer to ⇒ Operating
instructions for battery charger -VAS 5095 A- .
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♦ Observe ⇒ Operating instructions for battery charger -VAS
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♦ Observe battery manufacture's handling instructions!
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3
➤ , 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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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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If the LED lights up green ⇒ page 15 -4- the charger has switched
to "maintaining charge". The battery is fully charged.
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The charging current indicators ⇒ page 15 -2- and -3- light up
yellow. When only the light emitting diode (LED) -3- lights up yel‐
low, battery is partially discharged (approx. 90 %).
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spec
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Always set battery type 2.4 V/C
This applies for all batteries.
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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
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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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Special tools and workshop equipment required
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When in support mode the battery charger -VAS 5095 A- replaces
a defective vehicle battery whilst it is being exchanged. The on‐
board supply remains intact. The vehicles electrical equipment
(e.g. electric windows) can be used.
rrectness of i
t to the co
nform
spec
a
t
i
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n in
wit
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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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on, otherwise support mode is not possible.
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– Switch off charging unit ⇒ page 15 .
es, in part or in w
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– Exchange battery ⇒ page 31 .
rrectness of i
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wit
– Switch on vehicle parking light.
pe
rm
itte
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♦ 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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In the buffer mode the battery charger -VAS 5095 A- is charged
correctly and is maintained in a fully charged condition.
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Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
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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
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♦ Observe
AG. Volkswagen AG d
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⇒ Operating instructions for battery charger
-VAS
by
ara
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battery manufacture's handlingssinstructions!
urposes, in part or in wh
ole,
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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
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WARNING
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Charging battery with battery charger VAS 5900c
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3.2.2
do
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5 - INFO
ht
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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
Downloaded from www.Manualslib.com manuals search engine
19
un
le
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ab
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ce
n AG. Volkswagen AG do
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Jetta 2005 ➤ , Bora
o
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t
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au - Edition 05.2005
Electrical System
s
s
rrectness of i
t to the co
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spec
atio
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n in
wit
es, in part or in w
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hole
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♦ Battery charger -VAS 5900-
♦ The battery must have a temperature of at least 10 °C.
♦ If the battery has cell sealing plugs, do not open them while
ng
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– Switch off the ignition and all electrical consumers.
– Connect charger unit plug to power supply. The last selected
operating mode will appear on display ⇒ page 19 .
AG.
– Set battery to respective operating mode with INFO .
In the display the symbol -1- for “standard charge for wet batter‐
ies” or the symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.
– Set battery capacity (Ah) of battery for charging using respec‐
tive button “Up” ↑ or “Down” ↓ .
– Connect red terminal clamp “+” to positive terminal on battery.
– Connect black terminal clamp “-” to negative terminal on bat‐
tery.
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.
At a charge condition of approx. 80 - 85 % the charger unit
switches to the “final charge” mode. The fourth bar appears in
display -1-. The battery is ready for use.
20
Rep. Gr.27 - Starter, current supply, CC
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the battery is being charged.
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Note
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
At a charge condition of 100 % all bars appear in display.
Note
♦ In the battery type “standard charge” the parallel use of con‐
sumers while charging is possible. The charging period will be
longer.
♦ The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100 % charge the battery should remain connected for this
period.
Possible faults and fault rectification:
1-
Displayed battery voltage is not as per nominal voltage:
– Press respective button “Up” ↑ or “Down” ↓ until charging
sequence starts.
Displayed battery voltage is not as per nominal voltage –
charging sequence already started:
olkswagen AG
en AG. V
– Press START / STOP twice.
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:
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l purpos
hole
ercia
, is n
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3-
does
not
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– Press respective button “Up” ↑ or
sequence starts again.
ag
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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.
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Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
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WARNING
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Charging battery in service mode with
battery charger -VAS 5900ht
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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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ss
rrectness of i
t to the co
n
f
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m
spec
atio
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n in
wit
Note
es, in part or in w
l purpos
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♦ Battery charger -VAS 5900-
♦ The battery must have a temperature of at least 10 °C.
♦ If the battery has cell sealing plugs, do not open them while
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 .
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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.
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– Connect red terminal clamp “+” to positive terminal on battery.
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– Set battery capacity (Ah) of battery for charging using respec‐
tive button “Up” ↑ or “Down” ↓ .
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In the display the symbol -1- for “service charge for wet batteries”
or the symbol -2- for “service charge for gel/absorbent glass mat
batteries” will appear.
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condition of approx. 80 - 85 % the charger unit
c
ss
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
rrectness of i
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nform
spec
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urposes, in part or in wh
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At a
switches to the “final charge” mode. The fourth bar appears in
display -1-. The battery is ready for use.
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:
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Display remains unchanged.
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– 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
Downloaded from www.Manualslib.com manuals search engine
23
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
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♦ The terminal polarity protection in operating mode “charg‐
ing totally discharged batteries/support mode” is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ Operating instructions for battery
charger -VAS 5900- !
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 27 .
♦ 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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♦ 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.
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Ending battery charging sequence:
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– Disconnect
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– Disconnect red terminal clamp “+” of charger unit from nega‐
tive terminal on battery.
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3.2.5
Charging battery in support mode with
battery charger -VAS 5900WARNING
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– Pull charger unit plug out power supply socket.
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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.
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board supply remains intact. The
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(e.g. electric windows) canisebe
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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 .
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cted
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– Press respective button “Up” ↑ or “Down” ↓ to set the re‐
spective onboard supply voltage (6 V, 12 V or 24 V).
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Note
If a button is not pressed within 5 seconds the charger will return
to the main menu (select operating mode).
– Confirm the selected battery voltage with START / STOP .
– Connect red terminal clamp “+” of charger unit to positive ter‐
minal of vehicle.
– Connect black terminal clamp “-” of charger unit to negative
terminal of vehicle.
Then follows the enquiry for "is charger cable terminal polarity
correct".
– Check polarity of charger unit cables.
– Confirm polarity of charger unit cables with START / STOP .
26
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
ht
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– Press START / STOP for approx. 5 seconds. The menu
““charging totally discharged batteries/support mode” will be
activated.
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♦ Battery charger -VAS 5900-
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
The battery charger starts with support mode.
– Exchange battery ⇒ page 31 .
– Press START / STOP . The support mode is terminated.
– Disconnect black terminal clamp “-” of charger unit from neg‐
ative terminal of vehicle.
– Disconnect red terminal clamp “+” of charger unit from positive
terminal of vehicle.
– Pull charger unit plug out power supply socket.
3.2.6
Charging battery in maintenance mode
with battery charger -VAS 5900WARNING
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
At a charge condition of 100 % all bars appear in display.
♦ When a battery is being charged in the buffer mode and a
consumer draws current from the battery, the battery charger
-VAS 5900- automatically compensates the charge.
♦ The maintenance mode can be continued for an unlimited pe‐
riod.
♦ The battery is always ready for use.
♦ Observe battery manufacture's maintenance instructions!
3.3
Totally discharged batteries
WARNING
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
rrectness of i
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nform
spec
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r5900When the battery isisefully
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mode.
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– 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
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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.
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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
4
Disconnecting and reconnecting bat‐
teries
WARNING
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
4.1
Disconnecting battery
Note
♦ By disconnecting the battery earth wire (open circuit), safety
is ensured when carrying out work on the electrical system.
♦ The battery positive wire need only be disconnected for re‐
moval of the battery.
– Switch off the ignition and all electrical consumers.
– Release catch -arrow- and take cover off battery box.
– First unscrew battery earth clamp -1- from battery negative
terminal.
un
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4.2
positive
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terminal.
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unscrew battery positive clamp -2- from battery
sThen
Connecting battery
Caution
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Special tools and workshop equipment required
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Observe instructions on connecting battery terminals
⇒ page 4 .
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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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– 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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If necessary, table can be printed out.
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Switch ignition on and off again
using ignition key
Read fault memory: ⇒ Guided
fault finding using VAS 5051A .
Clock: Check time on clock and
change as necessary.
Electric windows: Open all
electric windows fully and close
again.
Functional check: of all electri‐
cal consumers.
Performed
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
5
Removing and installing battery
WARNING
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !
5.1
Models with a petrol engine
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
Removing:
– Disconnect the battery ⇒ page 29 .
rrectness of i
t to the co
nform
spec
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h re
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urposes, in part or in wh
ole,
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AG. Volkswagen AG d
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– Pull panel of battery box out upwards in direction of arrow.
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– Unscrew securing bolt -1- and remove battery holder -2-.
AG.
5. Removing and installing battery
Downloaded from www.Manualslib.com manuals search engine
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).
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♦ 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.
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Rep. Gr.27 - Starter, current supply, CC
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32
rrectness of i
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nform
spec
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ion
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– Tighten threaded connections to specified torque settings
⇒ page 36 .
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Installation is performed in the reverse order of installation; when
doing this, note the following:
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➤ , 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
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wit
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♦ Spring-type
Jetta 2005
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– Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024A- .
– Pull the vacuum hose -arrow- off air filter housing.
5. Removing and installing battery
Downloaded from www.Manualslib.com manuals search engine
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,
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– 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
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o
n in
wit
thi
s
– Pull panel of battery box out upwards in direction of arrow.
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Rep. Gr.27 - Starter, current supply, CC
do
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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
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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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– 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 ➤
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Electrical System - Edition 05.2005
gu
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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.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
7
Starter
Caution
Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
7.1
Checking starter -B-
– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐
formation System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Body
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spec
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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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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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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
– Remove air filter housing from vehicle.
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– Unscrew securing nut -1- from lower starter securing bolt.
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– Remove wiring retainer -2-.
7. Starter
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39
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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– Unscrew securing nut -1- from upper starter securing bolt.
– Remove wiring retainer -2-.
Prote
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Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 97 .
7.2.2
Vehicles with 1.6 l FSI engine
Special tools and workshop equipment required
40
Rep. Gr.27 - Starter, current supply, CC
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AG.
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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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– Disconnect the battery ⇒ page 29 .
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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
Downloaded from www.Manualslib.com manuals search engine
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-.
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– Unscrew securing nut -1- from upper starter securing bolt.
– Remove wiring retainer -2-.
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– Remove upper securing bolt of starter -arrow-.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew earth wire securing nut -1- and place earth wire -2to one side.
– Remove starter from vehicle upwards.
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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-
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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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clip pliers -VAS 5024- .
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Rep. Gr.27 - Starter, current supply, CC
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– 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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7. Starter
Downloaded from www.Manualslib.com manuals search engine
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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– 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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– Remove lower securing bolt of starter -arrow-.
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– Remove wiring retainer -2-.
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Rep. Gr. 50 ; Body front; Noise insulation .
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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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– Remove starter from vehicle upwards.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
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7. Starter
Downloaded from www.Manualslib.com manuals search engine
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-
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Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
Prote
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48
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– Disconnect the battery ⇒ page 29 .
