Professional Documents
Culture Documents
Workshop Manual
Jetta 2005 ➤
Bora 2006 ➤
Electrical System
Edition 05.2005
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27 - Starter, current supply, CC
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96 - Lights, lamps, switches - inside
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
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27 - Starter,ut current supply, CC . . . . . . . . . . . . . o.r a. ........................... 1
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Checking battery with magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.4 Checking low maintenance battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Check no load voltage of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Disconnecting and reconnecting batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.2 Connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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5.1 Models with a petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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5.2 Models with a diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Torque settings: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Removing and installing starter, automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Removing and installing starter, automated shift gearboxes . . . . . . . . . . . . . . . . . . . . . . . . 58
7.4 Removing and installing starter, manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8 Torque settings: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.1 Fastening B+ wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.2 Checking ribbed belt (poly V-belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.3 Check alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.4 Alternator, 1.6 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.5 Alternator, 1.6 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.6 Alternator, 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.7 Alternator, 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.8 Alternator 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.9 Alternator, 1.9 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.10 Alternator, 2,0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.11 Removing and installing ribbed belt (poly V-belt) pulley on alternator . . . . . . . . . . . . . . . . 137
9.12 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
10 Torque settings: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.1 General torque settings for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.2 1.6 l injection engine and 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.3 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
10.4 1.9 l and 2.0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
10.5 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
11 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Contents i
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1.1 Deactivating APP function of wiper motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1.2 Removing and installing the windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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1.3 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.5 Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.6 Removing and installing rain and light detector sensor G397 . . . . . . . . . . . . . . . . . . . . . . 163
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2.2 Removing and installing reservoir for windscreen and headlight washer systems . . . . . . 166
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2.3 Removing and installing washer pump V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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2.4 Removing and installing windscreen washer spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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2.5 Adjusting front windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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3.2 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 171
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3.3 Removing and installing pop-up spray jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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3.4 Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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3.5 Adjusting headlight washer system jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.6 Bleeding the headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Wash water line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6 Torque settings: Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
ii Contents
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
2.6 Removing and installing gas discharge light control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.7 Headlight range control unit J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.8 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.9 Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.10 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.1 Assembly overview - fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.2 Removing and installing fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.3 Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3.4 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4 Removing and installing sideAmarker . Volkswinagfront
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4.1 Removing and installing Vol
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5 Mirror turn signal db ar
rise bulb and entry light in exterior mirror an.te. . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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5.1 Removing aandut
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5.2 Removings and installing entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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6 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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6.1 Assembly overview - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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6.3 Removing and installing tail light bulb carrier in side panel . . . . . . . . . . . . . . . . . . . . . . . . 213
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6.4 Assembly overview - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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6.5 Removing and installing tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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6.6 Removing and installing tail light bulb carrier in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
7 Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7.1 Removing and installing number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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8 Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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8.1 Removing and installing high level brake light bulb M25 . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9 Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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10.2 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
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10.3 Removing and installing ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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11 Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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11.1 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
11.2 Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
11.3 Removing and installing parking aid sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
11.4 Removing and installing rear parking aid warning buzzer H15 . . . . . . . . . . . . . . . . . . . . . . 236
11.5 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
12 Torque settings: lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.1 Torque settings: headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.2 Torque settings: fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.3 Torque settings - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.4 Torque settings - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.5 Torque settings: vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Contents iii
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2.3 Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . 242
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2.4 Removing and installing switches and instruments illumination regulator E20 . . . . . . . . . . 242
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2.5 Removing and installing front passenger side airbag deactivated warning lamp K145 . . 243
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2.6 Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . 244
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2.7 Removing and installing left footwell light W9 and right footwell light W10 . . . . . . . . . . . . 244
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2.8 Removing and installing key operated switch to deactivate front passenger side airbag E224
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3 Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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3.1 Removing and installing window regulator switch in front passenger door E107 . . . . . . . . 248
3.2 Removing and installing switch module for driver side mirror adjustment . . . . . . . . . . . . . . 248
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3.3 Removing and installing driver side interior locking button for central locking system E308
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Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3.5 Removing and installing switch module for driver side window lift . . . . . . . . . . . . . . . . . . . . 250
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3.6 Removing and installing remote release button for fuel filler flap and rear lid E463 and key
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4 Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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4.1 Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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4.2 Removing and installing rear left window regulator switch, in door E52 and rear right window
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regulator switch, in door E54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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5 Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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5.1 Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . Prote AG.
256
5.2 Removing and installing rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6 Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.1 Removing and installing front interior light and reading light (vehicles with no sliding
sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.2 Removing and installing front interior light and reading light (vehicles with sliding sunroof)
........................................................................ 261
6.3 Rear interior and reading light (vehicles without ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
6.4 Rear interior and reading light (vehicles with ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
6.5 Removing and installing front passenger side illuminated vanity mirror W14 and driver side
illuminated vanity mirror W20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
6.6 Removing and installing garage door operating unit E284 . . . . . . . . . . . . . . . . . . . . . . . . 271
7 Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.1 Removing and installing TCS and ESP button E256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
8.1 Removing and installing treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . 274
8.2 Checking treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
9 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.1 Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.2 Immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.3 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
10 Anti-theft alarm system (ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
10.1 Activating and deactivating anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
10.2 Removing and installing anti-theft alarm ultrasonic sensor G209 . . . . . . . . . . . . . . . . . . . . 278
10.3 Removing and installing vehicle inclination sender G384 . . . . . . . . . . . . . . . . . . . . . . . . . . 278
10.4 Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
10.5 Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.1 Connecting vehicle Diagnosis, Testing and Information System VAS 5051A . . . . . . . . . . 281
2 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.1 Removing and installing fuse holder on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3 Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
iv Contents
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
3.1 Removing and installing relay carrier with safety cut-out on left of dash panel . . . . . . . . . . 285
3.2 Removing and installing relay carrier on onboard supply control unit, on left of dash panel
........................................................................ 286
4 Electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.1 Removing and installing electronics box on left in engine compartment . . . . . . . . . . . . . . 288
5 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.1 Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.3 Central control unit for convenience system J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
5.4 Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
6 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.2 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 302
6.3 Notes on repairs to wiring harness and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.4 Supplementary notes on repair of CAN bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
6.5 Wiring harness repair set V.A.G 1978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
7 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.2 Assembly overview - an aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.3 Installing a new aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8 Torque settings: Cables . . . . . . . . . . . . . . . A.G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . 307
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8.1 Torque settings: Electronics box in Vleft wage
olksside of engine compartment ot g . . . . . . . . . . . . . . . . . . 307
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8.2 Torque settings trailer detectorisecontrol
d b unit J345 . . . . . . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . 307
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Contents v
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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vi Contents
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
WARNING
Caution
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1. Battery 1
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.
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1. Battery 3
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Caution
The tightening torque for the battery terminal clamps -1- and the
additional clamps-2- can be found in this table “Tightening tor‐
ques: Battery” ⇒ page 36 .
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curing bolt to specified torque setting. ⇒ page 36
2. Checking battery 5
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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♦ Low maintenance ⇒ page 1
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♦ The magic eye can be located at various positions on the bat‐
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2. Checking battery 7
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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2. Checking battery 9
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
WARNING
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The no load voltage test is used to determine the capacity of the
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– Switch off ignition and all electrical consumers and pull out
ignition key.
– Disconnect negative terminal on battery ⇒ page 29 .
– Wait at least 2 hours. The battery must not be charged or dis‐
charged within this period.
– Check battery no load voltage with hand multimeter -V.A.G
1526 B- .
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2. Checking battery 11
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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Perform battery load test:
– Switch off the ignition and all electrical consumers.
– Check no load voltage of battery ⇒ page 10 .
– Set low-temperature test current for battery in Ampere (A) ac‐
cording to DIN standard.
If the battery values are shown in IEC or EN/ SAE instead of DIN
then convert figures using table
⇒ “2.6.3 Table: low-temperature test current”, page 13 or using
table on unit.
– Select low-temperature test current via low-temperature test
current selection switch ⇒ page 12 .
– Select measuring range 80 - 379 A or 380 - 499 A with ON/
OFF and functions switch ⇒ page 12 .
– Connect red terminal “+” of unit to positive terminal.
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2. Checking battery 13
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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♦ Perform test once only. Repeating the test falsifies the results.
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This chapter describes the basic functions of the battery charger
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t.
yi Co
Cop py
t. rig
♦ Observe ⇒ Operating instructions for battery charger -VAS
gh ht
pyri by
5095 A- .
o Vo
by c lksw
cted agen
Prote AG.
♦ Observe battery manufacture's handling instructions!
3. Charging battery 15
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
WARNING
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ If the battery has cell sealing plugs, do not open them while h re
hole
spec
the battery is being charged.
es, in part or in w
t to the co
at
terminal on battery.
om
ion
c
in t
his
ate
yellow. When only the light emitting diode (LED) -3- lights up yel‐
um
for
en
g
t.
yi Co
op py
If the LED lights up green ⇒ page 15 -4- the charger has switched
. C rig
ht ht
rig
to "maintaining charge". The battery is fully charged. py by
co Vo
by lksw
cted agen
– Switch off charging unit ⇒ page 15 . Prote AG.
WARNING
ce
le
the charge condition of the battery.
un
pt
an
d
itte
y li
erm
ab
ility
Note
ot p
wit
is n
h re
♦ Observe notes in chapter ⇒ page 27 .
ole,
spec
urposes, in part or in wh
t to the co
– Charge battery ⇒ page 16 .
rrectne
3.1.4 Charging battery in support mode with
battery charger -VAS 5095 A-
ss o
cial p
f inform
WARNING
mer
atio
om
n
c
i
or
n
tions ⇒ page 2 !
thi
te
sd
iva
o
pr
cum
r
fo
en
When in support mode the battery charger -VAS 5095 A- replaces
ng
t.
yi Co
a defective vehicle battery whilst it is being exchanged. The on‐ Cop py
board supply remains intact. The vehicles electrical equipment
t. rig
gh ht
yri by
(e.g. electric windows) can be used. cop Vo
by lksw
cted agen
Prote
Special tools and workshop equipment required
AG.
Caution
3. Charging battery 17
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
un
pt
♦ During the support mode the current draw is limited to 5 A.
an
d
itte
y li
erm
ab
– Switch on vehicle parking light.
ility
ot p
wit
is n
h re
ole,
spec
– Switch off charging unit ⇒ page 15 .
urposes, in part or in wh
t to the co
– Remove charger unit terminals from battery terminals.
– Set support mode/normal mode change-over switch to
⇒ page 15 “normal mode” again.
rrectne
3.1.5 Charging battery in buffer/ maintenance
ss
mode with battery charger -VAS 5095 A-
o
cial p
f inform
mer
WARNING
atio
om
n
c
i
or
n
Danger of injury! Observe warning notices and safety regula‐
thi
te
sd
a
tions ⇒ page 2 !
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
In the buffer mode the battery charger -VAS 5095 A- is charged Cop py
t. rig
correctly and is maintained in a fully charged condition. opyri
gh by
Vo
ht
c lksw
– Proceed as for charging battery ⇒ page 16 .
by
cted agen
Prote AG.
Note
WARNING
Note
AG. Volkswagen AG d
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♦ Observe ⇒ Operating instructions for battery chargerby Vo
-VAS gu
ara
5900- . orise
d
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♦ Observe battery manufacture's handlingssinstructions!
a c
ce
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un
pt
3.2.1 Description of battery charger -VAS
an
d
itte
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rm
ab
5900-
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Wet batteries (genuine VW batteries from 2004 with transpar‐
es, in part or in w
t to the co
♦ Absorbent glass mat batteries (genuine VW batteries from
2004 with black housing).
rrectness of i
Battery charger -VAS 5900-
l purpos
1 - Display
2 - Adjustment button “Up” ↑
nform
ercia
a
com
tion in
4 - START / STOP
r
te o
thi
s
iva
5 - INFO do
r
rp
cum
fo
en
ng
t.
3.2.2 Charging battery with battery charger -
yi Co
Cop py
t.
VAS 5900-
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
3. Charging battery 19
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Jetta 2005 ➤ , Bora oris 2006 ➤ nte
eo
th
Electrical System
s au - Edition 05.2005 ra
c
s
ce
le
un
pt
♦ Battery charger -VAS 5900-
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
Note
com
tion in
r
te o
thi
♦ The battery must have a temperature of at least 10 °C.
s
iva
do
r
♦ If the battery has cell sealing plugs, do not open them while
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Switch off the ignition and all electrical consumers. rig ht
py by
co Vo
by lksw
– Connect charger unit plug to power supply. The last selected Prote
cted AG.
agen
operating mode will appear on display ⇒ page 19 .
– Set battery to respective operating mode with INFO .
In the display the symbol -1- for “standard charge for wet batter‐
ies” or the symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.
– Set battery capacity (Ah) of battery for charging using respec‐
tive button “Up” ↑ or “Down” ↓ .
– Connect red terminal clamp “+” to positive terminal on battery.
– Connect black terminal clamp “-” to negative terminal on bat‐
tery.
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.
Note
ce
le
un
pt
an
d
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Ending battery charging sequence:
es, in part or in w
t to the co
– Press START / STOP .
– Disconnect black terminal clamp “-” of charger unit from neg‐
rrectness of i
ative terminal on battery.
– Disconnect red terminal clamp “+” of charger unit from nega‐
l purpos
nform
– Pull charger unit plug out power supply socket.
mercia
a
com
t
3.2.3 Charging battery in service mode with
ion in
r
te o
do
r
rp
cum
fo
WARNING
en
ng
t.
yi Co
Cop py
t. rig
Danger of injury! Observe warning notices and safety regula‐ yri
gh by
ht
tions ⇒ page 2 ! cop Vo
by lksw
cted agen
Prote AG.
Caution
3. Charging battery 21
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Caution
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
♦ The battery must have a temperature of at least 10 °C.
es, in part or in w
t to the co
♦ If the battery has cell sealing plugs, do not open them while
the battery is being charged.
rrectness of i
– Switch off the ignition and all electrical consumers.
l purpos
at
om
ion
In the display the symbol -1- for “service charge for wet batteries”
c
in t
or
or the symbol -2- for “service charge for gel/absorbent glass mat
his
ate
cum
or
en
ng
t.
tive button “Up” ↑ or “Down” ↓ .
yi Co
Cop py
ht. rig
– Connect red terminal clamp “+” to positive terminal on battery. rig ht
py by
co Vo
by lksw
– Connect black terminal clamp “-” to negative terminal on bat‐ cted agen
Prote AG.
tery.
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
The success of the “service charge” depends on the severity of
hole
spec
the sulphation of the battery.
es, in part or in w
t to the co
Possible faults and fault rectification:
1- Displayed battery voltage is not as per nominal voltage:
rrectness of i
– Press respective button “Up” ↑ or “Down” ↓ until charging
l purpos
sequence starts.
nf
2- Displayed battery voltage is not as per nominal voltage –
ercia
o
charging sequence already started:
rm
m
atio
m
n in
or c
thi
e
sd
iva
sequence starts.
o
r
rp
cu
o
m
f
en
ng
WARNING
3. Charging battery 23
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Jetta 2005 ➤ , Bora 2006 ➤ horis nte
eo
Electrical System - Edition 05.2005 aut ra
ss c
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p
♦ The terminal polarity protection in operating mode “charg‐
wit
, is n
ing totally discharged batteries/support mode” is not ac‐
h re
tive. Connect battery charger terminal clamps correctly to
hole
spec
battery terminals.
es, in part or in w
t to the co
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ Operating instructions for battery
charger -VAS 5900- !
rrectness of i
♦ Totally discharged battery is not recognised by battery
l purpos
charger ⇒ page 27 .
♦ Do not press START / STOP button when charger unit
nform
ercia
cables are connected incorrectly. The charger unit may be
damaged. m
at
om
ion
c
in t
or
his
te
do
riv
cum
for
en
g
Note
Note
an
itte
ab
wit
, is n
h re
spec
t to the co
WARNING
rrectness of i
tions ⇒ page 2 !
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Charging battery 25
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Caution
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f i
n
c
i
or
n thi
sd
va
o
pr
cum
activated.
r
fo
en
ng
t.
yi Co
– Press respective button “Up” ↑ or “Down” ↓ to set the re‐ . Cop py
spective onboard supply voltage (6 V, 12 V or 24 V).
