Service

Workshop Manual
Jetta 2005 ➤ Bora 2006 ➤
Engine ID

4-cylinder Injection engine (1.6 l engine, direct injection)
BLF Edition 08.2005

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Service Department. Technical Information

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

Repair Group
00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling system 20 - Fuel supply system 24 - Mixture preparation, Injection 26 - Exhaust system 28 - Ignition system
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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 MEX5R007820

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Jetta 2005 ➤ , Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1.1 1.2 1 1.1 1.2 1.3 1.4 1.5 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 3 3.1 4 4.1 4.2 4.3 1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5 1 1.1 1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
olksw en AG. V . . .a.ge Removing and installing engine .n .A .G .d .o .e.s n ............................... ag ksw l ot o V y Removing engine .u. ......................... b . . . . . . . . . . . . . . . . . . . . . . . .g ar. d an e tee ris to engine and gearbox support VAS 6095 Securing engine .................... o h or ut a.c . . . . . . . . . . . . . . . . . . . . . a Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s s
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1
1 1 2

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.... .... .... .... Checking and adjusting assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3
3 4 14 16 20 22 24 25 26 27 29 31 36 36 38 40 43 50 52 52 53 53 54 55 56 57 59 63 67 69 74 76 76 78 79 80 81 83 83 84

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt drive - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain drive - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing control housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel end - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten bolt for poly V-belt sprocket - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and conrods - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve gear - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of the lubrication system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Jetta 2005 ➤ , Bora 2006 ➤ . Volkswage AG gen AGinjection) n does 08.2005 wa 4-cylinder Injection engine (1.6 l engine, direct - Edition no olks 1.3 1.4 1.5 1.6 1.7 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 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 4.3 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
yV db ise r Oil cooler - Assembly overview . tho au s Removing and installing oil sump s
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........... ........... Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system - body side - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system engine side (thermostat side) - Assembly overview . . . . . . . . . . . . Parts of cooling system engine side (coolant pump side) - Assembly overview . . . . . . . . Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check cooling system for leaks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel fliter - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator pedal module - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activated charcoal filter system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air cleaner/engine cover - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine cover with air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake manifold - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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86 87 89 92 94 96 97 98 99 99 102 105 106 108 110 113 115 115 115 116 118 120 123 123 126 126 127 127 127 129 130 139 144 144 145 145 147 147 148 148 150 150 151 152 153 160 160 161 162

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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Contents

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. . . . . . . . . . . .. . . . . . . . . . .Exhaust system . . . . . . .. . . . . . . . . . . . . . . Removing and installing injectors . . . . . . . . . . . .n . . . . k. . . . . . .g . . . . . . . Check vacuum reservoir in intake manifold for leaks . . . . . . . . ..5 1. . . . . . . . . . . . . . . . . . . . a c ss Assembly overview . . .3 1. . . . . . . . . . . . . . . . . . . . . .6 2 2.4 1. . . . . . . . . . . . . . . . . . . . . . . . . a. . . . . . . . . . . . . . C op yi Contents iii . . . . . . . Removing and installing engine control unit . Removing and installing exhaust gas recirculation valve N18 . . . . . . direct injection) . . . . .10 1. . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . olkswagen AG en AG. Checking components .2 2. . . . . . . . . . . . . Removing and installing fuel rail . . . . . . . . ot g Vol by ua es. . . . . . . . . . . . . . . . .r a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalytic converters and attachments . . . . . . . . . . . . . . . . . Checking intake air preheating . . . .. . . . . . . . . . .. . . . . . . . .1 1. . . .. . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1. . .. .1 2. . . . . . agen lksw Vo by AG. . . . . . . . . . . . . . . . Reading and erasing engine control unit fault memory . . . . . . . . . . . .Assembly overview . . . . . . Engine control unit . . . . . . . . . . . .6 l engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Edition 08. . .12 1. . . . . .11 1. . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . .1 2. . .o . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark plug test data . . . . . .Exhaust gas recirculation system . . . .. . . . . . . Connecting and disconnecting front and rear silencers . . . . .. . . . . . . . . . . . . . . . . . . .1 3. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1. . . . . . Bora 2006 ➤ 4-cylinder Injection engine (1. . . . . . . . . . . . . . . . .2 1 1. . . . . . . . . . . . . . . . . . . Check function of intake manifold flap . . . . . . . .. . . . . . . . . . . . Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . .. . in part or in w l purpos hole ercia . . . . . . . . . . . . . V ra . . . . . . . .. . . . . .Ignition system . . . . . . . . . .9 1. . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly overview . . . . . . . . . . . . . . .ignition system . is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en ht rig py Co t.2 1. . Removing and installing pre-catalytic converter with exhaust manifold . . . .Jetta 2005 ➤ . . . . . . . . . . . ed Repairing ignition tee rissystem . . . . . . . . . . . . . . . . . . . . . . . . . . .13 2 2. . . . . . . . . . . . . . . . . . . . . . .. ility ab y li an pt ce 164 167 168 170 173 175 175 176 176 178 178 179 183 184 186 186 188 190 192 194 194 195 197 197 198 198 199 26 . . . . . . . . . . . . . d . . . . . . Prote cted by c o py rig ht . . . . . . . . .. . . Exhaust gas recirculation system . . . . . Fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Removing and installing intake manifold . . . . . . . . . . . . . Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . n ho t u Safety precautions .1 1. . . . . . . . . . .. . . . . . . . .. . . . . . . 197 28 . . . . . . . .o. . . . . . . . .. . . . . . . . . . . . . . . .2005 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 183 es. . . . .Assembly overview . . . . .sw . . . . Silencer with mountings . . . . . . . .. . . . . . . . . . . . . . . .3 3 3. . .2 1 1. . .. . . . . . . . . . . .

C op yi . agen lksw Vo by AG. Prote cted by c o p yri gh t . in part or in w l purpos hole ercia .Edition 08.2005 es. is n m ot com pe rm itte d un le n AG. Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en iv Contents ht rig py Co t. direct injection) .Jetta 2005 ➤ .

The engine code is also on the vehicle data plate and on the crankcase above the gearbox.Jetta 2005 ➤ . Technical data ht rig py Co t. The engine number consists of up to nine characters (alphanu‐ meric). proceed as follows: ho w olks – Open the cover -1.1 Engine number Engine code and engine number can be found on the sticker -arrow. observe the following: – Install the battery and observe the respective measures after connecting the battery ⇒ Electrical system. c o p yri gh t. Gr. Models with petrol engine . Remov‐ ss ing and installing battery. direct injection) .6 l engine. C op yi 1 .on the control housing. urposes. Gr. 27 . During this step. the “serial number”. If more than 999. and the second part (6 characters). cial p is n mer m ot p o c erm or e t a itte v i r d p – Removing battery ⇒ Electrical system. Re‐ moving and installing battery. Bora 2006 ➤ 4-cylinder Injection engine (1. Rep. Vehicles with petrol engine . the first of the six characters is replaced with AG. Prote cted by – Read the engine code and the serial number on the left of the cylinder block -arrow-. agen o yV If there is no sticker and you need the “engine codes” and d b the ise r “serial number”. un le t au es n ot g ua ran tee or ac ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng Install in reverse order of removal.Edition 08.999 engines with the same engine code are produced. agen lksw Vo by AG.and battery carrier. 1.2005 00 – 1 Technical data Technical data Engine number ⇒ page 1 Engine data ⇒ page 2 1. in part or in wh ole. – Remove bolts -arrows. Rep. Volkswagen AG d a letter. The first part (maximum 3 characters) makes up the “engine code”. 27 .of the electronics box and remove the cable -2-.

in part or in w l purpos hole ercia . Bora 2006 ➤ 4-cylinder Injection engine (1. is n m ot p om c r erm o e t a itte riv du p or nl f e g n A agen Output 85/6000 ksw l o yV Torque 155/4000 db ise r Bore 76. Prote cted by c o p yri gh t.Technical data ht rig py Co t. C op yi .5 tho au s s Stroke 86. direct injection) . ignition Motronic MED 9. Volkswagen AG d oes not gu ara nte eo ra c ility ab y li an pt ce Engine code Manufactured Emissions fulfil Displacement es. agen lksw Vo by AG.Edition 08.10 Mixture formation homogeneous Variable valve timing yes Knock control 1 sensor Lambda regulation 2 probes Three-way catalytic converter yes Exhaust gas recirculation yes Secondary air system no Electronic power control yes cm3 kW at rpm Nm at rpm ∅ mm mm rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 2 Rep.2 Engine data BLF 08.5. 95 Unleaded Injection.00 .05 ▸ EU 4 Standard 1598 G.2005 1. Gr.9 Compression ratio 12.Jetta 2005 ➤ .6 l engine.0 Valves per cylinder 4 RON min.

2005 ility ab y li an pt ce Removing and installing engine Removing and installing engine rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Removing engine ⇒ page 4 Fastening the engine to the assembly stand ⇒ page 14 Installing engine ⇒ page 16 Checking and adjusting assembly mounting ⇒ page 20 Assembly mounting ⇒ page 22 Special tools and workshop equipment required r fo ng ♦ Hose clamp to Ø 25 mm -3094ht rig py Co t.G 1331♦ Torque wrench -V. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG. 1. C op yi ♦ Multi-point bit 19 mm -3077♦ Multi-point bit 18 mm -3353- ♦ Torque wrench -V.6 l engine. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s Jetta 2005 ➤ .A.G 1332♦ Engine and gearbox jack V.G 1383 A- agen lksw Vo by AG.A.Edition 08. Bora 2006 ➤ 4-cylinder Injection engine (1. Removing and installing engine 3 . in part or in wh ole.A.10 – 1 urposes. direct injection) . Prote cted by c o p yri gh t.

2005 wagen AG olk en AG. Obtain radio code first if necessary. Therefore first check whether a coded radio is fitted. Prote cted by c o p yri gh t.Jetta 2005 ➤ . Bora 2006 ➤ 4-cylinder Injection engine (1. ♦ All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.. ♦ Pull engine coolant hoses off with spring-type clip pliers -VAS 4 Rep.1 Note Removing engine ♦ In subsequent work sequences the battery earth strap must be disconnected.6 l engine. in part or in wh ole. ♦ The engine is removed downwards together with the gearbox. ♦ Observe rules for cleanliness ⇒ page 115 . Gr. testing and information system VAS 5051- ♦ or vehicle diagnosis and service information system -VAS 5052♦ Double ladder -VAS 5085♦ Drip tray -VAS 6208♦ Engine bung set -VAS 6122♦ Grease -G 000 100♦ Engine bracket -T40075- un le ss ag ksw Vol y b ed ris o h t au does not gu ara nte eo ra c ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 1. agen lksw Vo by AG. C op yi .Removing and installing engine ht rig py Co t. 5024 A. cial p is n mer m ot p o c erm or e t a itte v i r d p ♦ Vehicle diagnosis.10 . V ♦ Spring-type clip pliers -VAS 5024 Aurposes. direct injection) -sEdition 08.

g. Rep. for fuel. hydraulic system.of the electronics box and remove the cable -2-. Rep.off. sa ac ♦ Ensure that there is sufficient clearance to all moving or hot components. brake liquid. Gr.Jetta 2005 ➤ .2005 Caution s no ks When doing any repair t gu compart‐ Vol work. – With ignition switched off disconnect battery earth strap ⇒ Electrical system. – Remove engine cover with air cleaner ⇒ page 161 . activated char‐ coal canister system.from air duct -2-. ht rig py Co t. especially in the engine by ara condi‐ d ment. agen lksw Vo by AG. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng s ♦ All wirings (e. Vehicles with petrol engine . direct injection) .6 l engine. – Removing battery ⇒ Electrical system. Prote cted by c o p yri gh t. ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Disconnect rubber bellows -1. – Remove bolts -arrows.Edition 08.and battery carrier. 27 . – Open the cover -1. pay attention to the following due to the cramped e nte ris o eo tions: h ut r n AG. Removing and installing engine 5 . Volkswagen AG do e wage es. Disconnecting and connecting the battery . coolant and refrigerant liquid. Bora 2006 ➤ 4-cylinder Injection engine (1. C op yi 1. Remov‐ ing and installing battery. vacuum) and electrical wirings are to be installed in the original way. – Release both locking devices and take air duct -2. 27 . Gr. in part or in w l purpos hole ercia .

Gr. ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en – Unscrew intake connecting piece on lock carrier -arrows-. 6 Rep. in part or in w l purpos hole ercia . Bora 2006 ➤ 4-cylinder Injection engine (1. Rep. Gr. – Bring lock carrier into service position ⇒ General body repairs. 50 . Gr.2005 – Remove warm air collector plate -arrows-. exterior. Noise insulation .. agen lksw Vo by AG. – – Remove right and left front part of wheel housing liner ⇒ Gen‐ eral body repairs. Gr. Rep.Removing and installing engine ht rig py Co t. Body front.Edition 08.. – Support the lock carrier on the other side using the multi-point bit 19 mm -3077. C op yi . – Drain coolant ⇒ page 102 . exterior.Jetta 2005 ➤ . es.10 . Rep. 66 . direct injection) . – Support the lock carrier on one side using the multi-point bit 18 mm -3353. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Remove pre-catalytic converter with nte is exhaust pipe from ex‐ r o eo h haust manifold -arrows-. AG. For subsequent work sequences the lock carrier must be sup‐ ported on the longitudinal member. 50 . Wheel housing liner.6 l engine. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Remove noise insulation ⇒ General body repairs. Lock carrier service posi‐ tion . Removing and installing front wheel housing liner . Prote cted by c o py rig ht . exterior.

Bora 2006 ➤ 4-cylinder Injection engine (1.(press ho locking ring inwards). 1.off activated charcoal canister and wind‐ screen washer system reservoir -arrow. direct injection) .to heat exchanger on bulk‐ head. Prote cted by c o py rig ht .-6-.6 l engine.(press locking ring inwards) ksw not l o V gu collect escaping fuel with a cloth.and hose -5. Before loosening lines. by a r – Disconnect breather line -1.2005 – Pull coolant hose -1.off expansion tank. WARNING The fuel line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact. C op yi 7 . Models with auxiliary heater agen lksw Vo by – Remove coolant hoses -3. Volksand does age – Disconnect fuel supply line -3. d ise sa ran tee or ac ility ab y li an pt ce un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Loosen bolts -arrows.Jetta 2005 ➤ . AG. – Pull vacuum hose -2. wagen AG n AG.-6. – Remove upper coolant hose from radiator. Removing and installing engine ht rig py Co t. Then release pres‐ sure by carefully removing the line. in part or in wh ole. – Remove retainer along with active charcoal filter system sol‐ enoid valve 1 -N80.and lay free. ut urposes. wrap a cloth around the connection. cial p is n mer m ot p o c erm or e t a itte v i r d p s – Seal the lines so that the fuel system is not contaminated by dirt etc.of assembly mounting on engine just a bit (less than 1 turn).Edition 08.from intake manifold. Models without auxiliary heating r fo ng – Remove connector -2.and -4.from active charcoal filter system solenoid valve 1 -N80.

10 .Removing and installing engine ht rig py Co t. C op yi .off brake servo. in part or in wh ole.and hose -5. r fo ng – Unlock duct for engine wiring harness -arrow. Gr.. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Jetta 2005 ➤ . cial p is n mer m ot p o c erm or e t a itte v i r d p – Remove coolant hose -3. Prote cted by c o p yri gh t.to control unit out of the wiring guide. – Release the front connector on the engine control unit and pull it off ⇒ page 179 .2005or ac a s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Pull the vacuum hose -arrow.– Remove connector -2.and -7.from intake manifold.on heater coolant shut-off valve -N279. un le AG.-6. – Remove coolant hoses -1.and pull off up‐ wards.to heat exchanger on bulkhead. – Open wiring bracket -arrows-. Bora 2006 ➤ oris e h t u 4-cylinder Injection engine (1. direct injection) .from active charcoal filter system solenoid valve 1 -N80.-6-. – Remove retainer along with active charcoal filter system sol‐ enoid valve 1 -N80.Edition 08. 8 Rep. Continuation for all vehicles urposes.6 l engine. agen lksw Vo by AG. – Take engine wiring harness -1.

of assembly mounting on gearbox just a bit (less than 1 turn). t au – Remove nut -1.2005 or a es. is n m ot p om c r erm o e t a itte riv du p or nl f e g n c s – s Release underneath bracket -2. – Fit the cable with a cable tie to the engine. ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en – Remove nut -1. – Take engine wiring harness to control unit off the wiring guide.off earth point.of the wiring -arrow-.from the assembly mounting.6 l engine.nte ris – Move e ho electrical connector -1. direct injection) .and the earth strap -2. ht rig py Co t. – Loosen bolts -arrows. AG. by ed AG. Volkswagen AG d agen oes 4-cylinder Injection ksw not l o V gu ara Jetta 2005 ➤ .free and disconnect. agen lksw Vo by Prote cted by c o p yri gh t. Removing and installing engine 9 .and pull earth strap -2.Edition 08. in part or in w l purpos hole ercia . Bora 2006 ➤ engine (1. C op yi 1.

2005 bengine (1. Caution Do not operate the clutch pedal anymore after removing the clutch slave cylinder. Prote cted by c o p yri gh t.G do agen es n Jetta 2005 ➤ . – Unscrew earth wire -1-.and lay to side. – Remove electrical wirings -2. Bora 2006 ksw ➤ ot g Vol y ua .on starter and lay to side. C op yi . do not open pipes.10 . agen lksw Vo by AG. thi sd o cu m en – Remove clutch slave cylinder -arrows. Volkswagen A – Unclip – Pull cable end-pieces off gearbox selector lever and relay lev‐ er.Removing and installing engine ht rig py Co t. 10 Rep.and -3.on both cables.6 l engine. es.and lay to side.Edition 08. nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Remove cable support bracket from gearbox -arrows. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ris tho u securing sclips -1sa and -2. direct injection) 4-cylinder Injection d ra e AG. Gr. in part or in w l purpos hole ercia .

yRep. Prote cted by c o p yri gh t .6 l engine. th es. kinked or bent.2005 – Separate electrical connector -1. Note To prevent damage to condenser also to the refrigerant lines/ho‐ ses. – Remove air conditioner compressor from bracket for ancilla‐ n does wage s k not l ries ⇒ Heating. is n m ot com The air conditioning system wiring must not be opened. Gr. ensure that the lines and hoses are not stretched.Jetta 2005 ➤ . Models with an air conditioning system – Pull activated charcoal canister off the bracket upwards -arrow-. – Lay engine wiring harness on bracket -2. Removing and installing air condi‐ nte ise r o eo tioner compressor .to side.and take retainer for electrical wiring off threaded stud. pe rm itte d Note un le au ss ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 1. in part or in w l purpos hole ercia . Air conditioning system.for Lambda probe -G39. Volkswagen AG AG. Bora 2006 ➤ 4-cylinder Injection engine (1.. Repair Vo gu b ara d work on refrigerant circuit.for refrigerant lines on right longitu‐ dinal member. – Unscrew nut -arrow.Edition 08. 87 ..for reversing light switch F4. To facilitate removing and installing the engine without opening the refrigerant circuit: – Remove bracket -arrow. – Remove ribbed belt ⇒ page 29 . agen lksw Vo by AG. Removing and installing engine ht rig py Co t. direct injection) . – Disconnect electrical connector -3. C op yi 11 .

and take pendulum support off. s k l o o Continuation for all vehicles – Remove alternator ⇒ Electrical nator. V by ed s i r ho ut a system.and -3. – Unclip retainer -2. Volkswagen AG do es n wage coolant hoses off auxiliary heater. Prote cted by c o p yri gh t .to lock carrier -1-. ht rig py Co t.Edition 08.and pull n AG.and -2. remove bolt -4. Models with auxiliary heater – Loosen nut -3-. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his – Separate connector -1.6 l FSI engine . do c um en – Unscrew bolts -2.off auxiliary heater. ss t gu ara nte eo ra c ility ab y li an pt ce 27 . in part or in w l purpos hole ercia . To do this pull e. C op yi . – Release spring-type clips of coolant hoses -1. – Observe that the wiring is not kinked. Gr.at oil level and oil temperature sender -G266.2005 – Fit air conditioner compressor -2. – Unscrew bolt -1. Alternator 1. Alter‐ es. – Place drip tray underneath.first.Jetta 2005 ➤ .6 l engine. Rep. direct injection) .. Bora 2006 ➤ 4-cylinder Injection engine (1.for the line to the oil level and oil tempera‐ ture sender -G266.Removing and installing engine agen lksw Vo by AG.g. 12 Rep. a wire through the right air conditioner compressor mounting.on subframe.10 .and take exhaust pipe -5. Gr.

Prote cted by c o p yri gh t .A. – Lift engine/gearbox assembly lightly.G 1383 A. Rep. steering. un le n AG. – Fit all electrical wirings and hoses on engine.to pin.and and gearbox. is n m ot com – Remove pre-catalytic converter along with exhaust pipe ⇒ page 183 .Jetta 2005 ➤ . Models with auxiliary heater Continuation for all vehicles es. – Remove right-hand drive shaft and left-hand drive shaft ⇒ Running gear. Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine. – Fit the engine bracket -T40075. Removing and installing engine 13 . Servicing drive shafts. pe rm itte d – Remove bolts -1. C op yi 1. Note To remove securing bolts for assembly mounting use double lad‐ der -VAS 5085.and tighten to 20 Nm. axles. 40 .2005 – Remove bolts -arrows-.to engine front first. The coolant hoses remain connected.. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a s s -2. – Pull off/disconnect all other electrical connections and hoses as necessary from engine and lay to one side. in part or in w l purpos hole ercia . direct injection) .to the rear side of the cylinder head -arrows.and pull coolant hoses off engine ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en – Fit pin of engine bracket -T40075. ht rig py Co t. – Fit engine bracket -T40075. Gr.Edition 08. agen lksw Vo by AG.to the engine and gearbox jack V. Removing and installing drive shafts . – Fit engine bracket -T40075..

gearbox and body are ♦ ility ab y li an pt ce ♦ Engine with gearbox must be guided carefully when lowered to prevent damage. the engine should be secured on the engine and gearbox support -VAS 6095. agen lksw Vo by AG. es.Jetta 2005 ➤ . AG. Gr. C op yi .of assembly mounting from engine bracket.2005 – Remove bolts -arrows. in part or in w l purpos hole ercia . Volkswagen AG d agen oes ksw not l o V gu Note by ara d e nte is r o eo h ut wiring connections between en‐ ra Check whether all hoses and a c s s disconnected.. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08. Prote cted by c o p yri gh t. gine. direct injection) .6 l engine.2 Securing engine to engine and gearbox support -VAS 6095- When working on the engine. – Pull engine/gearbox assembly forwards as far as possible and carefully lower. do c um en 14 Rep.Removing and installing engine ht rig py Co t. – Remove bolts -arrows.of assembly mounting from gearbox bracket. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his 1.10 .

Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r Engine and gearbox stand o eo h t u ra VAS 6095a c s s pe rm itte d ility ab y li an pt ce es. agen lksw Vo by AG. is n m ot com un le rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en Procedure – Move Engine/gearbox jack -V.Jetta 2005 ➤ . Prote cted by c o p yri gh t. in part or in w l purpos hole ercia .G 1383 A.Edition 08.2005 Special tools and workshop equipment required ♦ Lifting tackle -2024 A♦ Workshop crane VAS 6100♦ AG. Removing and installing engine 15 .A. – Remove engine/gearbox connecting bolts.to a workbench. direct injection) . ht rig py Co t.6 l engine. – Lower engine/gearbox assembly so that the gearbox is on the workbench. Bora 2006 ➤ 4-cylinder Injection engine (1. – Press gearbox off engine. C op yi 1.

♦ The holes in the hook rails are tho un le au ss d se ara nte e or ac ility ab y li an pt ce – Pull dowel sleeve -arrow B. V gu by olksw ri counted up from the hook.as follows and lift off engine/ gearbox jack -V. Bora 2006 ➤ 4-cylinder Injection engine (1.G 1383 A.A. observe the following: Caution ht rig py Co t.out of the cylinder block.4 on the barsmust does wage be towards the belt not olk pulley end.3 Installing engine r fo ng Install in reverse order of removal. coolant and refrigerant liquid. When doing any repair work. activated char‐ coal canister system. AG. hydraulic system.to prevent injuries and damages to the engine. for fuel. urposes. agen AG n AG. Gr. – Secure engine to engine and gearbox support -VAS 6095-arrows A. brake liquid. pay attention to the following due to the cramped condi‐ tions: ♦ All wirings (e... During this step. Belt pulley end: 2nd hole in hook rail at position 2 Flywheel end: 3rd hole on support bar in position 7 WARNING The hooks and locating pins must be secured with locking pins -arrows. Prote cted by 16 Rep.Removing and installing engine agen lksw Vo by c o p yri gh t . ♦ Ensure that there is sufficient clearance to all moving or hot components.and -arrow B-.with workshop crane -VAS 6100. vacuum) and electrical wirings are to be installed in the original way.Edition 08.2005 – Remove lifting tackle -2024 A. direct injection) . V ♦ The positions marked 1..10 .Jetta 2005 ➤ . in part or in wh ole. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1. especially in the engine compart‐ ment.6 l engine.g. C op yi .

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1. Removing and installing engine

17

Jetta 2005 ➤ , Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005 – Ensure that the intermediate plate is attached to the sealing flange and is slided onto the dowel sleeves -arrows-. – Check clutch release bearing for wear, renew if necessary. – Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with grease -G 000 100- . If necessary clean and remove corrosion. – Installing and checking clutch and clutch mechanism ⇒ 6speed manual gearbox 0AG; Rep. Gr. 30 ; Repairing clutch control . – Rock engine to align engine mounting stress-free, loosen en‐ gine mounting to body if necessary. Note ♦ Checking and adjusting assembly mounting ⇒ page 20 .gen AG. swa ♦ ♦
by Torque settings for assembly mounting ⇒ page ed 22 . ris o h ut Connecting bolts for engine/gearbox ⇒ 6-speed manual gear‐ sa s box 0AG; Rep. Gr. 34 ; Removing and installing gearbox .

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– When installing the engine/gearbox assembly, ensure suffi‐ cient clearance to assembly mountings and radiator. – Install pendulum support ⇒ page 22 . – Install drive shafts ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Servicing drive shafts; Removing and installing drive shafts . – Installing pre-catalytic converter with exhaust pipe ⇒ page 188 . – Install selector mechanism, adjust if necessary ⇒ 6-speed manual gearbox 0AG; Rep. Gr. 34 ; Servicing selector mech‐ anism . – Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐ box 0AG; Rep. Gr. 30 ; Repairing clutch control; Assembly overview - hydraulic system .
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– Install bulkhead in plenum chamber ⇒ General Body Repairs, Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .

18

Rep. Gr.10 - Removing and installing engine

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– Install ribbed belt ⇒ page 29 .

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– Install air conditioner compressor ⇒ Heating, Air conditioning system; Rep. Gr. 87 ; Repair work on refrigerant circuit; Re‐ moving and installing air conditioner compressor .
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– Install engine cover with air cleaner ⇒ page 161 . – Top-up coolant ⇒ page 102 . – Install noise insulation ⇒ General Body Repairs, Exterior; Rep. Gr. 50 ; Noise insulation . – Connect vehicle diagnosis, testing and information system VAS 5051- or vehicle diagnosis and service information sys‐ tem -VAS 5052- . – Interrogate all fault memories and then erase all fault entries which have been caused when the engine has been removed and installed. After erasing the fault memory of the engine control unit gen‐ erate readiness code. Observe applicable safety precautions during road test. – Carry out a road test. – After this, perform a vehicle system test and if necessary, rec‐ tify faults. Torque settings Threaded connection Nuts and bolts Torque setting M6 10 Nm M7 15 Nm M8 25 Nm M10 40 Nm M12 60 Nm Connecting bolts for engine/gearbox ⇒ 6-speed manual gear‐ box 0AG; Rep. Gr. 34 ; Removing and installing gearbox . Bolts for assembly mounting ⇒ page 22

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– Install the battery and observe the respective measures after connecting the battery ⇒ Electrical system; Rep. Gr. 27 ; Re‐ moving and installing battery; Models with petrol engine .

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Dimension -a- = 10 mm can be checked e.g. with suitable round bars.
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If dimension is too small or to large proceed as follows: – Removing battery ⇒ Electrical system; Rep. Gr. 27 ; Remov‐ ing and installing battery; Vehicles with petrol engines .

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– Fit support bracket -10 - 222 A- before the gas pressure damp‐ er for the front flap using adapter -10 - 222 A/8- . – Attach trigger snap of spindles to lifting eyes.
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– Remove bolts -arrows- of gearbox assembly mounting. – Renew all bolts one after the other (if they had not been re‐ moved when the engine was removed) and screw in loosely.

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21

Jetta 2005 ➤ , Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005 – Slide the engine with a lever between engine console -1- and arm -2- until the bolts are centered in the elongated holes: • • Between the engine support and the right longitudinal member must be a distance of -a- = 10 mm at least. Volkswa
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– Ensure that on gearbox side the edges of the arm -2- and the gearbox support -1- are parallel with one another. Dimension -x- must be the same on top and bottom. – Tighten bolts for gearbox side assembly mounting ⇒ page 22 . Assembly is carried out in the reverse sequence of removal. – Install the battery and observe the respective measures after connecting the battery ⇒ Electrical system; Rep. Gr. 27 ; Re‐ moving and installing battery; Models with petrol engine .

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Engine assembly mounting A = 20 Nm + 90° (1/4 turn) further Renew bolts. B = 40 Nm + 90° (1/4 turn) further Renew bolts. C = 60 Nm + 90° (1/4 turn) further Renew bolts.

22

Rep. Gr.10 - Removing and installing engine

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Pendulum support A = 40 Nm + 90° (1/4 turn) further Renew bolts. B = 100 Nm + 90° (1/4 turn) further Renew bolts. Removing: First remove bolt -B- then bolts -A-. Installing: First tighten bolts -A- then bolt -B-.