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Removing:
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♦ 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
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urposes, in part or in wh
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Rep. Gr. 50 ; Body front; Noise insulation .
rrectness of i
t to the co
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spec
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7. Starter
Downloaded from www.Manualslib.com manuals search engine
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
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– Remove wiring retainer -2-.
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Installing:
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– Remove upper securing bolt of starter -arrow-.
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⇒ page 97 .
50
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
7.2.5
Vehicles with 1.9 l TDI engine
Special tools and workshop
equipment required
♦ Torque wrench -V.A.G
1332-
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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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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.
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– Unlock lugs -arrows- and take cover off.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull hose -arrow- off air filter housing and take hose out.
– Pull air filter housing upwards out of brackets and remove.
– 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-.
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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.
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Rep. Gr.27 - Starter, current supply, CC
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AG.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Vehicles with 2.0 l SDI engine
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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-.
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– Push down protective cap in -direction of arrow- from solenoid
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew positive wire -1- and disconnect connector from ter‐
minal 50 -2-.
– Unscrew earth wire from starter securing bolt -arrow-.
– Unscrew starter securing bolt -arrow-.
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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
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Special tools and workshop
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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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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.
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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-
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Removing:
– Disconnect the battery ⇒ page 29 .
– Disconnect connector -arrow-.
7. Starter
Downloaded from www.Manualslib.com manuals search engine
61
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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– Unclip vacuum hose from its mounting -arrow-.
– Loosen spring-type clip -arrow- from hose -1- using spring type
clip pliers -VAS 5024- .
– Pull hose -1- off air filter housing.
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AG.
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– Unscrew air filter housing securing bolt -arrow-.
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– Open retainer -arrow- on front side of air filter housing and take
hose -1- off.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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– Loosen spring-type clip -1- using spring type clip pliers -VAS
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– Pull hose -2- off pipe union.
– Carefully lift air filter housing upwards out of the vehicle taking
into consideration the length of the hose.
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– Remove air filter housing from vehicle.
– Push down protective cap in -direction of arrow- from solenoid
switch.
7. Starter
Downloaded from www.Manualslib.com manuals search engine
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
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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
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7. Starter
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65
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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Special tools and workshop
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1331♦ Torque wrench -V.A.G
1332-
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5024-
66
Rep. Gr.27 - Starter, current supply, CC
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7.3.3
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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switch.
7. Starter
Downloaded from www.Manualslib.com manuals search engine
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.
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69
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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71
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Remove lower securing bolt of starter -arrow-.
– Remove starter from vehicle upwards.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull engine cover off upwards -arrows-.
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73
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull hose -arrow- off air filter housing and take hose out.
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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.
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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
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew positive wire -1- and disconnect connector from ter‐
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7. Starter
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77
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew starter securing bolt -arrow-.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Removing:
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79
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew air filter housing securing bolt -arrow-.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Remove air filter housing from vehicle.
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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.
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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
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83
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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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-
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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-.
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87
Jetta 2005 ➤ , Bora 2006 ➤AG. Volkswagen A
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– 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
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
7.4.5
Vehicles with 1.9 l TDI engine
Special tools and workshop
equipment required
♦ Torque wrench -V.A.G
1331♦ Torque wrench -V.A.G
1332♦ Spring-type clip pliers -VAS
5024-
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– Disconnect the battery ⇒ page 29 .
– Pull engine cover upwards -arrows A- and forwards
-arrow B-.
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7. Starter
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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.
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– Unlock lugs -arrows- and take cover off.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull hose -arrow- off air filter housing and take hose out.
– Pull air filter housing upwards out of brackets and remove.
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– 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-.
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Rep. Gr. 50 ; Body front; Noise insulation .
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Installation is carried out in the reverse order. When installing,
note the following:
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– Tighten threaded connections to specified torque settings
⇒ page 97 .
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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-
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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.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew positive wire -1- and disconnect connector from ter‐
minal 50 -2-.
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– Unscrew starter securing bolt -arrow-.
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– 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 .
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
8
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
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8. Torque settings: starter
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97
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
9
Alternator
Caution
Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
9.1
Fastening B+ wire to alternator
Caution
If the B+ wire is not secured with the prescribed torque the
following may occur:
♦ Battery not charge fully.
♦ Vehicle electrics/electronics fail completely (breakdown).
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♦ Damage to electronic components and control
to excessive voltage.
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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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– 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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-VAS 5051A- ⇒ page 281 .
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♦ Body
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– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ 27 - Starter, current supply
Alternator, 1.6 l injection engine
9.4.1
Assembly overview
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2 - Hexagon head collared
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❑ M8x50
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1 - Hexagon head collared bolt
❑ M8x108
❑ 23 Nm
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3 - Bracket
4 - Hexagon head collared nut
❑ M8
5 - Hexagon head collared
bolts
❑ M8x45
❑ 52 Nm
6 - Protective cap
7 - Hexagon head collared nut
❑ M8
8 - Cross-head screw
❑ M5x21
❑ 4.5 Nm
9 - Hexagon nut, flat
❑ M8
10 - Plain washer
❑ M5
11 - Phillips screws
❑ M4x19
❑ 2 Nm
12 - Cross-head screw
❑ M4x13
9. Alternator
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99
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
❑ 2 Nm
13 - Voltage regulator
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❑ Removing and installing voltage
regulator
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14 - Alternator
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16 - Compact bracket
❑ For alternator and air conditioner compressor
❑ Tightening sequence ⇒ page 145
17 - Tensioning element for poly V-belt
18 - Hexagon head collared bolt
❑ M8x90
❑ 23 Nm
9.4.2
Removing and installing alternator, 1.6 l
injection engine
Caution
♦ Locking pin -T10060 A-
Removing:
– Disconnect the battery ⇒ page 29 .
100
Rep. Gr.27 - Starter, current supply, CC
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AG.
♦ Torque wrench -V.A.G 1331-
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Special tools and workshop equipment required
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Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
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15 - Poly V-belt
❑ Checking ⇒ page 98 .
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull engine cover off upwards -arrows-.
– Disconnect connector of DF wiring -1- and pull protective cap
-2- off.
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Caution
urposes, in part or in wh
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– Unscrew B+ wiring -arrow- off alternator.
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Mark top and direction of rotation of poly V-belt before remov‐
ing. When installing observe direction of rotation marked on
removal. Installing opposite to the direction of rotation leads to
belt damage!
– Mark direction of rotation of poly V-belt.
– Release poly V-belt by turning the tensioning device with an
open-ended spanner AF 16 in -direction of arrow-.
– Lock tensioning element with retaining pin -T10060 A- .
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9. Alternator
Downloaded from www.Manualslib.com manuals search engine
do
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ht
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– 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
Downloaded from www.Manualslib.com manuals search engine
AG.
– Remove alternator.
agen
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– Unscrew wiring bracket -arrow- from alternator.
ht
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– Remove alternator securing bolts -arrows-.
rrectness of i
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ole,
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
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– Position wiring bracket -arrow- on rear of generator at 3
o'clock.
– Tighten threaded connections to specified torque settings
⇒ page 145 .
r
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ng
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– Start the engine and check belt running.
AG.
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– Switch off the engine.
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– Connect the battery ⇒ page 29 .
thi
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Observe instructions on connecting battery terminals
⇒ page 4 .
rrectness of i
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Drive threadedbysleeves
-A- out of the alternator
housing
for
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e
approx. 4 mm
nte
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c
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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
Downloaded from www.Manualslib.com manuals search engine
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,
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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
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10 - Protective cap
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9 - Plain washer
❑ M5
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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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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
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erm
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a
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– Disconnect the battery ⇒ page 29 .
– Remove upper securing bolt of alternator -arrow-.
ht
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– Remove noise insulation ⇒ General Body Repairs, Exterior;
Rep. Gr. 50 ; Noise insulation .
rrectness of i
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Removing:
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♦ Locking pin -T10060 A-
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by
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rig
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C
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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
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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
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Prote
cted
by
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rig
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.
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– Release poly V-belt by turning the tensioning device with an
open-ended spanner AF 16 in -direction of arrow-.
agen
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– 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
Downloaded from www.Manualslib.com manuals search engine
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his
– Disconnect connector of DF wiring -1- and pull B+ wiring -2off alternator.
do
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urposes, in part or in wh
ole,
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erm
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Drive threaded sleeves -A- out of the alternator housing for
approx. 4 mm in -direction of arrow-.
– Position wiring bracket -arrow- on rear of generator at 9
olkswagen AG
o'clock.
en AG. V
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– Tighten threaded connections
to specified torque settingsot gua
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ran
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⇒ page 145 .
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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
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Models with air conditioning system:
agen
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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
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1-
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9.5.3
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– Start the enginesand
check belt running.
sa
AG.
9. Alternator
Downloaded from www.Manualslib.com manuals search engine
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
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itte
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hole
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13 - Cross-head screw
❑ M4x13
❑ 2 Nm
ng
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iva
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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
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cu
m
en
11 - Plain washer
❑ M5
AG.
10 - Hexagon nut, flat
❑ M8
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9 - Cross-head screw
❑ M5x21
❑ 4.5 Nm
Prote
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.
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8 - Hexagon head collared nut
❑ M8
ht
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7 - Protective cap
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m
spec
atio
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wit
6 - Hexagon head collared
bolts
❑ M10x45
❑ 52 Nm
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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
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hole
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erm
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p
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f
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ng
♦ Torque wrench -V.A.G
1331-
n AG. Volkswagen AG do
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ht
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Co
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Special tools and workshop
equipment required
agen
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AG.
Prote
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by
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py
rig
ht
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C
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Removing:
– Disconnect the battery ⇒ page 29 .
9. Alternator
Downloaded from www.Manualslib.com manuals search engine
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
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t
itte
ir va
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nl
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AG. Volkswagen AG d
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– 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
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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
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m
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f
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– Unscrew air filter housing securing bolt
n AG. Volkswagen AG do
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-arrow-.
ac
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ss
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
do
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Prote
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by
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rig
ht
.
C
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– Loosen spring-type clip -1- using spring type clip pliers -VAS
5024 A- .
– Pull hose -2- off pipe union.
– Carefully lift air filter housing upwards out of the vehicle taking
into consideration the length of the hose.
9. Alternator
Downloaded from www.Manualslib.com manuals search engine
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
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Vo
by
Prote
cted
b
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c
op
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t
.
Co
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i
Rep. Gr.27 - Starter, current supply, CC
ht
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Co
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112
rrectness of i
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nform
spec
a
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wit
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urposes, in part or in wh
ole,
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is n
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tee
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t
or
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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
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itte
ir va
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AG. Volkswagen AG d
agen
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– 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
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agen
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by
AG.
Prote
cted
by
cop
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gh
t
.