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
WARNING
pt
du
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
t to the co
at
ion
c
in t
or
his
ate
WARNING
do
priv
cum
for
en
g
t.
yi Co
op
tions ⇒ page 2 ! C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
A battery is designated “totally discharged” when the "no load" Prote AG.
voltage is less than 12.2 V.
Caution
3. Charging battery 27
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
♦ Batteries that have not been used for a long time e.g. vehicles
that have been stored, will self-discharge.
♦ In totally discharged batteries, the electrolyte is comprised al‐
most entirely of water because the acid content is so low.
♦ Totally discharged batteries sulphate, that is, the entire plate
surfaces of the battery harden.
♦ If a battery is recharged shortly after it has totally lost its AG. Volkswagen AG d
charge, the sulphation will dissipate. agen oes
olksw not
V gu
by ara
♦ If these batteries are not recharged the plates continue
rised
to nte
harden and the ability to recharge is reduced.autA reduction in
ho eo
ra
the battery output is the result. ss c
ce
le
un
pt
an
d
y li
erm
ab
– Charge battery.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
– Then
ss unscrew battery positive clamp -2- from batteryc positive
terminal.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Caution
m
at
om
ion
c
in t
his
e
⇒ page 4 .
at
do
priv
cum
for
en
ng
t.
yi
Special tools and workshop equipment required
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
After connecting the battery and switching the ignition on the ESP
and TCS warning lamp -K155- lights up permanently. The warn‐
ing lamp goes out automatically if a distance of 15 to 20 km/h is
driven straight ahead. This activates the steering angle sender -
G85- again.
n AG. Volkswagen AG do
lkswage es n
o ot g
Caution d byV ua
ran
ir se tee
tho
or
Disconnecting and connecting the
ss
au
battery as described in the ac
Workshop Manual ⇒ page 29 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Fit battery positive clamp -2- to positive terminal of battery and
ility
ot p
wit
, is n
h re
– Fit battery earth clamp -1- to negative terminal of battery and
hole
t to the co
– Carry out the procedures as detailed in the table.
Steps after connecting battery
rrectness of i
Procedures Performed
l purpos
atio
m
n in
or c
change as necessary.
thi
te
sd
a
o
r
rp
cu
m
f
en
ng
again.
t.
yi Co
op py
Functional check: of all electri‐ t. C rig
gh ht
cal consumers. yri
p by
co Vo
by lksw
cted agen
If necessary, table can be printed out. Prote AG.
WARNING
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Removing:
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– Unscrew securing bolt -1- and remove battery holder -2-.
co Vo
by lksw
cted agen
Prote AG.
Caution
ce
e
nl
pt
doing this, note the following:
du
an
itte
y li
erm
ab
ility
⇒ page 36 .
ot p
wit
, is n
h re
hole
spec
– Connect the battery ⇒ page 29 .
es, in part or in w
t to the co
Caution
rrectness of i
nf
ercia
or
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing:
l purpos
nf
ercia
o
For vehicles with a 1.9 l TDI engine:
rm
m
atio
m
n in
c
-arrow B-.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024A- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
– Pull hose -arrow- off air filter housing and take hose out.
itte
y li
erm
ab
– Pull air filter housing upwards out of brackets and remove.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
– Pull panel of battery box out upwards in direction of arrow.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Fold handles -arrows- upwards and take battery out.
ility
ot p
Installing:
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
A loosely fitted battery creates the following dangers:
♦ Shortened service life due to damage from vibration (dan‐
rrectness of i
ger of explosion).
l purpos
nf
ercia
o
♦ Damage to battery housing by clamping bracket (possi‐
rm
m
atio
om
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
Installation is performed in the reverse order of installation; when
f
en
ng
t.
doing this, note the following:
yi Co
Cop py
t. rig
– Tighten threaded connections to specified torque settings gh ht
yri by
⇒ page 36 . cop Vo
by lksw
cted agen
Prote AG.
– After installing, check that battery is seated securely.
– Connect the battery ⇒ page 29 .
Caution
ce
le
un
pt
an
d
Threaded connections Torque settings
itte
y li
rm
ab
Battery clamp to battery terminal M6 6 Nm
pe
ility
ot
wit
, is n
h re
clamp
hole
spec
Securing bolt of battery holder M8x35 20 Nm
es, in part or in w
t to the co
Air filter housing to body 10 Nm
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7 Starter
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Starter 37
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Removing:
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
38
cted agen
Prote
Rep. Gr.27 - Starter, current supply, CC
AG.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
– Remove air filter housing from vehicle.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Push down protective cap orisin -direction of arrow- from solenoid
ed
nte
switch. aut
h eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Unscrew positive wire -1- and disconnect connector from ter‐
minal 50 -2-.
ss o
– Remove noise insulation ⇒ General Body Repairs, Exterior;
cial p
f in
Rep. Gr. 50 ; Body front; Noise insulation .
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
– Unscrew securing nut -1- from lower starter securing bolt.
cted agen
Prote AG.
7. Starter 39
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
Electrical System - Edition 05.2005 lksw
agen oes
not
Vo gu
d by ara
e
– Remove lower securing bolt of starter
horis -arrow-. nte
eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew securing nut -1- from upper starter securing bolt.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Remove upper securing bolt of starter -arrow-. Prote AG.
– Unscrew earth wire securing nut -1- and place earth wire -2-
to one side.
– Remove starter from vehicle upwards.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 97 .
AG. Volkswagen AG d
♦ Torque wrench -V.A.G 1332- lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing:
rrectness of i
– Disconnect the battery ⇒ page 29 .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Starter 41
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Unscrew securing nut -1- from upper starter securing bolt.
es, in part or in w
t to the co
– Remove wiring retainer -2-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew earth wire securing nut -1- and place earth wire -2-
to one side.
– Remove starter from vehicle upwards.
Installing: AG. Volkswagen AG d
agen oes
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Installation is carried out in the reverse order. Whenbyinstalling,
Vol not
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ara
note the following: rise
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– Tighten threaded connections to specified ss a torque settings
u ra
c
⇒ page 97 .
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le
un
pt
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itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Special tools and workshop
equipment required
♦ Torque wrench -V.A.G
rrectne
1331-
♦ Torque wrench -V.A.G
ss o
1332-
cial p
f inform
♦ Spring-type clip pliers -VAS
mer
5024-
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
7. Starter 43
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
– Loosen spring-type clip -arrow- from hose -1- using spring type
an
d
itte
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clip pliers -VAS 5024- .
erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
– Open retainer -arrow- on front side of air filter housing and take
form
mer
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
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o ot g
byV ua
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– Loosen spring-type clip -1- using spring typethoclip
ris
pliers -VAS tee
or
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ss
ce
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– Carefully lift air filter housing upwards out of the vehicle taking
y li
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ab
into consideration the length of the hose.
pe
ility
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wit
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es, in part or in w
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– Separate connector -arrow- on rear of air filter housing. rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 45
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew securing nut -1- from lower starter securing bolt.
– Remove wiring retainer -2-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Remove lower securing bolt of starter -arrow-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew earth wire securing nut -1- and place earth wire -2-
to one side.
rrectness of i
– Remove starter from vehicle upwards.
l purpos
Installing:
nf
ercia
or
note the following:
m
m
atio
m
n in
or c
⇒ page 97 .
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 47
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Pull engine cover off upwards -arrows-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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le
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pt
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d
itte
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erm
ab
ility
ot p
minal 50 -2-. h re
ole,
spec
– Remove noise insulation ⇒ General Body Repairs, Exterior;
urposes, in part or in wh
f inform
mer
atio
om
i
or
n thi
te
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 49
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Unscrew nut -1- from upper starter securing bolt.
es, in part or in w
t to the co
– Remove wiring retainer -2-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
m
f
en
ng
t.
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– Remove starter from vehicle downwards. t. Cop py
rig
gh ht
Installing: pyri by
Vo
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by c lksw
cted agen
Installation is carried out in the reverse order. When installing, Prote AG.
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 97 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Pull engine cover upwards -arrows A- and forwards
-arrow B-.
7. Starter 51
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Unscrew air filter housing securing bolt -arrow-.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull hose -arrow- off air filter housing and take hose out.
– Pull air filter housing upwards out of brackets and remove.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
ab
ility
ot p
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 53
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Remove upper securing bolt of starter -arrow-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Unscrew earth wire securing nut -1- and place earth wire end
ion
c
his
ate
cum
or
Installing:
f
en
ng
t.
yi Co
op
Installation is carried out in the reverse order. When installing, C py
t. rig
note the following:
gh ht
pyri by
Vo
co lksw
by
– Tighten threaded connections to specified torque settings cted agen
Prote AG.
⇒ page 97 .
ce
e
nl
pt
du
♦ Torque wrench -V.A.G
an
itte
y li
1332-
erm
ab
ility
ot p
♦ Spring-type clip pliers -VAS
wit
, is n
5024-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Pull engine cover upwards -arrows A- and forwards
-arrow B-.
7. Starter 55
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Release spring-type clip -1- using spring type clip pliers -VAS
5024- and disconnect connector -2-.
– Remove securing bolt -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– ut right side upwards off rubber mounting
Pull air filter housings aon ra
c
-arrow-. s
ce
e
nl
pt
du
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
y li
erm
ab
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
57
AG.
7. Starter
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
1332-
un
pt
an
d
itte
y li
♦ Spring-type clip pliers -VAS
erm
ab
5024-
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Release spring-type clip -1- using spring type clip pliers -VAS
5024- and remove securing bolt -2-.
– Release hose -3- and pull it off the air filter housing.
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
– Remove air filter housing from vehicle.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
minal 50 -2-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 59
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
spec
t to the co
Installing:
Installation is carried out in the reverse order. When installing,
rrectness of i
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Special tools and workshop
ility
ot p
equipment required
wit
, is n
h re
♦ Torque wrench -V.A.G
hole
spec
1331-
es, in part or in w
t to the co
♦ Torque wrench -V.A.G
1332-
♦ Spring-type clip pliers -VAS
rrectness of i
5024-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Disconnect connector -arrow-.
7. Starter 61
n AG. Volkswagen AG do
lkswage es n
Jetta 2005 ➤ , Bora 2006 ➤ d byV
o ot g
ua
ran
Electrical System - Edition 05.2005 ho
ir se tee
ut or
a ac
ss
– Unclip vacuum hose from its mounting -arrow-.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Loosen spring-type clip -arrow- from hose -1- using spring type
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open retainer -arrow- on front side of air filter housing and take
hose -1- off.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Loosen spring-type clip -1- using spring type clip pliers -VAS
rrectne
5024- .
s
– Pull hose -2- off pipe union.
s o
cial p
f
– Carefully lift air filter housing upwards out of the vehicle taking
inform
into consideration the length of the hose.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
– Separate connector -arrow- on rear of air filter housing. co Vo
by lksw
cted agen
Prote AG.
7. Starter 63
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
note the following:
an
d
itte
y li
– Tighten threaded connections to specified torque settings
erm
ab
ility
⇒ page 97 .
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 65
Jetta 2005 ➤ , Bora 2006 ➤
n AG. Volkswagen AG do
Electrical System - Edition 05.2005 lkswage es n
o ot g
byV ua
d ran
ir se
7.3.3 Vehicles with 2.0 l FSI turbo engine autho tee
or
ac
ss
ce
e
nl
pt
Special tools and workshop
du
an
itte
equipment required
y li
erm
ab
ility
♦ Torque wrench -V.A.G
ot p
wit
1331- , is n
h re
hole
spec
1332-
es, in part or in w
t to the co
♦ Spring-type clip pliers -VAS
5024-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Unbolt securing bolts -arrow-.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Loosen spring-type clips -1- using spring type clip pliers -VAS
5024- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
– Pull engine cover off upwards -arrows-. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Starter 67
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
e
pt
du
an
itte
y li
erm
ab
⇒ page 97 .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing:
l purpos
-arrow B-.
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 69
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Unscrew air filter housing
ut
ho
securing bolt -arrow-. eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Push down protective cap -direction of arrow- from solenoid
switch.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
– Unscrew positive wire -1- and disconnect connector from ter‐ gh ht
yri by
minal 50 -2-. cop Vo
by lksw
cted agen
Prote AG.
7. Starter 71
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
e
nl
pt
1331-
du
an
itte
y li
♦ Torque wrench -V.A.G
erm
ab
ility
1332-
ot p
wit
, is n
h re
hole
5024-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 73
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull hose -arrow- off air filter housing and take hose out.
– Pull air filter housing upwards out of brackets and remove.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
75
cted agen
Prote AG.
7. Starter
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Removing:
t.
yi Co
Cop py
t.
– Disconnect the battery ⇒ page 29 .
rig
gh ht
pyri by
Vo
co
– Push down protective cap -direction of arrow- from solenoid
by lksw
cted agen
Prote
switch.
AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Unscrew earth wire from starter securing bolt -arrow-.
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectnes
– Unscrew starter securing bolt -arrow-.
s o
cial p
f i
– Remove noise insulation ⇒ General Body Repairs, Exterior;
nform
Rep. Gr. 50 ; Body front; Noise insulation .
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 77
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
7.4.2 Vehicles with 2,0 l FSI engine
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
equipment required
♦ Torque wrench -V.A.G
rrectne
1331-
♦ Torque wrench -V.A.G
ss
1332-
o
cial p
f inform
♦ Spring-type clip pliers -VAS
mer
5024-
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Disconnect connector -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V
– Loosen spring-type clip -arrow-
ed by from hose -1- using spring typeguar
an
clip pliers -VAS 5024- h.oris tee
ut or
a ac
– Pull hose -1- off airssfilter housing.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Open retainer -arrow- on front side of air filter housing and take
hose -1- off.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Starter 79
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Pull air filter housing on right side upwards off rubber mounting
es, in part or in w
-arrow-.
t to the co
– Loosen spring-type clip -1- using spring type clip pliers -VAS
5024- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Pull hose -2- off pipe union.
um
fo
en
ng
t.
yi
– Carefully lift air filter housing upwards out of the vehicle taking
Co
Cop py
into consideration the length of the hose. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
– Unscrew positive wire -1- and disconnect connector from ter‐
ility
ot p
minal 50 -2-.
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 81
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing:
rrectness of i
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 83
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
– Loosen spring-type clips -1- using spring type clip pliers -VAS
itte
y li
5024 A- .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
– Pull engine cover off upwards -arrows-.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew positive wire -1- and disconnect connector from ter‐ AG. Volkswagen AG d
minal 50 -2-. lksw
agen oes
n o ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew earth wire from starter securing bolt -arrow-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
– Unscrew starter securing bolt -arrow-. Cop py
t. rig
gh ht
yri
– Remove noise insulation ⇒ General Body Repairs, Exterior; p by
o Vo
by c
Rep. Gr. 50 ; Body front; Noise insulation .
lksw
cted agen
Prote AG.
7. Starter 85
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
AG. Volkswagen AG d
– Push down protective cap -direction of arrow-
ksw from solenoid
agen oes
not
switch. y Vol gu
db e
ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Starter 87
Jetta 2005 ➤ , Bora 2006 ➤AG. Volkswagen A
agen05.2005
Electrical System V- oEdition
G do
es n
lksw ot
by gu
ara
ed nte
– Unscrew earth wire oris from starter securing bolt -arrow-. eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew starter securing bolt -arrow-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Unscrew nut -1- from lower starter securing bolt. Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing:
l purpos
-arrow B-.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 89
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unscrew air filter housing securing bolt -arrow-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull hose -arrow- off air filter housing and take hose out.
– Pull air filter housing upwards out of brackets and remove.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
– Push
ss a down protective cap -direction of arrow- from solenoid
ra
c
switch.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
minal 50 -2-.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 91
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
– Unscrew nut -1- from lower starter securing bolt.
y li
erm
ab
ility
– Remove wiring retainer -2-.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
io
– Remove starter.
n
c
in t
or
his
e
Installing:
at
do
priv
c
Installation is carried out in the reverse order. When installing,
um
for
en
note the following:
ng
t.
yi Co
op py
– Tighten threaded connections to specified torque settings t. C rig
gh ht
⇒ page 97 . pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
5024- nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Pull engine cover upwards -arrows A- and forwards
-arrow B-.