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ht rig py Co t.6 l engine.2005 13 – 1 Note Crankshaft groupwagen AG.Crankshaft group agen lksw Vo by When working on the engine. in part or in w l purpos hole ercia . Prote cted by c o py rig ht . Gr. for example. is n m ot com ♦ If large quantities of metal particles or other deposits (caused. clean the oil passages thoroughly and renew the oil filter in order to prevent further damage from occurring later. un le ss olks yV db e ris tho au s no t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Oil all contact surfaces before beginning with the assembly Overview ⇒ page 25 Belt drive . the engine should be secured on the engine and gearbox support -VAS 6095..Jetta 2005 ➤ . Bora 2006 ➤ 4-cylinder Injection engine (1. Volkswagen AG doe Dismantling and assembling engine pe rm itte d es.Edition 08. AG.Assembly overview ⇒ page 26 Chain drive . C op yi . Removing and installing poly V-belt ⇒ page 29 r te o iva r rp fo g n Removing and installing control housing ⇒ page 31 Note do c um en 24 Rep.13 . direct injection) .Assembly overview ⇒ page 27 . by partial seizure of the conrod bearings) are found in the engine oil when performing repairs. work.

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against turning ❑ The turning further an‐ gle can be measured with a commercially available angle measur‐ ing instrument e.6 l engine.g. Gr. 3 . To do this rework water pump wrench -V.Poly V-belt ❑ Check for wear ❑ Do not kink ❑ Mark D.R. in part or in w l purpos hole ercia . Alternator 1.13 .2 Belt drive .Crankshaft group AG.Bolt ❑ Observe tightening pro‐ cedure ⇒ page 40 ❑ Renew ❑ Contact surface of the securing bolt must be free of oil and grease ❑ Insert oiled (thread) ❑ Secure poly V-belt sprocket with counterhold -3415.. 27 . Alternator. Rep.Alternator ❑ Removing and installing ⇒ Electrical system. Ha‐ zet 6690 r te o iva r rp fo g n do c um en c o p yri gh t. Reverse direction of rotation may lead to destruction withagen AG.6 l FSI engine 11 . Bora 2006 ➤ 4-cylinder Injection engine (1.9 Nm 7 .G 1590. Gr. C op yi . direct injection) .Idler roller ❑ Tightening torque: 40 Nm 10 . Volkswagen AG do es n ksw used belts ot g Vol ua by d ran e ❑ Removing and installing s i tee r o h or ⇒ page 29 ut ac a s ❑ Ribbed sbelt routing in vehicles with air condi‐ tioner ⇒ page 30 ❑ Ribbed belt routing in vehicles without air con‐ ditioner ⇒ page 30 pe rm itte d ility ab y li an pt ce un le rrectness of i t to the co nform spec a t i h re o n in wit thi s 4 .20 Nm + 90° (1/4 turn) further ❑ Renew 26 Rep. is n m ot com 1 .O.G 1590. agen lksw Vo by Prote cted by 2 .Belt pulley for coolant pump ❑ Removing and installing ⇒ page 108 6 .Coolant pump ❑ Removing and installing ⇒ page 108 8 .Jetta 2005 ➤ .2005 1. with chalk or a felt tipped pen be‐ fore removing.A.A.⇒ page 108 5 .Edition 08.25 Nm 9 .Assembly overview es.20 Nm ❑ To loosen and tighten counterhold with coolant pump wrench -V.Poly V-belt sprocket for crankshaft ht rig py Co t.

in part or in w l purpos hole ercia . unscrew bolt ⇒ Item 11 (page 26) 1.6 l engine.Assembly overview r te o iva r rp fo g n 2 .Edition 08.25 Nm un le rrectness of i t to the co nform spec a t i h re o n in wit thi s 17 . Air system. is n m ot com 15 . 87 .Tensioning element for ribbed belt ❑ Turn with open jaw spanner to relieve tension on poly V-belt ❑ Secure tensioning device with a 4 mm hexagon key ❑ To remove.Bracket for ancillaries pe rm itte d 14 .Sliding rail ❑ For control chain 5 . Removing and installing air conditioner compressor 12 .3 Chain drive . 2 16 . C op yi 1 . Gr.Cylinder head with cam‐ shaft housing ❑ Sealing surface must not be reworked ❑ With integrated cam‐ shaft bearings ❑ Remove sealant rem‐ nants ❑ Apply sealing com‐ pound -AMV 188 100 02. Volkswagen AG d agen oes ksw not l o gu yV b ara d e 13 .25 Nm refrigerant ility ab y li an pt ce es. Repair work on a c s s circuit.2005 AG. Bora 2006 ➤ 4-cylinder Injection engine (1.Retainer ❑ For tensioning element and air conditioner com‐ pressor 4 . Rep.Cylinder block ❑ Dismantling and assem‐ bling cylinder block ⇒ page 36 ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 53 3 .before fitting ❑ When installing fit verti‐ cally from above with the dowel pins into the holes in the cylinder head ❑ Removing and installing ⇒ page 63 do c um en 27 . direct injection) .Air conditioner compressor nte is r o eo th uconditioning ra ❑ Removing and installing ⇒ Heating.Chain sprocket ❑ Note installation posi‐ tion: The journal must engage into the groove of the crankshaft! ❑ For oil pump and control chain drive ❑ Contact surfaces must be free of oil and grease 1.Jetta 2005 ➤ . Dismantling and assembling engine ht rig py Co t.Bush ❑ Qty. agen lksw Vo by AG. Prote cted by c o py rig ht .

Drive chain ❑ Mark D. Volkswagen AG do es n wage .Chain tensioner 18 .15 Nm urposes.Valve gear casing ❑ For a better guide purpose when installing.20 Nm + 90° (1/4 turn) further 15 . ❑ Install with silicone sealing compound -D 176 404 A210 . in part or in wh ole. direct injection) o olks 6 . Hazet 6690 23 . before removing 7 .Crankshaft group ht rig py Co t.Cover 14 .Oil pan ❑ Removing and installing ⇒ page 87 ❑ Clean sealing surface before fitting. agen lksw Vo by AG.2005 4-cylinder Injection engine (1.Bearing bush ❑ Renew if scored ❑ Observe tightening procedure ⇒ page 40 ❑ Contact surfaces must be free of oil and grease 21 .against turning ❑ Removing and installing poly V-belt ⇒ page 29 22 .O.against turning ❑ The turning further angle can be measured with a commercially available angle measuring instrument e.Chain sprocket ❑ Counterhold chain sprocket with counter-hold -T1017213 . insert two M6x80 studs into the camshaft housing and the cylinder block ❑ Removing and installing ⇒ page 31 20 . Prote cted by c o p yri gh t.Jetta 2005 ➤ .25 Nm yV db ise r tho au position) (installation s s un le t gu ara nte eo ra c ility ab y li an pt ce 8 .Chain tensioner with tensioning plate and tension spring ❑ For oil pump drive ❑ Tightening torque: 15 Nm ❑ Is replaced complete only 9 .Compression spring 17 .R. Bora 2006 ➤ n AG. C op yi . Gr.9 Nm r fo ng 19 .O-ring ❑ Renew 28 Rep. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 12 .13 .Poly V-belt sprocket ❑ Observe tightening procedure ⇒ page 40 ❑ Contact surfaces must be free of oil and grease ❑ Secure poly V-belt sprocket with counter-hold -3415.g.Edition 08.Piston ❑ For chain tensioner drive chain 16 .6 l engine.Bolt ❑ Observe tightening procedure ⇒ page 40 ❑ Renew ❑ Contact surface of the securing bolt must be free of oil and grease ❑ Insert oiled (thread) ❑ Secure poly V-belt sprocket with counter-hold -3415.13 Nm 11 .

To intake manifold 28 . Gr.4 Removing Removing and installing poly V-belt agen lksw Vo by – Mark direction of rotation of poly V-belt.R. Noise insulation .O. 10 Nm ❑ M6x22 mm ❑ Insert with locking fluid 27 .50 Nm + 90° (1/4 turn) further a 36 . do c um en AG. Rep.Bolt. 50 . Gr.2005 24 . 66 .Control chain ❑ Mark D. before removing (installation position) es.10 Nm 29 . Exterior.Oil separator 32 . Bora 2006 ➤ 4-cylinder Injection engine (1.Bolt. – Remove front right wheel housing liner ⇒ General Body Re‐ pairs.Tensioning plate 35 . Volkswagen AG gen AG does not gu ara nte eo ra c ility ab y li an pt ce 37 .Bearing bush un le ss rrectness of i t to the co nform spec a t i h re o n in wit thi s 1. is n m ot com 38 .Camshaft adjuster ksw Vol by d e ❑ Must not be dismantled ris ho t ❑ Removing and installing ⇒ page 69 au pe rm itte d . 1.Suction relief valve 30 .Guide pins ❑ Tightening torque: 20 Nm 40 .Edition 08. 29 . Wheel housing liner.Chain sprocket ❑ For exhaust camshaft ❑ Lock chain sprockets with counter-hold -T1017239 . Prote cted by c o p yri gh t. Removing and installing front wheel housing liner .Seal ❑ Renew 33 . Dismantling and assembling engine ht rig py Co t. direct injection) .Jetta 2005 ➤ . in part or in w l purpos hole ercia . exterior.10 Nm 31 . C op yi r te o iva r rp fo g n – Remove noise insulation ⇒ General body repairs. Rep. 10 Nm ❑ M6x45 mm 25 .50 Nm 26 .6 l engine.40 Nm + 90° (1/4 turn) further ❑ Counterhold chain sprockets with counter-hold -T10172❑ Bolt with left-hand thread ❑ Renew 34 .

6 l engine.Tensioning roller 3 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n ♦ When fitting poly V-belt.Belt pulley .13 .Idler roller 4 . Volkswagen AG do es n wage s k l ot g o yV ua b ran ed Ensure. Prote cted by c o p yri gh t . Belt drive with air conditioner compressor 1 . – Lock tensioning element using a 4 mm hexagon key -1-.Belt pulley . direct injection) . Gr. that all ancillaries (alter‐ s i tee r o h t or nator.Belt pulley .Alternator 4 .Tensioning roller 3 .2005 – To relieve tension on ribbed belt.Belt pulley .Coolant pump 2 .Alternator es. C op yi . 30 Rep.Belt pulley . before installing ribbed belt. Further assembly is basically the reverse of the dismantling pro‐ cedure.Poly V-belt 5 . Installing n AG.Edition 08. in part or in w l purpos hole ercia . – Remove ribbed belt.Coolant pump 2 . ac a ss Note ♦ proper seating of belt in belt pulleys. agen lksw Vo by AG. check direction of belt rotation and ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his 5 . Slide belt onto tensioning roller last.Crankshaft group ht rig py Co t.Air conditioner compressor 6 .Crankshaft do c um en Belt drive with no air conditioner compressor 1 . swing tensioning element in -direction of arrow. – Place ribbed V-belt onto crankshaft pulley first.using a 16 mm spanner.Belt pulley .Jetta 2005 ➤ .Crankshaft After completing repairs always: – Start engine and check belt running. air conditioner compressor) are u secured tightly. Bora 2006 ➤ 4-cylinder Injection engine (1.Belt pulley .

Prote cted by c o p yri gh t .5 Removing and installing control housing Special tools and workshop equipment required ♦ Support bracket -10-222 A♦ Adapter -10 .G.6 l engine.2005 1. ht rig py Co t.Edition 08.G.Jetta 2005 ➤ . exterior. Gr. direct injection) . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG. agen lksw Vo by AG. Dismantling and assembling engine 31 . – Remove noise insulation ⇒ General body repairs. Noise insulation . 50 . Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Drip tray for workshop hoist -VAS 6208- thi sd o cu m en Removing – Remove engine cover with air cleaner ⇒ page 161 . Bora 2006 ➤ 4-cylinder Injection engine (1.A.A. 1332- es.222 A/8♦ Counter-hold tool -3415♦ Pin -3415/1♦ Torque wrench -V. C op yi 1. 1331♦ Torque wrench -V. in part or in w l purpos hole ercia . Rep.

Air conditioning system. ht rig py Co t.and -3415/1.2005 ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Remove air conditioner compressor with connected coolant hoses from bracket ⇒ Heating. 1. 27 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Remove front right wheel housing liner ⇒ General Body Re‐ pairs. 66 . Repair work on refrigerant circuit. Gr.6 l engine. Prote cted by c o p yri gh t.13 .and take engine lifting eye off.6 l FSI engine . Alternator. Lock poly V-belt sprocket using counter-hold -3415. es. Volkswagen AG d agen oes ksw not l o gu yV b ara d Jetta 2005 ➤ . Rep. – Unscrew pressure control valve for crankcase heater element -arrows-. AG. 87 . – Mark ribbed belt direction of rotation and remove ⇒ page 29 ..⇒ Electrical system. in part or in w l purpos hole ercia . AG. Gr. Rep. Bora 2006 ➤ e nte is r o eo h 4-cylinder Injection engine ut (1. direct injection) . Alternator. Removing and installing wheel housing liner . C op yi . Exterior.Crankshaft group agen lksw Vo by – Remove coolant pump belt pulley ⇒ page 108 . Removing and in‐ stalling air conditioner compressor . 32 Rep. Gr. – Remove poly V-belt sprocket securing bolt. Rep. – Remove bolts -arrows. Gr.– Remove pre-catalytic converter along with exhaust pipe ⇒ page 188 . – Remove tensioning element bracket and air conditioner com‐ pressor. – Remove alternator and idler roller -2.Edition 08.

r te o iva r rp fo g n do c um en – Remove bracket -3. disconnect electrical connection on cool‐ ant shortage indicator sender -G32. Bora 2006 ➤ 4-cylinder Injection engine (1.and lay on the engine with con‐ nected hoses.of assembly mounting on engine just a bit (less than 1 turn).2005 – Remove breather line -1. tie if necessary. – On expansion tank. ht rig py Co t. Dismantling and assembling engine agen lksw Vo by AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. 33 . Prote cted by c o py rig ht .for activated charcoal canister. C op yi – Remove bolt on filler neck for fluid reservoir -2-. – Remove oil sump ⇒ page 87 . – Seal the lines so that the fuel system is not contaminated by dirt etc.Jetta 2005 ➤ . direct injection) .and free wiring harness. is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s – Pull activated charcoal canister off the bracket upwards -arrow-. in part or in w l purpos hole ercia . – Remove expansion tank -1. 1. AG.6 l engine.Edition 08.(press locking ring in). – Loosen bolts -arrows.

34 Rep. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s Observe that the bearing bush for the crankshaft remains in the control housing. Installing – Clean sealing surfaces carefully. – Remove bolts -1. agen lksw Vo by AG. – Remove bolts from -3. the bearing bush and the crankshaft pulley sprocket must be free of oil and grease. is n m ot com – Remove hexagon socket head bolts of the control housing and the hexagon bolts marked with -arrows-.222 A. in part or in w l purpos hole ercia . – Remove control housing.222 A/8. Gr.as shown and hook into lifting eye. Prote cted by do c um en Note Observe that the contact surfaces of the poly V-belt sprocket.Crankshaft group ht rig py Co t. – Place drip tray under the engine. Note pe rm itte d un le AG.and remove engine mounting.and -2.to -6. the securing bolt. Bora 2006 ➤ 4-cylinder Injection engine (1. r te o iva r rp fo g n – Drive crankshaft seal for poly V-belt sprocket out of the control housing.Edition 08.Jetta 2005 ➤ .6 l engine. – Put engine under slight tension.using adapter -10 . direct injection) . To do this raise the engine with the support device -10 . They must be free of oil and grease.lightly.13 .and remove support. C op yi .2005 – Fit support device -10 . c o p yri gh t. es.222 A.

Ensure the camshaft housing does not cant when doing this. – Install pendulum support ⇒ page 22 . ht rig py Co t. – Install alternator with idler roller ⇒ Electrical system. Removing and installing air conditioner compressor . is n m ot p om c r erm o e t a itte riv du p or nl f e g n Further installation is performed in the reverse order of removal. Torque settings: ♦ Bolts M6. – Install noise insulation ⇒ General body repairs. Gr.6 l FSI engine . 1. exterior. 66 . – Tighten control housing securing bolts uniformly using alter‐ nate sequence. 50 . During this step. Rep.2005 – Fit new seals -arrows.on the back of the control housing. exterior.6 l engine. Rep. lksw AG. Noise insulation . insert two M6x80 studs into the cylinder head and the cylinder block. Rep. – Install oil sump ⇒ page 87 . Repair work on refrigerant circuit. Alternator. – Installing coolant pump belt pulley ⇒ page 108 . Alternator. 50 Nm G do agen – Renew seal for crankshaft poly V-beltAsprocket es n ⇒ page 38 . 87 . – Install front right wheel housing liner ⇒ General body repairs.Jetta 2005 ➤ . direct injection) . Volkswagen ot g o yV ua db ran V-belt e Observe tightening procedure for the crankshaft poly tee ris o h securing bolt ⇒ page 40 . – For a better guide purpose when installing. Gr. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08. Dismantling and assembling engine 35 . 27 . Gr. 10 Nm ♦ Bolts M10. in part or in w l purpos hole ercia . Prote cted by c o py rig ht . 1. – Fit new seal onto dowel pins. – Installing pre-catalytic converter along with exhaust pipe ⇒ page 188 . Gr. Air conditioning system. – Fit air conditioner compressor with connected coolant hoses to bracket⇒ Heating. C op yi ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en agen lksw Vo by AG. observe the following: – Installing engine bracket ⇒ page 22 . Rep. sprocket t or u ac a ss – es. – Fit the control housing at the same time onto the studs and the dowel pins. Removing and installing wheel housing liner .

2005 2 Removing and installing sealing flange and flywheel Caution The crankshaft must not be removed. AG. ht rig py Co t. This deformation will cause a reduction of the bearing clearance. C op yi . in part or in w l purpos hole ercia . Even if the bearing shells are not renewed bearing damage could occur due to a different bearing clear‐ ance. Removing and installing clutch 36 Rep.belt pulley end.Jetta 2005 ➤ . Measuring the main bearing clearance is not possible with nor‐ mal workshop equipment. the cylinder block must be replaced complete with the crankshaft. Bora 2006 ➤ 4-cylinder Injection engine (1. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a s s page 38 ility ab y li an pt ce Tighten bolt for poly V-belt sprocket .Assembly overview Caution The crankshaft must not be removed. This deformation will cause a reduction of the bearing clearance.crankshaft ⇒ page 40 Renewing crankshaft sealing flange -flywheel end-.13 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his 2.Assembly overview ⇒ page 36 Renewing crankshaft oil seal . direct injection) . Just loosening the main bearing caps will cause deformation of the cylinder block bear‐ ing pedestals. Gr. Rep. Flywheel end . Just loosening the main bearing caps will cause deformation of the cylinder block bear‐ ing pedestals. Prote cted by Note Servicing clutch ⇒ 6-speed manual gearbox 0AG. Gr. If the bearing cap bolts are loosened.⇒ n AG. 30 . Even if the bearing shells are not renewed bearing damage could occur due to a different bearing clear‐ ance. vehicles with manual gearbox ⇒ page 43 Removing and installing flywheel ⇒ page 50 Crankshaft dimensions ⇒ page 52 es.Edition 08.6 l engine. agen lksw Vo by Measuring the main bearing clearance is not possible with nor‐ mal workshop equipment. do c um en If the bearing cap bolts are loosened. the cylinder block must be replaced complete with the crankshaft.1 Flywheel end .Crankshaft group c o p yri gh t .

⇒ page 43 12 . in part or in wh ole. Prote cted by 4 . Ha‐ zet 6690 urposes.Aluminium cylinder block 7 .Intermediate plate ❑ Must fit on dowel sleeves ❑ Do not damage/bend when assembling 10 .Flywheel ❑ To remove and install counterhold flywheel with counter-hold -T100449 . Volkswagen AG d agen oes ksw not l o ❑ Contact surface of the V gu y b ara d bolt must be free of oil rise nte o eo h and grease t u ra a c s s ❑ Insert oiled (thread) ❑ Secure poly V-belt sprocket with counterhold -3415.Seal ❑ Renew r fo ng 2 . direct injection) .12 Nm ❑ Renew 11 .Jetta 2005 ➤ .Engine speed sender -G28❑ With attached bolt agen lksw Vo by AG.Bearing bush ❑ Renew if scored ❑ Observe tightening pro‐ cedure ⇒ page 40 ❑ Contact surfaces must be free of oil and grease 2.Edition 08.6 l engine.Poly V-belt sprocket ❑ Contact surfaces must be free of oil and grease ❑ When removing and in‐ stalling secure with counter-hold -3415against turning ❑ Removing and installing poly V-belt ⇒ page 29 37 .g. C op yi 3 . Removing and installing sealing flange and flywheel ht rig py Co t.O-ring ❑ Renew 6 . c o p yri gh t.60 Nm + 90° (1/4 turn) further ❑ Renew 8 .2005 1 .against turning ❑ The turning further an‐ gle can be measured with a commercially available angle measur‐ ing instrument e.Sealing flange with sender wheel and seal ❑ Only renew sealing flange complete with seal and sender wheel ❑ Renewing crankshaft sealing flange -flywheel end. cial p is n mer m ot p o c erm or e t a itte v i r d p un le ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 5 . Bora 2006 ➤ 4-cylinder Injection engine (1.Bolt ❑ Observe tightening se‐ quence ⇒ page 40 ❑ Renew AG.

direct injection) . Front wheel housing liner . Removing and installing wheel housing liner. Prote cted by c o p yri gh t.2005 ❑ Tightening torque: 5 Nm Special tools and workshop equipment required ♦ Oil seal extractor -3203♦ Pin -3415/1- es. Bora 2006 ➤ 4-cylinder Injection engine (1. 38 Rep.Crankshaft group ht rig py Co t.Jetta 2005 ➤ . – Remove ribbed belt ⇒ page 29 . Gr.Edition 08. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Counter-hold tool -3415- ♦ Fitting appliance -T10117- thi sd o cu m en Removing – Remove front right wheel housing liner ⇒ General Body Re‐ pairs. Gr. Rep. in part or in w l purpos hole ercia .6 l engine.belt pulley end AG.13 . 66 .2 Renewing crankshaft oil seal . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 2. C op yi . agen lksw Vo by AG.

direct injection) . G. 2. Prote cted by c o py rig ht .crankshaft. the bearing bush and the crankshaft pulley sprocket must be free of oil and grease. To do this counterhold poly V-belt sprocket using counter-hold -3415and pin -3415/1. Volkswagen Installing nA wage olks V by ed ris o th au urposes. Bora 2006 ➤ 4-cylinder Injection engine (1. – Renew O-ring ⇒ Item 5 (page 37) . – Loosen knurled screw and turn inner part against mounting bush until the seal is pulled out..off bearing bush. – Place the sleeve -T10117/2. – Lubricate threaded head of oil seal extractor. – Unscrew bolt and take poly V-belt sprocket off. agen lksw Vo by – Using even blows.crankshaft ⇒ page 40 . AG. – Take the mounting bush off crankshaft journal and clean the contact surfaces of the crankshaft pulley sprocket and the mounting bush.Edition 08. the bolt.three turns (ap‐ prox. Removing and installing sealing flange and flywheel ht rig py Co t.6 l engine.2005 – Loosen bolt for poly V-belt sprocket .Jetta 2005 ➤ . un le Note ss AG do es n ot g ua ran tee or ac ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng – Tighten bolt for poly V-belt sprocket . press the seal into control housing up to limit stop using assembly device -T10117.onto the bush and the seal onto the bearing bush. in part or in wh ole. – Slide the bearing bush with the new O-ring onto the crankshaft journal. C op yi 39 . – Take sleeve -T10117/2. cial p is n mer m ot p o c erm or e t a itte v i r d p Observe that the contact surfaces of the poly V-belt sprocket. – Unscrew inner part of oil seal extractor -3203. Further assembly is basically the reverse of the dismantling pro‐ cedure. 5 mm) out of outer part and lock with knurled screw.. place it in posi‐ tion and exerting firm pressure screw it into oil seal as far as possible.

Jetta 2005 ➤ . in part or in w l purpos hole ercia . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ss y db ise r tho au Tighten bolt for poly V-belt sprocket .from coolant pipe -4-.G 1601♦ Counter-hold tool -3415♦ Pin -3415/1- rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Remove exhaust gas recirculation valve -N18. Collect leaking engine oil with a cloth. 40 Rep.off. Bora 2006 lkswagen AG AG.A.6 l engine. direct injection) . – Take caps -1.from cap -1-.crankshaft up to the crankshaft pulley sprocket must be free of oil and grease.2005 l ot o V 2. – Remove bolt -2. C op yi .3 es. – Remove bolts -5.⇒ page 195 . Vo➤ does agen ksw n 4-cylinder Injection engine (1. agen lksw Vo by AG. – Unhook wiring harness (not shown in the figure) on the coolant pipe -4-. Prote cted by c o p yri gh t.and -3.Crankshaft group ht rig py Co t.crankshaft ility ab y li an pt ce gu ara nte eo ra c Special tools and workshop equipment required ♦ Torque wrench -V. Note Observe that all contact surfaces from the bolt for the poly V-belt sprocket . – Place poly V-belt sprocket to the bearing bush and screw new bolt into for the poly V-belt sprocket.13 . Gr.Edition 08.

– Set the counter-hold -3415. – Now tighten bolt for poly V-belt sprocket in the 2nd stage as follows: Turn bolt 180° (1/2 turn) further. Tighten cable tie tightly. Volkswagen AG age ksw Vol – Tighten bolt for poly V-belt sprocket byin the 1st stage as follows: Tightening torque: 150 Nm pe rm itte d es.and secure in this position using a cable tie. C op yi 41 . agen lksw Vo by AG. Turning further can be done in several stages.Edition 08. Bora 2006 ➤ 4-cylinder Injection engine (1.with a coloured pen..Jetta 2005 ➤ .to camshaft hous‐ ing -2. 2. The position of the hole -3. Prote cted by c o p yri gh t .otherwise it will not turn when turning further. – Check exhaust camshaft position. direct injection) . r te o iva r rp fo g n do c um en – In this position mark the position of the bolt -3.2005 The bolt for the poly V-belt sprocket is spotted on the bolt head -arrow-. in part or in w l purpos hole ercia .to the poly Vbelt sprocket -1. is n m ot com un le ed ris ho t au ss does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Now mark position of exhaust camshaft -1. n AG. support counter-hold on wishbone -A. Removing and installing sealing flange and flywheel ht rig py Co t.6 l engine. The marking must not be made on the washer -2.is not relevant for the later check.into the openings of the poly Vbelt sprocket using pin -3415/1. Always use a new bolt.-arrows-.

6 l engine. direct injection) . – Check timing ⇒ page 67 .Jetta 2005 ➤ . in part or in w l purpos hole ercia . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Note – If the journal of the chain sprocket is not in the crankshaft groove anymore. o h t or u ac a ss es. They must be free of oil and grease.13 . AG. – Thoroughly clean also the contact surface of the chain sprock‐ et. If both markings -1.do not align.and -2. – Check timing ⇒ page 67 . If the markings -1.align.Crankshaft group ht rig py Co t. thi sd o cu m en 42 Rep.Edition 08. Replace a damaged chain sprocket. seal and bearing bush and clean thoroughly. Bora 2006 ➤ 4-cylinder Injection engine (1.2005 • Both markings -1. In this way it is checked whether the chain sprocket has turned on the crankshaft when the bolt for the poly V-belt sprocket was tightened.must align. Prote cted by c o py rig ht . If the timing is OK: ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit The crankshaft has been turned to the poly V-belt sprocket. remove and check it for damage. Volkswagen AG d agen oes ksw not l o gu yV b ar First check whethersthe in d journal of the chain sprocket is still an the e i tee r crankshaft groove. Gr.and -2. – Replace damaged parts. – Reinstall parts with a new bolt for the poly V-belt sprocket. – Remove poly V-belt sprocket. If the timing is not OK: – Adjust timing ⇒ page 69 .and -2. agen lksw Vo by AG. C op yi .

2. – Position engine at TDC for cylinder No.2005 o h t or u a a c ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Fitting appliance -T10134- ♦ Socket insert AF 24 -V. – Remove intermediate plate.4 Renewing crankshaft sealing flange -flywheel endes. Volkswagen AG do es n wage s k l ot g o Jetta yV ua 2005 ➤ .Edition 08. C op yi 43 .A. is n m ot com Special tools and workshop equipment required ♦ Torque wrench -V. 1332/11♦ Three M6×35 mm hexagon bolts ♦ Feeler gauges ♦ Vernier gauge r te o iva r rp fo g n do c um en Procedure Note ♦ To show the work sequence more clearly.G. agen lksw Vo by AG. Pressing sealing flange with sender wheel off crankshaft – Remove the flywheel ⇒ page 50 . 1331- pe rm itte d un le n AG. Bora 2006 ➤ b ran ed s i tee r Injection engine (1. Removing and installing sealing flange and flywheel ht rig py Co t. ⇒ page 67 . 1.A. – Remove oil sump ⇒ page 87 . 2. direct injection) 4-cylinder .6 l engine. Prote cted by c o p yri gh t . ♦ The work sequence is the same when the engine is in the ve‐ hicle and the gearbox removed. the sequence is de‐ scribed for a removed engine. in part or in w l purpos hole ercia .G.

Crankshaft group ht rig py Co t. in part or in w l purpos hole ercia . Note Sealing flange and sender wheel are pressed off the crankshaft with M6×35 mm bolts.and -2. This support ring serves the function of a fitting sleeve and may not be removed prior to installation. Gr. C op yi . c o p yri gh t . Continuation for all vehicles es.by a locating pin. twisted after removal from packaging. – Screw three M6×35 mm bolts into the threaded holes of the sealing flange -arrow-. The coolant hoses remain connected. thi sd o cu m en – Screw bolts alternately (maximum 1/2 turn (180 °) for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.6 l engine. Bora 2006 ➤ 4-cylinder Injection engine (1.-arrow-. – Undo sealing flange securing bolts.Edition 08. ♦ The sender wheel is held in its installation position on the as‐ sembly device -T10134. 44 Rep. ♦ Sealing flange and seal are one unit and must be replaced ♦ The assembly device -T10134. together with the sender wheel only. Pressing sealing flange with sender wheel onto crankshaft Note ♦ The sealing flange with a PTFE seal is equipped with a sealing ♦ Sealing flange and sender wheel must not be separated or agen lksw Vo by AG. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG. direct injection) .is held in its position relative to the crankshaft by a guide pin inserted into a hole in the crankshaft. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Remove engine speed sender -G28.2005 Models with auxiliary heater – Remove bolts -1.13 . Prote cted by lip support ring.Jetta 2005 ➤ .and pull coolant hoses off engine and gearbox.