Co
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i
9. Alternator
Downloaded from www.Manualslib.com manuals search engine
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
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ra
c
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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
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2-
Prote
cted
by
c
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py
rig
ht
.
C
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Tensioning roller
ht
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Co
t.
1-
rrectness of i
t to the co
nform
spec
a
t
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wit
thi
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urposes, in part or in wh
ole,
cial p
is n
mer
m
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o
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t
itte
ir va
du
p
or
nl
f
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g
n
ility
ab
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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
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n
2-
9.7.1
Assembly overview
Prote
cted
by
2 - Hexagon head collared
bolts
❑ M8x90
❑ 23 Nm
cop
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gh
t
.
Co
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1 - Hexagon head collared
bolts
❑ M8x45
❑ 23 Nm
AG.
Alternator, 2.0 l FSI turbo engine
agen
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9.7
rrectness of i
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nform
spec
at
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Tensioning roller
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Models with air conditioning
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3 - Compact bracket
❑ For alternator and air
conditioner compressor
❑ Tightening sequence
⇒ page 146
4 - Hexagon head collared
bolts
❑ M10x45
❑ 45 Nm
5 - Protective cap
6 - Hexagon head collared nut
❑ M8
7 - Cross-head screw
❑ M5x21
❑ 4.5 Nm
8 - Hexagon nut, flat
❑ M8
9 - Plain washer
❑ M5
10 - Phillips screws
❑ M4x19
❑ 2 Nm
11 - Cross-head screw
❑ M4x13
❑ 2 Nm
9. Alternator
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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-
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Rep. Gr.27 - Starter, current supply, CC
do
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116
rrectness of i
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spec
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Removing:
– Disconnect the battery ⇒ page 29 .
– Unbolt securing bolts -arrow-.
– Disconnect connector -arrow-.
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– Pull engine cover off upwards -arrows-.
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9. Alternator
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rrectness of i
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– 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.
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Rep. Gr.27 - Starter, current supply, CC
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Release poly V-belt by turning the tensioning element with an
open jaw spanner AF 16 in -direction of arrow- and lock ten‐ n AG. Volkswagen A
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o
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– 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.
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– Remove alternator securing bolts -arrows-.
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– 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
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Installing:
urposes, in part or in wh
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– Take alternator out of the vehicle.
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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
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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.
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Rep. Gr.27 - Starter, current supply, CC
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rig
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120
do
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– 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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– Tighten threaded connections to specified
⇒ page 145 .
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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
ng
Poly V-belt
AG.
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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
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2 - Multi-point socket
ed head bolt
ris
M8x60
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❑ 25 Nm
ss
3 - Multi-point socket head bolt
M8x110
❑ 25 Nm
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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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10 - Poly V-belt
❑ Checking ⇒ page 98 .
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9 - Alternator
❑ Removing and installing
alternator ⇒ page 127
do
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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
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
♦ Torque wrench -V.A.G 1331-
♦ Locking pin -T10060 A-
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f
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– Disconnect the battery ⇒ page 29 .
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– 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.
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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-.
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– Unscrew wiring bracket from alternator -arrow-.
– Take alternator out upwards.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
Caution
♦ When reinstalling used ribbed belts (poly V-belts) observe
the direction of rotation marked on removal!
♦ Ensure, before installing ribbed belt, that all ancillaries (al‐
ternator, air conditioner compressor) are secured tightly.
♦ Ensure ribbed belt (poly V-belt) is seated correctly in belt
pulley when installing.
– Drive threaded sleeves -A- out of the alternator housing for
approx. 4 mm in direction of arrow.
124
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
rrectness of i
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spec
a
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Caution
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Jetta 2005tho➤ , Bora 2006 ➤
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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
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o'clock.
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risspecified torque settings
– Tighten threaded connections hto
t o
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⇒ page 145 .
sa
or
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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
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10 - Belt pulley - Coolant pump
9. Alternator
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125
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
pe
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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
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5 - Hexagon head collared
bolts
❑ M10x65
❑ 40 Nm
AG.
4 - Compact bracket
❑ For alternator and air
conditioner compressor
❑ Tightening sequence
⇒ page 148
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3 - Hexagon head collared
bolts
❑ M8x90
❑ 20 Nm
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2 - Tensioning element for poly
V-belt
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1 - Hexagon head collared
bolts
❑ M8x45
❑ 20 Nm
un
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Assembly overview
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9.9.1
Alternator, 1.9 l TDI engine
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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
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in t
his
urposes, in part or in wh
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t
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– Disconnect the battery ⇒ page 29 .
– Pull engine cover upwards -arrows A- and forwards
-arrow B-.
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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.
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Rep. Gr.27 - Starter, current supply, CC
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Co
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128
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– Disconnect connector -2-.
urposes, in part or in wh
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is n
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– Pull vacuum hose -1- off.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
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– Unscrew charge air pipe securing bolt -arrow-.
– Disconnect connector of charge air pipe -arrow-.
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– Disconnect connector of DF wiring -1- and pull protective cap
-2- off.
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– Take charge air pipe out upwards.
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– Unscrew B+ wiring -arrow- off alternator.
– Pull fuel filter off the retainer and place to side (fuel hoses re‐
main connected).
Caution
Mark top and direction of rotation of poly V-belt before remov‐
ing. When installing observe direction of rotation marked on
removal. Installing opposite to the direction of rotation leads to
belt damage!
– Mark direction of rotation of poly V-belt.
9. Alternator
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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- .
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– 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:
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Installing:
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– Remove alternator.
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– 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
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itte
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Caution
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hole
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spec
atio
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wit
Observe instructions on connecting battery terminals
⇒ page 4 .
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–
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Tighten threadedauconnections
⇒ page 145 . ss
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ra
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– Connect the battery ⇒ page 29 .
– Start the engine and check belt running.
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– Switch off the engine.
9. Alternator
131
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
9.9.3
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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
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his
urposes, in part or in wh
ole,
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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
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Rep. Gr.27 - Starter, current supply, CC
cop
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132
AG.
Ribbed belt pulley - Alternator
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Tensioning roller
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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
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AG.
Removing and installing alternator, 2,0 l
TDI engine
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9.10.2
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11 - Poly V-belt
❑ Checking ⇒ page 98 .
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10 - Alternator
❑ Removing and installing alternator ⇒ page 133
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8 - Protective cap
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7 - Phillips screws
❑ M4x20
❑ 2 Nm
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6 - Hexagon head collared
bolts
❑ M10x45
❑ 40 Nm
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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
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133
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Removing:
Special tools and workshop equipment required
AG. Volkswagen AG d
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♦ Torque wrench -V.A.G 1331-
rrectness of i
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m
spec
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wit
es, in part or in w
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♦ Locking pin -T10060 A-
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134
Rep. Gr.27 - Starter, current supply, CC
Downloaded from www.Manualslib.com manuals search engine
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– Pull vacuum hoses off -arrow-.
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– Pull engine cover off upwards -arrows-.
thi
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– Disconnect the battery ⇒ page 29 .
Jetta 2005 ➤ , Bora 2006 ➤
Electrical
System - Edition 05.2005
. Volkswage
– Unbolt securing bolts -arrow-.
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– Disconnect connector of DF wiring -1- and pull protective cap
-2- off.
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– Pull fuel filter off the retainer and place to side (fuel hoses re‐
main connected).
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
Downloaded from www.Manualslib.com manuals search engine
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
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– 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
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136
rrectness of i
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nform
spec
at
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Installation is carried out in the reverse order. When installing,
note the following:
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Position wiring bracket -arrow- on rear of generator at 9
o'clock.
– Tighten threaded connections to specified torque settings
⇒ page 145 .
Caution
Observe instructions on connecting battery terminals
⇒ page 4 .
– Connect the battery ⇒ page 29 .
– Start the engine and check belt running.
– Switch off the engine.
9.10.3
Ribbed belt routing, 2,0 l TDI engine
Models without air conditioning system:
1-
Tensioning roller
2-
Ribbed belt pulley - Alternator
3-
Poly V-belt
4-
Ribbed belt pulley -
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
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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
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9.11
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Tensioning roller
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Special tools and workshop equipment required
9. Alternator
Downloaded from www.Manualslib.com manuals search engine
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
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by
c
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rig
ht
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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
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138
ht
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9.11.2
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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is n
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Removing:
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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.
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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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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
o
n
wit
in t
his
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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
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–
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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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
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by
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Rep. Gr.27 - Starter, current supply, CC
ht
rig
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140
do
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urposes, in part or in wh
ole,
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–
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Turn the torque wrench grip -2- through
d
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insert socket drive.
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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
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3400ac
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ed
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♦ Adapter
-VAS
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urposes, in part or in wh
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♦ Torque wrench -V.A.G
1332♦ TORX key -V.A.G 1603/1-
rrectness of i
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spec
a
t
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
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9.12.1
Voltage regulator for alternator
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9.12
rrectness of i
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spec
atio
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urposes, in part or in wh
ole,
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is n
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itte
ir va
du
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– Fit TORX key -V.A.G 1603/1- into alternator shaft.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
♦ Torque screwdriver -V.A.G 1624-
Removing:
– Remove alternator.
– Remove securing bolt and nuts -arrows- and take protective
cap off alternator.
n AG. Volkswagen AG do
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olks for voltage regulator -arrows-.
– Remove securingy Vbolts
t gu
b
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or
ac
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
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n
wit
in t
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– Remove voltage
regulator from alternator.
ho
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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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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:
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– Push protective cap into guides -arrows- until it audibly en‐
gages.
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– Tighten threaded connections to specified torque settings
⇒ page 145 .
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– 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
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10. Torque settings: alternator
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145
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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Tightening sequence for compact brack‐
et, models with air conditioning system
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10.2.2
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– Place compact bracket on cylinder block.
Before tightening to specified torque setting, screw in all bolts by
hand.
– Tighten securing bolts of compact bracket in following se‐
quence:
A - Hexagon head collared bolt, M10x45, 52 Nm, locating hole
B - Hexagon head collared bolt, M10x45, 52 Nm
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F - Hexagon head collared bolt, M10x45, 52 Nm
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Caution
In order to avoid damage to cylinder block and compact brack‐
et, you must respect the tightening sequence for the compact
bracket.
10.3.1
Torque settings
Threaded connections
Alternator to compact
bracket
Tensioning element to com‐
pact bracket
Compact bracket to cylin‐
der block
Air conditioner compressor
to compact bracket
146
Torque settings
M8x90
23 Nm
M8x90
23 Nm
M10x45
40 Nm
M8x100
23 Nm
Rep. Gr.27 - Starter, current supply, CC
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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
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Tensioning element to compact bracket
Compact bracket to cylinder block
Torque settings
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and
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10. Torque settings: alternator
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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
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♦ Observe dowel sleeve between compact bracket and cylinder
block.
♦ For the compact bracket no tightening torque must be ob‐
ng
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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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age
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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- .