7. Starter 93
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Release spring-type clip -1- using spring type clip pliers -VAS
5024- and disconnect connector -2-.
– Remove securing bolt -3-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
– Pull air filter housing on right side upwards off rubber mounting
nl
pt
du
an
-arrow-.
itte
y li
erm
ab
– Remove air filter housing from vehicle.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
switch.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Unscrew earth wire from starter securing bolt -arrow-.
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness
– Unscrew starter securing bolt -arrow-.
o
cial p
f in
– Remove noise insulation ⇒ General Body Repairs, Exterior;
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 95
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9 Alternator
Caution
Caution
ce
e
nl
pt
du
an
itte
y li
– The tightening torque for the securing nut of the B+ wire
erm
ab
ility
-arrow- an be found in the following table “Tightening torques”
ot p
⇒ page 145 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
his
ate
do
riv
cum
for
en
g
t.
yi Co
breaks) Cop py
t. rig
gh ht
yri
♦ Layer separation (top layer, draw strands) p by
o Vo
by c lksw
cted agen
♦ chassis breakout Prote AG.
Caution
ce
e
nl
pt
du
Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐
an
itte
y li
formation System -VAS 5051A- .
erm
ab
ility
ot p
– Using the “Go to” key, select “Function/component selection”
wit
, is n
and the following menu items one after the other:
h re
hole
♦ Body
spec
es, in part or in w
t to the co
♦ Electrical System
♦ 27 - Starter, current supply
rrectness of i
♦ Electrical components
l purpos
♦ C - Alternator
nf
ercia
orm
m
atio
om
n in
9.4.1 Assembly overview
or c
thi
te
sd
iva
o
r
rp
cu
1 - Hexagon head collared bolt
o
m
f
en
ng
t.
yi
❑ M8x108
Co
Cop py
t.
❑ 23 Nm
rig
gh ht
pyri by
Vo
co
2 - Hexagon head collared
by lksw
cted agen
Prote
bolts
AG.
❑ M8x50
❑ 23 Nm
3 - Bracket
4 - Hexagon head collared nut
❑ M8
5 - Hexagon head collared
bolts
❑ M8x45
❑ 52 Nm
6 - Protective cap
7 - Hexagon head collared nut
❑ M8
8 - Cross-head screw
❑ M5x21
❑ 4.5 Nm
9 - Hexagon nut, flat
❑ M8
10 - Plain washer
❑ M5
11 - Phillips screws
❑ M4x19
❑ 2 Nm
12 - Cross-head screw
❑ M4x13
9. Alternator 99
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
❑ 2 Nm
13 - Voltage regulator
AG. Volkswagen AG d
❑ Removing and installing voltage regulator
ksw
agen ⇒ page 142 oes n
ol ot g
yV ua
14 - Alternator ed
b ran
oris tee
❑ Removing and installing
au
th alternator ⇒ page 100 or
ac
ss
15 - Poly V-belt
ce
e
nl
pt
du
❑ Checking ⇒ page 98 .
an
itte
y li
erm
ab
16 - Compact bracket
ility
ot p
wit
, is n
h re
❑ Tightening sequence ⇒ page 145
hole
spec
17 - Tensioning element for poly V-belt
es, in part or in w
t to the co
18 - Hexagon head collared bolt
❑ M8x90
rrectness of i
❑ 23 Nm
l purpos
nform
ercia
injection engine
m
at
om
ion
c
in t
or
his
e
Caution
at
do
priv
cum
or
en
ng
t.
Workshop Manual ⇒ page 29 .
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Special tools and workshop equipment required
by lksw
cted agen
Prote AG.
♦ Torque wrench -V.A.G 1331-
Removing:
– Disconnect the battery ⇒ page 29 .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Unscrew B+ wiring -arrow- off alternator. au ac
ss
ce
e
nl
pt
du
Caution
an
itte
y li
erm
ab
ility
Mark top and direction of rotation of poly V-belt before remov‐
ot p
wit
, is n
h re
removal. Installing opposite to the direction of rotation leads to
hole
belt damage!
spec
es, in part or in w
t to the co
– Mark direction of rotation of poly V-belt.
rrectness of i
l purpos
nf
ercia
atio
– Remove ribbed belt.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 101
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Jetta 2005 ➤ , Bora 2006 ➤ aut
h
ra
s c
Electrical System - Edition 05.2005 s
ce
e
nl
pt
du
an
– Unclip coolant hose from hose retainer -1- and remove secur‐
itte
y li
erm
ing nut -2-.
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
– Unbolt securing bolts -arrow-.
rm
m
atio
m
– Take hose retainer together with tensioning element out of the o
n in
c
vehicle.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Position wiring bracket -arrow- on rear of generator at 3
rrectne
o'clock.
– Tighten threaded connections to specified torque settings
ss
⇒ page 145 .
o
cial p
f inform
mer
Caution
atio
om
n
c
i
or
n
Observe instructions on connecting battery terminals
thi
e
⇒ page 4 .
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– Connect the battery ⇒ page 29 .
Co
Cop py
t. rig
gh
– Start the engine and check belt running.
ht
pyri by
Vo
co lksw
by
– Switch off the engine.
cted agen
Prote AG.
9. Alternator 103
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
1 - Hexagon bolt
❑ 40 Nm
2 - Washer
3 - Idler roller
4 - Washer
5 - Valve gear casing
6 - Hexagon head collared nut
❑ M8 AG. Volkswagen AG d
agen oes
olksw not
7 - Cross-head screw d by
V gu
ara
ise nte
❑ M5x21 hor eo
aut ra
❑ 4.5 Nm ss c
ce
le
un
pt
an
d
itte
y li
❑ M8
rm
ab
pe
ility
9 - Plain washer
ot
wit
, is n
❑ M5
h re
hole
spec
10 - Protective cap
es, in part or in w
t to the co
11 - Phillips screws
❑ M4x19
rrectness of i
❑ 2 Nm
l purpos
12 - Cross-head screw
❑ M4x13
nform
ercia
❑ 2 Nm
m
a
13 - Voltage regulator
com
tion in
❑ Removing and installing
r
te o
thi
voltage regulator
s
iva
do
⇒ page 142
r
rp
cum
fo
14 - Alternator
en
ng
t.
yi Co
op
❑ Removing and installing alternator ⇒ page 105 C py
t. rig
gh ht
yri
15 - Poly V-belt
p by
o Vo
by c lksw
cted
❑ Checking ribbed belt (poly V-belt) ⇒ page 98
agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing:
– Disconnect the battery ⇒ page 29 .
rrectness of i
– Remove upper securing bolt of alternator -arrow-.
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 105
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect connector of DF wiring -1- and pull B+ wiring -2-
off alternator.
rrectness of i
Caution
l purpos
nform
ercia
a
com
t
belt damage!
ion in
r
te o
thi
s
iva
do
– Mark direction of rotation of poly V-belt.
r
rp
cum
fo
en
ng
t.
yi Co
– Release poly V-belt by turning the tensioning device with an Cop py
t. rig
open-ended spanner AF 16 in -direction of arrow-. gh ht
pyri by
Vo
o
by c lksw
– Lock tensioning element with retaining pin -T10060 A- . Prote
cted AG.
agen
Caution
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
9.5.3 Ribbed belt routing, 1.6 l FSI engine
Models without air conditioning system:
rrectness of i
1- Ribbed belt (poly V-belt) pulley – Coolant pump
l purpos
2- Tensioning roller
nform
4- Poly V-belt
a
com
tion in
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
Models with air conditioning system:
ht
pyri by
Vo
o
by c lksw
cted
1- Ribbed belt (poly V-belt) pulley – Coolant pump
agen
Prote AG.
2- Idler roller
3- Ribbed belt (poly V-belt) pulley – Alternator
4- Tensioning roller
5- Ribbed belt (poly V-belt) pulley – Air conditioner compressor
6- Poly V-belt
7- Ribbed belt (poly V-belt) pulley - Crankshaft
9. Alternator 107
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
un
pt
6 - Hexagon head collared
an
d
itte
y li
bolts
rm
ab
pe
❑ M10x45
ility
ot
wit
, is n
❑ 52 Nm
h re
hole
7 - Protective cap
spec
es, in part or in w
t to the co
8 - Hexagon head collared nut
❑ M8
rrectness of i
9 - Cross-head screw
❑ M5x21
l purpos
❑ 4.5 Nm
nform
ercia
a
com
tion in
11 - Plain washer
r
te o
thi
❑ M5
s
iva
do
r
rp
12 - Phillips screws
um
fo
en
ng
t.
❑ M4x19
yi Co
Cop py
❑ 2 Nm ht. rig
rig ht
py by
o Vo
13 - Cross-head screw
by c lksw
cted agen
Prote AG.
❑ M4x13
❑ 2 Nm
14 - Voltage regulator
❑ Removing and installing voltage regulator ⇒ page 142
15 - Alternator
❑ Removing and installing alternator ⇒ page 109
16 - Poly V-belt
❑ Checking ⇒ page 98 .
Caution
ce
e
pt
du
an
itte
y li
erm
ab
♦ Spring-type clip pliers -VAS
ility
ot p
5024 A-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
9. Alternator 109
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
– Unclip vacuum hose from its mounting -arrow-.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Loosen spring-type clip -arrow- from hose -1- using spring type
a
com
tio
thi
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open retainer -arrow- on front side of air filter housing and take
hose -1- off.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Unscrew air filter housing securing bolt -arrow-.
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen spring-type clip -1- using spring type clip pliers -VAS
5024 A- .
– Pull hose -2- off pipe union.
– Carefully lift air filter housing upwards out of the vehicle taking
into consideration the length of the hose.
9. Alternator 111
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Unscrew B+ wiring -arrow- off alternator.
ot
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
Mark top and direction of rotation of poly V-belt before remov‐
ing. When installing observe direction of rotation marked on
removal. Installing opposite to the direction of rotation leads to
rrectness of i
belt damage!
l purpos
a
com
tio
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
y li
erm
ab
wit
, is n
Installing:
h re
hole
spec
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 113
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Tighten threaded connections to specified torque settings
ility
ot p
⇒ page 145 .
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
Observe instructions on connecting battery terminals
⇒ page 4 .
rrectness of i
l purpos
at
om
ion
c
in t
r
his
ate
do
riv
cum
for
en
ng
1- Tensioning roller
t.
yi Co
Cop py
t. rig
2- Ribbed belt pulley - Alternator opyri
gh by
Vo
ht
c
3- Poly V-belt
by lksw
cted agen
Prote AG.
4- Ribbed belt pulley - Crankshaft
ce
le
2- Ribbed belt pulley - Alternator
un
pt
an
d
itte
3- Ribbed belt pulley - Air conditioner compressor
y li
rm
ab
pe
ility
4- Poly V-belt
ot
wit
, is n
5- Ribbed belt pulley - Crankshaft
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
9.7 Alternator, 2.0 l FSI turbo engine
l purpos
nform
mercia
a
com
tion in
1 - Hexagon head collared
r
te o
thi
bolts
s
iva
do
❑ M8x45
r
rp
cum
fo
❑ 23 Nm
en
ng
t.
yi Co
op py
2 - Hexagon head collared . C rig
ht ht
bolts
rig by
copy Vo
by lksw
❑ M8x90 Prote
cted AG.
agen
❑ 23 Nm
3 - Compact bracket
❑ For alternator and air
conditioner compressor
❑ Tightening sequence
⇒ page 146
4 - Hexagon head collared
bolts
❑ M10x45
❑ 45 Nm
5 - Protective cap
6 - Hexagon head collared nut
❑ M8
7 - Cross-head screw
❑ M5x21
❑ 4.5 Nm
8 - Hexagon nut, flat
❑ M8
9 - Plain washer
❑ M5
10 - Phillips screws
❑ M4x19
❑ 2 Nm
11 - Cross-head screw
❑ M4x13
❑ 2 Nm
9. Alternator 115
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
12 - Voltage regulator
❑ Removing and installing voltage regulator ⇒ page 142
13 - Alternator
❑ Removing and installing alternator ⇒ page 116
14 - Poly V-belt
❑ Checking ⇒ page 98 .
15 - Tensioning element for poly V-belt
Caution
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Unbolt securing bolts -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Loosen spring-type clips -1- using spring type clip pliers -VAS s
ce
le
5024 A- .
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 117
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
♦ All hoses of the charge air system are secured with hose clips
or with quick release couplings. When using quick release
couplings the following points must be observed:
♦ Unlock connection by pulling the securing clamp -arrow-.
♦ Pull hose/tube off without assistance of tools.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Caution
at
io
belt damage!
n
c
in t
or
his
ate
do
priv
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Loosen threaded connections of coolant pipe -arrows-.
rrectness of i
Note
l purpos
The coolant pipe can remain installed. To take out the alternator
it must be loosened.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
9. Alternator 119
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
ksw
– Unscrew wiring bracket -arrow- from alternator. by Vol not
gu
d ara
ise nte
– Take alternator out of the vehicle. thor eo
au ra
c
Installing: ss
ce
le
un
pt
Installation is carried out in the reverse order. When installing,
an
d
itte
y li
note the following:
rm
ab
pe
ility
ot
wit
Caution
, is n
h re
hole
spec
♦ When reinstalling used ribbed belts (poly V-belts) observe
es, in part or in w
t to the co
♦ Ensure, before installing ribbed belt, that all ancillaries (al‐
ternator, air conditioner compressor) are secured tightly.
rrectness of i
♦ Ensure ribbed belt (poly V-belt) is seated correctly in belt
l purpos
nform
ercia
a
com
ti
approx. 4 mm in -direction of arrow-.
on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ All hoses of the charge air system are secured with hose clips
or with quick release couplings. When using quick release
couplings the following points must be observed:
♦ Fit hose/tube without assistance of tools. agen
AG. Volkswagen AG d
oes
olksw not
♦ Check for secure fit of the lugs -arrow-. ed byV gu
ara
ris nte
ho eo
ut
– Tighten threaded connections to specified torque
ss a settings ra
c
⇒ page 145 .
ce
e
nl
pt
du
an
itte
y li
Caution
erm
ab
ility
ot p
wit
Observe instructions on connecting battery terminals
, is n
h re
⇒ page 4 .
hole
spec
es, in part or in w
t to the co
– Connect the battery ⇒ page 29 .
– Start the engine and check belt running.
rrectness of i
– Switch off the engine.
l purpos
nform
ercia
at
om
io
1- Tensioning roller
n
c
in t
or
his
e
do
priv
c
3- Poly V-belt
um
for
en
ng
t.
yi
4- Ribbed belt pulley - Crankshaft
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 121
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
1 - Compact bracket
❑ For alternator and air
conditioner compressor
wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
2 - Multi-point socket ed head bolt
by ara
M8x60 oris nte
eo
th
❑ 25 Nm au ra
c
ss
ce
e
nl
pt
du
an
M8x110
itte
y li
erm
ab
❑ 25 Nm
ility
ot p
wit
4 - Hexagon socket head bolt
, is n
h re
M8x30
hole
spec
❑ 25 Nm
es, in part or in w
t to the co
❑ Qty. 4
5 - Protective cap for alternator
rrectness of i
6 - Phillips screws
l purpos
❑ M4x20
❑ 2 Nm
nf
ercia
brushes
atio
om
n in
c
8 - Voltage regulator
or
thi
e
sd
iva
voltage regulator
r
rp
cu
o
⇒ page 142
f
en
ng
t.
yi Co
op
9 - Alternator C py
ht. rig
rig ht
❑ Removing and installing py by
o Vo
alternator ⇒ page 127
by c lksw
cted agen
Prote AG.
10 - Poly V-belt
❑ Checking ⇒ page 98 .