Fit assembling seal with sender wheel on assembly appliance -T10134– Screw hexagon nut -B.from new sealing flange. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng y db ua ran tee – Screw hexagon nut onto the threaded spindle until the inner part of assembly appliance and the assembly bell housing are at same height.Locating pin E .Guide pin for petrol engines (red knob) A .Jetta 2005 ➤ .Hexagon nut C .auth es. thi sd o cu m en 2.of threaded spindle.6 l engine.Guide pin for diesel engines (black knob) G .-arrow-. direct injection) . Removing and installing sealing flange and flywheel ht rig py Co t. ss or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Remove securing clip -arrow.in a vice on clamping sur‐ A G do agen es n ksw l face -A. Bora 2006 ➤ 4-cylinder Injection engine (1.Assembly bell housing D .Hexagon socket head bolt F .to just before clamping surface -A. ot g o V ise – Press assembly bell housing or -C.2005 Fitting appliance -T10134A . olkswagen A G. agen lksw Vo by AG. in part or in w l purpos hole ercia . C op yi 45 . V – Clamp assembly device -T10134.downwards so that it lies on hexagon nut -B.of threaded spindle. Prote cted by c o p yri gh t.Edition 08.Clamping surface B . Note The sender wheel must not be taken out of the sealing flange or twisted.

Crankshaft group agen lksw Vo by AG.6 l engine. – Push sealing lip support ring -A. in part or in w l purpos hole ercia . 46 Rep. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his – Place sealing flange with front side on assembly device T10134.Edition 08.13 .must align with marking -B. C op yi . Bora 2006 ➤ 4-cylinder Injection engine (1. direct injection) .2005 – Locating hole -A. es. – Place sealing flange with front side downwards on a clean flat surface. Gr.on sealing flange. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Upper edge of sender wheel and front edge of sealing flange must align -arrows-. AG. Prote cted by c o p yri gh t. Note do c um en Ensure sealing flange lies flat on assembly device.downwards in -direction of arrow.that locating pin -B.on sender wheel -C.Jetta 2005 ➤ . ht rig py Co t.can be inserted in sender wheel hole -A-.until it lies on flat surface.

r fo ng C . direct injection) . until hexagon nut -B. Bora 2006 ➤ 4-cylinder Injection engine (1. ensure that sender wheel remains fixed in assembly device.whilst tightening the three knurled screws -A-.lies against assem‐ bly bell housing -A-.with sealing flange to crankshaft flange • • Crankshaft flange must be free of oil and grease. B .Bolting assembly tool -T10134. so that locating pin cannot slide out of sender wheel hole.into the cylinder block to guide the sealing flange. Volkswagen AG d agen of crankcase sealing surface. – Screw two M6x35 mm bolts -A. in part or in wh ole. 1 cylinder. cial p is n mer m ot p o c erm or e t a itte v i r d p un le ss rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Screw hexagon socket head bolts -A.to end of threaded spindle. Removing and installing sealing flange and flywheel agen lksw Vo by AG.to crankshaft flange using hexagon socket head bolts -A-. Prote cted by c o py rig ht .2005 – Push sealing flange and support ring for sealing lip -B. 5 threads).Edition 08. 47 .against surface of assembly device -T10134. Note urposes. Engine positioned at TDC No. – Align flat side of assembly bell housing towards oil sump side AG.in -direction of arrow-.Jetta 2005 ➤ .6 l engine. oes n lksw o yV db e ris tho au ot g ua ran tee or ac ility ab y li an pt ce – Secure assembly tool -T10134.into crankshaft flange (ap‐ prox.onto crankshaft flange ht rig py Co t. – Press threaded spindle of assembly tool -T10134. – Screw hexagon nut -B. Note When installing sealing flange.Attaching assembling tool -T10134. C op yi 2.

Gr.Checking sender wheel installation position on crankshaft – Screw hexagon nut -E. Prote cted by . direct injection) .G 1332/11. a small air gap must be present between cylinder block and sealing flange.and sender wheel -B-.A.out of sealing flange..by hand in -direction of arrow. agen lksw Vo by c o p yri gh t . – Hand tighten both hexagon socket head bolts of assembly tool. – Remove assembly tool -T10134.A.from cylinder block. gen .until sealing lip support ring -B.Edition 08. ht rig py Co t. Note The guide pin for diesel engines (black knob) -F. Bora 2006 ➤ 4-cylinder Injection engine (1. – Set vernier gauge on crankshaft flange.contacts crankshaft -A-. 48 Rep.into threaded hole in crankshaft.G 1331. thi sd o cu m en – Remove sealing lip support ring. C op yi – The sender wheel is in the correct installation position on the crankshaft if a gap -a. – Remove the two bolts -A.Jetta 2005 ➤ . E . – Screw the three knurled screws -B. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit After hexagon nut is tightened to 35 Nm torque.to end of threaded spindle. Vo u b ran ed tee ris D . Note es.onto threaded spindle by hand es n wage s k l ot g lies against assembly bell y housing -C-.13 . This ensures that the sender wheel reaches its final installation position. Volkswa AG do until it n AG – Screw hexagon nut -E.= 0.5 mm exists between crankshaft flange -A.6 l engine. – Push guide pin for petrol engines (red knob) -F.and 24 mm insert -V. in part or in w l purpos hole ercia .must not be in‐ serted in threaded hole of crankshaft.to 35 Nm us‐ ing torque wrench -V.Crankshaft group AG..Pressing sender wheel ho onto crankshaft flange using assembly t or u tool -T10134ac a s a – Tighten hexagon nut of assembly tool -T10134.2005 – Push assembly bell housing -C.

Removing and installing sealing flange and flywheel ht rig py Co t.Re-pressing sender wheel pe rm itte d – Install intermediate plate. r te o iva r rp fo g n do c um en agen lksw Vo by – Screw hexagon nut -E. is n m ot com F . Is measurement -a.is achieved: – Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence. un le .onto threaded spindle by hand until it lies against assembly bell housing -C-. – Hand tighten both hexagon socket head bolts.too small: – Press sender wheel further ⇒ page 49 When dimension -a. ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Secure assembly tool -T10134. – – – Install flywheel ⇒ page 50 .Jetta 2005 ➤ . 2. tee ris ho t or u ac a Install oil sump ⇒ page 87 . AG.to crankshaft flange using hexagon socket head bolts -A-. Prote cted by c o py rig ht . es.Edition 08.by hand to sealing flange.between crankshaft flange and sender wheel.6 l engine. Bora 2006 ➤ 4-cylinder Injection engine (1. – Push assembly tool -T10134.2005 – Measure distance -a. in part or in w l purpos hole ercia .and tighten secur‐ t gua b d ran e ing bolt to 5 Nm. Volkswagen AG gen AG does swa k no l o Install engine speed sender -G28y V -arrow. C op yi 49 . direct injection) .

2.2005 – Tighten hexagon nut of assembly tool -T10134. – Check installation position of sender wheel on crankshaft again ⇒ page 48 . Note urposes. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en To avoid damaging the dual-mass flywheel during removal.Edition 08. Removing and installing gearbox .G 1332/11.and 24 mm insert -V.A. the bolts -B.to 45 Nm. C op yi .to 40 Nm us‐ ing torque wrench -V. – Check installation position of sender wheel on crankshaft again ⇒ page 48 .so that the bolts -B. – Rotate the dual-mass flywheel -A.must not be removed using a pneumatic or impact driver. direct injection) . If dimension -a. cial p is n mer m ot p o c erm or e t a itte v i r d p Removing un le n AG. Gr.must be unscrewed by hand only. – When removing bolts -B-. Gr. Bora 2006 ➤ 4-cylinder Injection engine (1.align centrally with the holes -arrows-. Prote cted by c o p yri gh t . r fo ng 50 Rep. make sure that screw heads do not jam on flywheel. 34 . agen lksw Vo by AG.Crankshaft group ht rig py Co t.13 . The bolts -B.A.is too small again: – Tighten hexagon nut for assembly tool assembly device T10134. in part or in wh ole. Rep.5 Removing and installing flywheel Special tools and workshop equipment required ♦ Counter-hold tool -3067- – Remove gearbox ⇒ 6-speed manual gearbox 0AG.Jetta 2005 ➤ .G 1331..6 l engine.

in hole on cylinder block. observe the following: w – Renew bolts and tighten to 60 Nm and 90° (1/4 turn) olks y V further.2005 – Insert counter-hold tool -3067. is n m ot com pe rm itte d un le b ed ris o h t au ss not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 2. During this step. agen lksw Vo by AG. – Unbolt flywheel. Prote cted by c o p yri gh t. C op yi 51 .6 l engine. Removing and installing sealing flange and flywheel ht rig py Co t.Jetta 2005 ➤ . • Installation position of counter-hold: A . AG. direct injection) . Installing Install in reverse order of removal.Edition 08. in part or in w l purpos hole ercia . Bora 2006 ➤ 4-cylinder Injection engine (1.To loosen – Mark position of flywheel in relation to engine.To tighten B . Volkswagen AG d agen oes es.

022 47. in part or in w l purpos hole ercia . Measuring the main bearing clearance is not possible with nor‐ mal workshop equipment.022 47.1 Crankshaft dimensions n AG. agen lksw Vo by AG.30 -0. Just loosening the main bearing caps will cause deformation of the cylinder block bear‐ ing pedestals.13 . Volkswagen AG do e wage ks Vol by d e ris tho u a ss Honing dimension dimensions in mm pe rm itte d Conrod bearing journal-∅ -0. Gr.Edition 08. is n m ot com un le Basic dimension s no t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s 2nd undersize 3rd undersize r te o iva r rp fo g n do c um en 52 Rep.80 -0.Crankshaft group ht rig py Co t. C op yi .6 l engine.037 -0. 3.037 1st undersize es. Even if the bearing shells are not renewed bearing damage could occur due to a different bearing clear‐ ance.022 47.037 -0. Bora 2006 ➤ 4-cylinder Injection engine (1.05 -0. direct injection) .037 -0.Jetta 2005 ➤ . This deformation will cause a reduction of the bearing clearance. Prote cted by c o p yri gh t .022 47. the cylinder block must be replaced complete with the crankshaft.55 -0.2005 3 Removing and installing crankshaft Caution The crankshaft must not be removed. If the bearing cap bolts are loosened.

direct injection) . Volkswagen AG d agen oes Checking cylinder bores ⇒ page 55 Piston and cylinder dimensions ⇒ page 55 es.Retaining ring 4 .Conrod ❑ Renew as set only ❑ Mark cylinder number -arrows A❑ Installation position: Marking -arrows Bfaces towards pulley end ❑ Guided axially via piston 5 .090 mm ❑ Do not rotate crankshaft when checking radial clearance 6 . Prote cted by c o p yri gh t.Piston ❑ Checking ⇒ page 54 ❑ Mark installation posi‐ tion and cylinder num‐ ber ❑ Arrow on piston crown points to belt pulley end ❑ Install using piston ring clamp 2 . Bora 2006 ➤ 4-cylinder Injection engine (1.Jetta 2005 ➤ .Ball socket ❑ Do not interchange used bearing shells.1 Note Pistons and conrods . 1 .143 . heat piston to 60 °C ❑ Remove and install drift -10 . in part or in w l purpos hole ercia .Assembly overview Oil all contact surfaces before beginning with the assembly work. Dismantling and assembling pistons and conrods r te o iva r rp fo g n do c um en ht rig py Co t.Piston pin ❑ If difficult to remove. is n m ot com pe rm itte d Check piston ⇒ page 54 un le ss 53 Pistons and conrods .Cylinder block ❑ Checking cylinder bores ⇒ page 55 ❑ Piston and cylinder dimensions ⇒ page 55 4. C op yi 53 . agen lksw Vo by AG.2005 4 ksw Dismantling and assembling pistons Vol by d e ris and conrods tho au AG.Assembly overview ⇒ page not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s 4.6 l engine. ❑ Insert bearing shells centrally Check radial clearance with Plastigage: ❑ New: 0.060 mm ❑ Wear limit: 0.020…0.Edition 08.

Bora 2006 ➤ 4-cylinder Injection engine (1. 15 mm from bottom end of cylinder.2 Check piston Special tools and workshop equipment required ♦ External micrometer 75. – Measure pistons approx. but do not turn further 9 .04 mm.100 mm Check piston thi sd o cu m en Checking piston ring gap – Push ring squarely from above down to approx. ..Oil scraper ring AG.0 1.20…0. 0.Conrod bearing cap ❑ The caps only fit in one position and only on the appropriate conrod.60 0.40…0. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit 4.13 .0 ---1) 54 Rep.6 l engine.Edition 08.Compression rings ❑ Offset gaps by 120° ❑ Remove and install compression rings using piston ring pliers. in part or in w l purpos hole ercia .50 0. direct injection) .20…1.. Gr. Nominal dimension ⇒ page 55 . C op yi AG.Jetta 2005 ➤ . at 90° to the piston pin axis. Volkswagen AG d ❑ Remove and install 3-part oil scraper ring carefully agenby hand oes ksw no l o y V to adjacent compression ring t gua b ❑ Offset end of upper steel band ring by e 120° d ran tee ris ❑ Install part ends of the oil scraper u ring tho offset to each other or ac a ❑ Checking ring gap ⇒ page 54 ss ❑ Clearance can not be measured 10 . this is due to the breaking procedure (industrially cracking) separating the cap from the conrod 8 .Crankshaft group ht rig py Co t. ❑ Checking ring gap ⇒ page 54 ❑ Checking ring-to-groove clearance ⇒ page 54 es. ❑ “TOP” faces towards piston crown. 12 mm from the lower edge of skirt. agen lksw Vo by Prote cted by c o py rig ht .2005 7 . 30 Nm + 90° (1/4 turn) further ❑ Renew ❑ Oil threads and contact surfaces ❑ To measure radial clearance. Deviation from nominal dimension max. tighten to respective tightening torque. Piston ring dimensions in mm 1st compression ring 2nd compression ring Oil scraper ring 1) No wear limit details new 0.10 Wear limit 1.Conrod bolt.

06 0.955 76.2005 piston ring-checking ring-to-groove clearance Clean groove before check. r te o iva r rp fo g n do c um en Basic dimen‐ sion 1st oversize 2nd oversize mm mm mm 76. Piston ring dimensions in mm 1st compression ring 2nd compression ring Oil scraper ring new Wear limit 0. in part or in w l purpos hole ercia . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s 4. Bora 2006 ➤ 4-cylinder Injection engine (1. C op yi 4. 12 mm from the piston lower edge 4.6 l engine. – Nominal dimension ⇒ page 55 .455 76. is n m ot com un le rrectness of i t to the co nform spec a t i h re o n in wit thi s – Take measurements at 3 positions in both lateral -A.15 0.02…0. Prote cted by c o py rig ht .04…0. as illustrated. Dismantling and assembling pistons and conrods agen lksw Vo by Honing dimen‐ sion Piston ∅2) Cylinder bore ∅ ht rig py Co t.08 mm.planes.and lon‐ gitudinal -B.as in‐ correct measurements would then be possible.705 76.08 0.Jetta 2005 ➤ .1 Checking cylinder bores pe rm itte d ility ab y li an pt ce Special tools and workshop equipment required ♦ Internal dial gauge 50…100 mm Checking cylinder bores es.2. Deviation from nominal dimension max.3 Piston and cylinder dimensions 55 .Edition 08. AG.01 2) Measure approx.15 Can not be measured AG. Note Measuring the cylinder bores must not be done when the cylinder block is fitted to the engine/gearbox bracket -VAS 6095.51 76. 0.76 77. direct injection) .

♦ The plastic packing pieces for protecting the open valves must ♦ If the cylinder head is replaced. not be removed until immediately before fitting cylinder head. work. valve gear Cylinder head ♦ When installing an exchange cylinder head.Assembly overview ⇒ page 57 Removing and installing camshaft housing ⇒ page 59 Removing and installing cylinder head ⇒ page 63 Checking valve timing ⇒ page 67 Adjusting valve timing ⇒ page 69 Checking compressions ⇒ page 74 . must also be renewed.Cylinder head. valve gear AG. all the coolant in the system ♦ Oil all contact surfaces before beginning with the assembly ♦ Dismantling and assembling intake manifold ⇒ page 162 Cylinder head .15 . Gr.Jetta 2005 ➤ . direct injection) . es. C op yi .6 l engine. all the contact surfaces between the support elements. 56 ht rig py Co t.2005 15 – 1 Note Cylinder head. roller rocker fingers and the cams must be oiled before installing the camshaft housing.Edition 08. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en Rep. agen lksw Vo by Prote cted by c o p yri gh t . in part or in w l purpos hole ercia . Bora 2006 ➤ 4-cylinder Injection engine (1. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG.

nip open and replace.O-ring ❑ Renew if damaged.Oil pressure switch -F1. Cylinder head 57 . ❑ Sealing surfaces to the camshaft housing must be free of oil and grease ❑ After renewing.Retainer 9 . ❑ If sealing ring is leaking..Edition 08. ❑ With hydraulic valve clearance compensation. cial p is n mer m ot p o c erm or e t a itte v i r d p 7 . in part or in wh ole.Assembly overview 1 . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r To air cleaner o eo h ut ra a c s s -G40Hall sender 11 .Cylinder head ❑ Removing and installing ⇒ page 63 ❑ Check for distortion ⇒ page 58 .10 Nm + 90° (1/4 turn) fur‐ ther ❑ Renew ❑ Remove from outside inwards ⇒ page 61 ❑ Tighten from centre out‐ wards ⇒ page 63 4 . ❑ Oil contact surfaces. C op yi 1.10 Nm 56- 8 . renew entire coolant. Bora 2006 ➤ 4-cylinder Injection engine (1. un le AG.6 l engine.10 Nm 3 . 15 .Support element ❑ Do not interchange.Stud. ❑ Use securing clip to clip onto support element when installing r fo ng agen lksw Vo by ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 12 . 25 Nm ❑ Checking ⇒ page 94 .1 Cylinder head .Dowel pins AG.Cylinder head bolt ❑ Renew ❑ Observe installation in‐ structions and se‐ quence when loosening and tightening ⇒ page 63 urposes. direct injection) . 14 . 16 .Roller rocker finger ❑ Check roller bearing for easy movement ❑ Oil contact surfaces. 6 Nm ❑ For air cleaner 10 .Cylinder head gasket ❑ Renew ht rig py Co t. 13 .Cable guide ❑ Fit on camshaft housing with 8 Nm 2 .2005 1.Jetta 2005 ➤ . Prote cted by c o p yri gh t.

Cylinder head. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 58 Rep.Guide pins ❑ Tightening torque: 20 Nm 18 . permissible distortion: 0. valve gear ht rig py Co t. C op yi . in part or in wh ole.Lifting eye 19 . ❑ Apply sealing compound -D 188 003 A1.High-pressure pump ❑ For fuel supply system ❑ With fuel pressure regulating valve -N276❑ Removing and installing ⇒ page 139 Checking cylinder head for distortion Max. cial p is n mer m ot p o c erm or e t a itte v i r d p 23 . they must be oil and grease free. renew entire coolant.Camshaft housing ❑ With integrated camshaft bearings ❑ Removing and installing ⇒ page 59 ❑ Remove sealant remnants ❑ Thoroughly clean sealing surfaces.6 l engine.20 Nm 20 . agen lksw Vo by AG.Oil strainer ❑ Fitted in cylinder head ❑ Renew 21 . Prote cted by c o p yri gh t.2005 ❑ Metal gasket ❑ After renewing.15 .Edition 08.O-ring ❑ Renew ❑ Coat with oil before inserting 24 . urposes.Bucket tappet ❑ Renew ❑ Oil contact surfaces.before fitting ❑ When installing fit vertically from above onto studs and dowel pins 22 . 17 .Jetta 2005 ➤ . Gr.05 mm un le AG. Bora 2006 ➤ 4-cylinder Injection engine (1. direct injection) .

Prote cted by c o p yri gh t . in part or in wh ole. agen lksw Vo by AG. direct injection) .6 l engine. Cylinder head 59 .2 Removing and installing camshaft housing Special tools and workshop equipment required ♦ Dial gauge -VAS 6079♦ Puller -T10094♦ Dial gauge adapter T10170♦ Camshaft clamp -T10171♦ Counter-hold tool -T10172♦ Locking pin -T40011- ♦ Spark plug spanner -3122 B- urposes. C op yi 1.Jetta 2005 ➤ .Edition 08. cial p is n mer m ot p o c erm or e t a itte v i r d p un le n AG. Bora 2006 ➤ 4-cylinder Injection engine (1. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng ht rig py Co t.2005 1.

Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Two M6x80 studs ♦ Sealants -D 188 003 A1- Removing camshaft housing ⇒ page 60 Installing camshaft housing ⇒ page 61 1. Bora 2006 ➤ 4-cylinder Injection engine (1.2005 ♦ Torque wrench -V.Edition 08. C op yi thi sd o cu m en ♦ The camshaft housing sealing surface must not be reworked. To do this use extractor -T10094⇒ page 198 .from camshaft housing.⇒ page 195 and remove camshaft sealing caps.R.Cylinder head. – Unscrew earth cable -3. wrap a cloth around the connection. valve gear AG. – Pull connector -1.G 1331- es. Prote cted by c o py rig ht .2. – Remove exhaust gas recirculation valve -N18. in part or in w l purpos hole ercia .. – Position crankshaft at TDC for cylinder No. Gr.and connector -2.1 Note Remove camshaft housing ♦ The camshafts are mounted in the camshaft housing on this engine. the control housing must be removed be‐ fore the camshaft housing can be removed ⇒ page 31 . ht rig py Co t. Therefore. Then turn crank‐ shaft against D.6 l engine.from high-pressure pump. – Disassembling the wiring with wiring harness from the cam‐ shaft housing. agen lksw Vo by .off Hall sender -G40.O. direct injection) . 45° of engine and remove camshaft sprockets with the control chain ⇒ page 69 . Before loosening fuel pipes. – Remove control housing ⇒ page 31 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. 60 Rep. Then release pressure by carefully removing the hose.A. WARNING The fuel line is under pressure! Wear protective glasses and protective gloves to avoid injuries and skin contact. 1.off inlet camshaft control valve 1 -N205. – Disconnect connector -4.15 .Jetta 2005 ➤ . – Remove ignition coils.

Jetta 2005 ➤ , Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005 – Pull connector and fuel supply line -arrows- off the high-pres‐ sure pump.

– Remove cable guide -2- and remove clip -4- from the highpressure line. Note

Lock the screwed connections on the high-pressure pump and on fuel rail when unbolting the union nuts with a spanner.
– Unscrew union nuts -3- and -1- of the high-pressure line. – Remove dipstick. – Remove fuel rail ⇒ page 168 . – Unscrew the left lifting eye. – Unscrew camshaft housing bolts in the sequence -15 … 1.
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1.2.2

Installing camshaft housing

Prerequisites The pistons must not be positioned at TDC.

– Remove sealant remnants on cylinder head camshaft housing with a commercially available sealant remover. – Prevent dirt and residual sealant from entering cylinder head. – Clean sealing surfaces carefully. They must be free of oil and grease.

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– Apply a thin even coat of sealant onto the clean camshaft housing sealing surface. See hatched area on illustration. Note

The sealant must not be applied too thick otherwise excess seal‐ ant can enter the oil channels and cause damage to the engine.

62

Rep. Gr.15 - Cylinder head, valve gear

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– Carefully fit the camshaft housing vertically onto the cylinder head studs -arrows- and the dowel pins of the cylinder head. Note

Ensure no oil remnants drop on the sealing surfaces.

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Sealant must be left dry for approx. 30 minutes after installing camshaft housing.
– Adjust timing ⇒ page 69 . Further assembly is basically the reverse of the dismantling pro‐ cedure. During this step, observe the following: ♦ Install control housing ⇒ page 31 . ♦ Installing fuel lines ⇒ page 139 . ♦ Installing exhaust gas recirculation valve -N18- ⇒ page 195 .
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To remove the cylinder head it is necessary to remove the engine with the gearbox. When working on the engine, the engine should be secured on the engine and gearbox support -VAS 6095- .
Remove cylinder head ⇒ page 64 Install cylinder head ⇒ page 65
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– Remove the engine ⇒ page 4 . – Remove gearbox and fit engine to engine and gearbox bracket -VAS 6095- ⇒ page 14 . If the cylinder head must be dismantled, remove the following components: ♦ Intake manifold ⇒ page 164 ♦ Fuel rail ⇒ page 168 ♦ Exhaust manifold ⇒ page 186 – Pull retaining clip for coolant pipe out -arrow-. Note

The thermostat is removed for a clearer illustration.

64

Rep. Gr.15 - Cylinder head, valve gear

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– Remove control housing ⇒ page 31 . – Pull thermostat housing off coolant pipe. AG. The inscription (Part No. – Remove exhaust gas recirculation valve -N18.Jetta 2005 ➤ . – Loosen socket head bolts in the sequence given and then re‐ move. – Ensure the roller rocker fingers and the support elements are not interchanged.2 • Install cylinder head k Vol by d e ris tho u a ss Prerequisites wagen AG .3. emery residue and cloths. Volks The pistons must not be positioned at TDC. c o p yri gh t . – Set No. Cylinder head 65 . – Carefully lift cylinder head off. 1 cylinder piston to top dead centre and then turn crankshaft back slightly. does gen AG swa Note not gu ara nte eo ra c ility ab y li an pt ce es. agen lksw Vo by Prote cted by do c um en ht rig py Co t. in part or in w l purpos hole ercia . – Carefully remove metal particles. 1.⇒ page 195 . direct injection) . – Fit new cylinder head bolts and tighten hand tight. – Place cylinder head on. – Fit new cylinder head gasket.6 l engine.2005 – Remove thermostat housing from cylinder head -arrows-. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used. rrectness of i t to the co nform spec at i h re o n wit in t his – Now carefully clean sealing surfaces of cylinder head and cyl‐ inder block.) must be legible. leakage. C op yi 1. – Remove camshaft housing ⇒ page 59 . Damage will cause – Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. is n m ot p om c r erm o e t a itte riv du p or nl f e g n ♦ Do not remove new cylinder head gasket from its packing until immediately before installing. grade must not be less than 100). ♦ Handle new gasket with extreme care.Edition 08. – Remove roller rocker finger together with support elements and place on a clean surface. Bora 2006 ➤ 4-cylinder Injection engine (1. When doing this observe the central‐ izing pins in cylinder block.

Prote cted by c o p yri gh t.2005 – Tighten cylinder head in tightening sequence as follows: – Tighten all bolts to 30 Nm. During this step. urposes.Edition 08. – Adjust timing ⇒ page 69 . r fo ng 66 Rep. in part or in wh ole. observe the following: AG. ♦ Installing fuel lines ⇒ page 139 .⇒ page 195 . – Install camshaft housing ⇒ page 59 . – Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end or support element.Jetta 2005 ➤ .Cylinder head. ♦ Install control housing ⇒ page 31 . – Renew oil strainer -arrow. direct injection) . cial p is n mer m ot p o c erm or e t a itte v i r d p un le Further assembly is basically the reverse of cedure. – Then tighten all bolts 90° (1/4 turn) using a rigid wrench.15 .6 l engine.and lay it into the cylinder head. valve gear ht rig py Co t. – Then tighten all bolts again 90 (1/4 turn) further. agen lksw Vo by AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c thessdismantling pro‐ ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en ♦ Installing exhaust gas recirculation valve -N18. Bora 2006 ➤ 4-cylinder Injection engine (1. C op yi . Gr.

AG. direct injection) . To do this use puller -T10094. – Remove bolt -2.off. agen lksw Vo by – Remove bolts -5.Edition 08.and the spark plug spanner 3122 B ⇒ page 198 . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Test procedure – Remove exhaust gas recirculation valve -N18.6 l engine. ht rig py Co t.and -3.from cap -1-. 1. Cylinder head 67 .Jetta 2005 ➤ . – Unhook wiring harness (not shown in the figure) on the coolant pipe -4-. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.4 Checking valve timing Special tools and workshop equipment required ♦ Spark plug spanner -3122 B♦ Torque wrench -V. C op yi r fo ng 1.A.from coolant pipe -4-. – Remove spark plug from cylinder No. c o p yri gh t. in part or in wh ole.2005 1. Bora 2006 ➤ 4-cylinder Injection engine (1. Prote cted by – Take caps -1.⇒ page 195 . Collect leaking engine oil with a cloth.G 1331♦ Dial gauge -VAS 6079♦ Puller -T10094♦ Dial gauge adapter T10170♦ Camshaft clamp -T10171- urposes.

45° against en‐ gine direction of rotation.⇒ page 195 . Then turn the crankshaft in engine D.Edition 08. During this step. permissible deviation of TDC cylinder No. ut es. Gr. The inscription “TOP” -arrow e 3.01 mm.up to limit stop and clamp with the clamping nut -arrow-.can not be inserted up to limit stop into the camshaft openings the timing is wrong and must be adap‐ ted again ⇒ page 69 .Cylinder head. the crankshaft must be turned again approx. ♦ Max. ♦ Installing exhaust gas recirculation valve -N18. Bora 2006 ➤ 4-cylinder Injection engine (1. direct injection) .with the extension -T10170/1. – Fit camshaft clamp -T10171.O.6 l engine. – Set crankshaft in engine D. – Set dial gauge -VAS 6079. Note the position of the dial gauge indicator. C op yi . Further assembly is basically the reverse of the dismantling pro‐ cedure.2005 – Turn the dial gauge adapter -T10170. 1: ±0. Volkswagen olks the holes The retaining pins -arrows 1.to limit stop into the spark plug thread. The holes -arrows.must be legible from ris ho above. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng nA wage s If the camshaft clamp -T10171. to TDC cylinder No.must engage Vinto by d -arrows 2-.in the camshafts must stand as shown. rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 68 Rep. If nec‐ essary turn crankshaft one turn further (360°).to limit stop into the camshaft openings. in part or in w l purpos hole ercia . 1.15 . to TDC cylinder No.can be in‐ serted into the camshaft openings up to limit stop.01 mm past the TDC. Prote cted by c o p yri gh t.R. valve gear ht rig py Co t. agen lksw Vo by AG.O. 1. sa AG do es n ot g ua ran tee or ac ility ab y li an pt ce The timing is OK when the camshaft clamp -T10171.R.Jetta 2005 ➤ . G. Note ♦ If the crankshaft was turned more than 0. observe the following: ♦ Renew seals for the camshaft sealing caps and lubricate be‐ fore installing.