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– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Drive
♦ Engine code
♦ 01 - On Board Diagnostic capable systems
♦ Engine control and/or direct diesel injection and pre-glow sys‐
tem
♦ Function
♦ Activating and deactivating cruise control system
do
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11. Cruise control system (CCS)
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
90 –
Instruments, GCI
1
Dash panel insert
General description:
Integrated in the dash panel insert are the following components:
♦ Control unit with display in dash panel insert -J285♦ Immobilizer control unit -J362♦ Speedometer
♦ Rev counter
♦ Fuel gauge
♦ Coolant temperature gauge
♦ Multi-function display
♦ Warning lamps, ⇒ page 152
To provide acoustic support to somen AofG.the
the
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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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Special tools and workshop equipment required
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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
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m
spec
atio
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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 .
ility
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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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erm
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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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– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
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♦ Diagnosis lead -VAS 5051/6A-
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♦ Body
♦ Electrical System
♦ 01 - On Board Diagnostic capable systems
♦ Dash panel insert
♦ Dash panel insert functions
♦ Adapting/renewing dash panel insert
1.2
Removing and installing dash panel in‐
sert
Note
Before removing the dash panel insert, the work procedure “Re‐
newing dash panel insert” should always be carried out in order
that the data stored in the control unit can be interrogated
⇒ page 150 .
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove steering wheel ⇒ General body repairs, interior; Rep.
Gr. 69 ; Airbag; Removing and installing steering wheel .
1. Dash panel insert
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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.
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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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8 - Brake pad wear
AG.
7 - Low coolant level
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6 - Rear fog lights
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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
2
Service interval display
2.1
Resetting service interval display
⇒ Maintenance ; Booklet 20.1
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spec
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
92 –
Windscreen wash/wipe system
1
Windscreen wiper system
Caution
Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
Note
Additional information:
⇒ Operating instructions
General description:
The wiper motor control unit -J400- and the wiper motor -V- are
joined together as one unit.
To remove the wiper blades, the wiper arms should be placed in
the “service/winter position”. The“service/winter position” is acti‐
vated within 10 seconds after ignition is switched off by pressing
windscreen wiper lever in “tip wipe”e⇒
Operating instructions for
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Fault detection and fault
ris display:
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1.1
Deactivating APP function of wiper mo‐
tors
Special tools and workshop equipment required
♦ Vehicle Diagnosis, Testing and Information System -VAS
5051A-
rrectness of i
t to the co
nform
spec
at
i
h re
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n
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in t
his
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es, in part or in w
l purpos
hole
ercia
, is n
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erm
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f
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For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
ility
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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
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
♦ Diagnosis lead -VAS 5051/6A-
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The windscreen wiper system is equipped with an APP function
(alternating park position system).
With the APP function, the wiper arm is moved up slightly once it
has reached the lowest position. This occurs every second time
the wiper system is switched off.
To fit the crank arm on the wiper motor, it is necessary for the
motor to be in the lowest park position. To ensure this position is
reached, the APP function must be deactivated (code wiper motor
control unit -J400- ).
Note
♦ The APP function cannot be activated.
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
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♦ After 100 cycles of wiper movement, the APP function is acti‐
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Special tools and workshop
equipment required
♦ Torque wrench -V.A.G
1331♦ Puller -T10130♦ Removal lever -80-200-
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.
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1. Windscreen wiper system
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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
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Removing plenum chamber cover
– Unclip plenum chamber cover -1-, starting from side, off top of
windscreen frame -arrow-.
AG.
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Rep. Gr.92 - Windscreen wash/wipe system
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– Turn thrust bolt -1- of puller -T10130- clockwise using 6 mm
spanner until wiper arm -4- is released from the shaft.
1.2.3
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– 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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-80-200- off crankriarm
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– Pull crank -2- off wiper motor shaft.
– Unscrew securing bolts -arrows- and remove wiper motor with
control unit from wiper frame.
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– Remove securing nut -1-.
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1. Windscreen wiper system
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
1.2.7
Installing wiper motor in wiper frame
– Insert wiper motor with control unit in wiper frame and secure
it in place with the securing bolts -arrows-.
– Tighten threaded connections to specified torque settings
⇒ page 178 .
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– Place crank arm of motor
not
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V
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-a- to limit stop -2- dshould
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1.2.8
Installing the windscreen wiper system
– Install wiper frame in reverse order of removal. Note when in‐
stalling that securing pin -2- of wiper frame must be inserted
in grommet -1- in bulkhead.
– Tighten threaded connections to specified torque settings
⇒ page 178 .
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– Connect the battery ⇒ page 29 .
Removing and installing wiper arms
AG.
1.3
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– Install wiper arms ⇒ page 160 .
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– Install air cowling, plenum chamber cover and plenum cham‐
ber seal in reverse order of removal.
Removing:
– Removing wiper arms ⇒ page 158 .
Installing:
Note
Securing nuts of wiper arms are not tightened to specified torque
until after wiper blade park position has been adjusted.
– Deactivate the APP function if not already done ⇒ page 155 .
– To move wiper motors to their park position, switch wind‐
screen wipers on and off with ignition on.
160
Rep. Gr.92 - Windscreen wash/wipe system
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– Fit connector to wiper motor connection and lock in position.
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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
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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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On RHD vehicles, the wiper blades are a mirror image.
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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.
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– Now adjust windscreen wiper blade park position.
1. Windscreen wiper system
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Driver's side:
Distance -A- between wiper blade and upper edge of plenum
chamber cover should be 10 mm.
– If necessary, adjust wiper blade park position by moving wiper
arm.
Removing wiper arms ⇒ page 158 .
– Tighten threaded connection to specified torque setting
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⇒ page 178 .
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Distance -B- between wiper blade and upper edge of plenum
chamber cover should be 10 mm.
– If necessary, adjust wiper blade park position by moving wiper
arm.
Removing wiper arms ⇒ page 158 .
– Tighten threaded connection to specified torque setting
⇒ page 178 .
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”. The“service/winter position” is
activated within 10 seconds after ignition is switched off by
pressing windscreen wiper lever in “tip wipe”.
– Place wiper arm in “service/winter position” by operating the
windscreen wiper lever within 10 seconds after ignition is
switched off in “tip wipe” position.
– Lift up wiper arm.
162
Rep. Gr.92 - Windscreen wash/wipe system
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AG.
♦ The aerodynamic wipers are very flexible. To lift the wiper
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Front passenger's side:
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Turn wiper blade -1- on wiper arm onto limit stop -arrow A-.
– Pull wiper blade -1- off axis of wiper arm -arrow B-.
Installing:
– Slide wiper blade onto axis of wiper arm.
– Turn wiper blade on axis of wiper arm onto stop.
Volkswa
gen AG
G.
gen Awindscreen.
– Carefully fold wiper arm back down
onto
does
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Removing and installing rain and light
detector sensor -G397-
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Removing:
urposes, in part or in wh
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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
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– Switch off ignition and all electrical consumers and pull out
ignition key.
AG.
– Pull connector -1- off rain and light detector sensor -G397-2-.
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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Installation is performed in the reverse order of installation;
when
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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.
Downloaded from www.Manualslib.com manuals search engine
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Rep. Gr.92 - Windscreen wash/wipe system
ht
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164
rrectness of i
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
olkswagen AG
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Windscreen washer system
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Additional information:
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⇒ 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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4 - Elbow
❑ Connection to left wind‐
screen spray jet
❑ Overview of washer wa‐
ter line hose couplings
⇒ page 174
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3 - Spray jet for windscreen
washer system, left
❑ Removing and installing
⇒ page 169
❑ Adjusting ⇒ page 169
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2
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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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
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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
ht
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166
do
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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
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– To unlock, turn the securing clips hose connections -3- and
-5- and pull them out of the windscreen washer pump -V5-4-.
– If necessary, collect washer fluid that leaks out with a suitable
container.
– Separate the connector -6- of windscreen washer fluid level
sender -7-.
– Take washer pump -V5- -4- upwards out of reservoir and sep‐
arate connector -2-.
– Pull headlight washer system pump -V11- -9- upwards out of
reservoir and separate connector and separate connector
-10-.
rrectness of i
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nform
spec
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The connections to the pump and hose lines are colour-coded in
order to prevent the washer water lines being incorrectly connec‐
ted to the front and rear washer water pump -V5- . The hose
fittings must be inserted into the correct colour-coded pump con‐
nections during assembly.
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2. Windscreen washer system
Downloaded from www.Manualslib.com manuals search engine
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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– Bleed the headlight washer system after completing work
⇒ page 173 .
Removing:
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Removing and installing washer pump V5-
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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
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– 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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– To unlock, turn the securing clips hose connections -3- and
-5- and pull them out of the windscreen washer pump -V5-4-.
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The connections to the pump and hose lines are colour-coded in
order to prevent the washer water lines being incorrectly connec‐
ted to the front and rear windscreen and rear window washer
pump -V59- . The hose fittings must be inserted into the correct
colour-coded pump connections during assembly.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
2.4
Removing and installing windscreen
washer spray jets
Removing:
– Push spray jets upwards -arrow A- and pull out of bonnet from
rear -arrow B-.
– Pull hose -1- off spray jet and disconnect connector -2-.
Installing:
– Fit connector -2- and hose -1- on spray jet.
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jets ⇒ page 169 .
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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
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2. Windscreen washer system
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169
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
3
Headlight washer system
Note
Additional information:
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
⇒ Operating instructions
General description:
Every fifth time the front windscreen washer system is activated
the headlights are also washed if the windscreen wiper lever on
the steering wheel is pulled for at least 1.5 seconds - provided
either dipped beam or high beam are switched on.
The “active time” of the headlight washer system can be variably
adjusted to between 0 and 12.75 seconds ⇒ page 294 .
To guarantee sound functioning, the headlight washer system
must be vented following assembly work or when activated for the
first time ⇒ page 173 .
Fault detection and fault display:
The onboard supply control unit -J519- is equipped with self-di‐
agnosis, which is designed to ease fault finding.
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
AG.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
3.1
Assembly overview - headlight washer system
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4 - Hose
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3 - Elbow
❑ Connection to left spray
jet pop-up cylinder
❑ Overview of washer wa‐
ter line hose couplings
⇒ page 174
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2 - Washer spray jet assembly
with left spray jets
❑ Removing and installing
spray jet assembly
⇒ page 173
❑ Adjusting spray jets
⇒ page 173
❑ Removing and installing
pop-up spray jet cylin‐
der ⇒ page 172
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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
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– Switch off ignition and all electrical consumers and pull out
ignition key.
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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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– Tighten threaded connections to specified torque settings
⇒ page 178 .
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– The pop-up spray jet cylinder hose must be attached to the
securing clip on the bracket.
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Installation is carried out in the reverse order. When installing,
note the following:
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Removing and installing spray jet as‐
sembly
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Pull spray jet with cover cap -1- onto stop out of bumper cover.