11 - Hexagon head collared
bolts M8x90
❑ 25 Nm
❑ Qty. 2
Caution
Removing:
Special tools and workshop equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Disconnect the battery ⇒ page 29 . aut ra
ss c
ce
le
pt
an
d
itte
y li
erm
ab
exterior; Rep. Gr. 50 ; Lock carrier service position
ility
ot p
wit
– Take off poly V-belt ⇒ Rep. Gr. 13
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
– Disconnect connector of DF wiring -1- and pull protective cap
inform
-2- off.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9. Alternator 123
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
Jetta 2005th ➤ , Bora 2006 ➤
o tee
or
u
Electrical
ss System - Edition 05.2005
a ac
ce
e
nl
pt
du
– Unscrew B+ wiring -arrow- off alternator.
an
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
Mark top and direction of rotation of poly V-belt before remov‐
hole
spec
ing. When installing observe direction of rotation marked on
es, in part or in w
t to the co
belt damage!
rrectness of i
– Remove upper and lower idler roller and tensioning roller for
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
ce
e
nl
pt
du
Caution
an
itte
y li
erm
ab
Observe instructions on connecting battery terminals
ility
ot p
⇒ page 4 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Start the engine and check belt running.
– Switch off the engine.
rrectness of i
l purpos
nf
ercia
orm
1- Upper idler roller
m
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
4- Poly V-belt for alternator and coolant pump
f
en
ng
t.
yi Co
op
5- Belt pulley - Air conditioner compressor C py
t. rig
gh ht
yri
6- Poly V-belt for air conditioner compressor
p by
co Vo
by lksw
cted agen
7- Belt pulley - Crankshaft
Prote AG.
9. Alternator 125
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
bolts
un
pt
an
d
itte
❑ M8x45
y li
erm
ab
❑ 20 Nm
ility
ot p
wit
is n
h re
V-belt
ole,
spec
urposes, in part or in wh
t to the co
bolts
❑ M8x90
rrectne
❑ 20 Nm
4 - Compact bracket
ss
❑ For alternator and air
o
cial p
f
conditioner compressor
inform
mer
❑ Tightening sequence
atio
⇒ page 148
om
n
c
i
or
n
5 - Hexagon head collared
thi
te
bolts
sd
iva
o
pr
c
❑ M10x65
um
r
fo
en
ng
❑ 40 Nm
t.
yi Co
Cop py
t. rig
6 - Hexagon head collared yri
gh by
ht
bolts cop Vo
by lksw
cted agen
❑ M10x45 Prote AG.
❑ 40 Nm
7 - Hexagon bolt with washer
and threaded piece
❑ M4x20, M4x15
❑ 2 Nm
8 - Protective cap for alternator
9 - Phillips screws
❑ M4x20
❑ 2 Nm
10 - Protective cap for carbon brushes
11 - Voltage regulator
❑ Removing and installing voltage regulator ⇒ page 142
12 - Alternator
❑ Removing and installing alternator ⇒ page 127
13 - Poly V-belt
❑ Checking ⇒ page 98 .
Caution
Removing:
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
– Disconnect the battery ⇒ page 29 .
es, in part or in w
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 127
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
♦ All hoses of the charge air system are secured with hose clips
or with quick release couplings. When using quick release
couplings the following points must be observed:
♦ Unlock connection by pulling the securing clamp -arrow-.
♦ Pull hose/tube off without assistance of tools.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Remove securing bolt -3-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
ion
c
his
e
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Disconnect connector of charge air pipe -arrow-.
hole
spec
– Take charge air pipe out upwards.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
sd
iva
-2- off.
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
9. Alternator 129
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Remove alternator securing bolts -arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
cum
fo
en
ng
– Remove alternator.
t.
yi Co
Cop py
t. rig
Installing: opyri
gh by
Vo
ht
c
Installation is carried out in the reverse order. When installing,
by lksw
cted agen
Prote
note the following:
AG.
Caution
Note
♦ All hoses of the charge air system are secured with hose clips
or with quick release couplings. When using quick release
couplings the following points must be observed:
♦ Fit hose/tube without assistance of tools.
G. Volkswage nA n AG d
wage oes
♦ Check for secure fit of they Vlugs
olks -arrow-. not
gu
b ara
ed nte
oris eo
– Tighten threadedauconnections
th to specified torque settings ra
⇒ page 145 . ss c
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p
⇒ page 4 .
h re
hole
spec
es, in part or in w
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 131
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005 agen
AG. Volkswagen AG d
oes
olksw not
byV gu
9.9.3 Ribbed belt routing, 1.9 l TDI engine d ara
ise nte
or eo
h
aut ra
Models without air conditioning system: ss c
ce
le
un
1- Tensioning roller
pt
an
d
itte
y li
2- Ribbed belt pulley - Alternator
erm
ab
ility
ot p
3- Poly V-belt
wit
is n
h re
4- Ribbed belt pulley - Crankshaft ole,
spec
urposes, in part or in wh
t to the co
rrectnes
Models with air conditioning system:
s o
cial p
f in
1- Tensioning roller
form
mer
atio
om
n
c
i
or
n thi
te
sd
a
4- Poly V-belt
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
❑ 40 Nm
an
itte
y li
erm
ab
6 - Hexagon head collared
ility
ot p
bolts
wit
, is n
❑ M10x45
h re
hole
spec
❑ 40 Nm
es, in part or in w
t to the co
7 - Phillips screws
❑ M4x20
❑ 2 Nm
rrectness of i
8 - Protective cap
l purpos
9 - Voltage regulator
nform
ercia
at
om
⇒ page 142
ion
c
in t
or
10 - Alternator
his
ate
do
riv
cum
for
11 - Poly V-belt
en
ng
t.
yi Co
op
❑ Checking ⇒ page 98 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9.10.2 Removing and installing alternator, 2,0 l
TDI engine
Caution
9. Alternator 133
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Removing:
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Locking pin -T10060 A-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
in t
or
his
e
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Disconnect connector of DF wiring -1- and pull protective cap
-2- off.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– Unscrew B+ wiring -arrow- off alternator.
co Vo
by lksw
cted agen
Prote AG.
– Pull fuel filter off the retainer and place to side (fuel hoses re‐
main connected).
Caution
9. Alternator 135
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
pt
du
y li
erm
ab
ility
Caution
ot p
wit
, is n
h re
spec
t to the co
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
1- Tensioning roller
t to the co
2- Ribbed belt pulley - Alternator rrectness of i
4- Poly V-belt
5- Ribbed belt pulley - Crankshaft
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
for
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
9.11.1 Removing and installing a ribbed belt
c by lksw
cted agen
Prote AG.
(poly V-belt) pulley with no freewheel
Special tools and workshop equipment required
9. Alternator 137
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Removing: ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Installing:
es, in part or in w
t to the co
Installation is performed in the reverse order of installation; when
doing this, note the following:
rrectness of i
– Tighten threaded connections to specified torque settings
⇒ page 145 .
l purpos
nform
mercia
at
om
ion
c
in t
his
ate
cum
or
ufacturer: Bosch
f
en
ng
t.
yi Co
op
Special tools and workshop equipment required
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing:
– Take off alternator ⇒ page 98 .
– Fit alternator in a vice on fitting points.
– Take protective cap off ribbed belt (poly V-belt) pulley with
freewheel.
AG. Volkswagen AG d
agen oes
Note olksw not
y V gu
d b ara
rise nte
The thread on the alternator shaft isauat left-hand thread, i.e. turn
ho eo
ra
to right when loosening and to leftsswhen tightening the threaded c
joint.
ce
le
un
pt
an
d
itte
y li
– Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley
rm
ab
pe
ility
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
139
cted agen
Prote AG.
9. Alternator
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
or
atio
⇒ page 145 .
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9.11.3 Removing and installing a ribbed belt (poly V-belt) pulley with freewheel,
manufacturer: Valeo
n AG. Volkswagen AG do
wage es n
Special tools and yV
olworkshop
ks ot g
ua
equipment isrequired
ed
b ran
or tee
h
♦ Adapter
aut
-VAS 3400- or
ac
ss
♦ Torque wrench -V.A.G
ce
le
un
pt
1332-
an
d
itte
y li
erm
ab
♦ TORX key -V.A.G 1603/1-
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Take off alternator ⇒ page 98 .
– Fit alternator in a vice on fitting points.
– Take protective cap off ribbed belt (poly V-belt) pulley with
freewheel.
Note
– Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley
with a freewheel of the alternator with a ring spanner AF 17.
9. Alternator 141
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Fit TORX key -V.A.G 1603/1- into alternator shaft.
ce
e
nl
pt
du
an
y li
erm
ab
V.A.G 1332- .
h re
hole
spec
⇒ page 145 .
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
9.12.1 Removing and installing voltage regula‐
cop Vo
by lksw
cted agen
tor, manufacturer: Bosch
Prote AG.
Removing:
– Remove alternator.
– Remove securing bolt and nuts -arrows- and take protective
cap off alternator.
n AG. Volkswagen AG do
wage es n
– Remove securingy Vbolts olks
for voltage regulator -arrows-.
ot g
ua
b
ed ran
– Remove voltage thoris
regulator from alternator. tee
u or
a ac
Installing: ss
ce
le
un
pt
y li
ab
ility
⇒ page 145 .
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
f inform
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 143
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Removing:
– Remove alternator.
– Remove spring clips -arrows- and take protective cap off al‐
ternator.
AG. Volkswagen AG d
agen
– Release locking lugs -arrow- andVpull
olks protective cap off voltage
w oes
not
gu
regulator. se
d by ara
n i tee
or
– Push voltage regulator acarbon
ut
h
brushes in housing of voltage or
ac
regulator and place voltage
ss
regulator in alternator.
ce
le
un
pt
⇒ page 145 .
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
gages.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
pt
du
der block
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
Tightening sequence for compact bracket to cylinder block
an
itte
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erm
ab
Procedure
ility
ot p
– Place compact bracket on cylinder block.
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Before tightening to specified torque setting, screw in all bolts by
hand.
rrectness of i
l purpos
nform
ercia
at
B - Hexagon head collared bolt, M10x45, 52 Nm
om
ion
c
in t
C - Hexagon head collared bolt, M10x45, 52 Nm
or
his
ate
do
riv
cum
for
en
ng
t.
yi Co
op
F - Hexagon head collared bolt, M10x45, 52 Nm
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
10.3 2.0 l FSI turbo engine
cted agen
Prote AG.
Caution
Note
pt
an
d
itte
y li
erm
ab
ility
10.4.1 Torque settings
ot p
wit
is n
h re
spec
urposes, in part or in wh
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
n AG. Volkswagen AG do
10.5.1 Torque settings olkswage es n
ot g
byV ua
ed ran
Threaded connections Torque settings
oris tee
th or
u
Alternator to compact M8x90 25 Nm ss
a ac
bracket
ce
e
nl
pt
du
an
y li
pact bracket
erm
ab
ility
ot p
der block
h re
hole
spec
es, in part or in w
t to the co
Note
block.
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
erm
ab
Information System -VAS 5051A- .
ility
ot p
wit
, is n
h re
and the following menu items one after the other:
hole
spec
es, in part or in w
♦ Drive
t to the co
♦ Engine code
♦ 01 - On Board Diagnostic capable systems
rrectness of i
♦ Engine control and/or direct diesel injection and pre-glow sys‐
l purpos
tem
♦ Function
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
90 – Instruments, GCI
1 Dash panel insert
General description:
Integrated in the dash panel insert are the following components:
♦ Control unit with display in dash panel insert -J285-
♦ Immobilizer control unit -J362-
♦ Speedometer
♦ Rev counter
♦ Fuel gauge
♦ Coolant temperature gauge
♦ Multi-function display
♦ Warning lamps, ⇒ page 152
To provide acoustic support to somen AofG.the
Volkvisual
swagendisplays,
AG do
the
dash panel features a warning
olksbuzzer,
wage which is actuated es nby the
o
control unit. db
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All warning lamps feature
tho LEDs. No provision has been made for or
au
repair of the dashs panel insert. In the event of defects, the dash
s ac
panel insert is renewed as a unit ⇒ page 150 .
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ual control unit option and not, as on other vehicles, part of the
ab
ility
wit
, is n
spec
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
rrectness of i
orm
m
the dash panel insert control unit has to be adapted to the dif‐
o
n in
c
thi
te
sd
iva
cu
the data of the engine control unit must be stored in the ex‐
o
m
f
en
ng
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♦ Diagnosis lead -VAS 5051/6A-
hole
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t to the co
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nf
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-VAS 5051A- to ⇒ page 281
o
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f
en
ng
t.
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– Select “guided fault finding” in Vehicle Diagnosis, Testing and Cop py
Information System -VAS 5051A- .
ht. rig
rig ht
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– Using the “Go to” key, select “Function/component selection”
by lksw
cted agen
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and the following menu items one after the other:
AG.
♦ Body
♦ Electrical System
♦ 01 - On Board Diagnostic capable systems
♦ Dash panel insert
♦ Dash panel insert functions
♦ Adapting/renewing dash panel insert
Note
Before removing the dash panel insert, the work procedure “Re‐
newing dash panel insert” should always be carried out in order
that the data stored in the control unit can be interrogated
⇒ page 150 .
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove steering wheel ⇒ General body repairs, interior; Rep.
Gr. 69 ; Airbag; Removing and installing steering wheel .
Note
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ility
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1- 36-pin connector
wit
is n
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2- Warning buzzer
ole,
spec
urposes, in part or in wh
t to the co
1.4 Warning lamp symbols in dash panel in‐
sert
rrectne
Note
ss o
cial p
f i
The warning lamps on the dash panel insert depend on the vehi‐
nform
cle's equipment, country and engine type.
mer
atio
om
n
c
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or
n thi
te
sd
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pr
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fo
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5 - Bulb failure
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6 - Rear fog lights
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7 - Low coolant level
h re
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spec
8 - Brake pad wear es, in part or in w
t to the co
9 - Washer fluid level
10 - Fuel reserve
rrectness of i
11 - Airbag display
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12 - Seat belt
13 - Anti-locking brake system
nform
ercia
(ABS)
m
a
14 - Electronic stabilisation
com
tion in
programme (ESP)
r
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s
15 - Brake fault/handbrake
iva
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16 - Cruise control system
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(CCS)
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17 - Daylight
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18 - Tyre pressure monitor
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19 - Water in fuel
20 - Rear seat backrest lock
21 - Shift Lock
❑ Warning lamp exists only on vehicles with automatic gearbox
22 - Oil level
23 - Bonnet open
24 - Door open
25 - Oil pressure
26 - Main beam
27 - Steering heating
28 - Trailer turn signals
29 - Glow plug system
❑ Warning lamp is fitted only on vehicles with diesel engine.
30 - Tank filler cap
31 - Exhaust filter
32 - Electronic steering (EPS-Electronic Power Steering)
AG. Volkswagen AG d
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Caution
Note
Additional information:
⇒ Operating instructions
General description:
The wiper motor control unit -J400- and the wiper motor -V- are
joined together as one unit.
To remove the wiper blades, the wiper arms should be placed in
the “service/winter position”. The“service/winter position” is acti‐
vated within 10 seconds after ignition is switched off by pressing
windscreen wiper lever in “tip wipe”e⇒ Operating instructions for
n AG. Volkswagen AG do
vehicle . olks
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Fault detection and fault
ris display:
ed nte
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The onboard supply au control unit -J519- is equipped with self-di‐ ra
c
ss
agnosis, which is designed to ease fault finding.
ce
le
un
pt
an
d
For fault finding, use the vehicle diagnosis, testing and informa‐
itte
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ab
pe
ility
ot
wit
, is n
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hole
tors
t to the co
nform
mercia
a
com
tion in
r
te o
thi
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fo
en
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t.
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Cop py
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rig ht
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by lksw
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AG. Volkswagen AG d
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spec
(alternating park position system).
urposes, in part or in wh
t to the co
With the APP function, the wiper arm is moved up slightly once it
has reached the lowest position. This occurs every second time
the wiper system is switched off.
rrectne
To fit the crank arm on the wiper motor, it is necessary for the
motor to be in the lowest park position. To ensure this position is
ss
reached, the APP function must be deactivated (code wiper motor
o
cial p
f
control unit -J400- ).
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
o
pr
cum
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fo
t.
vated automatically. This applies to wiper motors on which the
yi Co
op
APP function has been deactivated and also to new wiper mo‐
C py
ht. rig
tors.
rig ht
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co Vo
by lksw
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Prote AG.
– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
Information System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Body
♦ Electrical System
♦ 01 - On Board Diagnostic capable systems
♦ Onboard supply control unit
♦ Onboard supply control unit functions
♦ Control unit functions for wiper electronics
Caution
AG. Volkswagen AG d
agen oes
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ab
ility
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off.
spec
es, in part or in w
Note
rrectness of i
l purpos
To remove the wiper frame with rods and the wiper motor, wiper
arms, plenum chamber cover and air duct cover must be re‐
moved.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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– Position legs of puller -T10130- -2- under wiper arm-4- as wagen AG. Volkswagen AG doe
shown in the figure. yV
olks s no
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b ara
ed
– Turn thrust bolt -1- of puller -T10130- clockwisethountil
ris it comes nte
e or
into contact with the wiper shaft. The hexagon au nut -3- previ‐ ac
ss
ously loosened on the wiper arm serves as a means of centring
ce
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pt
du
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itte
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– Turn thrust bolt -1- of puller -T10130- clockwise using 6 mm
erm
ab
spanner until wiper arm -4- is released from the shaft.
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Unclip plenum chamber cover -1-, starting from side, off top of
windscreen frame -arrow-.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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rig ht
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by lksw
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pt
an
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ab
ility
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is n
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ole,
spec
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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t.
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– Place crank arm of motor ks-1-
wagon shaft of wiper motor.
does Distance
not
Vol be 3 ± 1 mm.
-a- to limit stop -2- dshould gu
by ara
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ris
– Place crank armaut of motor on shaft of wiper motor using se‐ or a
ho e
curing nut -3-.
ss c
ce
le
un
pt
an
d
itte
⇒ page 178 .
y li
erm
ab
ility
ot p
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is n
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spec
urposes, in part or in wh
t to the co
1.2.8 Installing the windscreen wiper system
rrectne
f inform
⇒ page 178 .
atio
om
i
or
n thi
te
o
r
cum
r
fo
en
ng
Removing:
– Removing wiper arms ⇒ page 158 .
Installing:
Note
AG. Volkswagen AG d
agen oes
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aut ra
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un
pt
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ab
pe
ility
♦ Puller -T10130-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
Note
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fo
t.
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Cop py
.
– Deactivate the APP function if not already done ⇒ page 155 .
ht rig
rig ht
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– Allow wiper to move to park position and then switch ignition
by lksw
cted agen
Prote
off.
AG.
Driver's side:
Distance -A- between wiper blade and upper edge of plenum
chamber cover should be 10 mm.
– If necessary, adjust wiper blade park position by moving wiper
arm.
Removing wiper arms ⇒ page 158 .
– Tighten threaded connection to specified torque setting
⇒ page 178 . wage
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Front passenger's side:
ce
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ab
chamber cover should be 10 mm.
ility
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is n
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arm.
ole,
spec
urposes, in part or in wh
t to the co
– Tighten threaded connection to specified torque setting
⇒ page 178 .
rrectness o
cial p
f inform
wipers
mer
atio
om
Removing:
n
c
i
or
n thi
te
sd
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pr
c
Note
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t.
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♦ Driver's and front passenger wiper blades should not be inter‐ Cop py
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changed during installation. gh ht
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♦ The aerodynamic wipers are very flexible. To lift the wiper Prote
cted agen
blades off the windscreen, touch them only in the area in which
AG.
– Turn wiper blade -1- on wiper arm onto limit stop -arrow A-.
– Pull wiper blade -1- off axis of wiper arm -arrow B-.
Installing:
– Slide wiper blade onto axis of wiper arm.
– Turn wiper blade on axis of wiper arm onto stop.
Volkswa
– Carefully fold wiper arm back down onto
swa
gen Awindscreen.
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detector sensor -G397-
ility
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Removing:
h re
hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
♦ Removal wedge -3409-
rrectness of i
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atio
om
n in
or c
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en
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t.
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– Switch off ignition and all electrical consumers and pull out
Co
op py
ignition key.
. C rig
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rig by
py Vo
– Remove interior mirror ⇒ General body repairs, interior; Rep.
co lksw
by
cted agen
Gr. 68 ; Removing and installing interior mirror . Prote AG.
– Pull connector -1- off rain and light detector sensor -G397-
-2-.
Note
Installing:
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gen AG does
Installation is performed in the reverse order of installation;
Vol
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a
when not
doing this, note the following: e d by gu
ara
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utho eo
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Note
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retainer for the rain and light detector sensor -G397- .
pe
ility
ot
wit
, is n
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sensor -G397- must not be soiled when installing.
hole
spec
♦ If the surface (coupling cushions) of the rain and light detector
es, in part or in w
t to the co
sensor -G397- is soiled, it can possibly be cleaned by “Apply‐
ing” and “Pulling off” one or more tapes.
♦ After installing the rain and light detector sensor -G397- there
rrectness of i
must be no air bubbles between windscreen and the surface
(coupling cushions).
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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olkswagen AG
en AG. V
2 Windscreen washer system
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th
Note au ra
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un
pt
Additional information:
an
d
itte
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ab
ility
⇒ Operating instructions
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2.1 Assembly overview of windscreen washer system
h re
ole,
spec
urposes, in part or in wh
t to the co
1 - Y-piece
❑ Distribution of wash wa‐
ter line to windscreen
rrectne
spray jets
s
2 - Spray jet for windscreen
s o
washer system, right
cial p
f inform
❑ Removing and installing
mer
⇒ page 169
atio
m
n
c
i
or
n thi
e
sd
va
o
pr
cum
r
fo
en
ng
t.
yi
⇒ page 169
Co
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❑ Adjusting ⇒ page 169 opy
rig by
Vo
ht
c lksw
4 - Elbow
by
cted agen
Prote AG.
❑ Connection to left wind‐
screen spray jet
❑ Overview of washer wa‐
ter line hose couplings
⇒ page 174
5 - Hose
❑ Hose repair
⇒ page 176
6 - Elbow
❑ Connection to right
windscreen spray jet
❑ Overview of washer wa‐
ter line hose couplings
⇒ page 174
7 - Filler pipe for reservoir for
windscreen washer and head‐
light washer systems
❑ Removing and installing
⇒ page 166
8 - Washer pump -V5-
❑ Removing and installing ⇒ page 168
9 - Windscreen washer system and headlight washer system reservoir
❑ Removing and installing ⇒ page 167
n AG. Volkswagen AG do
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2.2.1 Removing and installing filler pipe for ss
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windscreen and headlight washer sys‐
du
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tem reservoir
erm
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ility
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Removing:
wit
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hole
– Pull filler pipe -1- off union -3- on reservoir for windscreen and
spec
headlight washer systems.
es, in part or in w
– Unclip hose retainer from filler neck -3- and take it out of the
rrectness of i
vehicle.
l purpos
Installing:
Installation is carried out in the reverse order. When installing,
nform
ercia
at
om
ion
c
in t
or
his
ate
do
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cum
or
en
ng
t.
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cted agen
Prote AG.
Connecting pipe -1- and filler neck -2- must be fitted together so
that the guides -arrows- grip into one another.
pt
du
y li
ted to the front and rear washer water pump -V5- . The hose
erm
ab
h re
hole
spec
-5- and pull them out of the windscreen washer pump -V5-
t to the co
-4-.
– If necessary, collect washer fluid that leaks out with a suitable
rrectness of i
container.
l purpos
– Take washer pump -V5- -4- upwards out of reservoir and sep‐
or
atio
m
n in
or c
-10-.
sd
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rp
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ng
t.
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ab
2.3 Removing and installing washer pump -
ility
ot p
wit
, is n
V5-
h re
hole
spec
Removing:
es, in part or in w
t to the co
– Switch off ignition and all electrical consumers and pull out
ignition key.
rrectness of i
– Remove front bumper cover ⇒ Body Repairs, exterior; Rep.
Gr. 63 ; Front bumper .
l purpos
Note
nform
mercia
at
The connections to the pump and hose lines are colour-coded in
om
ion
order to prevent the washer water lines being incorrectly connec‐
c
in t
or
ted to the front and rear windscreen and rear window washer
his
ate
pump -V59- . The hose fittings must be inserted into the correct
do
priv
c
colour-coded pump connections during assembly.
um
for
en
ng
t.
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op
– To unlock, turn the securing clips hose connections -3- and C py
ht. rig
-5- and pull them out of the windscreen washer pump -V5- rig ht
py by
-4-.
co Vo
by lksw
cted agen
Prote AG.
– If necessary, collect fluid leaking out with a suitable container.
– Pull washer pump -V5- -4- upwards out of the reservoir.
– Disconnect connector -2-.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 178 .
– Bleed the headlight washer system after completing work
⇒ page 173 .
– Pull hose -1- off spray jet and disconnect connector -2-.
Installing:
– Fit connector -2- and hose -1- on spray jet.
. Volkswagen AG
gen AG d
– Push spray jet inoinstallation
lksw
a
hole until it isoheard
es n
ot g to lock in
place. byV ua
ed is
ra nte
or eo
– Adjust aspray
ut
h jets ⇒ page 169 . ra
ss c
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un
pt
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rm
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pe
ility
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, is n
spec
t to the co
Note
rrectness of i
If the spray field is not uniform because the spray jet is soiled,
l purpos
remove the spray jet and clean in opposite direction of spray with
water. In the following it is allowed to blow the spray jets in op‐
posite direction of spray with compressed air. Do not use objects
nform
ercia
a
com
tion in
thi
s
iva
do
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fo
en
ng
t.
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rig ht
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by lksw
cted agen
Prote AG.
Note
Additional information:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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by c lksw
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Prote AG.
ce
e
nl
pt
du
⇒ page 173
an
itte
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❑ Adjusting spray jets
erm
ab
ility
⇒ page 173
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wit
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pop-up spray jet cylin‐
hole
spec
der ⇒ page 172
es, in part or in w
t to the co
2 - Washer spray jet assembly
with left spray jets
❑ Removing and installing
rrectness of i
spray jet assembly
l purpos
⇒ page 173
❑ Adjusting spray jets
⇒ page 173
nform
ercia
at
pop-up spray jet cylin‐
om
ion
der ⇒ page 172
c
in t
or
his
te
3 - Elbow
a
do
priv
en
g
t.
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❑ Overview of washer wa‐
C py
t. rig
gh
ter line hose couplings
ht
pyri by
Vo
⇒ page 174
o
by c lksw
cted agen
Prote AG.
4 - Hose
5 - Elbow
❑ Connection to right
spray jet pop-up cylin‐
der
❑ Distribution of washer
water to spray jets on
headlight washer sys‐
tem
❑ Overview of washer water line hose couplings ⇒ page 174
6 - T-piece
❑ Distribution of washer water to spray jets on headlight washer system
7 - Elbow
8 - Headlight washer system pump -V11-
❑ Removing and installing ⇒ page 171
9 - Windscreen washer system and headlight washer system reservoir
❑ Removing and installing ⇒ page 166
10 - Filler pipe for reservoir for windscreen washer and headlight washer systems
❑ Removing and installing ⇒ page 166
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove front bumper cover ⇒ Body Repairs, exterior; Rep.
Gr. 63 ; Front bumper .
– Pull headlight washer system pump -V11- -9- upwards out of
the reservoir.
– Disconnect connector -10-.
– To remove the connecting pipe -8- pull securing clip on con‐
nection and pull connecting pipe -8- off headlight washer
system pump -V11- .
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 178 .
– Bleed the headlight washer system after completing work
⇒ page 173 .
AG. Volkswagen AG d
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3.3 Removing and installing pop-up spray d byV
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jet cylinder ise nte
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– Switch off ignition and all electrical consumers and pull out
an
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ignition key.
rm
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pe
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– Pull spray jets with cap -1- out of bumper cover onto stop.
ot
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– Unclip cap -1- from mounting points -arrows- on washer spray
hole
jet assembly.
spec
es, in part or in w
t to the co
– Remove front bumper cover ⇒ Body Repairs, exterior; Rep.
Gr. 63 ; Front bumper .
a
com
tio
Installing:
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securing clip on the bracket.
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– Tighten threaded connections to specified torque settings
rig by
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⇒ page 178 . by c lksw
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Prote AG.
– Bleed the headlight washer system after completing work
⇒ page 173 .
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3.4 Removing and installing spray jet as‐
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spec
– Switch off ignition and all electrical consumers and pull out
es, in part or in w
ignition key.
t to the co
– Pull spray jet with cover cap -1- onto stop out of bumper cover.
– Unclip cap -1- from mounting points -arrows- on washer spray
rrectness of i
jet assembly.
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ercia
– Lever locking hooks -arrow- up slightly and pull out spray jet
m
assembly.
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Installing:
in t
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The degree to which the cover cap of the spray jet is pulled down t. C rig
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onto the bumper cover can be adjusted using the clips on the yri
p by
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washer spray jet assembly. If the washer spray jet assembly is
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not pulled in far enough, the cover cap will not seat correctly. If
Prote AG.
the washer spray jet assembly is pulled in too far, the cover cap
and the bumper cover could be pushed out of shape.
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pt
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rotate the lock ring -1- -arrow- until it engages.
com
tion in
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5 Hose repair
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl‐
ene propylene diene monomer) and heat-shrink hose are availa‐
ble as spare parts
pt
– Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe
an
d
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is n
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spec
urposes, in part or in wh
t to the co
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mer
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c
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♦ Hot air gun -VAS 5179- or t. C rig
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♦ Repair points must not be subjected to pulling or bending
erm
ab
forces.
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♦ If the damaged section is longer than 20 mm, a new piece of
h re
corrugated pipe must be used and the procedure described
hole
spec
below must be performed twice.
es, in part or in w
t to the co
– Cut damaged section at right angles out of corrugated pipe
which is to be repaired.
rrectness of i
– Select the appropriate connectors -2- and -3- as well as the
l purpos
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at
– Push connector -2- into corrugated pipe -2- -arrow A-.
om
ion
c
in t
– Heat end of corrugated pipe -4-.
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ate
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– Cut heat-shrink hose so that ends of corrugated pipe are each
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covered by about 20 mm -dimension x- of heat-shrink hose.
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– Push heat-shrink hose over corrugated pipe, join connectors
agen
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and secure repair joints with heat-shrink hose.
AG. Volkswagen AG d
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Note
⇒ Operating instructions
In the vehicle there are fitted headlights of three different manu‐
facturers:
♦ AL (Automotive Lighting)
♦ Hella
Removal and installation of the headlights and its attachments is
the same, only the removing and installing of the actuator motors
are different.
Fault detection and fault display:
The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the headlights easier.
AG. Volkswagen gen AG do
swa es n
For fault finding, use the vehicle diagnosis,
by
Vol testing and informa‐
k ot g
ua
tion system -VAS 5051A- in “guided ris
e fault finding” mode.
d ran
tee
ho
ut or
1.1 Assembly overview,
ss
a
Headlight ac
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In the overview there are shown the three control motors of the
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stallation is different.
spec
es, in part or in w
t to the co
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nf
ercia
orm
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1. Headlight 179
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
n AG. Volkswagen AG do
1 - Securing bolts lkswage es n
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❑ 4 Nm ir se
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2 - Adjustment bushes
ss
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❑ Correcting installation
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position of headlight
an
itte
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⇒ page 182
erm
ab
ility
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bulb -M30- or right headlight
, is n
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main beam bulb -M32-
hole
spec
❑ Bulb H7U 12 V, 55 W
es, in part or in w
t to the co
❑ Renewing ⇒ page 185
4 - Left side light bulb -M1- or
right side light bulb -M3-
rrectness of i
❑ Bulb 12 V, W 5 W
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nform
ercia
5 - Cover cap
m
at
om
io
M5- or front right turn signal
n
c
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bulb -M7-
o
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ate
❑ Bulb 12 V, PY 21 W
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7 - Bulb holder with grip ele‐ . Cop py
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❑ For front left turn signal
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bulb -M5- or front right Prote AG.
turn signal bulb -M7-
8 - Body section
9 - Cover cap
10 - Bulb holder with grip ele‐
ment
❑ For left headlight dipped
beam bulb -M29- or right headlight dipped beam bulb -M31-
11 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31-
❑ Bulb H7 12 V, 55 W
❑ Renewing ⇒ page 184
12 - Headlights
❑ Removing and installing ⇒ page 181
❑ Correcting installation position of headlight ⇒ page 182
❑ Servicing headlight securing lugs ⇒ page 188
Note
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Release multi-pin connector -arrow- and pull off multi-pin con‐
nector.