Cylinder head 69 .2005 1. Bora 2006 ➤ 4-cylinder Injection engine (1. Prote cted by c o p yri gh t. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en ht rig py Co t. in part or in w l purpos hole ercia .Jetta 2005 ➤ . direct injection) .6 l engine.Edition 08. C op yi 1.5 Adjusting valve timing Special tools and workshop equipment required ♦ Dial gauge -VAS 6079♦ Puller -T10094♦ Dial gauge adapter T10170♦ Camshaft clamp -T10171♦ Counter-hold tool -T10172♦ Locking pin -T40011- es. agen lksw Vo by AG. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG.

and tighten the crankshaft bolt. direct injection) . – Remove exhaust gas recirculation valve -N18.G 1331un le AG.. in part or in wh ole. valve gear ht rig py Co t.Edition 08.15 .Cylinder head. To do this use counter-hold -3415. crankshaft belt pulley -2. Prote cted by c o p yri gh t.A. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce urposes.Jetta 2005 ➤ . Gr. C op yi .⇒ page 195 .6 l engine. agen lksw Vo by AG. – To turn the crankshaft install bearing bush.2005 ♦ Spark plug spanner -3122 B♦ Counter-hold tool -3415♦ Pin -3415/1♦ Torque wrench V. Bora 2006 ➤ 4-cylinder Injection engine (1.and crankshaft bolt -3. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng Procedure – Remove control housing ⇒ page 31 . 70 Rep.

to TDC cylinder No. Collect leaking engine oil with a cloth. Volkswagen AG gen AG nte eo ra c ility ab y li an pt ce es. – Remove bolts -5. Cylinder head 71 . do c um en – Mark with a felt tipped pen the direction of road of the control chain -3-. ed ris ho ut a ss .with the extension -T10170/1.to 40 Nm and bolt -4. To counterhold use counter-hold -T10172.Jetta 2005 ➤ . 1.has a left-hand thread. 1.(left-hand thread) and -4.from coolant pipe -4-.O. pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n – Press tensioning plate -1.). ht rig py Co t. – Fit camshaft adjuster -1.up to limit stop and clamp with the clamping nut -arrow-.O.2005 – Unhook wiring harness (not shown in the figure) on the coolant pipe -4-. 45° back. – Remove bolt -2. a do this use pullerdoes sw – Remove spark plug from cylinder No.from cap -1-. – Then turn crankshaft against engine D. C op yi 1.and -3.to limit stop into the spark plug thread.to 50 Nm (use counter-hold T10172.6 l engine. Prote cted by c o py rig ht . in part or in w l purpos hole ercia .and spark plug spanner -3122 B⇒ page 198 .in direction of arrow and lock piston with the pin -T40011..and remove cam‐ shaft adjuster -1.again.R. is n m ot com – Turn the dial gauge adapter -T10170.off. Note Centre bolt of the camshaft adjuster -2.R.Edition 08. agen lksw Vo by AG. Bora 2006 ➤ 4-cylinder Injection engine (1.. – Remove bolts -2. – Take caps -1. – Set crankshaft in engine D. Note the position of the dial gauge indicator. direct injection) .and tighten bolt -2.with control chain -3-. To not olk gu yV b ara -T10094. – Renew bolts -2.(left-hand thread) and -4. – Set dial gauge -VAS 6079.

is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit – To secure the camshaft -T10171.01 mm. permissible deviation of TDC cylinder No.must engage into the holes lkswagbe Vomust en Alegible AG. set the control chain on the camshaft sprockets and install removed camshaft sprocket again.. 1: ±0. 1...O. Gr.and -5.2005 – Turn the inlet and outlet camshaft until the camshaft clamp T10171. 1. AG.Edition 08. Note When tightening the camshaft bolts the crankshaft must not turn and the control chain -3. 1: ±0. do not tighten. yV u Note b ed ris o h t au ss ara nte e or ac ility ab y li an pt ce The camshafts must not be moved axially when turning. – Tension control chain by pulling out pin -T40011. the crankshaft must be turned again approx. – With the counter-hold -T10172.Cylinder head. Then turn the crankshaft in engine D.01 mm past the TDC. .can be fitted into the camshaft openings to limit stop. The retaining pins -arrows 1. Note If the crankshaft was turned more than 0. Bora 2006 ➤ 4-cylinder Injection engine (1. agen lksw Vo by c o p yri gh t. valve gear ht rig py Co t. Max. 72 Rep. – Remove camshaft clamp -T10171. C op yi thi sd o cu m en – Screw camshaft bolts into so that the camshaft sprockets can still be turned on the camshaft. The inscription “TOP”w-arrow 3from G do agen es n ks l ot g o above.6 l engine.must remain tensioned on both sides.(left-hand thread) to 40 Nm and -4. – Turn crankshaft two turns in engine direction of road to TDC cylinder No.must not be used as counterhold. to TDC cylinder No. direct injection) . 45° against engine direction of rotation.R. – Remove bolts of the camshaft sprockets. 1.15 .Jetta 2005 ➤ . Caution The camshaft clamp -T10171. permissible deviation of TDC cylinder No.to 50 Nm. in part or in w l purpos hole ercia . es. – Considering direction of road. hand-tight the M6 bolt -arrow-. – Take a camshaft sprocket off.in this position and tighten bolts -2. -arrows 2-. To do this is abso‐ lutely necessary to use counter-hold -T10172. Max.01 mm... Prote cted by – Turn crankshaft in engine direction of road to TDC cylinder No. hold the camshaft sprockets -1.

and turn bolt -2. C op yi 1. ht rig py Co t. thi sd o cu m en If the camshaft clamp -T10171. 1: ±0.has a left-hand thread.can be fitted: – Remove the camshaft clamp -T10171. Bora 2006 ➤ 4-cylinder Injection engine (1. – Turn crankshaft two turns again in engine direction of road to TDC cylinder No.can not be fitted: agen lksw Vo by Prote cted by c o p yri gh t . ♦ Installing exhaust gas recirculation valve -N18. Max. permissible deviation of TDC cylin‐ der No.(lefthand thread) and -4.Jetta 2005 ➤ . – Fit camshaft clamp -T10171. – Repeat adjustment. direct injection) . t au ss ara nte e or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit Note ♦ The centre bolt of the camshaft adjuster -2.to limit w stop ageninto the camshaft oes s k not l o openings. observe the following: ♦ Install control housing ⇒ page 31 . Cylinder head 73 . During this step.Edition 08. 1. ♦ Install Poly V-belt ⇒ page 29 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Repeat adjustment. hold the camshaft sprockets with the counter-hold -T10172. ♦ The camshaft sprockets must not turn on the camshaft when tightening.90° (1/4 turn) further using a rigid wrench. Volkswagen AG d – Fit camshaft clamp -T10171. gu yV ris If the camshaft clamp -T10171ho can not be fitted: b ed If the camshaft clamp -T10171..01 mm. AG. Further assembly is basically the reverse of the dismantling pro‐ cedure.2005 AG. in part or in w l purpos hole ercia . es.6 l engine. ♦ Renew seals for the camshaft sealing caps and lubricate be‐ fore installing.to limit stop into the camshaft openings.⇒ page 195 .

agen lksw Vo by AG. 74 Rep. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his do c um en ♦ Vehicle diagnosis.6 l engine. valve gear ht rig py Co t. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce es.15 . Bora 2006 ➤ 4-cylinder Injection engine (1.6 Check compression pressures Special tools and workshop equipment required ♦ Spark plug spanner -3122 B♦ Torque wrench -V. direct injection) .2005 1.Jetta 2005 ➤ .G 1331♦ Compression tester -V.Edition 08.A. C op yi . Gr.Cylinder head. in part or in w l purpos hole ercia .A.G 1763♦ Puller -T10094AG. testing and information system -VAS 5051- ♦ or vehicle diagnosis and service information system -VAS 5052Test prerequisites • Engine oil temperature must be at least 30 C. Prote cted by c o p yri gh t.

direct injection) . C op yi 1. Cylinder head 75 .Edition 08. If the fault memory was erased the readiness code must be generated.. Further assembly is basically the reverse of the dismantling pro‐ cedure. have a second ss mechanic to operate the starter until tester shows no further pressure increase.Jetta 2005 ➤ . un le e ris ho t au an tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s do c um en ht rig py Co t.6 l engine. in part or in w l purpos hole ercia . – Unscrew spark plugs with spark plug wrench -3122 B. To do this use puller -T10094⇒ page 198 . b d r AG.A.2005 Test procedure – Remove engine cover with air cleaner ⇒ page 161 . – Check compressions with compression tester -V. r te o iva r rp fo g n pe rm itte d – With the accelerator pedal fully depressed. – Interrogate engine control unit fault memory ⇒ page 178 .. – Remove ignition coils. Note n G do es n on wage See relevant test unit operating instructions for instructions ot g olks V y ua how to use test unit. is n m ot com New: 10…15 bar Wear limit: 7 bar Permissible difference between all cylinders: 3 bar – Install spark plugs with spark plug socket -3122 B. Bora 2006 ➤ 4-cylinder Injection engine (1. Volkswagen A Compression pressures: es. Prote cted by c o py rig ht . agen lksw Vo by AG.and tighten to 30 Nm.G 1763.

direct injection) .Edition 08. Bora 2006 ➤ 4-cylinder Injection engine (1.40 Nm + 90° (1/4 turn) fur‐ ther ❑ Left-hand thread ❑ Renew 2 .or Vehicle Diag‐ nosis and Service Infor‐ mation System -VAS 50526 . C op yi . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 1 .10 Nm 7 . Gr.Roller rocker finger ❑ Check roller bearing ❑ Oil contact surfaces ❑ Use securing clip to clip onto support element when installing 76 Rep.Assembly overview ⇒ page 76 Checking camshaft axial clearance ⇒ page 78 Reworking valve seats ⇒ page 79 Checking valve guides ⇒ page 80 Renewing valve stem seals ⇒ page 81 AG. agen lksw Vo by AG. in part or in w l purpos hole ercia . testing and in‐ formation system -VAS 5051. 8 .Camshaft pulley ❑ Note position when in‐ stalling the control chain 5 .2005 2 Repairing valve gear Valve gear .Camshaft variable timing adjustment valve 1 -N205❑ Checking ⇒ Vehicle di‐ agnosis.1 Valve gear .Camshaft housing ❑ Removing and installing ⇒ page 59 ❑ Remove sealant remnants ❑ Apply sealing compound -D 188 800 A1.15 .50 Nm + 90° (1/4 turn) fur‐ ther ❑ Renew 3 .O-ring ❑ Renew if damaged.Cylinder head. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s 2. Prote cted by c o p yri gh t.Assembly overview es.Camshaft adjuster ❑ Must not be dismantled ❑ Removing and installing ⇒ page 69 4 .10 Nm + 90° (1/4 turn) fur‐ ther ❑ Renew ❑ Tighten from centre out‐ wards ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 9 .6 l engine.Jetta 2005 ➤ . valve gear ht rig py Co t.before fitting ❑ When installing fit vertically from above onto studs and dowel pins 10 .

Cylinder head ❑ Reworking valve seat ⇒ page 79 ❑ Reworking sealing surface ⇒ page 78 19 .Outlet camshaft ❑ Do not interchange with inlet camshaft ❑ Checking axial clearance ⇒ page 78 ❑ Coat with oil before inserting (also axle bearing shoulder) 25 . Volkswagen AG do es n wage ❑ With cylinder head installed ⇒ page 81 s k l o o 15 .Valve spring ❑ Removing and installing with removed cylinder head using hold down tool for valve springs -3362n AG.Cotters 12 .Edition 08.Support element ❑ Check oil spray drillings ❑ With hydraulic valve clearance compensation ❑ Do not interchange ❑ Before installing check camshaft axial clearance ⇒ page 78 ❑ Oil contact surfaces 13 .Sealing cover ❑ For outlet camshaft ❑ Remove to remove coolant pipe/bracket ⇒ Item 22 (page 77) ht rig py Co t.Guide sleeve 2. c o p yri gh t . Prote cted by 23 .Valve guide ❑ Checking ⇒ page 80 .Inlet camshaft ❑ With cams for high pressure pump -arrow❑ Remove to remove bucket tappets of the high pressure pump and renew ❑ Do not interchange with outlet camshaft ❑ Checking axial clearance ⇒ page 78 ❑ Coat with oil before inserting (also axle bearing shoulder) 26 .Exhaust gas recirculation valve -N18. Bora 2006 ➤ 4-cylinder Injection engine (1. Repairing valve gear agen lksw Vo by AG.2005 11 . direct injection) .Coolant pipe/bracket ❑ Remove to remove sealing cap ⇒ Item 23 (page 77) 77 .Jetta 2005 ➤ .with exhaust gas recirculation potentiometer -G212❑ Removing and installing ⇒ page 195 r te o iva r rp fo g n 21 . is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s 18 .Valve stem seal ❑ Renewing ⇒ page 81 16 .Repair valve guide ❑ With collar 17 . V by ed s i r ho ut a ss t gu ara nte eo ra c ility ab y li an pt ce es. C op yi 22 .Valve spring plate 14 .6 l engine. in part or in w l purpos hole ercia .Sealing cover ❑ For inlet camshaft do c um en 24 .Valves ❑ Do not rework. Only lapping-in is permitted ❑ Valve dimensions ⇒ page 79 20 .

6 l engine. Note When the sealing surface has been reworked. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s Special tools and workshop equipment required ♦ Universal dial gauge bracket -VW 387- ility ab y li an pt ce es. C op yi .Cylinder head. Bora 2006 ➤ 4-cylinder Injection engine (1.2 Checking camshaft axial clearance AG.Jetta 2005 ➤ .2005 Reworking cylinder head sealing surface Cylinder head reworking limit: Dimension -a.25 mm min. in part or in w l purpos hole ercia . Prote cted by ht rig py Co t. is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Dial gauge -VAS 6097- r te o iva r rp fo g n do c um en Checking camshaft axial clearance Wear limit: max. 0. c o p yri gh t.15 . direct injection) . valve gear agen lksw Vo by Perform measurements with camshaft housing removed and sealing cover fitted.Edition 08. Gr.= 108. When performing this work en‐ sure that the minimum dimension ⇒ page 79 does not remain under.40 mm 78 Rep. AG. 2. the valves must be set deeper by the same amount (rework valve seats) otherwise the valves will strike the pistons.

Minimum dimension: Inlet valve 7. e G n A A G en does not gu ara nte eo ra c Note ility ab y li an pt ce Valves must not be reworked. permissible reworking dimension is calculated as fol‐ lows: – Insert valve and press firmly against seat. use a new valve for the calculation. If the reworking dimension is exceeded.0 5.953 100. perfect seating pattern. it is not sufficient to reface or renew valve seats and valves. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ag ksw Vol y b dimensions ed ris o h t au ss Jetta 2005 ➤ . Only lapping-in is permitted. Example: = Measured distance Minimum dimension max.9 45 Outlet valve 26. Outlet valve 7. permissi‐ ble reworking dimension. Repairing valve gear 79 .6 mm Measured distance minus minimum dimension = max.3 Reworking valve seats Special tools and workshop equipment required ♦ Depth gauge ♦ Valve seat refacing tool Note agen lksw Vo by c o p yri gh t.2005 a V g . calculate the maximum permissible reworking dimen‐ sions. 2. permissible reworking dimension from meas‐ ured distance and minimum dimension. – Calculate max. Before beginning to rework valve seats. rework dimension3) 8. Dimension ∅a ∅b c α mm mm mm ∠° Inlet valve 29. Note If the valve is to be renewed as part of a repair.973 100.6 mm 0. direct injection) . perm.Valve es.4 mm 3) The maximum permissible reworking dimension is shown on illustrations for reworking valve seats as dimension “b”. It is also necessary to check the valve guides for wear. C op yi thi sd o cu m en ♦ When repairing engines with leaking valves.5 5. Bora 2006 ➤ k s l w o 4-cylinder Injection engine (1.0 mm 7.6 l engine. Prote cted by ♦ Valve seats should be reworked only enough to produce a The max. – Measure distance between end of valve stem and upper edge of cylinder head. hydraulic valve compensation can no longer be guaranteed and the cylinder head should be renewed. ht rig py Co t.6 mm. in part or in w l purpos hole ercia .5 45 rrectness of i t to the co nf o r m spec atio h re n in wit 2. AG. This is particularly impor‐ tant on high mileage engines ⇒ page 80 .Edition 08.

Prote cted by c o p yri gh t. C op yi ♦ Universal dial gauge bracket -VW 387- ♦ Dial gauge -VAS 6097- 80 Rep.15 .8 mm = lower edge of cylinder head = 45° Valve seat angle = 30° upper correction angle = 60° lower correction angle ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Rework exhaust valve seat a b c Z α β γ = ∅ 25. Gr.Cylinder head. Special tools and workshop equipment required agen lksw Vo by 2. valve gear AG.Jetta 2005 ➤ . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte ∅ 28. Bora 2006 ➤ 4-cylinder Injection engine (1.0 mm = max.6 l engine. permissible reworking dimension c s s un le urposes.Edition 08.7 mm oris eo h ut ra a max. direct injection) . permissible reworking dimension = approx.8 mm = lower edge of cylinder head = 45° Valve seat angle = 30° upper correction angle = 60° lower correction angle r fo ng ht rig py Co t. in part or in wh ole.4 Checking valve guides . 1.5…1.2005 Rework inlet valve seat a b c Z α β γ AG. cial p is n mer m ot p o c erm or e t a itte v i r d p = = = 1.

Repairing valve gear 81 . use only an inlet valve in inlet guide and an exhaust valve in exhaust guide.6 l engine. – Determine rock. Wear limit: 0. in part or in w l purpos hole ercia .with press piece -3362/1♦ Extractor for valve stem seal -3364♦ Valve stem seal fitting tool -3365♦ Pressure hose -VW 653/3AG. direct injection) . is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his Removing do c um en – Remove camshaft housing ⇒ page 59 .Jetta 2005 ➤ . Bora 2006 ➤ 4-cylinder Injection engine (1.8 mm If rock tolerance is exceeded: – Replace cylinder head. Due to slight differences in stem diameters.2005 Test procedure – Insert a new valve into the guide. agen lksw Vo by Prote cted by ht rig py Co t. C op yi AG. 2.5 Renewing valve stem seals Special tools and workshop equipment required ♦ Spark plug spanner -3122 B♦ Hold down tool for valve springs -3362. The end of the valve stem must be flush with the guide.Edition 08. (with cylinder head installed) c o p yri gh t. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce es. 2.

– Now screw pressure hose -VW 653/3. valve gear AG.. agen lksw Vo by Prote cted by c o p yri gh t. – Set cylinder to “bottom dead centre”. Volkswagen AG d agen oes ksw not l cedure. in part or in w l purpos hole ercia .Edition 08. ss y db ise r tho au ua ran tee or ac ility ab y li an pt ce es. – Pull out valve stem seals using valve stem seal puller -3364..Jetta 2005 ➤ . Gr.6 l engine. rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en Rep. When doing this.15 . – Place new valve stem seal in valve stem seal fitting tool -3365. un le ♦ Installing fuel lines ⇒ page 139 . – Remove spark plugs with spark plug wrench -3122 B. Bora 2006 ➤ 4-cylinder Injection engine (1.. ensure that the roller rocker fingers are not interchanged. – Oil valve stem seal sealing lip and press carefully onto the valve guide. – Connect pressure hose to a compressed air system of at least 6 bar and remove valve springs.2005 – Remove roller rocker arms and place onto a clean surface. This will prevent the new valve stem seal being dam‐ aged. During this step. 82 ht rig py Co t.. Further assembly is basically the reverse of the dismantling pro‐ AG. Installing – Place the plastic sleeve supplied on the appropriate valve stem. is n m ot com pe rm itte d ♦ Installing exhaust gas recirculation valve -N18. direct injection) . – Install camshaft housing ⇒ page 61 .on with press piece -3362/1.Cylinder head. – Adjust timing ⇒ page 69 . – Screw hold down tool for valve springs -3362.into the spark plug thread.⇒ page 195 . C op yi . observe the following: o V g ♦ Install control housing ⇒ page 31 .

Jetta 2005 ➤ . marking if necessary ⇒ page 83 . direct injection) . Prote cted by c o p yri gh t .Max. thi sd o cu m en Top up to max.1 Markings on dipstick 1 . perform the following repairs: n AG. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng of does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit 1.1 Engine oil Oil capacities With oil filter 3.Area above hatched field up to max. Volkswagen AG wage olks yV b ed ris ho t au abovess the max. danger damage to catalytic converter! Markings ⇒ page 83 .5 l.Assembly overview ⇒ page 84 Oil cooler . engine oil specification) ⇒ page 83 Parts of the lubrication system . Bora 2006 ➤ 4-cylinder Injection engine (1. mark: Do not replenish with engine oil! b . in part or in w l purpos hole ercia . To prevent this from causing further damage. 1.Assembly overview ⇒ page 86 Removing and installing oil sump ⇒ page 87 Removing and installing oil pump ⇒ page 89 Removing and installing oil cooler ⇒ page 92 Checking oil pressure and oil pressure switch ⇒ page 94 es.Oil level within hatched field: Can be replenished with engine oil. C op yi Viscosity class and oil specification 83 . c .6 l engine. ⇒ Maintenance .5 l of engine oil! ht rig py Co t. mark a . mark. 0.Min. mark up to hatched field: Replenish with max.Edition 08. Removing and installing parts of lubrication system agen lksw Vo by AG.Area from min. mark 2 .2005 17 – 1 Note Lubrication Removing and installing parts of lu‐ brication system ♦ Finding metal shavings or a large quantity of small metal par‐ ♦ Thoroughly clean oil passages ♦ Renew oil filter ♦ The oil level must not be ticles during engine repair could indicate that the conrod bear‐ ings are damaged. Booklet 20. Engine oil (oil capacities.

Oil filter cover.8 Nm 6 .Jetta 2005 ➤ . in‐ sert two M6x80 studs into the camshaft hous‐ ing and the cylinder block ❑ For a better guide pur‐ pose of the control housing set the oil sump with two bolts 11 . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce urposes.Coolant pipes ❑ For oil cooler 5 . Gr. C op yi 16 .Valve gear casing ❑ Removing and installing control housing ⇒ page 31 ❑ For a better guide pur‐ pose when installing. Bora 2006 ➤ 4-cylinder Injection engine (1.Lubrication agen lksw Vo by AG.Seal ❑ Renew 10 .Bolt ❑ Observe tightening procedure ⇒ page 40 ❑ Renew 84 Rep.Sealing cover ❑ Renew seal if damaged 12 .10 Nm 8 .Assembly overview 1 .Oil filter AG.Valve ❑ With by-pass valve opening pressure: 2.50 Nm r fo ng 15 .Edition 08.6 l engine.17 .Dipstick ❑ The oil level must not be above the max. direct injection) .O-ring ❑ Renew 7 .Seal ❑ Renew 3 .2 Parts of the lubrication system . 25 Nm 18 .2005 1. in part or in wh ole. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 14 .5 bar ❑ With non-return valve .Oil cooler 4 . 10 Nm ❑ M6x22 mm ❑ Insert with locking fluid ht rig py Co t.Bolt. c o p yri gh t. mark! ❑ Markings ⇒ page 83 2 .Pressure regulating valve ❑ With breather hose 9 . Prote cted by 17 .Seal ❑ Renew if damaged 13 .

Drive chain ❑ For oil pump ❑ Mark D.Seal ❑ Renew ❑ Lubricate before installing 30 .against turning eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his 20 .2005 ❑ ❑ ❑ ❑ Contact surface of the securing bolt must be free of oil and grease Insert oiled (thread) . direct injection) .g.13 Nm ❑ Loosen and tighten the bolts on the flywheel end only using socket insert -T10058AG.Oil drain plug.20 Nm + 90° (1/4 turn) further 1. 25 .against a turning gen AG does ksw not l o V a commercially available angle gumeasuring instrument The turning further angle can be measured with y ara db e nte e. before removing (installation position) 28 .Jetta 2005 ➤ .Chain sprocket ❑ For oil pump ❑ Lock with counter-hold -T1017227 . Electrical fault finding and Fitting locations 31 .Poly V-belt sprocket ss ❑ Contact surfaces of the belt pulley must be free of oil and grease ❑ Removing and installing poly V-belt ⇒ page 29 ❑ Secure belt pulley with counter-hold -3415.Oil pan ❑ Removing and installing ⇒ page 87 ❑ Clean sealing surface before fitting ❑ Install with silicone sealing compound -D 176 404 A229 . Hazet 6690 ris ho ut es.O.Edition 08.Bearing bush ❑ Renew if scored ❑ Observe tightening procedure ⇒ page 40 ❑ Contact surfaces must be free of oil and grease 22 .10 Nm 32 .15 Nm 23 .Chain sprocket ❑ Note installation position: The journal must engage into the groove of the crankshaft! ❑ For oil pump and control chain drive ❑ Contact surfaces must be free of oil and grease 26 .Chain tensioner with tensioning plate and tension spring ❑ For oil pump drive ❑ Tightening torque: 15 Nm ❑ Is replaced complete only ht rig py Co t. in part or in w l purpos hole ercia . do c um en 24 .Seal ❑ Renew 21 .R. 30 Nm ❑ With attached seal ❑ Renew 33 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n a 19 . Volkswagen AG Secure belt pulley with counter-hold -3415. Removing and installing parts of lubrication system agen lksw Vo by Prote cted by c o p yri gh t. Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine. C op yi 85 .Oil level/ oil temperature sender -G266❑ Renew if damaged ❑ Checking: ⇒ Current flow diagrams.

2005 34 .8 Nm pe rm itte d 7 .6 l engine.Oil cooler ❑ Removing and installing ⇒ page 92 2 .Assembly overview 1 .3 Oil cooler .Jetta 2005 ➤ .Seal ❑ Renew 3 .Oil pump ❑ Renew complete only 36 .25 Nm 1. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en 86 Rep. in part or in w l purpos hole ercia .Lubrication ht rig py Co t.Edition 08.8 Nm es. agen lksw Vo by AG.Coolant pipes 5 .45 Nm 35 . Gr. Prote cted by c o p yri gh t. is n m ot com un le 6 .8 Nm AG. Bora 2006 ➤ 4-cylinder Injection engine (1. C op yi .O-ring ❑ Renew 4 .17 . direct injection) .

50 . 1. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s Special tools and workshop equipment required ♦ Socket -T10058pe rm itte d ♦ Torque wrench -V. Removing and installing parts of lubrication system ht rig py Co t. – Remove oil sump. – Removing pre-catalytic converter with exhaust pipe ⇒ page 188 . direct injection) . Gr.A.Edition 08.G.G. in part or in w l purpos hole ercia . – Pull 3-pin connector -1. is n m ot com un le rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en Removing – Remove noise insulation ⇒ General body repairs. Noise insulation . 1331♦ Used oil collection and ex‐ traction unit -V. agen lksw Vo by AG. – Drain engine oil.2005 1. – Remove sealant residue on cylinder block with a flat scraper. Bora 2006 ➤ 4-cylinder Injection engine (1. Loosen oil sump with light blows of a rubber headed hammer if necessary.4 Removing and installing oil sump AG. exterior. C op yi 87 . Rep.off oil level and oil temperature sender -G266.Jetta 2005 ➤ .. Prote cted by c o py rig ht . 1782♦ Silicone sealing compound -D 176 404 A2♦ Hand drill with plastic brush ♦ Flat scraper ♦ Safety goggles ♦ 2 threaded studs M6 ility ab y li an pt ce es. – Unbolt sump sealed with liquid gasket.A.6 l engine.

t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Observe the use by date of the sealing compound. Bora 2006 ➤ . Volkswagen AG gen AG does wainjection) 4-cylinder Injection engine (1.– es. C op yi . in part or in w l purpos hole ercia . for guide purposes. M6 studs are inserted into the cylinder block flange at two positions. Gr. a hand drill with a plastic brush attachment (wear ss Jetta 2005 ➤ .17 .Lubrication ht rig py Co t. direct . ♦ The oil sump must be installed within 5 minutes of applying the silicone sealant.6 l engine. Prote cted by c o p yri gh t .2005 s k no l o brush. protec‐ tive goggles). ♦ Sump can be offered up easier and with greater security if. They must be free of oil and grease.g. r te o iva r rp fo g n do c um en 88 Rep.Edition 08. agen lksw Vo by AG. is n m ot com Installing Note pe rm itte d – Clean sealing surfaces. un le V by ed s i r a rotating Remove sealant residue from oil sump twith ho u a e.

agen lksw Vo by AG. Removing and installing parts of lubrication system 89 . Prote cted by c o p yri gh t . to clean oil sump sealing surface. ♦ If the oil sump bolts have been fitted between the cylinder AG. observe that the oil sump bolts fit into the holes and not between the cylinder block and flyweel.. Bolts M6: 13 Nm Bolts M10: 40 Nm Note un le – Then tighten both M6 oil sump bolts on flywheel end lightly. Only then fill engine oil..Edition 08. Bora 2006 ➤ 4-cylinder Injection engine (1. otherwise ex‐ cessive sealing compound will enter the oil sump and may block the oil suction pipe strainer. ♦ Run bead along inner side of bolt holes -arrows-. Sealant bead must be: ♦ 2.3 mm thick. the es n wage ot g o s V oil sumpdmust be removed. – Tighten the oil sump bolts. as shown. – Apply silicone sealing compound.Jetta 2005 ➤ . – Tighten remaining oil sump bolts lightly.5 r fo ng Removing and installing oil pump Special tools and workshop equipment required ♦ Counter-hold tool -T10172ht rig py Co t. – Install oil sump immediately and tighten the two on the oppo‐ site side oil sump bolts lightly. the sealing surfaces ua cleaned and by ran ise the silicone sealing compound renewed. 3 mm ∅ of nozzle).2005 – Cut off tube nozzle at forward marking (approx. direct injection) . or ac Let sealing compound dry for approx. Note ♦ When placing the oil sump bolts to the flywheel end. 30 minutes after installing oil sump. cial p is n mer m ot p o c erm or e t a itte v i r d p – Tighten both M10 bolts for oil sump/gearbox lightly. ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1. C op yi 1. Note The sealing compound bead must not be thicker. in part or in wh ole. tee or urposes. Volkswagen th au ss AG do n block and the lk flywheel. and can not be removed anymore.6 l engine.