– Unclip cap -1- from mounting points -arrows- on washer spray
jet assembly.
– Lever locking hooks -arrow- up slightly and pull out spray jet
assembly.
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Note
The degree to which the cover cap of the spray jet is pulled down
onto the bumper cover can be adjusted using the clips on the
washer spray jet assembly. If the washer spray jet assembly is
not pulled in far enough, the cover cap will not seat correctly. If
the washer spray jet assembly is pulled in too far, the cover cap
and the bumper cover could be pushed out of shape.
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Installing:
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Electrical System - Edition 05.2005
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– Push washer spray jet assembly in pop-up cylinder until it en‐
gages.
– Fit cover cap on washer spray jet assembly and allow pop-up
cylinder to retract.
– Check the cover cap is seated correctly on the bumper cover.
– If necessary, adjust seat of cover cap by pushing washer spray
jet assembly in higher or lower position on pop-up cylinder.
– Bleed the headlight washer system after completing work
⇒ page 173 .
– Check headlight washer system spray jets and adjust if nec‐
essary ⇒ page 173 .
3.5
Adjusting headlight washer system jets
⇒ Maintenance ; Booklet 18.1
3.6
Bleeding the headlight washer system
To guarantee sound functioning, the headlight washer system
must be bled following assembly work or when operated for the
first time.
– Fill reservoir for windscreen and headlight washer systems.
– Start the engine.
– Switch “ON” the headlight.
– Operate headlight washer system several times (3-5 times, 3
seconds each time).
– Repeat this bleeding procedure until the pop-up cylinders and
spray jets are functioning soundly.
3. Headlight washer system
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173
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
4
Wash water line hose couplings
The following hose coupling types are used to connect the hoses
to pumps and spray jets and/or as points of separation:
4.1
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gether, until you hear and feel them engage.
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– To loosen the connection, rotate the lock ring -1- by 90°
-arrow- and pull off the hose connection.
– To secure the connection, push on the hose connection and
rotate the lock ring -1- -arrow- until it engages.
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Rep. Gr.92 - Windscreen wash/wipe system
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– To secure the connection, push on the hose connection and
push in the lock ring -1- until it engages.
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– To loosen the connection, pull up the lock ring -1- by approx.
1 mm -arrow- and pull off the hose connection.
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– 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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4. Wash water line hose couplings
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175
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
5
Hose repair
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl‐
ene propylene diene monomer) and heat-shrink hose are availa‐
ble as spare parts
5.1
General description
♦ The replacement parts can be found in the parts catalogue
(ETKA).
♦ Replacement parts are available for repair of both smooth and
corrugated pipes.
5.2
Repairing smooth pipe
Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re‐
paired with EPDM hose.
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– 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
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176
Rep. Gr.92 - Windscreen wash/wipe system
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– Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe
can each be pushed about 10 mm into the EPDM hose -2-.
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– 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-.
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and secure repair joints with heat-shrink hose.
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covered by about 20 mm -dimension x- of heat-shrink hose.
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5. Hose repair
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177
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
6
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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Rep. Gr.92 - Windscreen wash/wipe system
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178
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
94 –
Lights, lamps, switches - outside
1
Headlight
Note
♦ Before working on headlights, always switch off the headlights
and remove the ignition key.
♦ When dealing with complaints, it is absolutely essential that
the function and operation of the lighting system is first under‐
stood.
♦ Additional information:
⇒ Operating instructions
In the vehicle there are fitted headlights of three different manu‐
facturers:
♦ AL (Automotive Lighting)
♦ Hella
Removal and installation of the headlights and its attachments is
the same, only the removing and installing of the actuator motors
are different.
Fault detection and fault display:
The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the headlights easier.
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For fault finding, use the vehicle diagnosis,
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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.
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spec
at
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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
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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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6 - Front left turn signal bulb M5- or front right turn signal
bulb -M7❑ Bulb 12 V, PY 21 W
❑ Renewing ⇒ page 188
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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.
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– Unscrew securing screw -arrow- on upper headlight.
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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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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:
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. Volktorque
– Tighten all securing bolts to
setting
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⇒ page 238 .
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– Check headlighthorinstallation
position is central, i.e. shutlines
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are equal around
headlight.
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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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If it transpires during checking of the installation position that the
shutlines between headlight and body are uneven, the installation
position must be adjusted.
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Prote
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– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove radiator ⇒ General Body Repairs, Exterior; Rep. Gr.
66 ; Strips and trim .
182
Rep. Gr.94 - Lights, lamps, switches - outside
Downloaded from www.Manualslib.com manuals search engine
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– Check function of headlight.
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s
If the shutlines around the headlight are uneven, the installation
position must be adjusted ⇒ page 182 .
Jetta 2005 ➤ , Bora 2006 ➤
System - Edition 05.2005
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– Unscrew
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securing screw
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– Unscrew securing screw -arrow- on lower left headlight.
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– Unscrew securing screw -arrow- on lower right headlight.
AG.
– Adjust shutlines to body by pushing in or pulling out alignment
bush -arrow- on lower left or lower right headlight.
– Tighten threaded connections to specified torque settings
⇒ page 238 .
– Check and, if necessary, readjust headlight to ensure gaps are
even all round.
– Install radiator ⇒ General Body Repairs, Exterior; Rep. Gr.
66 ; Strips and trim; Removing and installing radiator .
– Check function of headlight.
Note
If a headlight is removed or adapted to the body it should always
be adjusted after installing or adapting it.
– Check headlight setting and adjust headlight as necessary
⇒ Maintenance ; Booklet 20.1
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
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– 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
Downloaded from www.Manualslib.com manuals search engine
AG.
Note
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Installing:
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– Pull dipped beam headlight bulb -2- in -direction of arrow- out
of bulb holder -1-.
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– Switch off ignition and all electrical consumers and pull out
ignition key.
or
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Place headlight dipped beam bulb -1- in the bulb holder that
the pin on the dipped beam headlight bulb lies in the recess
-arrow- of bulb holder -2-.
– Place bulb holder with dipped beam headlight bulb -1- in head‐
light and turn bulb holder with dipped beam headlight bulb in
-direction of arrow-.
olkswagein
– Place cover cap -1- in headlight recess
and
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– Check function of headlight.
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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
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1.4.2
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a and adjust headlight as necessary
– Check headlight setting
ss
⇒ Maintenance ; Booklet 20.1
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1. Headlight
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185
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull off cover cap -1-.
rrectness of i
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spec
a
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ion
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urposes, in part or in wh
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– 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
Downloaded from www.Manualslib.com manuals search engine
AG.
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Installing:
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– Take headlight main beam bulb -1- out of the headlight.
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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
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his
The diagrams show renewal of the side light bulb for the left
headlight.
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urposes, in part or in wh
ole,
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1.4.3
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– Pull, depending on the cable length, the bulb holder -1- with
the side light bulb as far it is possible out of the reflector.
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AG.
1. Headlight
Downloaded from www.Manualslib.com manuals search engine
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
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urposes, in part or in wh
ole,
cial p
is n
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1.4.4
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Note
Removing:
rrectness of i
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spec
a
t
ion
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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
cted
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
agen
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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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Co
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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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in t
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
2
Main headlights with gas discharge
bulbs
Note
♦ Before working on gas discharge headlights, always switch off
the headlights and remove the ignition. key.
Volkswag
AG
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♦ The automatic headlight range
otgas
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When dealing with
ac
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s
s
the function and operation of the lighting system is first under‐
pe
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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
ht
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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.
rrectness of i
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mat
spec
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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 .
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20 - Cover cap
❑ For front left turn signal bulb -M5- or front left turn signal bulb -M7- and for left side light bulb -M1- or right
side light bulb -M3-
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Turn cover cap -1- in -direction of arrow- and remove.
– 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
ht
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– Turn gas discharge bulb starter unit -N195- -1- in direction of
starter unit lettering “OPEN” and pull gas discharge bulb start‐
er unit -N195- off headlight.
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♦ The glass bulb may explode resulting in a risk of injury
from burning.
♦ Always wear eye protection and gloves when removing
and installing gas discharge bulbs!
– Turn bulb retainer -1- in -direction of arrow- and remove bulb
retainer.
2. Main headlights with gas discharge bulbs
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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
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Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Pull off cover cap -1-.
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The following diagrams show renewal of the main beam headlight
bulb for the left headlight.
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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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– Check headlight setting and adjust headlight as necessary
⇒ Maintenance ; Booklet 20.1
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– Check function of headlight.
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2. Main headlights with gas discharge bulbs
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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
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AG.
Note
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Installing:
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– Pull side light bulb -2- in -direction of arrow- out of the bulb
holder -1-.
rrectness of i
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– Pull off cover cap -1-.
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– Switch off ignition and all electrical
ignition key.
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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
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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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Installation is performed in the reverse order of installation; when
doing this, note the following:
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♦ Do not touch bulb glass when fitting bulbs. Fingers leave
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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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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
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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
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Installing:
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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
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When removing and installing components in visual area (con‐
nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
driver).
– 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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– 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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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:
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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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–
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Lock connector
-1- by pressing the locking clip -2- in
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-direction of arrow-.
♦ Automatic headlight range
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♦ Automatic headlight range control functions
♦ Coding automatic headlight range control
rrectness of i
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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- ).
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♦ If the values from the vehicle level sensors are outside the
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2.8.1
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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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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:
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– Switch off ignition and all electrical
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– Pull off connectorth-arrow-.
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202
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Unscrew the five securing bolts -1- and remove rear left vehi‐
cle sender -G76- -2-.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
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⇒ page 238 .
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– Check front left vehicle level sender -G76ise⇒ page 203 .
or
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urposes, in part or in wh
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Note
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– Perform basic setting of headlights ⇒
ss Maintenance ; Booklet
20.1 .
gu
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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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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
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
3
Fog lights
Fault detection and fault display:
The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the fog lights easier.
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
3.1
Assembly overview - fog light
Torque settings ⇒ page 238
1 - Front bumper
2 - Vent hose
4 - Fog light housing
❑ Removing and installing
⇒ page 205
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3.2
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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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– 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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Rep. Gr.94 - Lights, lamps, switches - outside
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– Remove fog light ⇒ page 205 .
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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 .
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3. Fog lights
207
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Removing and installing side marker
in front bumper
4.1
Removing and installing front side mark‐
er
Note
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4
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Jetta 2005 ➤ , Bora 2006 ➤
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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
Downloaded from www.Manualslib.com manuals search engine
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
5
Mirror turn signal bulb and entry light
in exterior mirror
Note
Additional information:
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
General description:
The exterior mirror turn signal bulbs are located in the housing of
the exterior mirror.
Furthermore there is located an entry light on each side in the
housing, which illuminates the entry area around the driver and
front passenger side.