– Remove front bumper ⇒ General body repairs; Rep. Gr. 63 ;
Front bumper
AG. Volkswagen AG d
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pt
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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priv
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for
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
1. Headlight 181
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
pt
du
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erm
ab
– Check function of headlight.
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Note
hole
spec
es, in part or in w
Note
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at
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t.
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If it transpires during checking of the installation position that the
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shutlines between headlight and body are uneven, the installation
ht
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position must be adjusted.
co lksw
by
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Prote AG.
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove radiator ⇒ General Body Repairs, Exterior; Rep. Gr.
66 ; Strips and trim .
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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spec
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t to the co
rrectness of i
– Unscrew securing screw -arrow- on lower left headlight.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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rig ht
py by
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by lksw
– Unscrew securing screw -arrow- on lower right headlight. cted agen
Prote AG.
Note
1. Headlight 183
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
The diagrams show renewal of the dipped beam headlight bulb swa
gen AG
. Volkswagen AG
does
for the left headlight. by
Volk not
gu
ara
ed nte
ris
ho e
Removing: au
t or
ac
ss
– Switch off ignition and all electrical consumers and pull out
ce
le
un
pt
ignition key.
an
d
itte
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rm
– Turn cover cap -1- in -direction of arrow- and remove.
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
– Turn bulb holder with dipped beam headlight bulb -1- in
com
tio
-direction of arrow- and remove from headlight.
n in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
Note
– Place headlight dipped beam bulb -1- in the bulb holder that
the pin on the dipped beam headlight bulb lies in the recess
-arrow- of bulb holder -2-.
– Place bulb holder with dipped beam headlight bulb -1- in head‐
light and turn bulb holder with dipped beam headlight bulb in
-direction of arrow-.
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Note
The diagrams show renewal of the main beam headlight bulb for
nform
ercia
at
om
ion
Removing:
c
in t
or
his
te
– Switch off ignition and all electrical consumers and pull out
a
do
riv
ignition key.
p
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Headlight 185
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
– Pull off multi-pin connector -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
– Press spring retaining clip -2- in -direction of arrow- under the
o
m
f
en
ng
Note
AG. Volkswagen AG d
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1.4.3 Renewing side light bulb
ed
ris nte
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un
Note
pt
an
d
itte
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rm
ab
The diagrams show renewal of the side light bulb for the left
pe
ility
headlight.
ot
wit
, is n
h re
hole
Removing:
spec
es, in part or in w
– Switch off ignition and all electrical consumers and pull out
t to the co
ignition key.
– Pull off cover cap -1-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
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rig ht
– Pull, depending on the cable length, the bulb holder -1- with
py by
co Vo
by lksw
the side light bulb as far it is possible out of the reflector.
Prote
cted AG.
agen
1. Headlight 187
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
– Pull side light bulb -2- in -direction of arrow- out of the bulb
holder -1-.
Installing:
Note
ce
le
un
pt
Note
an
d
itte
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erm
ab
The diagrams show renewal of the turn signal bulb for the left
ility
ot p
headlight.
wit
is n
h re
ole,
spec
Removing:
urposes, in part or in wh
t to the co
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Turn bulb holder with front turn signal bulb -1- in direction of
rrectne
arrow and remove from headlight.
s
– Push front turn signal bulb into bulb holder, turn front turn sig‐
s o
nal bulb anti-clockwise and pull front turn signal bulb out of
cial p
f in
bulb holder.
form
mer
Installing:
atio
om
n
c
i
or
n thi
te
Note
sd
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pr
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t.
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correctly. The ingress of water will lead to permanent damage Cop py
of the headlight.
t. rig
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pyri by
Vo
o
♦ Do not touch bulb glass when fitting bulbs. Fingers leave
c by lksw
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traces of grease on the glass, which evaporate when the bulb
Prote AG.
AG. Volkswagen AG d
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ara
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nl
pt
du
an
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Headlight 189
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
ce
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stood.
nl
pt
du
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itte
♦ Additional information:
y li
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ab
ility
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⇒ Operating instructions
wit
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hole
spec
tions
es, in part or in w
t to the co
Fault detection and fault display:
The automatic headlight range adjustment (HRA) and onboard
rrectness of i
supply control unit have a self-diagnosis function, which makes
fault finding on the headlights using gas discharge lamps easier.
l purpos
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode. nf
ercia
orm
m
atio
om
n in
or c
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te
sd
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t.
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Prote AG.
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Note
an
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ab
After any measures which could affect the headlight setting, the headlight must be checked and if necessary
ility
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spec
urposes, in part or in wh
1 - Vent hose
t to the co
❑ On headlight
2 - Left headlight range control
rrectne
motor -V48- or right headlight
range control motor -V49-
ss
❑ Headlight manufactur‐
o
cial p
f
er: AL (Automotive
inform
Lighting)
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
va
3 - Securing bolts
i
o
pr
cum
r
fo
t.
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control motor -V48- or
Co
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right headlight range
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rig
control motor -V49- py by
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4 - Cover cap Prote AG.
Note
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❑ Renewing ⇒ page 196
itte
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20 - Cover cap
ility
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❑ For front left turn signal bulb -M5- or front left turn signal bulb -M7- and for left side light bulb -M1- or right
, is n
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side light bulb -M3-
hole
spec
21 - Cover cap
es, in part or in w
t to the co
❑ For left headlight main beam bulb -M30- or right headlight main beam bulb -M32-
rrectness of i
2.2 Removing and installing headlights
l purpos
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om
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do
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en
ng
t.
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2.4.1 Renewing gas discharge bulb Cop py
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rig ht
py by
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Note
Prote AG.
The diagrams show renewal of a gas discharge bulb for the left
headlight.
Removing:
– Remove headlight ⇒ page 181 .
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
ss c
ce
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nl
pt
du
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ab
ility
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wit
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– Pull off connector -1-.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
The connector is ejected automatically when the gas discharge
bulb starter unit -N195- is removed.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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starter unit lettering “OPEN” and pull gas discharge bulb start‐
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WARNING yri
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Prote
♦ Within the bulb glass of gas discharge bulbs, pressures
AG.
can range from between 7 bar (cold) and 100 bar (hot).
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
♦ The glass bulb may explode resulting in a risk of injury
from burning.
♦ Always wear eye protection and gloves when removing
and installing gas discharge bulbs!
Note
pt
an
d
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erm
ab
wit
is n
Removing:
h re
ole,
spec
– Switch off ignition and all electrical consumers and pull out
urposes, in part or in wh
ignition key.
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
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ara
ed
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aut ra
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un
pt
an
d
itte
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rm
ab
– Take main beam bulb -1- out of headlight.
pe
ility
ot
wit
Installing:
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ When installing cap, ensure that it is seated correctly. The in‐
gress of water will lead to permanent damage of the headlight.
rrectness of i
♦ Do not touch bulb glass when fitting bulbs. Fingers leave
l purpos
a
com
thi
do
cum
fo
en
g
t.
yi Co
Cop py
– Check headlight setting and adjust headlight as necessary ht. rig
rig ht
⇒ Maintenance ; Booklet 20.1
py by
co Vo
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Prote AG.
Note
The following diagrams show renewal of the side light bulb for the
left headlight. AG. Volkswagen A n G do
wage es n
Volks ot g
Removing: ed
by ua
ran
oris tee
– Switch off ignition and all electrical consumers
au
th and pull out or
ac
ignition key. ss
ce
le
un
pt
– Pull off cover cap -1-.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
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– Pull, depending on the cable length, the bulb holder -2- with
the side light bulb as far it is possible out of the reflector -1-.
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– Pull side light bulb -2- in -direction of arrow- out of the bulb
holder -1-.
Installing:
Note
Note
The following diagrams show renewal of the turn signal bulb for
the left headlight.
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Pull off cover cap -1-.
– Pull, depending on the cable length, the bulb holder -1- with n AG. Volkswagen AG do
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the front turn signal bulb in -direction of arrow- and take them olks es n
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– Push front turn signal bulb -2- into bulb holder -1- and turn front
turn signal bulb -2- in -direction of arrow-.
rrectness of i
– Pull front turn signal bulb -2- out of the bulb holder -1-.
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– Remove headlight ⇒ page 181 .
ole,
spec
urposes, in part or in wh
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unit -1-.
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Note
When taking off the gas discharge light control unit the connectors
ss o
must not be removed. The connector is fitted tightly to the head‐
cial p
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light and is automatically disconnected when taking off the gas
form
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– Take off gas discharge light control unit -1- from headlight. i
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When installing the gas discharge light control unit secure correct
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seat of the seal. The ingress of water will lead to permanent dam‐
agen
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age of the headlight.
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driver).
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Removing:
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– Switch off ignition and all electrical consumers and pull out
ignition key.
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– Unlock the locking clip -1- in -direction of arrow- and pull off
connector -2- from control unit for headlight range control -
J431- .
– Unscrew securing bolt -arrow- and take control unit for head‐
light range control -J431- -1- of bracket -2-.
Installing:
Installation is performed in the reverse order of installation; when
doing this, note the following:
– Fit the control unit for headlight range control -J431- -3- into
the bracket -2- with the lug -2-.
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– Lock connector au-1- by pressing the locking clip -2- in
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and the following menu items one after the other:
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♦ Coding automatic headlight range control
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spec
If the control unit for headlight range control -J431- has been co‐
es, in part or in w
ded, the basic setting of the headlights must be performed after
t to the co
having coded the control unit ⇒ Maintenance ; Booklet 20.1 .
rrectness of i
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There is a vehicle level sender located on the front axle ( front left
vehicle level sender -G78- ) and on the rear axle ( rear left vehicle
level sender -G76- ).
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♦ If the vehicle level senders are replaced, check the values from
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the sensors ⇒ page 203 and carry out basic setting on head‐
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lights ⇒ Maintenance ; Booklet 20.1 .
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♦ If the values from the vehicle level sensors are outside the
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– Unscrew the five securing bolts -1- and remove rear left vehi‐
cle sender -G76- -2-.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settingsAG. Volkswagen AG d
⇒ page 238 . agen oes
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– Check front left vehicle level sender -G76-
or
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– Perform basic setting of headlights ⇒
ss Maintenance ; Booklet
a c
20.1 .
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⇒ Maintenance ; Booklet 20.1 .
es, in part or in w
t to the co
♦ If the values from the vehicle level sensors are outside the
specified tolerance, basic headlight setting cannot be carried
out.
rrectness of i
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gle of the vehicle by way of signals to the headlight range control
m
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unit -J431- .
o
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It must then be confirmed whether the rear left vehicle level sen‐
te
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sor -G76- and front left vehicle level sensor -G78- are supplying
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the headlight range adjustment unit -J431- with plausible signals.
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No fault entry is stored in the headlight range control unit -J431-
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workshop manual Prote AG.
Note
If the values of the vehicle level senders are outside the specified
tolerance, basic headlight setting cannot be carried out.
AG. Volkswagen AG d
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3 Fog lights
Fault detection and fault display:
The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the fog lights easier.
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
ce
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❑ Bulb H11 12 V, 55 W
pt
du
an
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ab
⇒ page 206
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4 - Fog light housing
, is n
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❑ Removing and installing
hole
spec
⇒ page 205
es, in part or in w
t to the co
5 - Cover cap
6 - Securing bolts
rrectness of i
7 - Spreader nuts
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Note
The diagrams show how the left fog light is removed and installed.
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove bolt -2-.
– Unclip cover cap -2- off locking device.
AG. Volkswagen AG d
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– Pull fog light housing out of front bumper and disconnect con‐
ility
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nector -arrow-.
wit
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Installing:
hole
spec
Installation is performed in the reverse order of installation; when
es, in part or in w
t to the co
doing this, note the following:
– Check functions of headlight.
rrectness of i
– Check fog light adjustment, adjusting if necessary ⇒ Mainte‐
nance ; Booklet 20.1 .
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nform
mercia
at
ion
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or
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Note
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The diagram shows how the left fog light is removed and installed.
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Removing:
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– Remove fog light ⇒ page 205 .
– Turn bulb holder -1- in -direction of arrow- and take out of fog
light.
The bulb for the fog light is permanently attached to the bulb
holder and cannot be renewed separately.
Fog light bulb : H11 12 V, 55 W
Installing:
Installation is performed in the reverse order of installation; when
doing this, note the following:
– Check functions of headlight.
– Check fog light adjustment, adjusting if necessary ⇒ Mainte‐
nance ; Booklet 20.1 .
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4 Removing and installing side marker
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4.1 Removing and installing front side mark‐
urposes, in part or in wh
t to the co
er
Removing
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Note
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Removal and installation of front side marker on left and right are
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identical.
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– Remove noise insulation ⇒ General Body Repairs, Exterior;
thi
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Note
Note
Additional information:
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The driver side exterior mirror turn signal bulb -L131- or the front
erm
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passenger side exterior mirror turn signal bulb -L132- is installed
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Note
t to the co
The complete driver side exterior mirror turn signal bulb -L131- or
the complete front passenger side exterior mirror turn signal bulb
rrectness of i
-L132- must be replaced if damaged.
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Removing:
nform
ercia
– Switch off ignition and all electrical consumers and pull out
ignition key.
m
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or
the front passenger side exterior mirror turn signal bulb -L132-
his
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nals .
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Installing:
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– Install driver side exterior mirror turn signal bulb -L131- or the cop Vo
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front passenger side exterior mirror turn signal bulb -L132- ⇒
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Prote AG.
General Body Repairs, Exterior; Rep. Gr. 66 ; Exterior rear
view mirror; Removing and installing side mounted turn sig‐
nals .
5. Mirror turn signal bulb and entry light in exterior mirror 209
Jetta 2005 ➤ , Bora 2006 ➤
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Electrical System - Edition 05.2005
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5.2 Removing and installing entry light in ex‐ r nte
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terior mirror ss c
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The driver side entry light in exterior mirror -W52- or the front
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passenger side entry light in exterior mirror -W53- is installed in
erm
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the housing of the left or right exterior mirror.
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Note
spec
es, in part or in w
t to the co
♦ To remove and install the entry lights the exterior mirror must
not be removed.
♦ Removal and reinstallation of entry lights is carried out in the
rrectness of i
same manner on both sides and is described for one side only.
l purpos
Removing:
nform
ercia
– Switch off ignition and all electrical consumers and pull out
m
ignition key.
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ion
c
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or
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ate
do
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t.
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– Pull bulb -1- in -direction of arrow- out of the carrier -2-.
rm
ab
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ility
Plug base bulb: 12 V, W6 W
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Installing:
h re
hole
spec
Installation is performed in the reverse order of installation; when
es, in part or in w
t to the co
Note
rrectness of i
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a
com
tion in
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te o
thi
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5. Mirror turn signal bulb and entry light in exterior mirror 211
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
6 Tail lights
1 - Securing nuts
2 - Left brake and tail light bulb
-M21- or right brake and tail
light bulb -M22-
3 - Tail light housing in side
panel
❑ Removing and installing
⇒ page 212
4 - Bulb for left brake, blinker
and tail light 2 -M72- or bulb for
right brake, blinker and tail light
2 -M73-
5 - Bulb carrier
❑ Removing and installing
⇒ page 213
AG. Volkswagen AG d
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urposes, in part or in wh
t to the co
rrectne
panel
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Removing:
form
mer
atio
– Switch off ignition and all electrical consumers and pull out
om
ignition key.
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c
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or
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– Tighten securing nuts -2- to specified tightening torque
an
d
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⇒ page 238 .
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ility
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Note
h re
ole,
spec
urposes, in part or in wh
The tail light connector in the side panel must “audibly” engage.
t to the co
– When installation is complete, check shutlines of tail light to
body.
rrectness o
cial p
f in
6.3 Removing and installing tail light bulb
form
mer
atio
om
n
c
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or
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Removing:
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Prote AG.
– Unclip retaining tabs -1- -in direction of arrow- and take bulb
carrier out of tail light housing -2-.