17 . Prote cted by – Set the chain sprocket into the chain and on the oil pump shaft. ht rig py Co t. c o p yri gh t .6 l engine. un le n AG. – Take chain sprocket off oil pump and out of chain. – Take oil pump out of the cylinder block. – Press chain tensioner in -direction of arrow. agen lksw Vo by – Press chain tensioner in -direction of arrow.Jetta 2005 ➤ .using a screw‐ driver. C op yi . Gr. is n m ot com pe rm itte d rrectness of i t to the co nform spec a t i h re o n in wit thi s – Loosen securing bolts -arrows.of the oil pump and remove. – Remove chain sprocket securing bolt.2005 Removing – Remove oil sump ⇒ page 87 . – Lock the chain sprocket of the oil pump using counter-hold T10172. Bora 2006 ➤ 4-cylinder Injection engine (1.Lubrication AG. in part or in w l purpos hole ercia . Installing r te o iva r rp fo g n do c um en 90 Rep.using a screw‐ driver. Note Do not remove bolt yet. – Remove chain sprocket securing bolt.. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce es.Edition 08. direct injection) .

C op yi 1.A. r te o iva r rp fo g n do c um en ht rig py Co t. agen lksw Vo by AG. 1331. un le AG. Volkswagen AG d agen oes ksw not l o gu yV b aa d e 4-cylinder Injection engine r(1.as shown. pe rm itte d – Observe correct seat of chain sprocket on oil pump shaft -arrow-. es. – Tighten securing bolt to 20 Nm + 90° (1/4 turn) further.G.– Install chain sprocket securing bolt.6 nte l engine. in part or in w l purpos hole ercia . – Install oil sump ⇒ page 87 . is r o eo h ut ra a c s s Jetta 2005 ➤ . is n m ot com – Lock the chain sprocket using counter-hold -T10172..2005 ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Place torque wrench -V. Removing and installing parts of lubrication system 91 . Prote cted by c o py rig ht . Bora 2006 ➤ direct injection) .Edition 08.

50 . – Release both locking devices and take air duct -2.6 l engine. Gr. direct injection) . Gr. Noise insulation . Bora 2006 ➤ 4-cylinder Injection engine (1. agen lksw Vo by Removing ht rig py Co t. Prote cted by c o py rig ht . Rep.from air duct -2-.Lubrication AG.A. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce urposes. – Remove engine cover with air cleaner ⇒ page 161 .6 Removing and installing oil cooler Special tools and workshop equipment required ♦ Hose clamp to Ø 25 mm -3094♦ Torque wrench V.G.17 .A.2005 1.G.off. in part or in wh ole. C op yi . cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng – Drain coolant ⇒ page 102 . exterior. 1331♦ Torque wrench V.Jetta 2005 ➤ .Edition 08. 92 Rep. 1410♦ Spring-type clip pliers VAS 5024 A♦ Drip tray for workshop hoist -VAS 6208un le AG. – Remove noise insulation ⇒ General body repairs. – Disconnect rubber bellows -1.

Bora 2006 ➤ 4-cylinder Injection engine (1. Alternator 1. Torque settings Component Nm 8 8 10 ht rig py Co t. Rep.2005 – Remove warm air collector plate -arrows-. Prote cted by c o py rig ht ..6 l FSI engine . 27 . observe the following: Note es. 27 .and pull oil cooler -2Installing pe rm itte d ility ab y li an pt ce Install in reverse order of removal. During this step. r te o iva r rp fo g n Coolant pipes for oil cooler Oil cooler to cylinder block Warm air collector plate to exhaust manifold do c um en 1. direct injection) . Rep. Gr. AG.for coolant pipes on cylinder block and on oil cooler.6 l FSI engine . Alternator. C op yi 93 .Edition 08. – Install alternator ⇒ Electrical system. – Disconnect coolant hoses on oil cooler using hose clamps -3094. is n m ot com un le rrectness of i t to the co nform spec a t i h re o n in wit thi s Renew O-ring.6 l engine.Jetta 2005 ➤ . – Remove securing bolts -arrows. Removing and installing parts of lubrication system agen lksw Vo by AG. Gr. Alternator 1. – Remove alternator ⇒ Electrical system. Volkswagen AG d agen oes ksw not l o gu yV b ara d block. – Place drip tray underneath. – Add coolant or renew if the oil cooler has been removed ⇒ page 102 . Alter‐ nator. in part or in w l purpos hole ercia . – Pull coolant pipes out of oil cooler forwards. e off cylinder nte is r o eo h ut ra a c s s – Remove bolts -1.

C op yi .6 l engine. Electrical fault finding and Fitting locations and ⇒ vehicle diagnosis.G. V 1. 94 Rep. testing and information system VAS 5051- ♦ or vehicle diagnosis and service information system -VAS 5052- thi sd o cu m en Prerequisites • • Engine oil level OK. Engine oil temperature at least 80 °C (radiator fan must have run once). is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Special tools and workshop equipment required ss ag ksw Vol y b ed ris o h t au does not gu ara nte eo ra c ility ab y li an pt ce ♦ Oil pressure gauge -V.A. Note Functional check and repair of the visual and acoustic oil pressure display ⇒ Current flow diagrams.Jetta 2005 ➤ . direct injection) -A Edition 08. in part or in w l purpos hole ercia .G.2005 olkswagen G en AG. 1527 B♦ Adapter set -V. agen lksw Vo by AG.A.A.7 Checking oil pressure and oil pressure switch es.G.Lubrication ht rig py Co t. Prote cted by c o p yri gh t.or vehicle diagnosis and service information system -VAS 5052. Bora 2006 ➤ 4-cylinder Injection engine (1. Gr. testing and information system -VAS 5051. 1342♦ Voltage tester -V..17 . 1594 C- rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Vehicle diagnosis.

s es.3. – Start engine and increase speed slowly.Jetta 2005 ➤ .-2. At 2000 rpm and an oil tem‐ perature of 80 °C the oil pressure should be min.A. Prote cted by c o py rig ht .using from adapter set -V.0 bar..2005 Test procedure – Disconnect electrical wiring on oil pressure switch -F1-arrow-. Removing and installing parts of lubrication system ht rig py Co t.A.0.6 l engine. renew oil pressure switch -F1.0 bar. 1594 C. agen lksw Vo by AG..G. otherwise renew oil pressure switch. by .. At higher engine speeds the oil pressure must not exceed 7.to battery positive (+) and oil pressure switch.G. If LED does not light up: rrectness of i t to the co nf o r m spec atio h re n in wit – If the LED lights up.7 bar the LED must light up.. does not gu ara nte eo ra c ility ab y li an pt ce LED must not light up.Edition 08.A.and screw into the oil pressure gauge -V. in part or in w l purpos hole ercia . 2. 1527 B. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng s adapter cables – Connect voltage tester -V. C op yi 95 . Bora 2006 ➤ 4-cylinder Injection engine (1.of tester to earth (-). – Increase engine speed further. thi sd o cu m en 1. direct injection) .G. – Remove oil pressure switch -F1. 1342. Volkswagen AG ed ris ho t au – Connect brown wire -1. n AG – Screw tester into the cylinder head in place of the oil pressure wage olks V switch. At 0.

Parts of cooling system . In case of repair. 1274/9. vacuum) and electrical wirings are to be installed in the original way. ♦ To avoid damages to the wiring ensure sufficient clear‐ ance to all moving or hot components. activated char‐ coal canister system. spring-type clips. in part or in wh ole.Jetta 2005 ➤ .Edition 08.A. 1274. u ra a c s s urposes. ♦ Hoses are secured with spring-type clips. brake liquid.6 l engine. route stress-free so that they d by V ara nte do not come into contact with other components (observe orise eo h t markings on coolant connection and hose).and radiator fan 2 V177. pay attention to the following due to the cram‐ ped conditions: ♦ All wirings (e. Prote cted by c o p yri gh t.and adapters -V. agen lksw Vo by AG. direct injection) .G..Assembly overview ⇒ page 97 Parts of cooling system engine side (thermostat side) .A.are recommended for fitting ♦ AG. only use spring-type clips. hydraulic system. C op yi . cial p is n mer m ot p o c erm or e t a itte v i r d p -V. Gr.Assembly overview ⇒ page 98 Parts of cooling system engine side (coolant pump side) . If necessary.Cooling system ht rig py Co t. especially in the engine com‐ partment. for fuel.G.A. Bora 2006 ➤ 4-cylinder Injection engine (1.body side .2005 19 – 1 Cooling system Removing and installing parts of cool‐ ing system Caution ♦ When doing any repair work.G. Volkswagen AG d agen oes ksw not l o gu When installing coolant hoses.⇒ page 105 Removing and installing radiator ⇒ page 106 Removing and installing coolant pump ⇒ page 108 Removing and installing thermostat ⇒ page 110 Checking cooling system for leaks ⇒ page 113 r fo ng 96 Rep.As‐ sembly overview ⇒ page 99 Coolant hose schematic diagram ⇒ page 99 Draining and filling with coolant ⇒ page 102 un le ♦ Carry out leak test of cooling system with cooling system tester ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Removing and installing radiator fan -V7. ♦ Hose clip pliers -VAS 5024 A. 1274/8.and V. coolant and refrigerant liquid. Note ♦ When the engine is warm. release pressure before beginning repair work.g.19 . the cooling system is under pres‐ sure.

and adapt‐ er for cooling system V.Assembly overview 1 .Sealing cover ❑ Check with cooling sys‐ tem tester -V. is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s 10 .Jetta 2005 ➤ .G 1274/9.Radiator fan 2 -V177❑ Removing and installing ⇒ page 105 17 .Radiator fan -V7❑ Removing and installing ⇒ page 105 ❑ With radiator fan control unit -J2931.Radiator ❑ Removing and installing ⇒ page 106 ❑ After renewing. renew entire coolant 4 .5 Nm 14 .⇒ page 113 ❑ The pressure relief valve must open at a pressure of 1.A.5 Nm 16 .6 l engine. in part or in w l purpos hole ercia .G 1274and adapter for cooling system tester -V.Air ducting ❑ Removing and installing ⇒ page 105 15 .1 Parts of cooling system .Connector 19 .A.Spacer ❑ For refrigerant pipe tester 12 .Connector 18 .4…1. Removing and installing parts of cooling system AG.5 Nm 11 .Edition 08.G 1274.Retainer ❑ For radiator ht rig py Co t.6 bar 6 . Prote cted by 9 . direct injection) .A.O-ring ❑ Renew if damaged 3 . agen lksw Vo by c o p yri gh t .A. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce es.Base plate ❑ Fit in lock carrier 13 . Bora 2006 ➤ 4-cylinder Injection engine (1.Seal 5 . C op yi 8 .G 1274/8⇒ page 113 r te o iva r rp fo g n do c um en 97 .2005 1.Upper coolant hose ❑ From thermostat hous‐ ing on cylinder head 2 .body side .Expansion tank ❑ Carry out leak test of cooling system with cooling system tester V.Connector 7 .3 Nm n AG.

O-ring ❑ Renew 1.Coolant temperature send‐ er -G62❑ If necessary.Compression spring 4 .To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 99 12 .Thermostat Control range: ❑ Long thermoelement 87 °C…102 °C ❑ Short thermoelement 103 °C…120 °C 14 .2005 20 .10 Nm ❑ Insert with locking fluid 6 .Jetta 2005 ➤ . release pressure in cooling sys‐ tem before removing 8 .From heat exchanger ❑ Coolant hose schematic diagram ⇒ page 99 13 . direct injection) .Thermostat housing 10 .Seal ❑ Renew r te o iva r rp fo g n do c um en 11 .Cooling system ht rig py Co t. C op yi . Gr.19 .Coolant pipe ❑ Coolant hose schematic diagram ⇒ page 99 98 Rep.6 l engine. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss rrectness of i t to the co nform spec a t i h re o n in wit thi s 5 . agen lksw Vo by AG.Pipe union n AG.Rod pe rm itte d 2 .O-ring ❑ Renew un le 1 . in part or in w l purpos hole ercia . is n m ot com 3 .Coolant pump housing on cylinder block 15 .Radiator outlet coolant temperature sender -G8323 .Retainer ❑ For wiring harness 7 .To expansion tank ❑ Coolant hose schematic diagram ⇒ page 99 17 . Prote cted by c o p yri gh t .Lower coolant hose ❑ From connection for thermostat 21 .Retaining clip ❑ Check for secure seat‐ ing 9 .Assembly overview ility ab y li an pt ce es. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08.Retaining clip 22 .Pipe union 16 .2 Parts of cooling system engine side (thermostat side) .

1590⇒ page 108 ❑ When installing note fix‐ ing arrangement ❑ Removing and installing poly V-belt ⇒ page 29 es.A.2005 18 .9 Nm 3 .6 l engine.Jetta 2005 ➤ .5 Nm 20 .20 Nm 4 . in part or in w l purpos hole ercia . Removing and installing parts of cooling system ht rig py Co t.4 Coolant hose schematic diagram Models without auxiliary heater ⇒ page 100 Models with auxiliary heater ⇒ page 101 1.Assembly over‐ view ility ab y li an pt ce 1 .To top of radiator ❑ Coolant hose schematic diagram ⇒ page 99 1. ❑ Coolant hose schematic diagram ⇒ page 99 21 .A. Bora 2006 ➤ 4-cylinder Injection engine (1. Prote cted by c o p yri gh t .Belt pulley ❑ To loosen and tighten use water pump wrench -V. C op yi 99 .G. 1590❑ Change water pump wrench -V.G.3 Parts of cooling system engine side (coolant pump side) .Edition 08. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG.From bottom of radiator. agen lksw Vo by AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 1. direct injection) .Coolant pump ❑ Removing and installing ⇒ page 108 ❑ Check for ease of move‐ ment ❑ With integrated seal ❑ If damaged or leaking renew complete 2 .Retaining clip ❑ Check for secure seating 19 .

renew entire coolant 12 .19 .Cylinder head/cylinder block ❑ After renewing. renew entire coolant 9 . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r . renew entire coolant 10 . Gr. direct injection) .1 Models without auxiliary heating 1 .Intake manifold es.Exhaust gas recirculation valve -N18. C op yi . in part or in w l purpos hole ercia .with exhaust gas recirculation potentiometer G2124 5 .Lower coolant hose 8 .ssrenew c entire coolant ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 100 Rep. Prote cted by c o py rig ht .Expansion tank 2 . Bora 2006 ➤ 4-cylinder Injection engine (1.Thermostat housing 11 .Coolant hose ❑ From exhaust gas recir‐ culation valve -N18with exhaust gas recir‐ culation potentiometer G2123 .6 l engine.Heater unit heat exchanger o eo h ut ra a ❑ After renewing.Coolant hose ❑ To exhaust gas recircu‐ lation valve -N18.Radiator ❑ After renewing.with exhaust gas recircula‐ tion potentiometer G2126 .Edition 08. agen lksw Vo by AG.2005 1.Coolant pipe 13 .Upper coolant hose 7 .Cooling system ht rig py Co t.Jetta 2005 ➤ .Engine oil cooler ❑ After renewing. is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG.4.Coolant pump 14 .

is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng 12 . C op yi 101 .Intake manifold 7 .Edition 08. Rep. renew entire coolant 10 . direct injection) . Prote cted by c o py rig ht .4. Gr. in part or in w l purpos hole ercia .Circulation pump -V55❑ Removing and installing recirculating pump ⇒ auxiliary heater.Expansion tank 2 . Gr. Removing and installing auxiliary heat‐ er Thermo Top V AG. 82 .6 l engine.2 Models with auxiliary heater 1 . Rep. renew entire coolant 9 .2005 1. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es.with exhaust gas recirculation potentiometer G2126 .Heater coolant shut-off valve -N279❑ Location: Secured to engine compartment bulkhead 5 .Auxiliary heater Thermo Top V ❑ Removing and installing auxiliary heater ⇒ auxiliary heater. 82 .Engine oil cooler ❑ After renewing.Non-return valve 3 . Bora 2006 ➤ 4-cylinder Injection engine (1.Cylinder head/cylinder block ❑ After renewing.Thermostat housing 8 . renew entire coolant 11 .Exhaust gas recirculation valve -N18.Radiator ❑ After renewing. Removing and installing auxiliary heater Thermo Top V rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 1. agen lksw Vo by AG. Removing and installing parts of cooling system ht rig py Co t.Heater unit heat exchanger ❑ After renewing. renew entire coolant 4 .Jetta 2005 ➤ .

19 .A.6 l engine. Gr. Prote cted by c o p yri gh t. – Open sealing cap of expansion tank. direct injection) . 1306.A. in part or in wh ole.G.5 Draining and filling coolant Special tools and workshop equipment required urposes. Bora 2006 ➤ 4-cylinder Injection engine (1.G. – Remove noise insulation ⇒ General body repairs. Wear eye protection and protective clothing to prevent eye damage and scalding.2005 1. Cover sealing cap with a cloth and open cap carefully. C op yi .Jetta 2005 ➤ . 102 Rep. cial p is n mer m ot p o c erm or e t a itte v i r d p ♦ Drip tray -V. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en ♦ Adapter for cooling system tester -V. Rep.or VAS 6208- ♦ Spring-type clip pliers -VAS 5024 A♦ Cooling system charging unit -VAS 6096- un le ♦ Refractometer -T10007- AG.Cooling system ht rig py Co t. Noise insulation .Edition 08. 1274/8- r fo ng Draining WARNING Hot steam can escape when opening expansion tank. agen lksw Vo by AG. 50 . Gr. exterior.

C op yi 103 . For this reason the system must be filled all year round with frost and corrosion protection ad‐ ditives. much coolant will leak es. as otherwise frost protection is re‐ duced again and cooling effectiveness is also reduced. The antifreeze must be at least 40% of mixture. t u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his – Pull coolant hose -arrow. Removing and installing parts of cooling system AG. ♦ G 12 lilac according to “TL VW 774 F” can be mixed with cool‐ agen lksw Vo by F”.on expansion tank off and guide completely downwards to drain remaining coolant. amount of G 12 can be increased.Edition 08. is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG.6 l engine.Jetta 2005 ➤ . ♦ The coolant concentration must not be reduced by adding wa‐ ter even in warmer seasons and in warmer countries. Note Observe disposal regulations! Filling Note do c um en ♦ Only use coolant additive G 12 in accordance with “TL VW 774 ant additive G 12 red. gasket is replaced. scaling and also raise boiling point of coolant. the coolant improves engine ♦ Frost protection (anti-freeze) must be guaranteed to approx. ♦ G 12 and coolant additives marked in accordance with “TL VW 774 F” prevent frost and corrosion damage.8 l 4) The quantity of coolant can vary depending upon vehicle equipment. ♦ Because of its high boiling point. Identification characteristics: Coloured lilac (purple) ht rig py Co t. but only up to 60 % (frost protection to about -40 °C). Volkswagen AG d oes not o gu yV b ara d e pulled off on the lower radiator un‐ nte ris o eo h out on the bumper cover. heat exchanger. – Open spring-type clamp -arrow. reliability under heavy loads. in part or in w l purpos hole ercia .8 l Water4) 3. ♦ If for climatic reasons a higher frost protection is required.35 l 2. Bora 2006 ➤ 4-cylinder Injection engine (1. cylinder head or cylinder head Recommended mixture proportions: Frost protection to -25 °C -35 °C Anti freeze proportion 40 % 50% G 124) 2. the ♦ If radiator.and pull coolant hose lksw If quick release coupling is ion. particularly in countries with trop‐ ical climates.2005 en agoff.25 l 2. -25 °C (approx. 1. Prote cted by c o p yri gh t . do not reuse old coolant. direct injection) . -35 °C in countries with an arctic climate) in the washer system.

– Start engine and maintain an engine speed of about 2000 rpm for approx. ht rig py Co t.. Bora 2006 ➤ 4-cylinder Injection engine (1. – Fit expansion tank cap. – Run engine until radiator fans cuts-in. 3 minutes.Cooling system AG.of the vehi‐ cle diagnosis. 50 .to expansion tank.to the diagnosis connection in the driver footwell.or the vehicle diagnosis. mark on expansion tank. – Connect the connector of the diagnostic cable -2.19 . C op yi . Volksw – Install noise insulation ⇒ General body exterior. is n m ot p om c r erm o e t a itte riv du p or nl f e g n by ed ris o th au ss ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his – Fit coolant hose -arrow. Continuation for vehicles with and without auxiliary heater 104 Rep.2005 – Fit the coolant hose on the union and secure with spring-type clamp. Without cooling system charging unit -VAS 6096- do c um en – Fill with coolant up to max. The coolant circuit of the auxiliary heater can be bled only this way correctly. Noise insulation . Vo g es. – Run engine until radiator fans cuts-in.6 l engine. does wage s k not l Gr. testing and information system -VAS 5051. Models without auxiliary heating agen lksw Vo by Prote cted by c o p yri gh t . nrepairs. 3 minutes. testing and information system -VAS 5052. – Switch off heater blower. direct injection) . – Let the engine run with the same speed for one minute and initiate simultaneously in the same minute the selective final control diagnosis for the heater coolant shut-off valve -N279(shut-off valve is supplied with current). Gr. Models with auxiliary heater Caution The auxiliary heater may only be switched on when the coolant circuit is filled as described in the following.Jetta 2005 ➤ . AG. With cooling system charging unit -VAS 6096– Fill coolant circuit using cooling system charging unit VAS 6096. agen AG Rep. in part or in w l purpos hole ercia .-1. ⇒ Operating instructions for cooling system charging unit VAS 6096 . – Start engine and maintain an engine speed of about 2000 rpm for approx.Edition 08.

Cover sealing cap with a cloth and open cap carefully. marks when the engine is cold.6 l engine. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Check coolant level when expansion tank is closed. Volkswagen AG d agen oes ksw not l o V gu2006 ➤ y b Jetta 2005 ➤ .and remove lower securing bolts -arrows. 1. – Remove noise insulation ⇒ General body repairs. in part or in w l purpos hole ercia . exterior.and radiator fan 2 -V177ht rig py Co t. – Take air ducting out downwards. the coolant level must be on the max.of the air ducting. 1. Bora ara d nte ise r o engine (1. Prote cted by c o p yri gh t. direct injection) Edition 08. Wear eye protection and protective clothing to prevent eye damage and scalding. – Replenish coolant. WARNING es. and max.4-cylinder Injection • When the engine is at operating temperature. Rep. Gr. – Disconnect connector -1. mark and between the min.A. C op yi 105 .of the air ducting. 50 . Special tools and workshop equipment required ♦ Torque wrench -V. Removing and installing parts of cooling system agen lksw Vo by AG.G 1783- do c um en ♦ Spring-type clip pliers -VAS 5024 A- Removing – Remove upper securing bolts -arrows.2005 eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his Hot steam can escape when opening expansion tank. Noise insulation . AG.6 Removing and installing radiator fan V7. if necessary.

Rep. Front bumper.2005 – Disconnect connection -1.and place wiring to side. Gr. 1. 1331- es. Prote cted by c o p yri gh t . r te o iva r rp fo g n Removing do c um en – Remove front bumper cover ⇒ General body repairs.G. agen lksw Vo by – Pull coolant hoses off radiator.Cooling system AG. is n m ot com pe rm itte d un le n AG. Installing Install in reverse order of removal.A. Gr.6 l engine. – Remove nuts -arrows. Bora 2006 ➤ 4-cylinder Injection engine (1. 63 .19 . in part or in w l purpos hole ercia . ht rig py Co t. 106 Rep. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Drain coolant ⇒ page 102 .Edition 08. direct injection) . Removing and installing front bumper cover . observe the following: – Install air ducting from below and tighten bolts to 5 Nm.and take radiator off. During this step.7 Removing and installing radiator Special tools and workshop equipment required ♦ Refractometer -T10007♦ Spring-type clip pliers -VAS 5024 A♦ Torque wrench -V. exterior. C op yi .Jetta 2005 ➤ .

exterior. – Take radiator out downwards. Removing and installing parts of cooling system ht rig py Co t. Bora 2006 ➤ 4-cylinder Injection engine (1. Front bumper cover substructure . Front bumper. c s s Note ility ab y li an pt ce – Remove bolts -1. direct injection) . C op yi 107 .6 l engine. in part or in wh ole. During this step. Volkswagen AG d agen oes ksw not l o gu yV b ara d the refrigerant lines/ho‐ To prevent damage to condenser also to e nte is r o ses. kinked or eo h ut ra a bent. agen lksw Vo by AG. observe the following: r fo ng – Renew coolant if a new radiator has been installed. – Fill with coolant ⇒ page 102 . – Remove left and right bumper cover guide ⇒ General body repairs.for fitting refrigerant pipe. exterior. 1.2005 – Remove cowling with radiator fans ⇒ page 105 . – Remove securing bolts -2.from radiator mounting.from radiator mounting.Edition 08. 50 . Models without air conditioning system – Remove bolts -1. Prote cted by c o py rig ht . Installing Install in reverse order of removal. Gr. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Remove bolt -arrow. Lock carrier . – Take radiator out downwards. Rep. – Swing radiator slightly to back.Jetta 2005 ➤ . Rep.of condenser. AG. urposes. Gr. Models with an air conditioning system – Bring lock carrier into service position ⇒ General body repairs. 63 . ensure that the lines and hoses are not stretched.

2005 1.G. Prote cted by c o p yri gh t. Gr. 1590 – Due to the modified securing bolts for the belt pulley coolant pump file the three curves for a = 1 mm minimum. plete with seal. Volkswagen AG d agen oes ksw not l o V gu y ara Special tools and e workshop db nte is r equipment required o eo h t u ra a c s ♦ Torque s wrench -V.G. C op yi . agen lksw Vo by AG. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG.G. 1590♦ Spring-type clip pliers -VAS 5024 A♦ Drip tray for workshop hoist -VAS 6208♦ Refractometer -T10007- rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en Change water pump wrench V.19 .8 Removing and installing coolant pump es.6 l engine. in part or in w l purpos hole ercia .Edition 08. direct injection) .A. Bora 2006 ➤ 4-cylinder Injection engine (1.Jetta 2005 ➤ . 108 Rep.A. Removing Note ♦ The integrated coolant pump seal must not be separated from the coolant pump.A.Cooling system ht rig py Co t. 1331- ility ab y li an pt ce ♦ Water pump wrench V. ♦ Damaged or leaking coolant pumps must be replaced com‐ – Remove engine cover with air cleaner ⇒ page 161 .

– Remove ribbed belt ⇒ page 29 .Edition 08. agen lksw Vo by AG.Coolant pump is removed via the wheel case. Front wheel housing liner . – Install Poly V-belt ⇒ page 29 . pe rm itte d un le – Drain coolant ⇒ page 102 . 66 . -arrows. is n m ot com – Remove the front right wheel housing liner: ⇒ General body repairs. Removing and installing wheel housing liner.and remove coolant pump from the cylinder block. Gr. – Tighten belt pulley of coolant pump to 20 Nm. in part or in w l purpos hole ercia . During this step. – Unscrew belt pulley . 1590. Rep. Volkswagen AG does wage s k not l o 4-cylinder Injection engine (1.and take engine t u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s Note The belt pulley . – Fill with coolant ⇒ page 102 .2005 by ara ed nte s i r eo ho lifting eye off. r te o iva r rp fo g n do c um en – Remove bolts -arrows.Coolant pump.G. – Tighten securing bolts to 25 Nm. Installing Install in reverse order of removal. Rep. Removing and installing parts of cooling system ht rig py Co t. Prote cted by c o p yri gh t . Bora 2006 ➤ n AG. To do this counterhold with modified water pump wrench -V.. observe the following: – Fit coolant pump into the cylinder block. C op yi 109 .– Remove bolts es. 66 . Front wheel housing liner .6 l engine. direct injection) V gu .A. Jetta 2005 ➤ . – Install front right wheel housing liner ⇒ General body repairs. Gr. Removing and installing wheel housing liner. 1.

1306♦ Torque wrench V.9 Removing and installing thermostat Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V. agen lksw Vo by AG. – Removing battery ⇒ Electrical system. Gr. Gr.1. Bora 2006 ➤ tho eo u ra c 4-cylinder Injection engine s (1. 1331- es.2005 ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his ♦ Spring-type clip pliers VAS 5024 A- do c um en Removing – With ignition switched off disconnect battery earth strap ⇒ Electrical system. C op yi . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r Jetta 2005 ➤ . in part or in w l purpos hole ercia .A.G.G. Disconnecting and connecting the battery .19 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG.Edition 08.Cooling system ht rig py Co t. 110 Rep. Rep. 27 . Prote cted by c o p yri gh t. Gr.6 s a l engine.A. Rep. 27 . Vehicles with petrol engine . direct injection) . Remov‐ ing and installing battery. – Remove engine cover with air cleaner ⇒ page 161 .