1 - Driver side exterior mirror turn signal bulb -L131- or front pas‐
senger side exterior mirror turn signal bulb -L1322 - Driver side entry light in exterior mirror -W52- or front passen‐
ger side entry light in exterior mirror -W53Fault detection and fault display:
The onboard supply control unit is equipped with self-diagnosis
AG. Volkswagen AG d
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which makes fault finding easier.
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Removing and installing turn signal bulb
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For fault finding, use the vehicle diagnosis, testing andriinforma‐
se
ho
tion system -VAS 5051A- in “guided fault finding” mode.
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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 ➤
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Electrical System - Edition 05.2005
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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
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5.2
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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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– 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
Downloaded from www.Manualslib.com manuals search engine
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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:
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– Pull bulb -1- in -direction of arrow- out of the carrier -2-.
Installing:
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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
6
Tail lights
6.1
Assembly overview - tail light in side panel
Torque settings ⇒ page 238
1 - Securing nuts
2 - Left brake and tail light bulb
-M21- or right brake and tail
light bulb -M223 - Tail light housing in side
panel
❑ Removing and installing
⇒ page 212
4 - Bulb for left brake, blinker
and tail light 2 -M72- or bulb for
right brake, blinker and tail light
2 -M73-
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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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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.
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spec
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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
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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
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Removing:
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Removing and installing tail light in tail‐
gate
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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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nform
spec
a
t
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wit
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urposes, in part or in wh
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
7
Number plate lights
7.1
Removing and installing number plate
light -X-
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove securing bolts -arrows- of number plate light -X- .
– Take the lens off together with the number plate light -X- .
Number plate light -X- : Soffitte 12 V, C 5 W
Installing:
rrectness of i
t to the co
nform
spec
a
t
ion
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his
urposes, in part or in wh
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Install in reverse order of removal.
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7. Number plate lights
Downloaded from www.Manualslib.com manuals search engine
217
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
8
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.
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Rep. Gr.94 - Lights, lamps, switches - outside
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218
rrectness of i
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nform
spec
at
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Removing:
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
9
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
ho
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-J527- , it must be coded
⇒ page 227 .
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Note
♦
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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
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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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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 .
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– Remove steering column trim ⇒ General
oes
swabody repairs, interior;
n
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trim;
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and ot gua
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installing steering column switch
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♦ Airbag coil connector and return ring with slip ring -F138⇒ page 223
♦ Steering angle sender -G85- ⇒ page 224
♦ Turn signal switch ⇒ page 224
♦ Windscreen wiper switch -E- ⇒ page 225
♦ Steering column switch base ⇒ page 226
Installing:
Install in reverse order of removal.
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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♦ Steering column electronics control unit -J527- ⇒ page 221
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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
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– Unscrew bolt -1-.
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05.2005
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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
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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-.
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The
(depending on manufacturer) of
nector is shown in the following diagram:
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If a new steering angle sensor -G85- is installed, this procedure
must be followed by a “basic setting” ⇒ page 228 .
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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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♦ The “turn signal switch” comprises of the following compo‐
rrectness of i
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nents turn signal switch -E2- , headlight dipper/flasher switch
-E4- and, if fitted with cruise control system cruise control sys‐
tem switch -E45-
♦ For reasons of clarity, the steering column switch is shown with
cruise control system switch -E45- .
Removing:
– Release retaining clips -arrows- using a 1.0 mm feeler gauge
-1- and take “turn signal switch” off backwards.
Installing:
Downloaded from www.Manualslib.com manuals search engine
AG.
Rep. Gr.94 - Lights, lamps, switches - outside
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The “turn signal switch” should be heard to engage.
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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
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Removing:
Removing and installing windscreen
wiper switch -E-
es, in part or in w
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9.2.5
Electrical System
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For reasons of clarity, the steering column switch is shown in the
removed state.
– Release retaining clips -arrows- using 1.0 mm feeler gauge
-1- and take windscreen wiper switch -E- off backwards.
Installing:
Installation is performed in the reverse order of installation; when
doing this, note the following:
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The windscreen wiper switch -E- should be heard to engage.
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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
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have been removed before boring the shearVohead
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♦ Please remove the components in the specified se‐
quence.
rrectness of i
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nform
spec
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♦ 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
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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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– Remove steering column electronics control unit -J527⇒ page 221 .
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– Remove steering column trim ⇒ General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trim; Removing and
installing steering column switch trim .
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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– Connect the vehicle diagnosis, testing
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♦ Body
♦ Electrical System
♦ 01 - On Board Diagnostic capable systems
♦ Steering wheel electronics
♦ Steering wheel electronics functions
♦ Coding control unit for steering wheel electronics
9.3.2
Steering column electronics control unit
-J527- final control diagnosis
– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
Information System -VAS 5051A- .
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♦ 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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– 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
sa
s
Information System -VAS 5051A- .
♦ 01 - On Board Diagnostic capable systems
♦ Steering wheel electronics
♦ Steering wheel electronics functions
9. Steering column switch
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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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Rep. Gr.94 - Lights, lamps, switches - outside
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♦ 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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♦ The steering lock could be destroyed.
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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”
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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
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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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To remove ignition key on vehicles withisean
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always move selector lever to position
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lock
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– Remove steering column electronics control unit -J527⇒ page 221 .
– Release locking device -2- using a screwdriver.
– Pull ignition key withdrawal lock solenoid -N334- -1- in direc‐
tion of arrow and out of its mounting.
– The electrical connection will be disconnected automatically.
Installing:
– Installation is performed in the reverse order of installation;
when doing this, note the following:
Downloaded from www.Manualslib.com manuals search engine
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Rep. Gr.94 - Lights, lamps, switches - outside
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After reconnecting the battery, carry out final control diagnosis to
activate ignition key withdrawal lock solenoid -N334⇒ page 227 .
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
11
Parking aid
Note
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♦ For complaints with the parking
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The parking aid system or PDC (Park Distance Control) supports
the driver during parking maneuvers by indicating the distance
from the rear of the vehicle to the obstacle by way of acoustic
signals.
The parking aid system comprises:
♦ Parking aid control unit -J446♦ Rear parking aid warning buzzer -H15♦ Rear left centre parking aid sensor -G204♦ Rear left inner parking aid sensor -G334♦ Rear right inner parking aid sensor -G335♦ Rear centre right parking aid sender -G205Fault detection and fault display:
The parking aid system is equipped with self-diagnosis, which is
designed to simplify fault finding.
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agnosis ⇒ page 236 .
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tion system -VAS 5051A- in “guided fault finding” mode.
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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.
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Rep. Gr.94 - Lights, lamps, switches - outside
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6 - Rear centre left parking aid
sender -G204❑ In the rear bumper cover
❑ Removing and installing
⇒ page 235
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⇒ 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
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♦ 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 .
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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
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Removing and installing rear parking
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– Pull off connector -1-.
– Release securing clips -arows- remove rear parking aid warn‐
ing buzzer -H15- from retainer.
Installing:
Install in reverse order of removal.
11.5
Final control diagnosis
– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
♦ 01 - On Board Diagnostic capable systems
♦ Parking aid
236
Rep. Gr.94 - Lights, lamps, switches - outside
Downloaded from www.Manualslib.com manuals search engine
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Information System -VAS 5051A- .
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Removing:
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The rear parking aid warning buzzer -H15- is
ss fitted on the
shelf plate. It is accessible via the luggage compartment.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
♦ Parking aid functions
♦ Final control diagnosis
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11. Parking aid
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237
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
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Front left vehicle level sender -G78Rear left vehicle level sender -G76-
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
96 –
Lights, lamps, switches - inside
1
Lights and switches in engine com‐
partment
Note
The Jetta or the Bora have no lights in the engine compartment.
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Note
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Removing and installing bonnet contact
switch -F266-
♦ The bonnet contact switch -F266- is integrated into the bonnet
lock and cannot be replaced individually.
♦ If the bonnet contact switch -F266- is found to be defective,
the entire bonnet lock must always be replaced.
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– Remove front bonnet lock ⇒ General Body Repairs, Exterior;
Rep. Gr. 55 ; Bonnet; Removing and installing coupling lock;
Removing .
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1. Lights and switches in engine compartment
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239
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
2
Lights and switches in dash panel
2.1
Removing and installing light switch E1-
The following components are integrated into the light switch E1- :
♦ Fog light switch -E7♦ Rear fog light switch -E18♦ Light switch illumination bulb -L9Removing:
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– Turn grip of light switch to position “0”.
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– Hold light switch and press rotary position indicator of light
switch firmly inwards -1- and turn slightly to right -2-.
– Hold grip in this position and insert light switch in dash panel
-3-.
– Turn rotary knob to “0” release and engage switch.
240
Rep. Gr.96 - Lights, lamps, switches - inside
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– Fit connector to light switch.
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– Disconnect connector -arrow-.
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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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– 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
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Removing:
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Renew bulb:
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– Disconnect connector -arrow-.
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– Lever lens carefully out using removal wedge -VAS 3409- or
a screwdriver.
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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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Installation is carried out in the reverse order. When installing,
note the following:
2.3
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– Check functions of glove box switch. The lamp must not light
when the lid is closed.
Removing and installing glove compart‐
ment light switch -E26-
The glove compartment light switch can be found on the rear of
the glove compartment.
Removing:
– 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
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2.4
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Installing:
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– Unlock locking lug -1- and slide the switch out of the guide
-arrow-.
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– 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-.
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– Unlock locking lugs -arrows- and take adjuster and regulator
out.
Installing:
Install in reverse order of removal.
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Removing:
Removing and installing front passenger
side airbag deactivated warning lamp K145-
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– Switch off the ignition and all electrical consumers.
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– 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
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consumers.
– Remove centre vent ⇒ Heating, air conditioning system; Rep.
Gr. 80 ; Servicing heating system; remove vent; Remove cen‐
tre vent .
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spec
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– Remove connectors -arrows-.
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– Release locking lugs -arrows- and remove hazard warning
light switch.
Install in reverse order of removal.
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
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– Switch off the ignition
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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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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removal wedge -VAS 3409- or a screwdriver.
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– Disconnect connector -arrow-.
Renew bulb:
2. Lights and switches in dash panel
Downloaded from www.Manualslib.com manuals search engine
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,
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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
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– Disconnect connector -arrow-.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Release locking lugs -arrows- and remove key switch.
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Install in reverse order of removal.
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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
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wit
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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
Downloaded from www.Manualslib.com manuals search engine
AG.
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– Release locking lugs -arrows- and remove switch from the in‐
stallation frame.
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– Disconnect connector -arrow-.
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– Remove lever shell, upper part out of the closing lever ⇒ Gen‐
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐
ling door trim; Front door trim, front passenger side .
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:
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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.
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– Disconnect connector -1- and tighten securing bolts -2-.
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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.
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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
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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
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♦ 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
Downloaded from www.Manualslib.com manuals search engine
AG.