Installing:
Install in reverse order of removal.
1 - Securing nuts
2 - Bulb carrier
❑ Removing and installing
⇒ page 215
3 - Left reversing light bulb -
M16- or right reversing light
AG. Volkswagen AG d
bulb -M17- ksw
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❑ 12 V, P 21 W ed by gu
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4 - Tail light housing in tailgate aut
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❑ Removing and installing s
ce
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⇒ page 214
un
pt
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5 - Plain washer
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– Pull connector -2- off.
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– Remove securing nuts -1- on tail light in tailgate.
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– Remove tail light.
h re
hole
Installing:
spec
es, in part or in w
t to the co
Installation is performed in the reverse order of installation; when
doing this, note the following:
rrectness of i
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at
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body.
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Note
The lower tail light trim must not be removed. For reasons of
clarity the lower tailgate trim is not shown in the following figure.
– Unclip the two retaining tabs -in direction of arrow- and take
bulb carrier -1- out.
Installing:
Install in reverse order of removal.
AG. Volkswagen AG d
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Note
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In the event of damage, the complete high level brake light -M25- Vol
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unit must be renewed. ise
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Removing: ss
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nl
pt
– Switch off ignition and all electrical consumers and pull out
du
an
itte
ignition key.
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erm
ab
ility
– Remove strip roof leading edge ⇒ General body repairs, in‐
ot p
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terior; Rep. Gr. 70 ; Removing and installing strip roof leading
, is n
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edge .
hole
spec
– Pull connector -1- off.
es, in part or in w
t to the co
– Press high level brake light bulb -M25- to rear window
-in direction of arrow-
rrectness of i
Installing:
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nform
mercia
at
om
ion
c
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or
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ate
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Caution
AG. Volkswagen AG d
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♦ After installing a new tsteering
horis column electronics control unit nte
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-J527- , it must be coded
s au ⇒ page 227 . ra
c
s
♦ In the event of faults in the steering column switch, the coding
ce
le
un
pt
of the steering column electronics control unit -J527- must be
an
d
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checked ⇒ page 227 .
erm
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ility
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is n
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ole,
spec
urposes, in part or in wh
t to the co
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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with cruise control sys‐
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tem cruise control sys‐
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❑ The illustration shows
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the “turn signal switch”
ole,
spec
urposes, in part or in wh
t to the co
2 - Steering column switch
base
rrectne
❑ Removing and installing
⇒ page 226
ss
3 - Windscreen wiper switch -
o
cial p
f
E-
inform
mer
atio
⇒ page 225
om
n
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4 - Securing bolt
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t.
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❑ Removing and installing
Co
op py
⇒ page 221 t. C rig
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yri by
❑ Coding ⇒ page 227 cop Vo
by lksw
cted agen
❑ Final control diagnosis Prote AG.
⇒ page 227
6 - Airbag coil connector and
return ring with slip ring -F138-
❑ Removing and installing ⇒ page 223
7 - Steering angle sender -G85-
❑ Removing and installing ⇒ page 224
❑ Basic settings ⇒ page 228
Caution
Note
Removing:
For removal of the complete steering column switch, inc. base
module, the switch is dismantled and the steering lock housing is
also removed. For assembly of the steering lock housing, new
shear head bolts are required. Even if just one component of the
steering column switch is removed or renewed, the sequence de‐
scribed as follows must be observed.
– Disconnect the battery ⇒ page 29 .
– Remove steering wheel ⇒ General body repairs, interior; Rep.
Gr. 69 ; Airbag; Removing and installing steering wheel .
G. Volkswage
– Remove steering column trim ⇒ General lksw
abody
gen A repairs, interior;
n AG d
oes
not
Rep. Gr. 68 ; Compartments, covers by
V and trim; Removing and
o gu
ara
installing steering column switch
ris trim .
ed
nte
ho eo
ut
Remove components of steering
ss
a column switch in the sequence ra
c
as follows:
ce
le
un
pt
an
d
y li
erm
ab
♦ Airbag coil connector and return ring with slip ring -F138-
ility
ot p
⇒ page 223
wit
is n
h re
♦ Steering angle sender -G85- ⇒ page 224
ole,
spec
urposes, in part or in wh
t to the co
♦ Windscreen wiper switch -E- ⇒ page 225
♦ Steering column switch base ⇒ page 226
rrectne
Installing:
ss
f inform
atio
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
♦ After new control unit has been installed, it must be coded
yi Co
op
⇒ “9.3 Steering column electronics control unit J527 ”,
C py
t. rig
gh
page 227 .
ht
pyri by
Vo
o
by c lksw
♦ In the event of faults in the steering column switch, the coding
cted agen
Prote AG.
of the control unit must be checked ⇒ page 227 .
ce
le
un
pt
an
d
itte
– Unscrew bolt -1-.
y li
rm
ab
pe
ility
– Insert a thin rod, e.g. of ∅ 2.5 mm -2- approx. 45 mm in the
ot
wit
hole -arrow 1- in steering column electronics control unit -
, is n
h re
J527- to release the locking tab -arrow 2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
-arrow- of the steering column electronics control unit -J527- .
Co
Cop py
t. rig
gh ht
– Carefully pull the steering column electronics control unit - yri
p by
o Vo
J527- downwards off the steering column switch. by c lksw
cted agen
Prote AG.
Note
Ensure when fitting the connector that none of the pins become
bent and that the connector can be heard to engage.
Note
The coil connector should not be moved out of the central position
during removal and the road wheels should be in the “straight
ahead” position.
Note
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
-1-.
o
n
c
i
or
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
If a new steering angle sensor -G85- is installed, this procedure
gh ht
pyri by
must be followed by a “basic setting” ⇒ page 228 .
co Vo
by lksw
cted agen
Prote AG.
ce
♦ The “turn signal switch” comprises of the following compo‐
e
nl
pt
du
an
itte
y li
-E4- and, if fitted with cruise control system cruise control sys‐
erm
ab
tem switch -E45-
ility
ot p
wit
, is n
h re
cruise control system switch -E45- .
hole
spec
es, in part or in w
t to the co
Removing:
– Release retaining clips -arrows- using a 1.0 mm feeler gauge
-1- and take “turn signal switch” off backwards.
rrectness of i
Installing:
l purpos
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
Removing:
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
For reasons of clarity, the steering column switch is shown in the
hole
spec
removed state.
es, in part or in w
t to the co
– Release retaining clips -arrows- using 1.0 mm feeler gauge
-1- and take windscreen wiper switch -E- off backwards.
rrectness of i
Installing:
l purpos
nf
ercia
orm
m
Note
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Caution
ce
le
un
pt
♦ Please remove the components in the specified se‐
an
d
itte
quence.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Caution
spec
urposes, in part or in wh
t to the co
Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
rrectne
Removing:
ss
– Disconnect the battery ⇒ page 29 .
o
cial p
f inform
Remove the following components in sequence:
mer
atio
– Remove steering wheel ⇒ General body repairs, interior; Rep.
om
i
or
n thi
te
cum
r
fo
t.
yi Co
op
– Remove steering column electronics control unit -J527- C py
t. rig
⇒ page 221 .
gh ht
pyri by
Vo
o
by c lksw
– Remove coil spring for airbag/coil connector with slip ring - cted agen
Prote AG.
F138- ⇒ page 223 .
– Remove steering angle sender -G85- ⇒ page 224 .
– Remove the turn signal light switch -E2- ⇒ page 224 .
– Remove windscreen wiper switch -E- ⇒ page 225 .
– Disconnect connector -arrow- at reader coil -3-.
The basic brace can be removed once all the components moun‐
ted on it have been dismantled:
– Drill out securing bolts -1- of steering lock housing -3-.
Note
Installing:
– Place the steering lock housing into the basic for the steering
column switch.
– Push base module of steering column switch -2- as far as
possible onto steering column.
– Fit connector -arrow- at reader coil -3-.
– Tighten the new shear head bolts -1- to steering column.
– Tighten the new shear head bolts -1- until bolt heads shear off.
– Install all parts in reverse order of removal.
pt
du
y li
ab
ility
ot p
♦ Body
wit
, is n
h re
♦ Electrical System
hole
spec
t to the co
at
io
in t
or
his
e
do
riv
cum
for
en
g
t.
yi Co
op
and the following menu items one after the other: C py
t. rig
gh ht
yri
♦ Body
p by
co Vo
by lksw
cted agen
♦ Electrical System
Prote AG.
n AG. Volkswagen AG do
lkswage es n
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ir se tee
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u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
housing
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
Disconnecting and connecting the battery as described in the
Workshop Manual ⇒ page 29 .
rrectness of i
l purpos
Note
nform
mercia
a
com
tio
steering column switch base first.
n in
r
te o
thi
s
iva
do
r
rp
c
Caution
um
fo
en
ng
t.
yi Co
♦ The steering lock could be destroyed.
Cop py
t. rig
gh ht
yri
♦ If the steering lock is actuated without lock cylinder, it will
p by
co Vo
lksw
block and must be renewed.
by
cted agen
Prote AG.
Removing:
– Disconnect the battery ⇒ page 29 .
– Remove basic brace for steering column switch ⇒ page 226
Caution
Removing:
– Disconnect the battery ⇒ page 29 .
– Remove steering wheel ⇒ General body repairs, interior; Rep.
Gr. 69 ; Airbag; Removing and installing steering wheel .
– Remove steering column trim ⇒ General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trim; Removing and
installing steering column switch trim .
– Remove steering column electronics control unit -J527-
⇒ page 221 .
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
For reasons of clarity, the diagram shows a removed lock cylinder
urposes, in part or in wh
– Using steel rod -2- disengage -arrow- safety bar -3- of lock
s
cylinder -1-.
s o
cial p
f i
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Installing:
Note
For reasons of clarity, the ignition key is not shown in the following
diagram.
Note
– Pull steel rod -2- out of lock cylinder -1- and check lock cylinder
is seated correctly in the steering lock housing.
– Fit connector to immobilizer reader coil.
– Install all parts in reverse order of removal.
pt
an
d
itte
y li
erm
Removing: ab
ility
ot p
wit
– Disconnect the battery ⇒ page 29 .
is n
h re
ole,
Installing:
– Insert ignition switch in steering lock housing until it can be
ss
heard to engage.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
pt
du
an
itte
y li
Removing:
erm
ab
ility
ot p
⇒ page 221 .
, is n
h re
hole
Installing:
l purpos
at
om
io
Note
n
c
in t
or
his
te
do
riv
cum
or
⇒ page 227 .
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
11 Parking aid
Note
. Volkswagen AG
gen AG
♦ For complaints with the parkingksaid
wa system it is absolutely
oes es‐ d
not
Vol
sential to understand theefunction
db
y and operation of the system.guara
is nte
or
♦ Additional information
au ⇒ Operating instructions
th eo
ra
ss c
ce
e
nl
General description:
pt
du
an
itte
y li
The parking aid system or PDC (Park Distance Control) supports
erm
ab
the driver during parking maneuvers by indicating the distance
ility
ot p
wit
, is n
signals.
h re
hole
spec
The parking aid system comprises:
es, in part or in w
t to the co
♦ Parking aid control unit -J446-
♦ Rear parking aid warning buzzer -H15-
rrectness of i
♦ Rear left centre parking aid sensor -G204-
l purpos
nf
ercia
orm
♦ Rear centre right parking aid sender -G205-
m
atio
om
n in
Fault detection and fault display:
or c
thi
te
o
r
cu
o
m
f
en
ng
For fault finding, use the vehicle diagnosis, testing and informa‐
t.
yi Co
op
tion system -VAS 5051A- in “guided fault finding” mode. C py
t. rig
gh ht
yri by
To check the entire parking aid system, perform final control di‐ cop Vo
by lksw
agnosis ⇒ page 236 . cted agen
Prote AG.
pt
an
itte
sender -G204-
y li
erm
ab
wit
h re
⇒ page 235
hole
spec
es, in part or in w
t to the co
The parking aid control unit is located behind the right luggage
compartment panel trim.
nf
ercia
Removing:
rm
m
atio
m
– Switch off ignition and all electrical consumers and pull out
o
n in
c
ignition key.
or
thi
te
sd
a
o
r
rp
cu
m
f
en
area trims .
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
pt
an
itte
y li
erm
wit
, is n
h re
Note
hole
spec
es, in part or in w
out in the same way for all sensors and is described below for just
one sensor.
rrectness of i
Removing:
l purpos
– Switch off ignition and all electrical consumers and pull out
ignition key.
nform
ercia
at
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
. Volkswagen AG
gen AG
11.4 Removing and installing rear parking ksw aid
a does
not
y Vol gu
b
warning buzzer -H15-
ara
ed nte
ris
ho eo
ut ra
The rear parking aid warning buzzer -H15- is ss fitted on the
a
rear c
shelf plate. It is accessible via the luggage compartment.
ce
e
nl
pt
du
an
Removing:
itte
y li
erm
ab
– Pull off connector -1-.
ility
ot p
wit
, is n
Installing:
t to the co
nf
ercia
orm
m
atio
m
n in
or c
thi
te
sd
o
r
cu
o
m
f
en
ng
♦ Body
♦ General Body Repairs
♦ 01 - On Board Diagnostic capable systems
♦ Parking aid
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
238
by lksw
cted agen
Rep. Gr.94 - Lights, lamps, switches - outside Prote AG.
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
Note
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
♦ The bonnet contact switch -F266- is integrated into the bonnet
ility
ot p
wit
is n
h re
♦ If the bonnet contact switch -F266- is found to be defective,
ole,
spec
the entire bonnet lock must always be replaced.
urposes, in part or in wh
t to the co
– Remove front bonnet lock ⇒ General Body Repairs, Exterior;
Rep. Gr. 55 ; Bonnet; Removing and installing coupling lock;
Removing .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
– Hold rotary part in this position and pull lighting switch (using
y li
erm
ab
rotary part) out of dash panel -3-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Disconnect connector -arrow-.
m
m
atio
om
Installing:
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Lever lens carefully out using removal wedge -VAS 3409- or
ility
ot p
a screwdriver.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
n in
or c
thi
e
Renew bulb:
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unlock locking tabs -1- and take thermal protection plate -2-
off the lens or the light.
ce
le
un
pt
note the following:
an
d
itte
y li
rm
ab
– Check functions of glove box switch. The lamp must not light
pe
ility
when the lid is closed.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.3 Removing and installing glove compart‐
ment light switch -E26-
rrectness of i
l purpos
nform
ercia
Removing:
m
a
– Switch off the ignition and all electrical consumers.
com
tion in
r
do
installing glove compartment .
r
rp
cum
fo
en
g
– Unlock locking lug -1- and slide the switch out of the guide
n
t.
yi Co
op
-arrow-. C py
ht. rig
rig ht
by
Installing: copy Vo
by lksw
cted agen
Prote
Install in reverse order of removal.
AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Unlock locking lugs -arrows- and take adjuster and regulator
hole
out.
spec
es, in part or in w
t to the co
Installing:
Install in reverse order of removal.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
sd
iva
o
r
rp
m
f
en
ng
K145-
t.
yi Co
Cop py
t. rig
gh
Removing:
ht
pyri by
Vo
co lksw
by
cted
– Switch off the ignition and all electrical consumers.
agen
Prote AG.
ce
e
pt
du
an
itte
y li
tre vent .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
thi
light switch.
te
sd
iva
o
r
Installing:
rp
cu
o
m
f
en
ng
t.
Install in reverse order of removal.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
♦ When removing and installing components in visual area (con‐
ility
ot p
wit
is n
h re
ole,
srewdriver).
spec
urposes, in part or in wh
t to the co
so that only one light is described.
rrectne
Removing:
– Switch off the ignition and all electrical consumers.
ss o
– Lever footwell light out of the trim under the dash panel using
cial p
f in
removal wedge -VAS 3409- or a screwdriver.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unlock locking tabs -1- and take thermal protection plate -2-
off the lens or the light.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
pt
du
an
itte
y li
erm
ab
side airbag -E224-
ility
ot p
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
Observe safety measures when working on airbag ⇒ General
body repairs, interior; Rep. Gr. 69 ; Safety measures when
working on airbags .
rrectness of i
l purpos
Removing:
nf
ercia
n in
or c
sd
iva
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
3.1 Removing and installing window regula‐
erm
ab
ility
tor switch in front passenger door -
ot p
wit
is n
E107-
h re
ole,
spec
urposes, in part or in wh
t to the co
Note
rrectne
tures a button illumination bulb -L76- , which must not be replaced
individually.
ss o
cial p
f
Removing:
inform
mer
atio
om
– Remove lever shell, upper part out of the closing lever ⇒ Gen‐
n
c
i
or
n
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐
thi
te
sd
a
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pr
cum
r
fo
en
ng
t.