50 . es. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng .on coolant tempera‐ ture sender -G62. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo ➤ h t Jetta 2005 u ra a c s s rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Remove both coolant hoses from thermostat housing -arrows-. AG.Edition 08. C op yi 111 .of the electronics box and remove the cable -2-. Removing and installing parts of cooling system agen lksw Vo by – Disconnect electrical connection -arrow. Noise insulation . Rep. in part or in w l purpos hole ercia .. Gr. exterior.6 l engine.– Open the cover -1. 1. direct injection) . – Remove noise insulation ⇒ General body repairs. c o p yri gh t. – Drain coolant ⇒ page 102 . Bora 2006 ➤ 4-cylinder Injection engine (1. Prote cted by ht rig py Co t.and battery carrier.2005 ility ab y li an pt ce AG. – Remove bolts -arrows.

C op yi .6 l engine. Bora 2006 ➤ 4-cylinder Injection engine (1. – Moisten new O-ring with coolant and fit into pipe union. ss – Install the battery and observe the respective measures after connecting the battery ⇒ Electrical system.as shown in the figure and fit to electronics box -1-. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Route wiring -2. Rep.Cooling system ht rig py Co t.of pipe union to 5 Nm.Edition 08. Gr. – Clean or smooth sealing surface for O-ring. Re‐ moving and installing battery. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a battery carrier first and tighten bolts -arrows-. in part or in w l purpos hole ercia . • Installation position: The hole in the tappet for thermostat must show upwards. agen lksw Vo by AG. – Install engine cover with air cleaner ⇒ page 161 . Models with petrol engine . Installing Install in reverse order of removal. Gr. tappet and thermostat off. Rep. Noise insulation . Gr.2005 – Remove bolts -arrows. – Install noise insulation ⇒ General Body Repairs. direct injection) . observe the following: Note O-rings. 50 . Exterior. ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 112 Rep. – Install es. 27 . Prote cted by c o p yri gh t . – Take spring.19 . – Tighten bolts -arrows. During this step. spring and tappet. – Top-up coolant ⇒ page 102 . n AG.Jetta 2005 ➤ . – Fit thermostat.and take respective pipe union off. Renew.

10 Check cooling system for leaks: Special tools and workshop equipment required ♦ Cooling system tester V. 1274♦ Adapter for cooling system tester -V.A. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG. direct injection) .G.6 l engine. Removing and installing parts of cooling system 113 .G. – Open cap on coolant expansion tank. Wear eye protection and protective clothing to prevent eye damage and scalding. Cover sealing cap with a cloth and open cap carefully. 1274/8♦ Adapter for cooling system tester -V.Edition 08. agen lksw Vo by Prote cted by c o p yri gh t.A. C op yi 1. r fo ng ht rig py Co t.G.A. 1274/9- urposes.2005 1. AG. in part or in wh ole.Jetta 2005 ➤ . Bora 2006 ➤ 4-cylinder Injection engine (1. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Test procedure • Engine at operating temperature WARNING Hot steam can escape when opening expansion tank.

on coolant reservoir.A. – Generate a pressure of approx.6 l engine. urposes.Edition 08. Bora 2006 ➤ 4-cylinder Injection engine (1. in part or in wh ole. 1274/8.A.G. – Operate hand pump. C op yi .2005 – Set cooling system tester -V. If the pressure drops: – Search for the leak and eliminate fault.G. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.with adapter V.19 . 1274/9.4…1.G. direct injection) .Cooling system ht rig py Co t.6 bar.with adapter V. 1274.Jetta 2005 ➤ . Gr.A. Check pressure relief valve in sealing cap – Set cooling system tester -V. Prote cted by c o py rig ht .G.A. 1 bar using the tester hand pump.on coolant reservoir. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 114 Rep. • The pressure relief valve must open at a pressure of 1. agen lksw Vo by AG. 1274.

in part or in w l purpos hole ercia .1 Safety precautions when working on fuel supply system Caution When doing any repair work. if the battery is not disconnected. do c um en agen lksw Vo by Prote cted by c o p yri gh t . C op yi 1. for fuel. ♦ Place parts that have been removed on a clean surface and cover.and the electrical connection must be disconnected. the fuel pump control unit -J538. coolant and refrigerant liquid.must be pulled out of the cover -1. Therefore. Use lint-free cloths only! AG. pay attention to the following due to the cramped condi‐ tions: ♦ All wirings (e. for safety reasons. direct injection) . a radial fan with a displacement greater than 15 m3/h can be used providing that motor is not in air flow. vacuum) and are es nto be installed in w s k l ot g o the original y Vway.6 l engine. activated char‐ coal filter system. brake AG. ua b d un le r ee ♦ Touavoid damages to the wiring ensure sufficient clear‐ tho or ac a ance to all moving or hot components.Assembly overview ⇒ page 116 Emptying fuel tank ⇒ page 118 Removing and installing fuel tank ⇒ page 120 Fuel filter with attachments . Removing and installing parts of fuel supply system 115 .Assembly overview ⇒ page 123 Removing and installing fuel filter ⇒ page 123 1. If no exhaust extraction system is available. Observe rules for cleanliness ⇒ page 115 . Volkswagen AG d agenelectrical wirings o liquid.2 Rules for cleanliness ht rig py Co t. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08. hydraulic system. When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank the following must be observed: ♦ Before beginning work.-2. ss ise ran t ility ab y li an pt ce es. is n m ot com pe rm itte d The fuel pump is activated when switching on the ignition and by the driver's door contact switch. Fuel tank with attachments . especially in the engine compart‐ ment.g. pay careful at‐ tention to the following “5 rules”: ♦ Thoroughly clean all joints and surrounding areas before dis‐ mantling. before opening the fuel system.Jetta 2005 ➤ .2005 20 – 1 Fuel supply system Removing and installing parts of fuel supply system Safety precautions when working on fuel supply system ⇒ page 115 . When working on the fuel supply/injection system. place an extraction hose close to sender opening in fuel tank to extract escaping fuel fumes and switch on exhaust extraction system. ♦ Prevent skin contact with fuel! Wear fuel-resistant gloves! rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n 1.

Prote cted by c o py rig ht .Assembly overview 1 . in part or in wh ole.Fuel supply system ht rig py Co t.♦ urposes.3 Fuel tank . 5 . agen lksw Vo by AG.Securing bolt 2 . Bora 2006 ➤ oes wage not olks V g08. un le e ris ho t u Carefully cover opened components sa be carried out immediately.25 Nm ❑ Renew 7 .Assembly overview ⇒ page 123 ❑ Removing and installing ⇒ page 123 14 .).20 .6 l ua b d r . insert seal "dry" into fuel tank opening ❑ Moisten inner edges of seal with fuel when installing fuel delivery unit only r fo ng 4 .Heat shield 12 . cial p is n mer m ot p o c erm or e t a itte v i r d p ♦ Install clean parts only: Only unpack replacement parts im‐ mediately prior to installation. Do not use parts that have not been stored in their packing (e.Breather line ❑ To activated charcoal filter ❑ Clipped onto side of fuel tank ❑ Check for secure seating 15 .Lock washer 9 .Edition 4-cylinder Injection engine (1.Sealing cover ❑ Renew seal if damaged 3 .g.Cable guide ❑ For ABS wiring 6 .Securing strap ❑ Note installation posi‐ tion 11 .10 Nm 116 Rep.Earth connection ❑ Check for secure seat‐ ing. direct injection) . Gr. in tool boxes etc. s n AG d n AG Jetta 2005 ➤ . C op yi .Supply line ❑ To connecting pipe for high-pressure pump ❑ Check for secure seat‐ ing 13 . Volkswage or seal if repairs cannot an tee or ac ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.Fuel tank ❑ Removing and installing ⇒ page 120 8 . Do not move vehicle unless absolutely necessary.2005 yengine.Seal ❑ Renew ❑ When installing.Fuel filter ❑ Installation position: Ar‐ row shows in direction of flow ❑ Fuel filter . ♦ When the system is open: Do not work with compressed air if this can be avoided.Exhaust system bracket 10 .

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During this step. ♦ Ensure line connections are tight. testing and informa‐ tion system -VAS 5052. testing and information system -VAS 5051. – Remove fuel tank from side. Gr. Before loosening en AG release pres‐ lines. ♦ A second mechanic is required to assist when supporting the fuel tank. Nm 10 25 122 Rep. ♦ Press locking ring inwards to release fuel lines. check that the supply and return lines are still clipped onto the fuel tank. if necessary ⇒ page 190 . C op yi r fo ng Installing . – Unhook electrical wiring -2. ♦ If fuel delivery unit was replaced. cial p is n mer m ot p o c erm or e t a itte v i r d p the connection point. AG.M8 ♦ Renew bolts. supply line black).G 1383 A. Installation is carried out in reverse order of removal. o V g – urposes. WARNING The fuel line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact.20 . Bora 2006 ➤ 4-cylinder Injection engine (1.and black supply line -2.6 l engine.. ♦ Check fuel tank/body earth connection on filler neck.of ABS speed sensor on filler neck bracket. ♦ After installing fuel tank.Edition 08.A. wrap a cloth around the connection. ht rig py Co t.on c Disconnect ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en ♦ In vehicles with auxiliary heater. AG. Torque settings Component Fuel tank to body . separate front and rear silencer first. adapt the engine control unit to the fuel pump ⇒ vehicle diagnosis. When doing this support fuel tank with engine/gearbox jack V. observe the following: ♦ Do not interchange supply and return lines (return line blue.or vehicle diagnosis. the line for the metering pump -V54. direct injection) . Prote cted by c o p yri gh t.M6 Fuel tank to body . – Remove front silencer.2005 – Remove tank filler neck bolts -1-.. Note un le y ua db ran ise tee r o h or ut a a ss white breather line -1.must be disconnected additionally.Jetta 2005 ➤ . in part or in wh ole.Fuel supply system agen lksw Vo by ♦ Install breather and fuel hoses free of kinks. VolkswagThen does agen ksw not l sure by carefully removing the line. – Remove tensioning strap and securing bolts -arrows-.

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in part or in w l purpos hole ercia .6 l engine.G 1527 B- 2.G 1594C♦ Multimeter -V.A.G 1715♦ Torque wrench -V.A. Bora 2006 ➤ 4-cylinder Injection engine (1. is n m ot com pe rm itte d un le n AG. agen lksw Vo by AG.A.Jetta 2005 ➤ .A. Repairing fuel supply 131 . Prote cted by c o p yri gh t . Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en ht rig py Co t.A.2005 ♦ Key -T10202♦ Remote control -V.Edition 08.G 1332♦ Measuring container es.G 1348/3A♦ Adapter set -V. C op yi ♦ Voltage tester -V. direct injection) .

interior. testing and information system -VAS 5051AG. 132 Rep. 72 . is n m ot com pe rm itte d un le rrectness of i t to the co nform spec a t i h re o n in wit thi s ♦ Vehicle diagnosis and service information system -VAS 5052Checking function and voltage supply ⇒ page 132 Checking fuel pressure ⇒ page 133 Checking holding pressure ⇒ page 135 Checking delivery rate ⇒ page 136 Checking current consumption ⇒ page 138 2. do c um en – Switch ignition on. Note AG.Edition 08. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es.5 V. Bora 2006 ➤ 4-cylinder Injection engine (1.1 • • Checking function and voltage supply Fuse for fuel pump OK ⇒ Current flow diagrams. Rep. – Switch off ignition.Fuel supply system agen lksw Vo by . Gr. in part or in w l purpos hole ercia . Fuel pump must be heard to run briefly.-2-. • The fuel pump runs very quietly. Gr. Fuel pump does not run – Remove seat bench ⇒ General body repairs. direct injection) .6. ht rig py Co t.6 l engine. Rear seats.along with the fuel pump control unit J538. Electrical fault finding and Fitting locations. – Unclip the cover -1. Prote cted by c o py rig ht .20 .Jetta 2005 ➤ . C op yi r te o iva r rp fo g n Battery charge at least 11.2005 ♦ Vehicle diagnosis. Removing and installing seat bench .

– Connect voltage tester -V. – Disconnect fuel supply line -3. LED lights up briefly (voltage supply OK): – Remove the fuel delivery unit ⇒ page 127 . WARNING agen lksw Vo by 2. If no open circuit can be found: r fo ng urposes.G 1594 C.2 Checking fuel pressure ht rig py Co t. in part or in wh ole.Jetta 2005 ➤ . – Check that the electrical wires between flange and fuel pump are connected.(press locking ring inwards) and collect escaping fuel with a cloth. Before loosening lines. C op yi 2. wrap a cloth around the connection.6.A.to the outer contacts of the connector with auxiliary cables from adapter set -V. – Switch on ignition. Electrical fault finding and Fitting locations.A. Then release pres‐ sure by carefully removing the line. LED does not light up briefly: – Locate and eliminate open circuit referring to current flow di‐ agram ⇒ Current flow diagrams. Repairing fuel supply 133 . Bora 2006 ➤ 4-cylinder Injection engine (1.2005 – Pull connector off -1-. The fuel line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact. AG. direct injection) . Prote cted by c o py rig ht .G 1527 B. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Fuel pump is defective.6 l engine.. • The LED must light up briefly. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG. Renew fuel delivery unit ⇒ page 127 .Edition 08.

Fuel supply system agen lksw Vo by AG. Specification: 3.A. If fuel pressure is OK.G 1318.instead of the fuel supply line. When 6 bar have been reached. reopen the cut-off tap immediately to prevent damage to the pressure tester. Pressure limiting valve in fuel filter is defec‐ tive. If pressure has risen: – Fuel pump is OK.A.and the adapter set -V. direct injection) .5 to 5.G 1318. Replace fuel fil‐ ter.2005 – Install the pressure tester -V.20 . n AG.Jetta 2005 ➤ .G 1318/17between fuel filter and supply pipe. The pressure must rise to 6.A. Renew fuel delivery unit ⇒ page 127 .Edition 08.0 bar. If pressure does not rise: – Fuel pump is defective. The handle points in direction of flow. – Start engine and run at idling speed. If the specification is not obtained: es. Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine. Connect pres‐ sure tester -V.A.A. If no fault is detected: ks Vol by d e ris ho t and fuel pump for kinking au ss s no t gu ara nte eo ra c ility ab y li an pt ce – Pressure limiting valve in fuel filter defective. C op yi do c um en 134 Rep. Volkswagen AG doe wage If the specification is exceeded: – Check return line between fuel filter and blockages. – Read fuel pressure on pressure gauge.G 1318/1. ht rig py Co t. . Prote cted by c o p yri gh t. Renew fuel filter. The lever then points in position -A-. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his – Check fuel delivery rate upstream of fuel filter. check holding pressure ⇒ page 135 .with adapter set -V.0 bar. – Open shut-off tap on pressure gauge. At a fuel pressure of 8 bar. Gr. – Open shut-off tap of pressure tester. – Slowly close cut-off tap of pressure tester. in part or in w l purpos hole ercia . Caution Close the cut-off tap only slowly. – Switch on ignition repeatedly until fuel pressure does not rise any more on pressure gauge.G 1318/17.with the adapter V. immediately reopen cut-off tap.

Connect pressure tester -V.0 bar. pressure must not drop below 3.0 bar. es. AG. Repairing fuel supply ht rig py Co t.0 bar.is con‐ nected. – Open shut-off tap on pressure gauge. The handle points in direction of flow.G 1318. Prote cted by 2. If no fault in the fuel line is detected: – Check fuel pipe to high-pressure pump for leaks. c o p yri gh t .5 to 5.A. – Check the non-return valve in the fuel delivery unit.6 l engine.5 to 5. Bora 2006 ➤ ed Jetta 2005 ➤ s i tee r o h t or Injection engine (1. – Read fuel pressure on pressure gauge.3 • Checking holding pressure Fuel pressure is OK and pressure tester -V. The lever then points in direction -B-. Checking fuel pressure ⇒ page 133 . agen lksw Vo by – Immediately close pressure tester cut-off tap. – Observe pressure drop on gauge.A. in part or in w l purpos hole ercia . Volkswagen AG do es n wage s k l ot g o yV ua b ran . C op yi 135 . direct injection) . do c um en If the pressure drops again: If no fault is detected: – Renew high-pressure pump ⇒ page 139 . If pressure does not drop any further: – Check fuel line to fuel filter for leaks. – Read fuel pressure on pressure gauge.Edition u ac 08. Specification: 3. Specification: 3. – Switch on ignition repeatedly until fuel pressure does not rise any more on pressure gauge. After 10 minutes. If the pressure drops further: – Switch on ignition repeatedly until fuel pressure does not rise any more on pressure gauge.G 1318.2005 a ss ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his – Switch on ignition repeatedly until fuel pressure does not rise any more on pressure gauge.4-cylinder 2.G 1318/17between fuel filter and supply pipe.with adapter set -V.A.6. is n m ot p om c r erm o e t a itte riv du p or nl f e g n n AG.

Replace fuel fil‐ ter. If the pressure does not drop: AG.of connector and -5(-).A. Prote cted by c o py rig ht .of fuel pump and contact -1(+). Bora 2006 ➤ 4-cylinder Injection engine (1. WARNING The fuel line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact.Edition 08.0 bar. Gr. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 2. – Unclip the cover -1. agen lksw Vo by AG. – Remove filler cap from fuel tank filler neck.along with the fuel pump control unit J538. r fo ng – Pull connector off -1-.6 l engine. Removing and installing seat bench . – Observe pressure drop on gauge. cial p is n mer m ot p o c erm or e t a itte v i r d p – Pressure limiting valve in fuel filter defective. 72 . Before loosening lines. Then release pres‐ sure by carefully removing the line.2005 – After pressure has built up. Volkswagen AG d agen oes ksw not l o gu yV b ara d defective.. pressure must not drop below 3. renew fuel delivery e nte is r o eo h ut ra a c s s un le ility ab y li an pt ce urposes.to contact -1(+). interior.Fuel supply system ht rig py Co t. immediately close pressure tester cut-off tap.-2-.A. – Connect contacts -6(-). Gr. Rep.20 . wrap a cloth around the connection. Rear seats. – Connect remote control -V. direct injection) .of fuel pump using an adapter cable from auxiliary measuring set -V. After 10 minutes. in part or in wh ole. C op yi .of connector using adapter ca‐ bles.G 1594 C.6.Jetta 2005 ➤ . 136 Rep. If the pressure drops: – Fuel pump non-return valve is unit ⇒ page 127 .G 1348/3A.4 Checking delivery rate – Remove seat bench ⇒ General body repairs.

The lever then points in position -B-.G 1594C. is n m ot p om c r erm o e t a itte riv du p or nl f e g n b ed ara nte e – Close shut-off tap of pressure tester.A. – Open shut-off tap of pressure tester. in part or in w l purpos hole ercia . WARNING s or ac ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his Danger of spray when shut-off tap is opened..A. Bora 2006 ➤ 4-cylinder Injection engine (1.of pressure tester and hold it in measuring container. c o p yri gh t .and adapter set -V. Hold container over free connection of pressure tester.G 1318/16.onto adapter tho u 1318/11. agen lksw Vo by do c um en – Operate remote control for 30 seconds and measure battery voltage.A.2005 – Disconnect fuel supply line -3.G 1348/3A.A.G 1318.with connector -V. Prote cted by 2.G 1318/17.Edition 08. Wear protective glasses and clothing to avoid injuries and skin contact.A. From this point on do not move position of shut-off tap.to the fuel supply es n wage s k l ot g o line. Repairing fuel supply ht rig py Co t. AG. – The fuel pump delivery rate is dependent upon battery voltage.Jetta 2005 ➤ . The lever then points in the through flow direction -A-. yV u ris-V. C op yi 137 . – Operate remote control -V. Therefore connect multimeter -V. – Drain measuring container.A.to vehicle battery. At the same time slowly close shut-off tap until pressure gauge shows 4 bar.G – Push hose adapter -V. Volkswagen AG do 1318/23.(press locking ring inwards) and collect escaping fuel with a cloth.A. direct injection) .G 1715.G n AG. sa es. – Connect pressure tester -V.6 l engine.with adapter ca‐ bles from auxiliary measuring set -V.A.

wrap a cloth around the connection. Gr.g. this will equate to a minimum delivery rate ho of approx. yV b As the voltage at the pump is approx. If no fault is detected: WARNING urposes. intermittent failure of fuel supply system): – Measure current consumption of fuel pump ⇒ page 138 .G 1318. 2. 2 volts less than ed the battery ris voltage. 580 t au cm3/30 seconds. Rear seats.G 1318/17. 138 Rep. Before loosening lines. Prote cted by c o py rig ht . – Pull fuel supply line -1.5 Checking current consumption – Remove seat bench ⇒ General body repairs. Rep. Volkswagen AG d agen oes not gu ara nte eo ra c ility ab y li an pt ce – Check fuel lines for possible restrictions (kinks) or blockages.20 . Gr.Edition 08. r fo ng – Repeat delivery rate check.with adapter set -V. ss AG. in part or in wh ole. Only when up to now no fault has been detected: – Replace fuel delivery unit. If delivery quantity has been attained.2005 – Compare the quantity of fuel delivered with specification.6 l engine. interior.A. agen lksw Vo by AG.5 volts is measured at the olkbattery.off fuel filter inlet (press locking ring inwards) and collect leaking fuel with a cloth. Example: sw During the test a voltage of 12. If the minimum delivery rate is again not attained: – Remove the fuel delivery unit ⇒ page 127 and check the filter strainer for soiling. direct injection) . C op yi .A. 72 . but nevertheless you sus‐ pect a fuel supply system fault (e.Jetta 2005 ➤ . cial p is n mer m ot p o c erm or e t a itte v i r d p If the minimum delivery rate is not attained: un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en The fuel line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact. Removing and installing seat bench .Fuel supply system ht rig py Co t. If the minimum delivery rate is now attained: – Renew fuel filter ⇒ page 123 .to fuel supply line -1-. Then release pres‐ sure by carefully removing the line. 2 volts less than battery voltage). – Connect pressure tester -V. *) Minimum delivery rate cm3/30 seconds **) Voltage at fuel pump with engine not running and pump run‐ ning (approx. Bora 2006 ➤ 4-cylinder Injection engine (1.6.

7 Removing and installing high-pressure pump Special tools and workshop equipment required ♦ Torque wrench -V.to the cable -B. 9 amps. the check can be performed during a road test.G 1410- ht rig py Co t.along with the fuel pump control unit J538. – Check the current draw of the fuel pump. AG. Repairing fuel supply 139 . – Start engine and run at idling speed. direct injection) .A. AG.Jetta 2005 ➤ . Renew fuel delivery unit ⇒ page 127 .Edition 08. Bora 2006 ➤ 4-cylinder Injection engine (1. 2.-2-.to contact 1 of the 5-pin connector. but a 2nd person is necessary. agen lksw Vo by Prote cted by c o p yri gh t.of the multimeter -V. 2. cial p is n mer m ot p o c erm or e t a itte v i r d p un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en – Connect the current clamp -A. in part or in wh ole. Specification: max.6 l engine.2005 – Unclip the cover -1. C op yi If the current draw is exceeded: r fo ng If the fuel system malfunction is intermittent.G 1715or the vehicle diagnosis.A. testing and information system -VAS 5051. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce urposes. Note – Fuel pump is defective.

off the high-pres‐ sure pump. direct injection) . WARNING The fuel line and the high pressure line is under pressure! Wear protective glasses and clothing to avoid injuries and skin con‐ tact.(press locking ring inwards) and collect escaping fuel with a cloth. Then release pressure by carefully removing the line. agen lksw Vo by AG. – Disconnect fuel supply line -3.2005 ♦ Spring-type clip pliers -VAS 5024 A- Prerequisites • Engine must be cold. Gr.6 l engine. Before loosening lines. Removing – Remove engine cover with air cleaner ⇒ page 161 .20 . in part or in w l purpos hole ercia .Jetta 2005 ➤ . Prote cted by c o py rig ht . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit – Pull connector and fuel supply line -arrows. C op yi . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. wrap a cloth around the connec‐ tion. thi sd o cu m en 140 Rep. Bora 2006 ➤ 4-cylinder Injection engine (1.Fuel supply system ht rig py Co t. Note Collect leaking fuel with a cloth.Edition 08. AG.

ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en ♦ Moisten tappet of high pressure pump with clean engine oil. in part or in w l purpos hole ercia . Installing Install in reverse order of removal.Edition 08.out of the camshaft housing.2005 – Remove cable guide -2. Note Lock the screwed connections on the high-pressure pump and on fuel rail when unbolting the union nuts with a spanner. – Unscrew union nuts -3.from the highpressure line. C op yi Note 2. – Remove high pressure pump -3. Prote cted by agen lksw Vo by c o p yri gh t. Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine. Volkswage A agen ksw l o yV db ise r tho au s s Remove securing bolts -1-. ♦ The O-ring of the high pressure pump must always be renew.of the high-pressure line. Repairing fuel supply 141 . G.and remove clip -4. During this step.and -1.evenly. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – -2.Jetta 2005 ➤ . direct injection) .and tappet -1.and -3. n AG d oes not gu ara nte eo ra c es. observe the following: ht rig py Co t. AG.

Gr. Prote cted by c o py rig ht .into the groove of the high pressure pump -3-.evenly. . 142 Rep.into the – Fit a new oiled O-ring -2. Tightening torque of the securing bolt of the cable guide: 10 Nm Note Lock the screwed connections on the high-pressure pump and on fuel rail when tightening the union nuts with a spanner.and press clip -4.onto the high-pressure line.Fuel supply system agen lksw Vo by AG. es.of the high-pressure line to 30 Nm. -2. V – Slide the tappet -1. direct injection) Edition 08. ht rig py Co t. in part or in w l purpos hole ercia .of the high-pressure line to 25 Nm.handtight. Bora 2006 ➤ not olks gu yV b ara d 4-cylinder Injection engine (1.and -3. – Tighten union nut -1. – Tighten union nut -3.20 . – Install cable guide -2.does wag Jetta 2005 ➤ .2005 e n s olkswagen AG en AG. tee or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en – Tighten securing bolts -1-.on the camshaft housing.6 l engine. C op yi Tightening torque: 10 Nm – Tighten union nuts of the high pressure line -1. – Fit the high pressure pump -3.and -3. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng ri ho ut a camshaft ss housing.

Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Install air cleaner ⇒ page 161 .Jetta 2005 ➤ .Edition 08.6 l engine. – Connect fuel supply line -3-.2005 – Fit fuel supply line and the connector -arrows. es. agen lksw Vo by AG. Bora 2006 ➤ 4-cylinder Injection engine (1. direct injection) . Prote cted by c o p yri gh t. Repairing fuel supply ht rig py Co t. thi sd o cu m en 2. C op yi 143 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG.to the highpressure pump. in part or in w l purpos hole ercia .

the throttle valve positioner opens the throttle valve by the same amount.Jetta 2005 ➤ .g. the engine control unit can open or close the throttle valve independently of the accel‐ erator pedal position sender. The throttle valve is operated by the throttle valve positioner which is controlled by the engine control unit. o olks d The position of the accelerator pedal is transmitted rto ise the engine o h control unit by two accelerator pedal position senders (variable t au resistors together in one housing) connected to ss the accelerator pedal. the EPC warning lamp. when the accelerator is depressed halfway. the throttle valve control module. direct injection) . agen lksw Vo by AG. air conditioning system. The throttle valve is operated over the complete engine speed and load range by an electric motor (throttle valve positioner) in the throttle valve module.g. Gr. That is. C op yi .1 Function of EPC system With the electronic power control system (EPC) (also known as E-gas) the throttle valve is not operated by a cable. the engine control unit and so on. There is no n AG. ABS/ESP and so on). Bora 2006 ➤ 4-cylinder Injection engine (1. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 144 Rep.2005 3 Servicing electronic power control (EPC) Function of EPC system ⇒ page 144 Accelerator pedal module . When the engine is not running and the ignition is switched on. This has the advantage of preventing throttling losses at the throttle valve. V by t gu ara nte eo ra c ility ab y li an pt ce The position of the accelerator pedal (driver's requirement) is a main input value for the engine control unit.6 l engine.Fuel supply system ht rig py Co t.20 .Edition 08. This also results in significantly improved consumption and ex‐ haust emission values at certain load conditions. Volkswagen A G do es n wage mechanical connection between accelerator and throttle valve. automatic gearbox. the engine control unit calculates the optimal throttle valve opening angle for the respective situation. in part or in w l purpos hole ercia . Prote cted by c o p yri gh t. es.Assembly overview ⇒ page 145 Removing and installing accelerator pedal module ⇒ page 145 3. The throttle is then approximately half open. e. accelerator pedal position sender. This means that the throttle valve can already be completely open even though the accelerator pedal is depressed half way. controlling or monitoring the position of the throttle valve. When the engine is running (under load). After evaluating the torque requirements of various components (e. the engine control unit moves the throttle valve exactly as pre‐ scribed by the accelerator pedal position sender. “EPC” is a system comprising all components which contribute to determining.

C op yi 3.Edition 08.for re‐ lease tool ❑ Removing and installing ⇒ page 145 3 .6 b ara d e nte is r o eo h ut ra a c s s Jetta 2005 ➤ . y V 4-cylinder Injection engine (1. Prote cted by c o py rig ht . agen lksw Vo by AG.Connector ❑ Black. 2 . Servicing electronic power control (EPC) 145 .with accelerator position sender 2 -G185❑ Cannot be adjusted ❑ The accelerator pedal position passes the po‐ sition of the pedal on to the engine control unit ❑ Openings -A.Cover 3.Accelerator position sender -G79. Bora 2006 ➤ direct injection) . Volkswagen AG d agen oes ksw not l o gu l engine.2 AG.10 Nm r fo ng urposes.1 . 6-pin.3 Removing and installing accelerator pedal module Special tools and workshop equipment required ♦ Release tool -T10238- ht rig py Co t. in part or in wh ole.2005 Accelerator pedal module .Assembly overview ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 4 . cial p is n mer m ot p o c erm or e t a itte v i r d p un le 3.