– Replace relevant door lock ⇒ General Body Repairs, Exterior;
Rep. Gr. 57 ; Front door; Removing and installing door lock .
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In the event of component defects - front door locks:
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In the event of repair, the complete component must be renewed.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
urposes, in part or in wh
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When removing and installing components
in
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area
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nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
driver).
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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
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♦ Front left window regulator switch -E40-
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The following components (in models with 2 doors) are integrated
into the switch module for the driver side window lift:
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In the event of repair, the complete component must be renewed.
♦ Button illumination bulb -L76Note
In the event of repair, the complete component must be renewed.
Removing:
– Switch off the ignition and all electrical consumers.
– Carefully lever installation frame out of door trim using removal
wedge -VAS 3409- or screwdriver -arrow-.
3. Lights and switches in front doors
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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 .
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AG.
Rep. Gr.96 - Lights, lamps, switches - inside
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– Disconnect connector -arrow-.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– 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
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3. Lights and switches in front doors
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253
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
4
Lights and switches in rear doors
4.1
Components - front door locks
The following components (depending on equipment) are inte‐
grated into the rear left door lock:
♦ Rear left door contact switch -F10♦ Rear left central locking lock unit -F222-
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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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Removing:
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grated into the rear right door lock:
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System
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Install in reverse order of removal.
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Installing:
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– Release locking lugs -arrows- and remove switch from the in‐
stallation frame.
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4. Lights and switches in rear doors
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255
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
5
Lights and switches in luggage com‐
partment
5.1
Removing and installing luggage com‐
partment light -W3-
kswagen AG
. Volrequired
Special tools and workshop equipment
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♦ 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
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by
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– Switch off the ignition and all electrical consumers.
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Removing:
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– Lever light out of the luggage compartment trim using removal
wedge -VAS 3409- or a screwdriver.
Rep. Gr.96 - Lights, lamps, switches - inside
Downloaded from www.Manualslib.com manuals search engine
AG.
256
rrectness of i
t to the co
nform
spec
at
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erm
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Disconnect connector -arrow-.
Renew bulb:
– Press contact plate -1- of the light outwards and take festoon
bulb -2- out of the socket.
– Renew festoon bulb (12 V, 10 W).
Installing:
Install in reverse order of removal.
5.2
Removing and installing rear lid lock unit
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The rear lid lock unit -F256is integrated into the tailgate lock
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– Renew tailgate lock ⇒ General Body Repairs, Exterior; Rep.
Gr. 55 ; Tailgate; Removing and installing coupling lock; Re‐
moving .
ra
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s unit -F256- is found to be defective, the entire
If the rear lid lock
tailgate lock must always be replaced.
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5. Lights and switches in luggage compartment
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257
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
6
Lights and switches in roof trim
6.1
Removing and installing front interior
light and reading light (vehicles with no
sliding sunroof)
The following components are integrated in the interior light and
reading light:
♦ Front interior light -W1♦ Left centre reading light -W39♦ Left centre reading light -W40Note
The interior light and reading light as well as the switches for the
interior light and reading light are connected together and can not
be separated. When repairing, renew the complete component.
6.1.1
Removing and installing front interior
light and reading light
Special tools and workshop equipment required
ility
ab
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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
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♦ 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-.
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Install in reverse order of removal.
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Installing:
rrectness of i
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spec
a
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Replace front interior light -W1-
Special tools and workshop equipment required
♦ Removal wedge -VAS 3409-
6. Lights and switches in roof trim
Downloaded from www.Manualslib.com manuals search engine
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:
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– Carefully lever lens for interior lightedout
ris
-VAS 3409- or screwdriver -arrow-.
o
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– 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
Downloaded from www.Manualslib.com manuals search engine
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– Fit the contact to the new festoon bulb (12 V, 10 W).
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– Pull contact -arrow- off defective festoon bulb.
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Turn bulb holder -arrows- of the defective reading light for 90°
to the left.
– Take the holder with the bulb out of the reading light.
– Pull glas base bulb carefully out of the holder.
ksW).
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– Renew glas base bulben(12
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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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♦ Sunroof switch -E8-
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The interior light and reading light as well as the switches for the
interior light and reading light are connected together and can not
be separated. When repairing, renew the complete component.
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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
Downloaded from www.Manualslib.com manuals search engine
261
Jetta 2005 ➤ , Bora 2006 ➤
n AG. Volkswagen AG do
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Electrical System - Edition 05.2005
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Note
When removing and installing components in visual area (con‐
nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
driver).
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.
C
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– 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
Downloaded from www.Manualslib.com manuals search engine
AG.
– Take the interior light out of the headliner console.
agen
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– Unbolt securing bolts -arrow-.
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Removing:
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♦ Removal wedge -VAS
t gu
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V
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s
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Remove connectors -arrows-.
Installing:
Install in reverse order of removal.
6.2.2
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Removing and installing sunroof switch
-E8un
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Removing:
– Remove interior light ⇒ page 261 .
rrectness of i
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f
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m
spec
atio
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wit
es, in part or in w
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, is n
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– Disconnect connector -arrow-.
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Install in reverse order of removal.
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6.2.3
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Installing:
thi
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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
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263
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
♦ Removal wedge -VAS 3409-
Note
When removing and installing components in visual area (con‐
nectors, covers, trims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
driver).
Removing:
– Switch off the ignition and all electrical consumers.
– Carefully lever lens for interior light
removal wedge
swausing
olkout
gen AG
en AG. V
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-VAS 3409- or screwdriver
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agen
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Rep. Gr.96 - Lights, lamps, switches - inside
ht
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264
rrectness of i
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atio
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n
thi
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urposes, in part or in wh
ole,
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ir va
du
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ility
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– 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
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es, in part or in w
l purpos
hole
ercia
, is n
m
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a
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6.2.4
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– 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:
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Prote
cted
by
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.
C
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– Renew glas base bulb (12 V, 5 W).
ht
rig
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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
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agen
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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
Downloaded from www.Manualslib.com manuals search engine
AG.
Installing:
agen
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Prote
cted
by
c
o
py
rig
ht.
C
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– Disconnect connector -arrow-.
ht
rig
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t.
– Release locking lugs -arrows- and remove interior light and
reading light from the headliner.
do
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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
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ng
6.3.1
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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-
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cted
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♦ Rear left reading light -W11-
ht
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♦ Rear left footwell light -W45-
do
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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
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ng
– Pull glas base bulb carefully out of the holder -arrows-.
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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
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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
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rrectness of i
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m
spec
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wit
es, in part or in w
l purpos
hole
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, is n
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– Pull the entire complete trim -1- (including lens and reflectors)
-arrows- vertically downwards and out from the interior and
reading light.
Downloaded from www.Manualslib.com manuals search engine
AG.
Rep. Gr.96 - Lights, lamps, switches - inside
agen
lksw
Vo
by
268
Prote
cted
by
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Install in reverse order of removal.
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Installing:
ng
– Unlock connectors -1- and -2- and pull both connectors off.
thi
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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
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erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
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ng
–
AG. Volkswagen AG d
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Switch off the ignition and all electrical consumers.
b
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is
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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
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py
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AG.
Prote
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by
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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
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ara
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ra
c
– Disconnect connector -arrow-.
Downloaded from www.Manualslib.com manuals search engine
AG.
Rep. Gr.96 - Lights, lamps, switches - inside
agen
lksw
Vo
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Prote
cted
by
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py
rig
ht.
C
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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
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pt
ce
olk
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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
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wage
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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
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ng
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his
Note
ility
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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
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ht
.
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Downloaded from www.Manualslib.com manuals search engine
do
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um
en
6. Lights and switches in roof trim
271
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
7
Lights and switches in centre console
7.1
Removing and installing TCS and ESP
button -E256-
Removing:
– Switch off the ignition and all electrical consumers.
– Take bellow carefully off centre console -arrows-.
– Unbolt securing bolts
– Remove connectors -arrows-.
AG.
Downloaded from www.Manualslib.com manuals search engine
agen
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Vo
by
Prote
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by
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rig
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.
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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
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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
e
t
a
itte
v
i
r
du
p
or
nl
f
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g
n
– Take mounting frame with ashtray out of the centre console.
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is
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-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
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py
Co
t.
es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
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t
a
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v
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AG. Volkswagen AG d
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Prote
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7. Lights and switches in centre console
Downloaded from www.Manualslib.com manuals search engine
273
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
8
Horn
8.1
Removing and installing treble tone horn
-H2- and bass tone horn -H7Note
♦ The treble tone horn -H2- and the bass tone horn -H7- are
controlled in parallel from the onboard supply control unit J519- .
♦ The procedure for removal and installation of treble tone horn
-H2- and bass tone horn -H7- is the same and is therefore
described for just one horn.
♦ The horns are installed to the left and the right of theAGlongitu‐
. Volkswagen
dinal members.
Removing:
AG do
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ot g
ua
ran
tee
or
ac
urposes, in part or in wh
ole,
cial p
is n
mer
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ot p
o
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erm
te o
a
itte
ir v
du
p
or
nl
f
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ng
ility
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ce
– Switch off the ignition and all
agen
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ed
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o
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t
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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
Downloaded from www.Manualslib.com manuals search engine
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- .
agen
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cop
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t
.
Co
py
i
Checking treble tone horn -H2- and bass
tone horn -H7-
ht
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py
Co
t.
8.2
do
c
um
en
Installing:
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
9
Immobilizer
General description:
The vehicle is equipped with an immobilizer of the 4th generation.
Modifications by comparison with the immobilizer of the 3rd gen‐
eration:
♦ An adaptation of components of other group marks to Volks‐
wagen vehicles is no longer possible.
♦ Vehicle keys are preprogrammed with a base code by the
manufacturer. This base code includes a specific manufactur‐
ers code. It is only possible to learn a key of a vehicle if they
are programmed with the right manufacturers code.
Fault detection and fault display:
olkswamakes
gen AG fault
AG. V
The immobilizer is equipped with self-diagnosis
which
does
agen
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finding easier.
gu
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ris
For fault finding, use the vehicle
diagnosis, testing and informa‐
tho
u
tion system -VAS 5051Ain
“guided fault finding” mode.
sa
s
pe
rm
itte
d
un
le
Immobilizer control unit -J362es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
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f
o
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m
spec
atio
h re
n in
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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9.1
ara
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– 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
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9.3.1
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– Removing and installing the radio container (transmission unit
for radio-controlled central locking) for the ignition key ⇒ Gen‐
eral Body Repairs, Exterior; Rep. Gr. 57 ; Central locking;
Removing and installing battery for the (folding) main key with
radio remote control .
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– 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
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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
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Rep. Gr.96 - Lights, lamps, switches - inside
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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
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Activating and deactivating anti-theft
alarm system
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10.1
Activating anti-theft alarm system:
The anti-theft alarm system is switched on automatically when the
vehicle is locked. The system is then immediately armed.
Note
Completely close all windows and doors before locking the vehi‐
cle to prevent the anti-theft alarm system triggering an unneces‐
sary alarm.
Deactivating anti-theft alarm system:
– Unlock the driver door.
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
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t
or
u
er is removed ⇒ page 277 .
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Removing:
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– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove glove compartment ⇒ General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trim; Removing and
installing glove compartment; Removing .
– Unscrew the securing bolts -1- and remove vehicle inclination
sender -G384- from the bracket.
– Release the connector -2- and pull it away from the vehicle
inclination sender -G384- .
Installing:
Install in reverse order of removal.
278
Rep. Gr.96 - Lights, lamps, switches - inside
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AG.
Additional information:
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Central locking and anti-theft alarm sys‐
tem aerial -R47-
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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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♦ Drill -VAS 5134-
♦ Twist drill ∅ 6 mm
♦ Pop rivet pliers -VAS 5072-
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Note
The anti-theft alarm system must be deactivated before the alarm
horn is removed ⇒ page 277 .
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
10. Anti-theft alarm system (ATAS)
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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
.
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– 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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– Fit connector to the alarm horn -H12- .
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– Perform measures for corrosion protection ⇒ General Infor‐
mation; Body Repairs, General Body Repairs .
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
97 –
Wiring
1
Vehicle Diagnosis, Testing and Infor‐
mation Systems
WARNING
♦ During testing or measuring operations using a vehicle di‐
agnosis information system, there is a risk of serious or
even fatal injury!
♦ If the vehicle diagnosis information system is lodged in the
activity area of an airbag during a testing or measuring
operation, a triggered airbag can result in serious or even
. Volkswagen AG
fatal injury!
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♦ During testing and measuring
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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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– Connecting vehicle Diagnosis, Testing and Information Sys‐
tem -VAS 5052- ⇒ page 282 .
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Connecting vehicle Diagnosis, Testing
and Information System -VAS 5051AAG.
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– Connecting Vehicle Diagnosis, Testing and Information Sys‐
tem -VAS 5051A- ⇒ page 281 .
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⇒ 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,
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– 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- :
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Only these leads are to be used for diagnosis, as they are the only
ones fitted with CAN lines and therefore allowing CAN diagnosis
and/or CAN communication.
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♦ Diagnosis lead -VAS 5051/5A- (3 m)
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♦ Diagnosis lead -VAS 5051/6A- (5 m)
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
2
Removing and installing fuse holder
2.1
Removing and installing fuse holder on
left of dash panel
Special tools and workshop equipment required
♦ Removal wedge -VAS 3409-
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When removing and
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nectors, covers,sstrims etc.) apply a commercial adhesive tape
Note
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Caution
Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
Removing:
– Disconnect the battery ⇒ page 29 .
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– Remove storage compartment on driver side ⇒ General body
repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
rrectness of i
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m
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where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
driver).
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2. Removing and installing fuse holder
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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– Remove lateral cover -1- out of the dash panel, by inserting
the removal wedge -VAS 3409- or a screwdriver in the recess
-2- and lever off cover -1- in -direction of arrow-.
– Take fuse assignment card -1- out of fuse holder -2-.
ng
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AG.
Rep. Gr.97 - Wiring
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Install in reverse order of removal.
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Installing:
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– 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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Removing:
– Disconnect the battery ⇒ page 29 .
– Remove storage compartment on driver side ⇒ General body
repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
– Unscrew bolts -arrows- of the bracket.
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– Pull relays -arrows- out of the relay carrier.
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Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
AG.
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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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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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The onboard supply control unit -J519- and the
a
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attached to the onboard supply control unit,s on left of dash
urposes, in part or in wh
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♦
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
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carry out the procedure
⇒ “5.1.2 Coding onboard supply control unit J519 ”,
page 293 to read out the stored codes.
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove cover, footwell, on driver side ⇒ General body re‐
pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
– 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
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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
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may only be pulled
“OPEN”.
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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
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spec
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urposes, in part or in wh
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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:
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are fitted “correctly”.
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3. Removing and installing relay carrier
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287
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
4
Electronics boxes
4.1
Removing and installing electronics box
on left in engine compartment
rrectness of i
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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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– 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-.
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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
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en
urposes, in part or in wh
ole,
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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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Whether the additional
vehicle equipment.
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i
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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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Rep. Gr.97 - Wiring
ht
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290
thi
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– 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
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ht
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urposes, in part or in wh
ole,
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erm
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p
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4. Electronics boxes
Downloaded from www.Manualslib.com manuals search engine
291
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
5
Control units
5.1
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Onboard supply control unit -J519un
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Note
♦ The onboard supply control unit -J519- and the relay carrier
rrectness of i
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spec
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wit
♦ Additional information:
es, in part or in w
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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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♦ Turn signal control
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♦ Exterior light control
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♦ Electrical load management
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The onboard supply control unit -J519- is responsible for the fol‐
lowing in the vehicle:
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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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.
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cted
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Removing and installing onboard supply
control unit -J519ht
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5.1.1
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For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
rrectness of i
t to the co
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spec
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♦ 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
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unit
unit functions
♦ Modifying headlight cleaning system
5.2
Data bus diagnostic interface -J533-
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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-
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Note
If the data bus diagnostic interface -J533- is to be removed, first
carry out the procedure
⇒ “5.2.1 Renewing data bus diagnostic interface J533 ”,
page 295 , so that access can be gained to the codes stored
within.
Fault detection and fault display:
The data bus diagnostic interface -J533- is equipped with selfdiagnosis, which is designed to ease fault finding.
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
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
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en
urposes, in part or in wh
ole,
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♦ Onboard
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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
5.2.1
Renewing data bus diagnostic interface
-J533-
– Connect Vehicle Diagnosis, Testing and Information System
-VAS 5051A- ⇒ page 281 .
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
Information System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Body
♦ Electrical System
♦ 01 - On Board Diagnostic capable systems
♦ Data bus diagnostic interface
♦ Data bus diagnostic interface functions
♦ Renewing data bus diagnostic interface
5.2.2
Removing and installing data bus diag‐
nostic interface -J533-
Removing:
Note
– 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:
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Note
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Central control unit for convenience sys‐
tem -J393agen
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Install in reverse order of removal.
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es, in part or in w
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hole
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that access can be gained to the codes stored within.
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Before removing
data
bus
diagnostic
interface
-J533nte , it is es‐
is
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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
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y li
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ce
♦ Rear lid lock
urposes, in part or in wh
ole,
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is n
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♦ Radio-wave receiver
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Fault detection and fault display:
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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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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cted
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Note
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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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AG.
Prote
cted
by
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py
rig
ht.
C
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Coding convenience system central
control unit -J393-
ht
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5.3.2
rrectness of i
t to the co
nform
spec
at
i
h re
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n
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in t
his
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en
es, in part or in w
l purpos
hole
ercia
, is n
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erm
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t
a
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i
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s
Installing:
Volkswagen AG
does
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– Connect Vehicle Diagnosis, Testing and Information System
-VAS 5051A- ⇒ page 281 .
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
Information System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Body
♦ General Body Repairs
♦ 01 - On Board Diagnostic capable systems
♦ Comfort system
♦ Comfort system central control unit functions
♦ J393 - Coding convenience system central control unit
5. Control units
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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
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ce
♦ Activating and deactivating
delay when driver's door is opened”
urposes, in part or in wh
ole,
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is n
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erm
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ng
♦ Activating and deactivating
mote control unit”
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“comfort operation via radio re‐by V
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t
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ra
a
“anti-theft alarm system
c
ss - alarm
♦ “Sensitivity of interior monitoring system”
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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
Downloaded from www.Manualslib.com manuals search engine
AG.
cop
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t
.
Co
py
i
– Connect Vehicle Diagnosis, Testing and Information System
-VAS 5051A- ⇒ page 281 .
agen
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Vo
by
Convenience system central control unit
-J393- - Read alarm sources of anti-theft
alarm system
ht
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t.
5.3.4
do
c
um
en
♦ 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/
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⇒ “5.4.3 Final control diagnosis trailer detector controleunit
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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
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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:
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– Tighten threaded connections to specified
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⇒ page 307 .
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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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♦ Coding trailer detector control unit
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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
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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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301
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
6
Wiring harness and connector re‐
pairs
6.1
Safety instructions
Caution
For repair work on airbag and seat belt tensioner wiring har‐
nesses, only contacts, connectors and wiring designed specif‐
ically for this purpose may be used ⇒ Parts catalogue (ETKA)!
♦ Observe country-specific regulations.
♦ Observe vehicle stickers indicating high voltage components.
Before carrying out repairs, discharge residual voltage.
♦ Wires from airbag and belt tensioner wiring harness must only
AG. Volkswagen AG d
be repaired using wiring harness repair set -V.A.Gw1978agen .
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⇒ Operating instructions wiring harness repair
ed
is
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⇒ General body repairs interior; Rep. Gr.
au 69
ss
General notes concerning repairs to ve‐
hicle electrical system
urposes, in part or in wh
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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
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♦ Perform wiring harness repairs
Vol only with yellow wires. Mark
gu
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repair locations with yellow
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or
Supplementary notes on repair of CAN
bus wiring
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♦ An unshielded two-wire line -1- and -2- with a cross section of
0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
♦ The colour codes of the CAN bus wiring can be gleaned from
the following table:
Drivetrain CAN, high
Convenience CAN, high
Infotainment CAN, high
CAN Low wire (all)
orange/black
orange/green
orange/violet
orange/brown
♦ Perform wiring harness repairs only with yellow wires. Mark
repair locations with yellow tape.
♦ When repairs are performed, both bus wires must have the
same length. When wires -1- and -2- are twisted together, the
twist spacing should be A=20 mm.
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♦ No section of wiring greater than B=50 mm, e.g. in the vicinity
of heat-shrink sleeves -arrow-, should not be twisted.
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♦ 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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303
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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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
olkswagen AG
en AG. V
7
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Renewal
of aerial wiring
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7.1
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A new repair
concept has been developed for repair
work
on aer‐
eo
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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
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♦ Aerial wires must not be repaired, but if repair is required, they
must be replaced only by connecting wires and adapter cables
offered as genuine parts.
♦ Replacement parts can be found in the electronic parts cata‐
logue: Special catalogue; Electrical connections; Genuine ac‐
cessories; Subgroup 35 from illustration No. 035-20.
♦ These genuine parts are suitable for all aerial wires and wire
diameters which may need to be replaced.
♦ No provision has been made for replacement of individual
aerial connectors in the event of repair.
♦ The wires can be used retroactively for all VW models, with all
installed aerial wire diameters.
do
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♦ 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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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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305
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‐
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ing wire -2- at the calculated length as genuine
ris parts from the
ho
parts catalogue (ETKA).
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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
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– 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
8
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
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8. Torque settings: Cables
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307
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