Testing and Information System -VAS 5051. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Unbolt securing bolt ⇒ Item 3 (page 145) . es. C op yi . AG. – Disconnect connector and pull cable guide off accelerator pedal module.onto the connector again. Torque setting Component Accelerator pedal module to body Nm 10 146 Rep.into the hole of the vehicle floor. direct injection) . Gr.Edition 08.and slide the rubber grommet -1.to the accelerator pedal module -5.Jetta 2005 ➤ . ht rig py Co t.as shown into the openings provided to the stop and take accelerator pedal module off. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte (page 145) is using a r o eo h ut ra a c s s – Remove cover for steering column -arrows-.20 . AG. Prote cted by c o py rig ht . – Install steering column cover again. – Secure accelerator pedal module with the bolt -3.Fuel supply system agen lksw Vo by – Fit connector -2. – Fit the centre pin -7. ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Slide the release tool -T10238..6 l engine. adapt the accelerator pedal module to the engine control unit⇒ Vehicle Diagnosis. Bora 2006 ➤ 4-cylinder Injection engine (1. Installing thi sd o cu m en – Press the accelerator pedal module onto the securing pins -6-. – If the accelerator pedal module has been renewed.or Vehicle Diagnosis and Service Information System -VAS 5052.and fit cover cap -4-.2005 Removing – Lever off the protective cap ⇒ Item 4 screwdriver. in part or in w l purpos hole ercia .

Prote cted by c o p yri gh t . Observe rules for cleanliness ⇒ page 115 .Assembly overview ⇒ page 148 Checking fuel tank breather ⇒ page 148 4. in part or in w l purpos hole ercia .1 Functional check Depending upon the air pressure and ambient temperature.Jetta 2005 ➤ .are recommended for fitting agen lksw Vo by ♦ Always replace clamp-type clips with spring-type clips. 4. Observe safety precautions ⇒ page 115 . The opening period depends on the input signals.(also called regeneration valve). Bora 2006 ➤ 4-cylinder Injection engine (1. fuel vapour will form above the level of fuel in the tank. Volkswagen AG do es n wage s k l charcoal filter. ot g Vo is a sponge. The fuel va‐ pours stored in the activated charcoal and fresh air are fed to combustion in metered quantities. the activated charcoal filter system solenoid valve 1 -N80. ♦ Hose clip pliers -VAS 5024 A.e. Note t au ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en spring-type clips. The pressure retention valve prevents fuel vapours from being drawn from the tank when the solenoid valve is open and intake manifold vacuum is present. open circuit) the solenoid valve remains closed.Edition 08. ♦ Hose connections are secured with either spring-type or 147 .6 l engine.2005 4 Activated charcoal filter system Function ⇒ page 147 Activated charcoal filter system . C op yi clamp-type clips. Fuel vapours from the highest point in the fuel tank pass through the gravity valve (which closes at an angle of 45°) and through a pressure retention valve (in limited quantities) to the activated n AG. It therefore ensures that the evacu‐ ation of the activated charcoal filter has priority. AG. The activated charcoal filter will not be purged. direct injection) . Activated charcoal filter system ht rig py Co t. rlike The activated charcoal stores these vapours ho by ed es. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng When the Lambda control is active when ss driving (engine warm). When there is no electrical signal (i. Intake manifold vacuum draws fresh air through the vent opening on the underside of the activated charcoal filter during the purging procedure (regenerating the activated charcoal). The active charcoal filter system prevents these HC emissions escaping to the atmosphere. is activated (pulsed) from engine con‐ trol unit depending upon load and engine speed.

C op yi . agen lksw Vo by AG. right 2 .Breather hose AG.2005 4.Connecting hose ❑ Check for secure seat‐ ing ❑ From fuel tank 4 .Pressure retention valve with connecting hose 3 .Edition 08. Gr. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s ility ab y li an pt ce es.Assembly overview 1 . in part or in w l purpos hole ercia .Retainer ❑ For activated charcoal filter 8 .2 Activated charcoal filter system .Fuel supply system ht rig py Co t.3 Checking fuel tank breather Special tools and workshop equipment required ♦ Hand vacuum pump -VAS 6213- 148 Rep.Connecting hose ❑ To intake manifold ❑ Check for secure seat‐ ing 7 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en 4.Activated charcoal filter ❑ Location: In engine compartment.10 Nm 5 .Jetta 2005 ➤ .6 l engine. Bora 2006 ➤ 4-cylinder Injection engine (1. Prote cted by c o p yri gh t. direct injection) .20 .Activated charcoal canister solenoid valve 1 -N80❑ Valve closed with igni‐ tion switched off ❑ When the engine is warm the valve will be activated from the en‐ gine control unit (pulsed) 6 .

– Pull off breather line -1. Bora 2006 ➤ 4-cylinder Injection engine (1. AG. If no vacuum builds up: – Renew activated charcoal filter.(press locking ring in).to the ac‐ tivated charcoal filter. thi sd o cu m en agen lksw Vo by If no vacuum builds up: ht rig py Co t.2005 ♦ Adapter set -V. A vacuum must build up. – Temporarily seal breather connection ⇒ Item 8 (page 148) and operate vacuum pump again several times.A. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit Test prerequisites • Test procedure Ignition must be switched off.G 1318/17AG. direct injection) . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. If vacuum a builds-up: – Check breather hose ⇒ Item 8 (page 148) on activated char‐ coal filter for soiling and clean if necessary.to the breather line -1.6 l engine.G 1318/17. – Operate hand vacuum pump -VAS 6213. in part or in w l purpos hole ercia . Prote cted by c o py rig ht . Vac‐ uum must not build-up. C op yi 4.Edition 08.with the adapter set -V. – Then connect the hand vacuum pump -VAS 6213.Jetta 2005 ➤ . Activated charcoal filter system 149 .several times.A.

Before carrying out repairs and fault finding the fault memory must be interrogated.5 V is necessary. Injection agen oes n lksw Repairing injection system pe rm itte d Safety precautions ⇒ page 151 .2005 24 – 1 AG.Jetta 2005 ➤ . ♦ When the driver's door is opened the fuel pump is activated for 2 seconds to build-up fuel pressure. Gr. ♦ Observe procedures after connecting battery ⇒ Electrical sys‐ tem. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08. Rules for cleanliness ⇒ page 152 .24 . ♦ Do not use sealants containing silicone. it is possible that the control unit will de‐ tect and store a fault. Volkswagen AG d Mixture preparation. If a coded radio is installed. ♦ During some checks. It reduces the danger of a fire in a crash as the fuel pump is switched off by the fuel pump relay.6 l engine. Therefore.1 General notes on injection . obtain radio code before dis‐ connecting battery. will not be burnt in the engine and dam‐ age the Lambda probe.Assembly overview ⇒ page 162 Removing and installing intake manifold ⇒ page 164 Fuel rail with injectors . 27 . Injection agen lksw Vo by AG. after completing all tests and repairs. Rep. Gr.Assembly overview ⇒ page 167 Removing and installing fuel rail ⇒ page 168 r te o iva r rp fo g n Removing and installing injectors ⇒ page 170 Clean throttle valve control unit -J338. The starting charac‐ teristics are thereby improved. Also the vacuum hoses and connections must be checked (unmetered air). c o p yri gh t . Vo by ed s i r ho ut a ss ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s Air cleaner/engine cover . The use of clamp or screw-type clips is not permissible. is n m ot com un le Observe general notes on injection ⇒ page 150 . Particles of silicone drawn into the engine. in part or in w l purpos hole ercia . ht rig py Co t. a voltage of at least 11.Mixture preparation. ♦ Models with an airbag are fitted with a crash fuel shut-off sys‐ tem. C op yi 1. Connecting and disconnecting battery .only with ignition switched off.⇒ page 173 do c um en ♦ Fuel hoses in engine compartment must be secured only with spring-type clips ⇒ Electronic parts catalogue “ETKA” . Prote cted by ♦ The engine control unit is equipped with self-diagnosis. Fitting locations overview ⇒ page 153 Technical data ⇒ page 160 es. Safety precautions ⇒ page 151 Rules for cleanliness ⇒ page 152 Technical data ⇒ page 160 150 Rep. read the fault memory and erase if necessary ⇒ page 178 . ♦ For trouble-free operation of electrical components. ♦ Disconnect the battery earth strap. direct injection) .Assembly overview ⇒ page 160 Removing and installing engine cover with air cleaner ⇒ page 161 Intake manifold .

Before loosening lines. pay attention to the following due to the cramped condi‐ agen oes ksw not l tions: o g yV ris ♦ All wirings (e. ♦ If the engine is to be turned at starter speed without starting: es. brake a s s are to be installed in liquid. the fuel pump control unit -J538. Before loosening fuel pipes. wrap a cloth around the connection. hydraulic system.Jetta 2005 ➤ . To prevent injuries to persons and/or damage to the injection and ignition system. Volkswagen AG d ment. b ed ua ran tee or ac ility ab y li an pt ce ♦ To avoid damages to the wiring ensure sufficient clear‐ ance to all moving or hot components.g. ♦ Do not touch or pull off ignition wiring when engine is running or turning at starter speed. Then release pressure by carefully loosening the banjo bolts.2 Safety precautions WARNING ♦ The fuel line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact. vacuum) and electrical wirings the original way. for safety rea‐ sons.2005 1.and the electrical connection must be discon‐ nected.6 l engine. coolant and refrigerant liquid. Bora 2006 ➤ 4-cylinder Injection engine (1.must be pulled out of the cover -1. C op yi 151 . Repairing injection system ht rig py Co t.-2. if the battery is not disconnected. ♦ Switch off ignition before connecting or disconnecting injection and ignition system wiring as well as measuring instrument cables. direct injection) . agen lksw Vo by AG. before opening the fuel system. Observe following if test and measuring instruments are required during a test drive: ♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location. there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. the following must be observed: ♦ The fuel pump is activated when switching on the ignition and by the driver's door contact switch. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 1. If test and measuring instruments are operated from front pas‐ senger's seat and the vehicle is involved in an accident. ♦ The fuel pressure in the high-pressure pipe can reach 120 bar! Wear protective glasses and clothing to avoid injuries and skin contact. Caution When doing any repair work. wrap a cloth around the connection. in part or in w l purpos hole ercia . Therefore. for fuel. activated char‐ ho ut coal canister system. Then release pressure by carefully removing the line.Edition 08. especially in the engine compart‐ AG. Prote cted by c o py rig ht .

on the ignition coil with final output stage -arrow-.3 Rules for cleanliness When working on the fuel supply/injection system. direct injection) . – To install the ignition coil for final output stage fit the connector until it engages audibly. – Place assembly tool -T10118. in tool boxes etc. s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 1.g. pay careful at‐ tention to the following “5 rules”: ♦ Thoroughly clean all joints and surrounding areas before dis‐ mantling. – Carefully loosen connector lock and pull connector off. – – urposes. Injection Prote cted by . ♦ Place parts that have been removed on a clean surface and cover.24 .6 l engine.sinto the cylinder head. cial p is n mer m ot p o c erm or e t a itte v i r d p un le n AG. in part or in wh ole. Use lint-free cloths only! r fo ng ht rig py Co t.Jetta 2005 ➤ . AG. agen lksw Vo by c o p yri gh t . ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. Do not move vehicle unless absolutely necessary. C op yi ♦ When the system is open: Do not work with compressed air if this can be avoided. ♦ Install clean parts only: Only unpack replacement parts im‐ mediately prior to installation.2005 – Pull all 4-pin connectors -arrows. – To do this set the puller -T10094. Bora 2006 ➤ 4-cylinder Injection engine (1. Do not use parts that have not been stored in their packing (e.Edition 08. 152 Rep.Mixture preparation. Volkswagen AG do es n wage s k l ot g o as shown. – Pull ignition coil with output stage out a bit.). Place puller -T10094yV ua b ran ed s i t r o Press the uignition coil with output stage in direction of ee or th ac a -arrow.as shown. Gr.off ignition coils.

or Vehicle diagnosis and service information system -VAS 5052.. C op yi 153 .or Vehicle diagnosis and service information system -VAS 505210 . Bora 2006 ➤ 4-cylinder Injection engine (1.⇒ page 157 4 .4 Fitting locations overview The components A to K are not shown on the illustration. agen lksw Vo by AG. Prote cted by c o p yri gh t . 1 . Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss 7 . testing and infor‐ mation system -VAS 5051.Jetta 2005 ➤ .. in part or in wh ole. direct injection) .Throttle valve module -J338.2005 1.and throttle valve drive angle sender 2 for electric throttle -G188❑ When renewing. cial p is n mer m ot p o c erm or e t a itte v i r d p 5 .Pressure regulating valve ❑ Fitted on control hous‐ ing 2 . testing and infor‐ mation system -VAS 5051.6 l engine.Activated charcoal canister solenoid valve 1 -N80❑ Fitting location on rear intake manifold ⇒ page 157 un le n AG. erase learnt values and adapt engine control unit Vehicle diagnosis.Fuel pressure regulating valve -N276❑ Fitting location ⇒ page 157 urposes.and intake air temperature sender -G42❑ Fitting location ⇒ page 158 ♦ Intake manifold flap poten‐ tiometer -G336⇒ page 158 ♦ Intake manifold flap valve N316.Intake manifold pressure sender -G71. erase learnt values and adapt engine control unit Vehicle diagnosis. throttle valve drive for electric throttle -G186❑ Throttle valve drive angle sender 1 for electric throttle -G187.Exhaust gas recirculation valve -N18. Repairing injection system ht rig py Co t.Radiator outlet coolant temperature sender -G83❑ Fitting location ⇒ page 159 11 .High-pressure pump ❑ Perform removal and in‐ stallation of the high pressure pump only when engine is cold ❑ When installing the high-pressure pump. ❑ Fitting location ⇒ page 156 r fo ng ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 9 .Edition 08.Motronic control unit -J220with ambient temperature sender ❑ Removing and installing ⇒ page 179 6 . ❑ Install lines free of stress 8 .Vacuum actuator for intake manifold flap 3 . observe that the fuel system is not contaminated by dirt.and exhaust gas recirculation potentiometer -G212❑ Fitting location ⇒ page 156 ❑ When renewing.Coolant temperature sender -G62❑ Fitting location ⇒ page 156 1.

Fuel pressure sender -G247❑ Fitting location ⇒ page 157 J . 4 cyl.24 . testing and information system -VAS 5051. 120 bar max.) directly into the cylinder.⇒ page 159 F . G . injector -N33agen lksw Vo by AG. The injectors are high-pressure injectors which inject the fuel under high pressure (approx. injector -N32❑ No.6 l engine.Connector for Lambda probe -G39❑ Fitting location ⇒ page 155 un le 13 .with accelerator position sender 2 -G185❑ In footwell on accelerator pedal (both senders are installed together in a housing) ❑ Fitting location ⇒ page 156 E .“MIL” malfunction indicator lamp ❑ In dash panel insert r fo ng .Lambda probe after catalytic converter -G130❑ Fitting location ⇒ page 155 154 Rep.Accelerator position sender -G79. 1 cyl.Intake air temperature sender 2 -G299❑ Intergrated in the engine cover ❑ Fitting location ⇒ page 158 K . cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 15 .Fuel pump control unit -J538❑ Fitting location ⇒ page 155 B .Hall sender -G40❑ Fitting location ⇒ page 159 14 . injector -N31❑ No. C op yi C . Gr. Prote cted by c o py rig ht .Ignition coils with output stages ❑ Ignition coil 1 with final output stage -N70❑ Ignition coil 2 with final output stage -N127❑ Ignition coil 3 with final output stage -N291❑ Ignition coil 4 with final output stage -N292- 16 .or Vehicle Diagnosis and Service Information System -VAS 5052A . Injection ht rig py Co t.Jetta 2005 ➤ .Engine speed sender -G28❑ Fitting location ⇒ page 158 H .2005 12 . Bora 2006 ➤ 4-cylinder Injection engine (1.Camshaft variable timing adjustment valve 1 -N205❑ Checking ⇒ Vehicle diagnosis.Mixture preparation.Edition 08. direct injection) . 3 cyl. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce urposes. injector -N30❑ No.Lambda probe -G39❑ Fitting location ⇒ page 155 AG.Injectors ❑ In fuel rail tube ❑ No.“EPC” warning lamp ❑ In dash panel insert D .2 cyl. in part or in wh ole.Knock sensor 1 -G61❑ Fitting location ⇒ page 159 I .Motronic relay ❑ Motronic current supply relay -J271.

C op yi 1. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08.6 l engine. Fuel pump with fuel pump control unit -J5381 .Jetta 2005 ➤ . cial p is n mer m ot p o c erm or e t a itte v i r d p un le ss yV db ise r tho au n AG.Fuel pump control unit -J5383 .with connector -2agen lksw Vo by AG.Fuel delivery unit ht rig py Co t.2005 ge wa-arrowLambda probe -G39olks urposes. Volkswagen AG do es n ot g ua ran tee or ac ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Connector -arrow.Connector for fuel pump control unit -J5382 .-1. Repairing injection system 155 . direct injection) . in part or in wh ole. Prote cted by c o py rig ht .for Lambda probe -G39- r fo ng Lambda probe after catalytic converter -G130.

Bora 2006 ➤ 4-cylinder Injection engine (1. C op yi .-arrowun le n AG.Jetta 2005 ➤ .6 l engine.24 .with exhaust gas recircu‐ lation potentiometer -G212. Prote cted by c o p yri gh t .-arrow- r te o iva r rp fo g n do c um en 156 Rep. direct injection) . Gr.Edition 08. is n m ot com pe rm itte d Exhaust gas recirculation valve -N18.(in driver's footwell) Throttle valve module -J338- es. Injection ht rig py Co t.Accelerator position sender -G79.2005 -1. agen lksw Vo by AG. in part or in w l purpos hole ercia .with accelerator position sender 2 -G185.Mixture preparation. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s Coolant temperature sender -G62.

Prote cted by c o p yri gh t. C op yi agen lksw Vo by AG.-arrowht rig py Co t.Jetta 2005 ➤ .-arrow- Fuel pressure regulating valve -N276. 1. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. direct injection) .-arrowAG. in part or in w l purpos hole ercia .6 l engine. Repairing injection system 157 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit Fuel pressure sender -G247.2005 Active charcoal filter system solenoid valve 1 -N80. Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08.-arrow- thi sd o cu m en Intake manifold flap valve -N316.

Injection ht rig py Co t. agen lksw Vo by AG.24 .6 l engine. Prote cted by c o p yri gh t.-arrow- 158 Rep. in part or in wh ole.Jetta 2005 ➤ . Bora 2006 ➤ 4-cylinder Injection engine (1. cial p is n mer m ot p o c erm or e t a itte v i r d p un le AG.and intake air temperature sender -G42.Mixture preparation. direct injection) . Gr. C op yi .-arrow- urposes.2005 Intake manifold pressure sender -G71. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en Intake air temperature sender 2 -G299.-arrow- r fo ng Engine speed sender -G28.Edition 08.-arrow- Intake manifold flap potentiometer -G336.

Repairing injection system 159 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG. agen lksw Vo by AG.-arrow- Radiator outlet coolant temperature sender -G83.Edition 08.2005 Knock sensor 1 -G61. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u sender -G40-arrowac a ss ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit Relay and fuse carrier in electronics box R1 . in part or in w l purpos hole ercia .Jetta 2005 ➤ . direct injection) .not installed thi sd o cu m en ht rig py Co t. Bora 2006 ➤ 4-cylinder Injection engine (1. C op yi 1.-arrow- Hall es.Motronic current supply relay -J271R2 . Prote cted by c o p yri gh t .6 l engine.

3 Nm ❑ Observe tightening se‐ quence (figures can be found on the air cleaner housing lower part) 2 . 160 ht rig py Co t.Vacuum line ❑ From camshaft housing 6 .5 Technical data BLF 1 rpm 630…730 Motronic MED 9.10 from approx.Air intake hose AG. direct injection) .6 Air cleaner/engine cover . in part or in w l purpos hole ercia .Jetta 2005 ➤ . agen lksw Vo by Prote cted by c o p yri gh t. Bora 2006 ➤ 4-cylinder Injection engine (1.5. 1 . Injection AG.6 l engine.Filter element 5 .2005 1.Edition 08.Intake air temperature sender 2 -G2998 .3 Nm 7 .24 .Rubber bush 4 . 5700 Engine code Idling check Idling speed 5) Engine control unit System Engine speed governor 1 rpm 5) Cannot be adjusted. 1.Air cleaner upper section 10 . Gr.Spring clip 11 . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es.O-ring ❑ Renew 9 .Air cleaner housing lower part 3 .Assembly overview Removing and installing air cleaner ⇒ page 161 . C op yi .Mixture preparation. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit thi sd o cu m en Rep.

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Mixture preparation.6 l engine.24 .2005 – Pull cover downwards on the marked points -arrows-.8 Intake manifold .Activated charcoal canister solenoid valve 1 -N80❑ Repairing parts of the activated charcoal filter system ⇒ page 147 8 . Bora 2006 ➤ 4-cylinder Injection engine (1.Throttle valve module J338❑ Clean ⇒ page 173 ❑ When renewing.Edition 08.or Vehicle diagnosis and service information system VAS 5052ht rig py Co t. direct injection) .Jetta 2005 ➤ .Distributor ❑ Clipped on suction relief valve for crankcase breather sa ac ility ab y li an pt ce un le rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en 3 . Volkswagen AG gen AG does ❑ Check for secure seat‐ Volkswa not gu y b ara ing d e nte ris o eo ❑ From fuel filter uth r urposes.10 Nm . Injection agen lksw Vo by AG. Prote cted by 6 . 7 .Vacuum hose ❑ To active charcoal filter system solenoid valve 1 -N80c o p yri gh t . – Fit the oil dipstick -1. C op yi r fo ng 5 . Gr.Assembly overview 1 . cial p is n mer m ot p o c erm or e t a itte v i r d p s 2 . erase learnt values and adapt engine control unit Vehi‐ cle diagnosis.Fuel supply line ❑ Secure with spring-type clips .Vacuum hose ❑ From active charcoal filter system solenoid valve 1 -N80- 162 Rep. in part or in wh ole.again into guide tube to limit stop. 1.Seal ❑ Renew ❑ Press in onto limit stop 9 . testing and information system -VAS 5051.Fuel supply hose ❑ To high-pressure pump 4 .

Jetta 2005 ➤ , Bora 2006 ➤ 4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005 10 - Intake manifold ❑ Check vacuum reservoir in intake manifold ⇒ page 175 ❑ Removing and installing ⇒ page 164 11 - 8 Nm 12 - 5 Nm 13 - Connecting pipe ❑ For exhaust gas recirculation system 14 - Fuel pressure sender -G247- , 20 Nm ❑ With attached seal 15 - Union nut, 30 Nm 16 - 8 Nm 18 17 - High-pressure line
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0 Ω∼ (at room tempera‐ ture) ❑ Removing and installing ⇒ page 170 4 . cylinder 4 -N33❑ Injector. Repairing injection system 167 .2005 1.Jetta 2005 ➤ . in part or in w l purpos hole ercia .Pressure limiting valve ❑ Renew removed valve ❑ Before installing moisten O-rings lightly with clean engine oil ❑ Press in by hand using a 8 mm hexagon socket 8 .Vacuum hose ht rig py Co t.Fuel rail AG. cylinder 2 N31❑ Injector.O-ring ❑ Renew ❑ Before installing mois‐ ten with clean engine oil 3 . Bora 2006 ➤ 4-cylinder Injection engine (1.20 Nm 9 . C op yi 1.Retaining clip ❑ Ensure seated correctly AG.Seal ❑ Renew ❑ Do not oil or grease Prote cted by ss c ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 7 . direct injection) .Assembly overview 1 . cylinder 1 N30❑ Injector.6 l engine.Return hose ❑ From the high pressure pump ❑ Blue or with blue mark‐ ing ❑ Secure with spring-type clips ❑ Check for secure seating agen lksw Vo by 5 . Volkswagen AG d at injector and retaining agen oes ksw not l o plate V gu y b ara d e nte is ❑ Fit with the opened side r o eo h t u to the injector connector ra a es.Injector. is n m ot p om c r erm o e t a itte riv du p or nl f e g n 2 . c o p yri gh t. cylinder 3 N32❑ Resistance 12.Edition 08.10 Fuel rail with injectors . 6 .0…17.

Before loosening fuel pipes. – Remove bolts -arrows. direct injection) . Prote cted by c o p yri gh t .6 l engine. agen lksw Vo by AG.5 mm drill -arrow-. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng n AG.24 . Note es. – Remove intake manifold ⇒ page 164 . – Separate electrical connectors -1.to -6-. Gr. Then release pressure by carefully loosening the banjo bolts.Mixture preparation.and take cable guide off. C op yi .Edition 08. Injection ht rig py Co t.2005 1. – Unscrew union nuts -3. – Press operating bar of vacuum actuator in direction of actuator and lock with a ∅ 2. wrap a cloth around the connection. in part or in w l purpos hole ercia . Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit Lock the screwed connections on the high-pressure pump and on fuel rail when unbolting the union nuts with a spanner. – Remove bolt -2.of the cable guide and remove clip -4. Bora 2006 ➤ 4-cylinder Injection engine (1.Jetta 2005 ➤ .of the high-pressure line. thi sd o cu m en 168 Rep.11 Removing Removing and installing fuel rail WARNING The fuel pressure in the high-pressure pipe can reach 120 bar! Wear protective glasses and clothing to avoid injuries and skin contact.and -1.from the high-pressure line.

6 l engine. Prote cted by c o py rig ht .Edition 08. C op yi do c um en – Connect hand vacuum pump -VAS 6213.as shown.and remove fuel rail. – Install intake manifold ⇒ page 164 . – Check the function of the charging flaps using hand vacuum pump -VAS 6213. Installing Install in reverse order of following: Note AG. Torque settings Component Fuel rail on cylinder head Line guide to fuel rail 7 High-pressure lines to High-pressure pump Fuel rail Line bracket to fuel rail Nm 20 30 25 7 AG. Further installation is performed in the reverse order of removal. Repairing injection system 169 . During this step. observe the o eo h ut ra a c s s ility ab y li an pt ce Renew O-rings and seals. Note Otherwise the charging flaps between the fuel rail and the cylinder head may jam. – Fit the line bracket -1-. – Connect the fuel return line -2-. – When placing the fuel rail on the cylinder head the charging flaps must be raised lightly. ht rig py Co t. agen lksw Vo by 1. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r removal.2005 – Remove fuel return line -2.Jetta 2005 ➤ . – Pull drill or retaining clip -arrow. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his The operating bar of the vacuum actuator must be locked with a ∅ 2. • es. direct injection) . in part or in w l purpos hole ercia . – Then fit the fuel rail -arrows-. – Removing and installing injectors ⇒ page 170 . – Remove bolts -arrows.. – Produce vacuum and check function of vacuum actuator on operating rod.for fuel line bracket and unclip line bracket. Bora 2006 ➤ 4-cylinder Injection engine (1. – Remove bolt -1.out.on fuel rail. so that it will not be possible anymore to operate them when installed.5 mm drill -arrow-.

170 Rep.Jetta 2005 ➤ . C op yi .Mixture preparation. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his do c um en Removing – Remove fuse of fuel pump from fuse holder ⇒ Current flow diagrams.6 l engine.Edition 08. Gr. direct injection) . otherwise it is possible that the fuel pump will be activated when opening the driver’s door. Prote cted by c o py rig ht . Bora 2006 ➤ 4-cylinder Injection engine (1.12 Removing and installing injectors Special tools and workshop equipment required ♦ Torque wrench -V. Injection ht rig py Co t.2005 1. 1331♦ Spring-type clip pliers -VAS 5024 A♦ Tool set for FSI engines T10133AG. Note Removing fuse interrupts the voltage supply to the fuel pump for reasons of safety. Then release pressure by carefully pulling hose off con‐ nection.A.24 . agen lksw Vo by AG.G. WARNING Fuel system is under pressure! Wear eye protection and pro‐ tective clothing to prevent injuries and skin contact. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. Electrical fault finding and Fitting locations. Before loosening hose connections. wrap a cloth around the connec‐ tion. in part or in w l purpos hole ercia .

– Pull the injector out of the cylinder head by carefully knocking it.2005 does wa – DisconnectVfuel ring inwards).. ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en – Fit the slide hammer -T10133/3. Volkswagen AG gen AG es. ht rig py Co t. – Tighten knurled nut of the puller hand-tight. C op yi 1. ss c – Place the puller -T10133/1..Edition 08. un le – Remove intake manifold ⇒ page 164 . Repairing injection system 171 .on the injector -1-. Bora 2006 ➤ 4-cylinder Injection engine (1. in part or in w l purpos hole ercia . agen lksw Vo by Prote cted by c o p yri gh t.6 l engine. direct injection) . Ensure that the hooks of the puller engage in the injector recesses -arrows-.Jetta 2005 ➤ . dirt u ra a . – Pull spacer sleeve off injector. Installing AG. – Clean the hole in the cylinder head using the nylon cylinder brush -T10133/4.on the puller -T10133/1. not olks supply line -3. is n m ot com pe rm itte d – Remove fuel rail ⇒ page 168 .(press locking gu y b ara d e nte – Seal othe by ris lines so that the fuel system is not contaminated eo h tetc.

Bora 2006 ➤ 4-cylinder Injection engine (1. agen lksw Vo by AG. 180°). thi sd o cu m en 172 Rep.24 . – Clean groove for seal.Mixture preparation. Gr. in part or in w l purpos hole ercia . C op yi . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit – Press calibration sleeve -T10133/7.on the assem‐ bly cone -T10133/5. l o V ss by ed ris o th au gu ara nte eo ra c ility ab y li an pt ce es. – Pull off calibrating sleeve -T10133/7. Injection ht rig py Co t. – Slide the seal with the fitting sleeve -T10133/6.2005 – Carefully clean injector in area of seal -arrow-.Jetta 2005 ➤ . direct injection) .Edition 08.. Volkswagen AG d agen oes ksw not the seal groove.with a new seal -1. Prote cted by c o py rig ht .6 l engine.and slide the seal into AG.by turning in opposite direction. – Place the assembly cone -T10133/5. – Carefully cut open seal with a knife.onto injector to stop by turning gently (approx. Remove resid‐ uals using a wire brush. – Turn the mounting sleeve -T10133/6.on the injector -2-.

– Install fuel rail ⇒ page 168 . if necessary wait until the seal shrinks. Note un le s – Renew O-ring on injector. AG.6 l engine. 180°). – Separate electrical connection -1. sa ra c ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en The seal must not be oiled.Edition 08. – Install spacer sleeve.by turning ed nte rs o eo direction. – Install intake manifold ⇒ page 164 . Adaption must only be performed with a new or cleaned throttle valve module. r fo ng 1. a w ks n b arain opposite – Pull off icalibrating sleeve -T10133/8. Bora 2006 ➤ 4-cylinder Injection engine (1.Jetta 2005 ➤ . – Remove bolts -arrows. Note The injector must easily be fitted. direct injection) . Repairing injection system 173 .2005 – Press calibration sleeve . agen lksw Vo by ht rig py Co t. cial p is n mer m ot p o c erm or e t a itte v i r d p – Moisten O-ring with clean engine oil before installing. C op yi – If injectors are renewed.or vehicle diagnosis and service information system -VAS 5052. Prote cted by c o py rig ht .on throttle valve module J338.and take throttle valve module -J338off. ♦ When cleaning the throttle valve housing it must not be – Remove engine cover with air cleaner ⇒ page 161 . in part or in wh ole. because soiling/coking in closed throttle valve can lead to incorrect adaption values. 1.-T10133/8onto injector to stop by Volkswagen AG gen AG does turning gently (approx. testing and information sys‐ tem -VAS 5051.13 Note Cleaning throttle valve module -J338- ♦ If a new engine control unit is installed the throttle valve mod‐ ule must be adapted. h ut ol yV ot g u urposes. – Fit the injector into the cylinder head.. scratched. Further assembly is basically the reverse of the dismantling pro‐ cedure.. erase learnt values and adapt engine control unit ⇒ Vehicle diagnosis.

especially in the area -arrows. agen lksw Vo by AG.24 .or Vehicle diagnosis and service informa‐ tion system -VAS 5052.Edition 08. – Wait until the acetone is fully evaporated and reinstall the cleaned throttle valve module. testing and information system -VAS 5051. – Erase learnt values and adapt engine control unit to throttle valve control part ⇒ Vehicle diagnosis. – Wipe off throttle valve housing using a lint-free cloth. WARNING Acetone is highly inflammable. in part or in w l purpos hole ercia . is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. Prote cted by c o py rig ht .Mixture preparation.Jetta 2005 ➤ . Please observe the accidental regulations and safety notes when handling with highly inflam‐ mable fluids. es. – Clean throttle valve union thoroughly. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 174 Rep. Wear protective glasses and clothing to avoid injuries and skin contact. with a suitable object (e. Do not use compressed air when cleaning the throttle valve. Injection ht rig py Co t.2005 – Open the throttle valve by hand and..6 l engine.g.of the closed throttle valve using commercially avail‐ able acetone and a brush. a wedge made of plastic or wood) block the throttle valve in its open position -arrow-. C op yi . direct injection) . Bora 2006 ➤ 4-cylinder Injection engine (1. Gr.

to intake manifold on intake manifold.6 l engine. is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG.Edition 08. es. whether all vacuum hoses on the intake manifold are damaged and seated correctly.2005 2 Checking components Check vacuum reservoir in intake manifold for leaks ⇒ page 175 Check function of intake manifold flap ⇒ page 176 Checking intake air preheating ⇒ page 176 2.Jetta 2005 ➤ . Checking components 175 . in part or in w l purpos hole ercia . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en ht rig py Co t. Prote cted by c o p yri gh t.1 Check vacuum reservoir in intake mani‐ fold for leaks Special tools and workshop equipment required ♦ Hand vacuum pump -VAS 6213- Test prerequisites Perform visual check. C op yi 2. agen lksw Vo by AG. Bora 2006 ➤ 4-cylinder Injection engine (1. direct injection) . Test procedure – Remove vacuum hose -arrow.from intake manifold flap valve -N316.

the function of the intake manifold flap can be checked simultaneously. – Connect hand vacuum pump -VAS 6213.3 bar: The vacuum reservoir in the intake manifold is OK. Prote cted by Note c o p yri gh t. 3 up to 5 minutes.Edition 08. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng Special tools and workshop equipment ♦ Hand vacuum pump -VAS 6213- ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit Test procedure – After installing a new fuel rail. remove the retaining clip -arrow.to intake manifold. direct injection) . C op yi . AG. – Observe pressure for approx.2 Check function of intake manifold flap es.3 bar. – Renew intake manifold ⇒ page 164 . – Operate the hand vacuum pump until the pressure drop gauge indicates a pressure of 0. – Close the knurled screw on the hand vacuum pump -VAS 6213. 2. in part or in w l purpos hole ercia . Note The volume in the vacuum reservoir may require 20 lifts to pro‐ duce a pressure of 0.3 Checking intake air preheating Special tools and workshop equipment required ♦ Chilling agent spray (commercially available) Checking regulating flap – Remove engine cover with air cleaner ⇒ page 161 . thi sd o cu m en – Produce vacuum and check function of vacuum actuator on lever arm..of the vacuum actuator. – Remove intake connecting piece of the air cleaner.6 l engine. ht rig py Co t. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u required ra a c s s 2. Injection AG. Gr. If the pressure remains at 0.Mixture preparation. Bora 2006 ➤ 4-cylinder Injection engine (1.24 .2005 – Connect hand vacuum pump -VAS 6213.as shown.3 bar.Jetta 2005 ➤ . agen lksw Vo by When the intake manifold is removed. If the vacuum drops. 176 Rep.

Below +10 °C the flap opens the warm air connection.6 l engine. – Spray thermoelement -2.2005 – Check control flap position -1-.Jetta 2005 ➤ . Checking components 177 .Edition 08. To do this the air cleaner lower part must be removed ⇒ page 160 . Prote cted by c o py rig ht . direct injection) . • • Over +23 °C the flap must close the warm air connection. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n do c um en ht rig py Co t. Note The function of the thermoelement can be checked easily by spraying with commercial chilling agent. Bora 2006 ➤ 4-cylinder Injection engine (1. is n m ot com pe rm itte d un le AG. agen lksw Vo by AG. in part or in w l purpos hole ercia .with chilling agent. es. C op yi 2.

Gr.6 l engine. C op yi do c um en Connect vehicle diagnosis.as follows: – Fit the connector of the diagnosis cable -2. in part or in w l purpos hole ercia . is n m ot com ♦ Vehicle diagnosis. Volkswagen AG d agen oes ksw not l o gu page 179 d by V ara e nte is r o eo h ut ra a c s s Reading and erasing engine control unit fault memory ⇒ page 178 Removing and installing engine control unit ⇒ 3. – Start engine and run at idling speed. 178 Rep. testing and information system -VAS 5051- pe rm itte d un le Reading and erasing engine control unit fault memory ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s r te o iva r rp fo g n ♦ or vehicle diagnosis and service information system -VAS 5052ht rig py Co t. testing and information system -VAS 5051. Select vehicle system: – Press button “01-Engine electronics” on display.or vehicle diagnosis and service information system -VAS 5052. Only when engine does not start: – Switch ignition on.2005 3 Engine control unit AG. Select operating mode: – Press button on display for “Vehicle self-diagnosis”.Mixture preparation.Jetta 2005 ➤ .24 . Bora 2006 ➤ 4-cylinder Injection engine (1. .to the diagnosis connection in the driver footwell.1 Special tools and workshop equipment required es.Edition 08. direct injection) . Injection agen lksw Vo by AG. Prote cted by c o py rig ht .

92 .2. – Remove plenum chamber bulkhead ⇒ General body repairs. Windscreen wiper system. Plenum chamber bulkhead.2005 wage (1. Gr.and per‐ form “Renewing engine control unit”. Removing – Switch off ignition.as tho uidentification a well as the chassis number and the number of the ss Jetta 2005 ➤ .. testing and information system -VAS 5052.or vehicle diagnosis and service information system -VAS 5052. 3. Engine control unit 179 . Rep. do c um en 3.Erase fault memory” on display.Note es. testing and information system -VAS 5051. C op yi Note 3.or vehicle diagnosis. Select diagnostic function: – Press button “02 . Then press key “Print”. Re‐ moving and installing the windscreen wiper system . in part or in w l purpos hole ercia . these are shown one below the other on the display. exterior.2 Removing and installing engine control unit Removing and installing engine control unit without theft protec‐ tion ⇒ page 179 . – Press function “06 . Removing and installing engine control unit with theft protection ⇒ page 180 . ht rig py Co t.1 Removing and installing engine control unit without theft protection Note If the engine control unit must be renewed. 50 . Gr. ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his A print-out can be made if needed. agen lksw Vo by AG. is n m ot p om c r erm o e t a itte riv du p or nl f e g n V by ed s i r The display shows the control unit identification and coding -2. – Press button “05 . – Remove wiper arms and the plenum chamber cover ⇒ Elec‐ trical system. If the fault memory was erased the readiness code must be gen‐ erated ⇒ vehicle diagnosis. connect vehicle diag‐ nosis.6 l engine. – If faults are stored in the engine control unit. – Press the ← key. testing and information system -VAS 5051. Bora 2006 ➤ n AG.Edition 08. direct 4-cylinder Injection engine s k l o o t gu ara nte eo ra c immobilizer (centre part). – If no fault is stored in engine control unit “0 fault(s) detected” is displayed.Assembly overview . Rep. Volkswagen AG do es ninjection) . Plenum chamber bulkhead .Read fault memory” on display.End output”. Prote cted by c o p yri gh t .

Plenum chamber bulkhead. Gr. – Slide the engine control unit onto the retaining plate.2. Gr. Re‐ moving and installing the windscreen wiper system . – Unlock the rear engine control unit connector and pull it off. – Remove wiper arms and the plenum chamber cover ⇒ Elec‐ trical system. exterior. testing and information system -VAS 5051. d b direct injection) . connect vehicle diag‐ nosis. Rep. Injection ht rig py Co t. testing and information system -VAS 5052. – Now fit front connector -1. agen lksw Vo by Prote cted by c o p yri gh t. es. is n m ot p om c r erm o e t a itte riv du p or nl f e g n – Release the front connectors -1and pull it off.2005uara AG.2 Removing and installing anti-theft en‐ gine control unit Special tools and workshop equipment required ♦ Hot air blower from wiring harness repair set -VAS 1978- ♦ Insert injector from wiring harness repair set -VAS 1978Note If the engine control unit must be renewed. in part or in w l purpos hole ercia . – Push lock -2.24 . Bora 2006 ➤ es n ksw ot g Vol y 4-cylinder Injection engine (1. e ris ho t u engine athe from ss control unit nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 3. Installing – Connect rear connector to engine control unit and lock it. 92 .against the engine control unit.or vehicle diagnosis. . Volkswagen – Lever off latching device -2.Assembly overview . – Install bulkhead in plenum chamber ⇒ General body repairs.to engine control unit and lock it in position. – Install wiper arms and the plenum chamber cover ⇒ Electrical system.a bit. 50 . Windscreen wiper system.and per‐ form “Renewing engine control unit”.AG do agen Jetta 2005 ➤ . Gr. Removing – Switch off ignition. Rep. Removing and installing the windscreen wiper system . 92 .Edition 08. 180 Rep. C op yi AG.Mixture preparation. Rep. Windscreen wiper system.6 l engine. Plenum chamber bulkhead . Gr. – Continuously slide the engine control unit out of the retainer -arrow-.

Note Apply locking fluid to the shear bolts thread. – Guide the injector of the hot air blower to a shear head bolt. Plenum chamber bulkhead .as follows: r o eo h ut ra a – Switch potentiometer for stemperature adjustment -2. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Perform hot air blower adjustments is -4. – Insert a screwdriver -A. Rep. Prote cted by c o p yri gh t. ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit When heating up the shear head bolts. 20 to 25 seconds. Wear protective gloves to pre‐ vent injuries.Jetta 2005 ➤ .to maxi‐ c s Cover lines. WARNING es. direct injection) . connectors and control units in the near area of the engine control unit to avoid damages by burns. Gr.6 l engine. ht rig py Co t. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. 50 . Engine control unit 181 .between the protective housing and the retaining plate -arrow-. mum heating power (600 °C).2005 – Remove bulkhead in plenum chamber ⇒ General body re‐ pairs. C op yi thi sd o cu m en agen lksw Vo by AG. Plenum chamber bulkhead. The procedure for the second shear head bolt is the same.to position 3. Caution – Set the two-stage switch for air mass -3.Assembly overview . Bora 2006 ➤ 4-cylinder Injection engine (1. the protective housing parts will heat up considerably. – Remove shear head bolt applying grip pliers at bolt head. – Switch on the hot air blower and heat up the bolt for approx. 3. in part or in w l purpos hole ercia . exterior. By heating up the shear head bolts with the hot air blower the inhibitation of the locking fluid is reduced.Edition 08.

in part or in w l purpos hole ercia . Gr. – Push lock -2. – Unlock the rear engine control unit connector and pull it off. C op yi .Mixture preparation.to engine control unit and lock it in position.6 l engine.2005 – Lever the protective housing out upwards using the screw‐ driver -A. Plenum chamber bulkhead . – Tighten the new shear head bolts -1.against the engine control unit. ht rig py Co t. Removing and installing the windscreen wiper system . Plenum chamber bulkhead. – Release the front connectors -1. – Install wiper arms and the plenum chamber cover ⇒ Electrical system. exterior. Rep. direct injection) . – Slide the protective housing onto the retaining plate. agen lksw Vo by Prote cted by c o p yri gh t.24 . Gr.Edition 08.and pull it off sideways from the retaining plate -arrow-.Assembly overview . Windscreen wiper system.evenly until bolt heads shear off. es.Jetta 2005 ➤ . – Continuously slide the engine control unit out of the retainer -arrow-.from the engine and pull it off. Installing – Connect rear connector to engine control unit and lock it. Gr. Rep. – Slide the engine control unit onto the retaining plate. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. 50 . 92 . Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is control unit r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Now fit front connector -1.a bit. 182 Rep. – Lever off latching device -2. Bora 2006 ➤ 4-cylinder Injection engine (1. thi sd o cu m en – Install bulkhead in plenum chamber ⇒ General body repairs. Injection AG.

G. direct injection) .A. ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his ♦ The flexible element of the front exhaust pipe must not be bent ♦ Renew self-locking nuts. in part or in w l purpos hole ercia . Bora 2006 ➤ 4-cylinder Injection engine (1.otherwise it will be damaged. Prote cted by c o p yri gh t. agen lksw Vo by AG. is n m ot p om c r erm o e t a itte riv du p or nl f e g n is not under stress. loosen double and single clamps and align silencer and pre-catalytic converter so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.Edition 08. 1523 A♦ Hot bolt paste -G 052 112 A3- do c um en Catalytic converters and attachments . more than 30° . and that there is sufficient clearance to the bodywork. Special tools and workshop equipment required ♦ Lambda probe open ring spanner set -3337♦ Torque wrench -V.G.6 l engine.2005 26 – 1 Note Exhaust system Removing and installing parts of ex‐ haust system AG. If necessary.Jetta 2005 ➤ .A. C op yi 183 . 1331♦ Body saw -V. Removing and installing parts of exhaust system ht rig py Co t. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a that the system ensure c s s ♦ After working on the exhaust system es.Assembly overview ⇒ page 184 1.

Exhaust system ht rig py Co t.Main catalytic converter with exhaust pipe 12 . 4-pin ❑ Fitting location of con‐ nector: On vehicle floor ❑ Lambda probe after cat‐ alytic converter -G130with lambda probe open ring spanner set -3337❑ Grease only thread with hot bolt paste -G 052 112 A3. hot bolt paste -G 052 112 A3. Gr.Seal ❑ Renew 5 . black. direct injection) .. 14 . is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit 15 . C op yi thi sd o cu m en .To front silencer 13 .Lambda probe after cata‐ lytic converter -G130. nip open and replace agen lksw Vo by AG.40 Nm ❑ Renew ❑ Note tightening se‐ quence ⇒ page 185 7 .25 Nm ❑ Renew 6 .Front cross member AG.Jetta 2005 ➤ .2005 Silencer with mountings .Retainer 9 .Exhaust manifold ❑ Removing and installing ⇒ page 186 4 .26 ..Connector ❑ Black. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. 55 Nm ❑ Connector.60 Nm 10 .Assembly overview ⇒ page 186 Removing and installing exhaust manifold ⇒ page 186 Removing and installing pre-catalytic converter with exhaust manifold ⇒ page 188 Connecting and disconnecting front and rear silencers ⇒ page 190 Aligning exhaust system free of stress ⇒ page 192 1.25 Nm ❑ Renew 16 .must not get into slots in probe body ❑ If sealing ring is leaking.Assembly overview 1 . 6-pin ❑ For Lambda probe -G39.Warm air collector plate 2 .Edition 08.and lambda probe heater -Z19- 184 Rep. Prote cted by c o p yri gh t.Washer 8 .10 Nm 3 .6 l engine.1 Catalytic converters and attachments . in part or in w l purpos hole ercia . Bora 2006 ➤ 4-cylinder Injection engine (1.25 Nm 11 .

Bora 2006 ➤ 4-cylinder Injection engine (1. r te o iva r rp fo g n do c um en 1. pe rm itte d Tightening sequence for pre-catalytic converter on exhaust mani‐ fold and engine un le ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s – Slide bracket -4. in part or in w l purpos hole ercia .Edition 08. – Tighten nut -3-.6 l engine. – Tighten bolts -5-.Jetta 2005 ➤ .Retainer 22 .Bellows AG.. agen lksw Vo by AG.and tighten nuts -1.to cylinder block to limit stop and tighten bolts -6-.Mounting ❑ Renew if damaged 21 .Pre-catalytic converter with exhaust pipe ❑ Observe tightening sequence when installing ⇒ page 185 23 . Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s es. Prote cted by c o p yri gh t. – Tighten nuts -1-.on threaded studs by hand. Removing and installing parts of exhaust system ht rig py Co t.2005 17 .and bracket -2.23 Nm ❑ Note tightening sequence ⇒ page 185 20 .40 Nm ❑ Note tightening sequence ⇒ page 185 19 . is n m ot com – Fit pre-catalytic converter -7.Lambda probe -G39. 55 Nm 18 . direct injection) . C op yi 185 .Cable guide ❑ For alternator feeder connection 24 .

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2005 ♦ Torque wrench -V. – Release both locking devices and take air duct -2. Gr.6 l engine. ht rig py Co t. es. Note thi sd o cu m en 1.off. 1331- Removing – Remove engine cover with air cleaner ⇒ page 161 . exterior. Noise insulation . AG. Bora 2006 ➤ 4-cylinder Injection engine (1. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng – Remove warm air collector plate -arrows-. Prote cted by c o py rig ht .A. Rep. Removing and installing parts of exhaust system agen lksw Vo by The flexible element of the pre-catalytic converter must not be bent more than 30° . in part or in w l purpos hole ercia . C op yi 187 .Edition 08. 50 . Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit – Remove pre-catalytic converter with exhaust pipe from ex‐ haust manifold -arrows-. – Remove noise insulation ⇒ General body repairs. direct injection) .Jetta 2005 ➤ .G. – Disconnect rubber bellows -1. AG.otherwise it will be damaged.from air duct -2-.

188 Rep. 1331- Removing – Remove engine cover with air cleaner ⇒ page 161 . – Grease threaded studs thread on cylinder head using hot bolt paste -G 052 112 A3. Bora 2006 ➤ 4-cylinder Injection engine (1. – Remove nut -1. Installing Install in reverse order of removal. un le n AG. observe the following: Note pe rm itte d – Remove exhaust manifold from cylinder head -arrows-.from exhaust manifold/gearbox bracket. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s Renew seals and self-locking nuts.Exhaust system agen lksw Vo by AG. Take bracket off. Exhaust manifold to cylinder head Warm air collector plate to exhaust manifold Pre-catalytic converter to exhaust manifold Pre-catalytic converter to cylinder block Bracket for exhaust manifold to gearbox Prote cted by 256) 10 406) 23 60 c o p yri gh t . Component r te o iva r rp fo g n Torque settings Nm ht rig py Co t. Gr. During this step.26 .G. in part or in w l purpos hole ercia .Edition 08.6 l engine.A. is n m ot com – Take exhaust manifold and seal for exhaust manifold off from above.Jetta 2005 ➤ .. es. C op yi . direct injection) . do c um en 6) Renew 1.4 Removing and installing pre-catalytic converter with exhaust manifold Special tools and workshop equipment required ♦ Torque wrench -V.2005 – Remove bolts -arrows-.

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Edition 08.2005 Special tools and workshop equipment required ♦ Body saw -V. direct injection) .Jetta 2005 ➤ . agen lksw Vo by AG. – Align rear silencer horizontally and hold in this position. – Cut through exhaust pipe -arrow 2. C op yi 191 . e.G. g.G.at right angles. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng rrectness of i t to the co nf o r m spec atio h re n in wit ♦ Chain pipe cutter -VAS 6254- thi sd o cu m en ♦ Safety goggles Separate WARNING To prevent damage by metal particles. – Position the repair clamp-type clip at the side markings -arrow 1. 1523 A.. using body saw -V. – Fit front silencer into retainers. wear protective goggles and protective clothes. Connect Note A second mechanic is required to tighten the repair clamp-type clip. Bora 2006 ➤ 4-cylinder Injection engine (1.or chain pipe cutter -VAS 6254. Prote cted by c o p yri gh t.or AG.and -arrow 3-.6 l engine.A. 1. Front socket remains fitted loosely on the pipes.A. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce es. in part or in w l purpos hole ercia . 1523 A. Removing and installing parts of exhaust system ht rig py Co t.

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6 l engine. Gr. direct injection) . is n m ot com pe rm itte d ment -N18.Edition 08.Jetta 2005 ➤ .To expansion tank ❑ Coolant hose schematic diagram ⇒ page 99 16 .1 Assembly overview .5 Nm 9 . agen lksw Vo by AG.Seal ❑ Renew ❑ The lug must show downwards 10 . Bora 2006 ➤ 4-cylinder Injection engine (1. erase learnt values and adapt engine control unit Vehi‐ cle diagnosis. Prote cted by c o p yri gh t .10 Nm 11 .Seal ❑ Renew 6 .18 Nm 14 .or Vehicle diagnosis and service information system VAS 5052❑ Removing and installing ⇒ page 195 12 .Exhaust gas recirculation valve -N18. 6-pin 4 . in part or in w l purpos hole ercia .Seal ❑ Renew ❑ Note installation position ⇒ page 195 r te o iva r rp fo g n do c um en 15 .8 Nm 7 . Volkswagen AG do es n wage s k l ot g Vo y ua b Assembly overview .Connecting pipe ❑ Bolt stress free 8 .⇒ page 195 un le n AG.Connecting pipe ❑ Install free of stress 13 .From T-piece on cooler inlet ❑ Coolant hose schematic diagram ⇒ page 99 194 Rep.Cylinder head 2 .2005 2 2.Camshaft housing 3 .Exhaust gas recirculation system es.Exhaust gas recirculation system ran ed s i tee r ⇒ page 194 o h t or u ac a s s Removing and installing left brake pad wear indicator shear ele‐ Exhaust gas recirculation system ility ab y li an pt ce rrectness of i t to the co nform spec a t i h re o n in wit thi s 1 .Connector ❑ Gray.26 .Intake manifold 5 .Exhaust system ht rig py Co t. testing and information system -VAS 5051. C op yi .with exhaust gas recirculation potentiometer G212❑ When renewing.

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Gr. AG. agen lksw Vo by AG. ♦ Observe installation position of seal on cylinder head ⇒ page 195 ♦ Connect connecting pipes free of bolts screw in hand-tight.-4.Edition 08. C op yi . direct injection) . in part or in wh ole. – Remove connecting pipe -3-. Prote cted by c o p yri gh t. When doing this swivel out of intake manifold upwards.from cam‐ shaft housing and lay to side with connected coolant hoses. cial p is n mer m ot p o c erm or e t a itte v i r d p rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng 196 Rep. Volkswagen AG d agen oes ksw not l o V gu stress. observe the following: ♦ Renew seals and gasket in intake manifold. – Remove exhaust gas recirculation valve -N18. Installing Install in reverse order of removal.6 l engine. – Pull connector off -2-. During this step.2005 – Remove connecting pipe -1-.Jetta 2005 ➤ . Before tightening all y b ara d nte ise r o eo h t u ra a c s s un le ility ab y li an pt ce urposes.26 . Bora 2006 ➤ 4-cylinder Injection engine (1.Exhaust system ht rig py Co t. ♦ Torque settings ⇒ page 194 . ♦ The lug of the seal connecting pipe/ exhaust gas recirculation valve must show downwards.

⇒ vehicle diagnosis. in part or in w l purpos hole ercia . there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. c o p yri gh t. Repairing ignition system ht rig py Co t.2005 ut ra c s s ility ab y li an pt ce rrectness of i t to the co nf o r m spec atio h re n in wit General notes on ignition system ♦ The engine control unit is equipped with self-diagnosis. it could be that the immobilizer blocks the engine control unit.1 Safety precautions To prevent injuries to persons and/or damage to the injection and ignition system. Observe following if test and measuring instruments are required during a test drive: ♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location.Edition 08. spark plugs ⇒ page 199 .4-cylinder 28 – 1 Ignition system Repairing ignition system es.6 l engine. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara 2006 ➤ d Jetta 2005 ➤ . 1. testing and information system -VAS 5051. repairs or component tests and then stalls. Bora nte ise r o eo h Injection a engine (1.. ♦ Switch off ignition before connecting or disconnecting injection and ignition system wiring as well as measuring instrument cables.or ve‐ hicle diagnosis and service information system -VAS 5052. direct injection) .ignition system ⇒ page 198 . ♦ During some checks. Therefore after completing all checks and repairs the fault memory must be interrogated and if necessary erased. 1. is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng AG. the control unit must be adapted. Prote cted by Assembly overview . agen lksw Vo by thi sd o cu m en Test data. ♦ If the engine starts only for a short period of time after per‐ forming fault finding. In this case. Safety precautions ⇒ page 197 . the following must be observed: ♦ Do not touch or pull off ignition wiring when engine is running or turning at starter speed. C op yi 197 . it is possible that the engine control unit will detect and store a fault. a voltage of at least 11.5 V is necessary. If test and measuring instruments are operated from front pas‐ senger's seat and the vehicle is involved in an accident. Removing and installing ignition coils with output stage ⇒ page 198 . ♦ For trouble-free operation of electrical components.

O-ring ❑ Renew if damaged 9 . 4-pin ❑ Unlock with assembly tool -T101182 .6 l engine.28 .Earth wire ❑ Loosen or tighten when the ignition is switched off 13 . is n m ot p om c r erm o e t a itte riv du p or nl f e g n AG. 3-pin ❑ For Hall sender -G407 . direct injection) . Bora 2006 ➤ 4-cylinder Injection engine (1.Edition 08. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s ility ab y li an pt ce rrectness of i t to the co nform spec at i h re o n wit in t his do c um en 11 .Jetta 2005 ➤ .Cable guide ❑ Fit on camshaft housing with 8 Nm 12 . Prote cted by c o p yri gh t.2 Assembly overview .Ignition coil 3 with final out‐ put stage -N291❑ Ignition coil 1 with final output stage -N70❑ Ignition coil 2 with final output stage -N127❑ Ignition coil 4 with final output stage -N292❑ Removing and installing ⇒ page 198 3 .2005 1.Connector ❑ Black.ignition system 1 . C op yi .3 Removing and installing ignition coils with output stage Special tools and workshop equipment required 198 Rep.Ignition system agen lksw Vo by AG.10 Nm es.10 Nm ❑ Loosen or tighten when the ignition is switched off 1.20 Nm ❑ The torque setting influ‐ ences the function of the knock sensor 6 . 30 Nm ❑ Remove and install with spark plug spanner -3122 B❑ Type and electrode gap ⇒ page 199 ht rig py Co t. in part or in w l purpos hole ercia .Connector ❑ Black. Gr.Connector ❑ Black.Hall sender -G408 . 2-pin ❑ For knock sensor 1 G61❑ Gold-plated connector contacts 4 . 10 .Knock sensor 1 -G61❑ Gold-plated connector contacts 5 .Spark plug.

6 l engine. Firing order 1-3-4-2 199 . C op yi do c um en BLF Spark plugs agen lksw Vo by AG. ility ab y li an pt ce – Slide the connector on the ignition coil with output stage until it audibly engages. es.2005 ♦ Assembly tool -T10118- ♦ Puller -T10094- Removing – Fit puller -T10094.Jetta 2005 ➤ .on the ignition coil with final output stage -arrow-.on the V by ed s i r ho ut a ignition coil with ss age – Carefully loosen connector lock and pull o connector off.Edition 08.068 AA 1. in part or in w l purpos hole ercia . direct injection) .4 Spark plug test data Engine code c o p yri gh t . Repairing ignition system ht rig py Co t. – Place assembly tool -T10118. Bora 2006 ➤ 4-cylinder Injection engine (1.into the cylinder head. lksw final n AG. – Pull ignition coil with output stage out a bit. Volkswagen AG do es n ot g ua ran tee or ac output stage. Prote cted by VW/Audi 101. Installing – Fit puller -T10094. is n m ot p om c r erm o e t a itte riv du p or nl f e g n rrectness of i t to the co nform spec at i h re o n wit in t his 1. – Press the ignition coil with output stage in direction of -arrow.000.as shown.

6 l engine.9…1. Gr.Jetta 2005 ➤ .28 .1 mm 30 Nm 60. agen lksw Vo by c o p yri gh t . direct injection) . cial p is n mer m ot p o c erm or e t a itte v i r d p un le n AG. Rep.2005 Engine code Manufacturer's designation Electrode gap Torque setting Change interval BLF FGR 6HQ E0 0.000 km urposes. Bora 2006 ➤ 4-cylinder Injection engine (1. in part or in wh ole.Ignition system Prote cted by 200 ht rig py Co t. C op yi .Edition 08. Volkswagen AG do es n wage s k l ot g o yV ua b ran ed s i tee r o h t or u ac a ss ility ab y li an pt ce rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en r fo ng AG.