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cted agen
Prote AG.
– Release locking lugs -arrows- and remove switch from the in‐
stallation frame.
Installing:
Install in reverse order of removal.
Note
Removing:
– Remove switch module window lifter, driver side
⇒ page 250 .
– Unclip installation frame for switch from trim.
– Release locking lugs -arrows- and remove switch from the in‐
stallation frame.
Installing:
Install in reverse order of removal. AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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le
un
pt
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spec
es, in part or in w
system -E308-
t to the co
rrectness of i
Note
l purpos
The driver side interior locking button for central locking system -
E308- features a button illumination bulb -L76- , which must not
nform
ercia
be replaced individually.
m
a
com
ti
Removing:
on in
r
te o
thi
do
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rp
t.
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op
– Disconnect connector -1- and tighten securing bolts -2-.
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– Take door opener with switch out of the door trim.
op Vo
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3.4 Components - front door locks ise nte
or eo
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aut ra
s c
The following components (depending on equipment) are inte‐ s
ce
e
pt
du
an
itte
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♦ Driver door contact switch -F2-
erm
ab
ility
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♦ Driver door central locking motor -V56-
hole
spec
♦ Driver door central locking deadlock function motor -V161-
es, in part or in w
t to the co
The following components (depending on equipment) are inte‐
grated into the passenger side door lock:
rrectness of i
♦ Front passenger door contact switch -F3-
l purpos
nform
ercia
at
-V162-
om
ion
c
in t
or
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ate
Note
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In the event of component defects - front door locks: yri
p by
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cted
– Replace relevant door lock ⇒ General Body Repairs, Exterior;
agen
Prote AG.
Rep. Gr. 57 ; Front door; Removing and installing door lock .
AG. Volkswagen AG d
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lksw not
Note by Vo gu
ara
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rise nte
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When removing and installing components in visual area (con‐
th
au ra
nectors, covers, trims etc.) apply
s a commercial adhesive tape
s c
ce
e
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
nl
pt
du
driver).
an
itte
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erm
ab
ility
ot p
The following components (in models with 4 doors) are integrated
wit
into the switch module for the driver side window lift:
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Rear right window regulator switch, in driver door -E55-
rrectness of i
♦ Front right window regulator switch in driver door -E81-
l purpos
nform
mercia
at
om
Note
ion
c
in t
or
his
e
do
priv
cum
for
en
ng
t.
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into the switch module for the driver side window lift:
Co
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♦ Front left window regulator switch -E40-
ht
pyri by
Vo
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by
cted
♦ Front right window regulator switch in driver door -E81-
agen
Prote AG.
Note
Removing:
– Switch off the ignition and all electrical consumers.
– Carefully lever installation frame out of door trim using removal
wedge -VAS 3409- or screwdriver -arrow-.
– Release locking lugs -arrows- and remove switch from the in‐
stallation frame.
Installing:
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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ss c
ce
le
un
pt
an
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ab
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is n
t to the co
Note
rrectne
The remote release button for fuel filler flap and rear lid -E463-
features a button illumination bulb -L76- , which must not be
ss
replaced individually.
o
cial p
f inform
mer
Removing:
atio
m
n
c
i
or
n thi
e
sd
va
o
pr
cum
r
side .
fo
en
ng
t.
yi Co
– Disconnect connector -arrow-. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
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ng
t.
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Prote AG.
ce
grated into the rear right door lock: le
un
pt
an
d
itte
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erm
ab
ility
♦ Rear right central locking lock unit -F223-
ot p
wit
is n
h re
ole,
spec
♦ Rear right door central deadlock function locking motor -V164-
urposes, in part or in wh
t to the co
Note
rrectne
In the event of repair, the complete component must be renewed.
ss o
In the event of component defects - rear door locks:
cial p
f inform
– Replace relevant door lock ⇒ General Body Repairs, Exterior;
mer
atio
om
n
c
i
4.2 Removing and installing rear left window
or
n thi
te
sd
a
o
pr
cum
r
en
ng
t.
yi
E54-
Co
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Removing: op Vo
by c lksw
cted agen
Prote
– Switch off the ignition and all electrical consumers.
AG.
– Remove lever shell, upper part out of the closing lever ⇒ Gen‐
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐
ling door trim; Rear door trim .
– Disconnect connector -arrow-.
ce
le
un
stallation frame.
pt
an
d
itte
y li
Installing:
erm
ab
ility
ot p
Install in reverse order of removal.
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
at
om
srewdriver).
do
priv
cum
for
en
ng
t.
Removing:
yi Co
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t. rig
– Switch off the ignition and all electrical consumers. gh ht
pyri by
Vo
co lksw
by
– Lever light out of the luggage compartment trim using removal Prote
cted AG.
agen
wedge -VAS 3409- or a screwdriver.
– Press contact plate -1- of the light outwards and take festoon
bulb -2- out of the socket.
– Renew festoon bulb (12 V, 10 W).
Installing:
Install in reverse order of removal.
pt
du
an
itte
y li
ab
moving .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
The interior light and reading light as well as the switches for the
interior light and reading light are connected together and can not
be separated. When repairing, renew the complete component.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
driver).
m
atio
om
n in
or c
Removing:
thi
te
sd
iva
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
– Unbolt securing bolts -arrow-.
hole
spec
– Take the interior light out of the headliner console.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
Installing:
en
ng
t.
yi Co
op
Install in reverse order of removal. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Removing:
– Switch off the ignition and all electrical consumers.
wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
– Carefully lever lens for interior lightedout
by using removal wedge ara
-VAS 3409- or screwdriver -arrow-.
thoris nte
eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press contact -1- of light to side -arrow- and remove festoon
bulb -2- with the contact from the interior light.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Pull contact -arrow- off defective festoon bulb.
c by lksw
cted agen
Prote AG.
– Fit the contact to the new festoon bulb (12 V, 10 W).
Installing:
Install in reverse order of removal.
– Turn bulb holder -arrows- of the defective reading light for 90°
to the left.
– Take the holder with the bulb out of the reading light.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
t to the co
reading light:
♦ Front interior light -W1-
nform
ercia
a
com
tion in
thi
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
The interior light and reading light as well as the switches for the
p by
o Vo
by c lksw
interior light and reading light are connected together and can not
Prote
cted AG.
agen
be separated. When repairing, renew the complete component.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness
Note
o
cial p
f inform
When removing and installing components in visual area (con‐
mer
atio
m
n
c
i
or
n
driver).
thi
te
sd
iva
o
pr
c
Removing:
um
r
fo
en
ng
t.
yi
– Switch off the ignition and all electrical consumers.
Co
Cop py
t. rig
gh
– Carefully lever trim out of interior light using removal wedge -
ht
pyri by
Vo
VAS 3409- or screwdriver -arrow-.
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
lksw not
6.2.2 Removing and installing sunroof switch Vo gu
d by ara
ise nte
-E8- aut
hor eo
ra
ss c
Removing:
ce
e
nl
pt
du
an
– Remove interior light ⇒ page 261 .
itte
y li
erm
ab
– Disconnect connector -arrow-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
– Release locking lugs -arrows- and remove switch from the in‐
ion
c
stallation frame.
in t
or
his
ate
Installing:
do
priv
cum
or
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Removing:
– Switch off the ignition and all electrical consumers.
– Carefully lever lens for interior light
olkout
swausing removal wedge
-VAS 3409- or screwdriver w en AG. V
ag-arrow-.
gen AG
does
ks n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.
AG. Volkswagen AG d
agen oes
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le
un
pt
6.2.4 Left centre reading light -W39- and right
an
d
itte
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erm
ab
ility
ot p
wit
is n
Removing:
h re
ole,
spec
urposes, in part or in wh
t to the co
– Turn bulb holder -arrows- of the defective reading light for 90°
to the left.
– Take the holder with the bulb out of the reading light.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
The interior light and reading light as well as the switches for the
interior light and reading light are connected together
AG. Vo and
lkswagen AG docan not
agen
be separated. When repairing,Vorenewlksw the complete component. es n
ot
y gu
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rise nte
6.3.1 Removing and installing rear interior au
tho eo
ra
c
ss
and reading light (vehicles without
ce
e
nl
pt
ATAS)
du
an
itte
y li
erm
ab
Removing:
ility
ot p
wit
– Switch off the ignition and all electrical consumers.
, is n
h re
hole
– Release locking lugs -arrows- and take trim with lens off inte‐
spec
rior light and reading light.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
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t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
Installing:
h re
hole
spec
Install in reverse order of removal.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
ti
with ATAS)
on in
r
te o
thi
do
cum
fo
en
g
t.
yi Co
Cop py
♦ Rear left reading light -W11- ht. rig
rig ht
py by
o Vo
♦ Rear right reading light -W12-
by c lksw
cted agen
Prote AG.
♦ Anti-theft alarm ultrasonic sensor -G209-
Note
♦ The switches -1- of the reading lights are integrated in the rear
interior and reading light and cannot be renewed separately.
♦ The anti-theft alarm ultrasonic sensor -G209- -2- cannot be
renewed separately.
♦ The anti-theft alarm ultrasonic sensor -G209- , comprising four
individual sensors -2-, leads and a control element on the back
of the interior and reading light, must not be moved from its
predefined position.
Note
Removing:
– Switch off the ignition and all electrical consumers.
– Pull the entire complete trim -1- (including lens and reflectors)
-arrows- vertically downwards and out from the interior and
reading light.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
– Unlock connectors -1- and -2- and pull both connectors off.
iv
o
pr
cum
r
fo
Installing:
en
ng
t.
yi Co
op
Install in reverse order of removal. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
light.
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Installing:
m
a
Install in reverse order of removal.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Removing:
– Switch off the ignition and all electrical consumers.
– Lever light carefully out of the roof trim using removal wedge
. Volkswagen AG
-VAS 3409- or a screwdriver. swa
gen AG does
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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6.6 Removing and installing garage door ss a c
ce
e
operating unit -E284-
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
♦ The garage door operating unit -E284- is located in the sun
hole
spec
visor on the driver side.
es, in part or in w
t to the co
♦ The sun visor and the garage door operating unit -E284- may
only be replaced together.
rrectness of i
– Remove the sun visor on the driver side with garage door op‐
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
– Unbolt securing bolts -arrow-.utho
or
a ac
ss
– Take mounting frame with ashtray out of the centre console.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Release locking lugs -arrows- and remove switch from the in‐
stallation frame.
Installing:
Install in reverse order of removal.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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co lksw
by
cted agen
Prote AG.
8 Horn
Note
♦ The treble tone horn -H2- and the bass tone horn -H7- are
controlled in parallel from the onboard supply control unit -
J519- .
♦ The procedure for removal and installation of treble tone horn
-H2- and bass tone horn -H7- is the same and is therefore
described for just one horn.
♦ The horns are installed to the left and the right of theAGlongitu‐
. Volkswagen
dinal members. wage
n AG do
es n
Volks ot g
by ua
ed ran
Removing: oris tee
th or
au ac
– Switch off the ignition and all electrical consumers.
ss
ce
e
nl
pt
– Remove front bumper ⇒ General body repairs; Rep. Gr. 63 ;
du
an
itte
Front bumper
y li
erm
ab
ility
– Disconnect connector -arrow-.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
in t
or
his
e
Installing:
at
do
priv
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9 Immobilizer
General description:
The vehicle is equipped with an immobilizer of the 4th generation.
Modifications by comparison with the immobilizer of the 3rd gen‐
eration:
♦ An adaptation of components of other group marks to Volks‐
wagen vehicles is no longer possible.
♦ Vehicle keys are preprogrammed with a base code by the
manufacturer. This base code includes a specific manufactur‐
ers code. It is only possible to learn a key of a vehicle if they
are programmed with the right manufacturers code.
Fault detection and fault display:
The immobilizer is equipped with self-diagnosis
agen which
AG. Volkswamakes
gen AG fault
does
finding easier. o lksw not
yV gu b ara
ed
For fault finding, use the vehicleris diagnosis, testing and informa‐ nte
tho e
tion system -VAS 5051A- s auin “guided fault finding” mode. or
ac
s
ce
9.1 Immobilizer control unit -J362-
le
un
pt
an
d
itte
y li
The immobilizer control unit -J362- is integrated in the dash panel
erm
ab
insert. If the control unit is defective the complete dash panel in‐
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
The immobilizer reader coil -D2- is joined to the ignition switch
and cannot be renewed individually.
– Removing and installing ignition switch ⇒ page 231 . rrectness
f inform
– Removing and installing the ignition key battery with radio re‐
mer
n
c
i
or
sd
va
o
pr
cum
r
en
ng
Note
9. Immobilizer 275
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
ce
e
nl
pt
du
an
itte
y li
erm
ab
-VAS 5051A- ⇒ page 281 .
ility
ot p
wit
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
, is n
h re
Information System -VAS 5051A- .
hole
spec
– Using the “Go to” key, select “Function/component selection”
es, in part or in w
t to the co
and the following menu items one after the other:
♦ Body
rrectness of i
♦ General Body Repairs
l purpos
nf
ercia
or
♦ Comfort system central control unit functions
m
m
atio
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Additional information:
⇒ Operating instructions
General description:
The functions of the ATAS are integrated into the central control
unit for comfort system -J393- .
Fault detection and fault display:
The anti-theft alarm system is equipped with self-diagnosis which
makes fault finding easier.
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
Note thoris nte
eo
au ra
c
ss
Once the anti-theft alarm system has been triggered, the alarm
ce
e
nl
pt
du
an
control unit -J393- can be interrogated ⇒ page 298 .
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
alarm system
hole
spec
es, in part or in w
t to the co
The anti-theft alarm system is switched on automatically when the
vehicle is locked. The system is then immediately armed.
rrectness of i
l purpos
Note
nform
ercia
Completely close all windows and doors before locking the vehi‐
cle to prevent the anti-theft alarm system triggering an unneces‐
m
at
sary alarm.
om
ion
c
in t
or
his
e
do
priv
cum
en
g
t.
yi Co
Cop py
♦ when the ignition is switched on.
t. rig
gh ht
pyri by
Vo
o
Unlock the car mechanically (emergency open) by c lksw
cted agen
Prote AG.
– Unlock the driver door.
The anti-theft alarm system remains active, although no alarm is
triggered.
– Switch ignition on within 15 seconds.
Note
If you do not switch on the ignition, the alarm will trigger after 15
seconds.
AG. Volkswagen AG d
Note ksw
agen oes
not
ol
byV gu
ara
d
The anti-theft alarm system must be deactivated before
orise
the send‐ nte
eo
er is removed ⇒ page 277 . aut
h
ra
c
ss
ce
le
un
Removing:
pt
an
d
itte
y li
– Switch off ignition and all electrical consumers and pull out
rm
ab
pe
ignition key.
ility
ot
wit
, is n
t to the co
– Release the connector -2- and pull it away from the vehicle
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
10.4 Central locking and anti-theft alarm sys‐
. C rig
ht ht
rig by
py
tem aerial -R47-
co Vo
by lksw
cted agen
Prote AG.
Note
Additional information:
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Twist drill ∅ 6 mm
rrectness of i
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Pull alarm horn -H12- -1- in -direction of arrow- out of the
rrectne
aperture in the bodywork.
– Pull connector off -2-.
ss o
cial p
f
Installing:
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
97 – Wiring
1 Vehicle Diagnosis, Testing and Infor‐
mation Systems
WARNING
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
ole,
ing etc. can be carried out using the vehicle diagnosis, testing
spec
and information system -VAS 5051A- and the vehicle diagno‐
urposes, in part or in wh
t to the co
♦ All working instructions can be found in “guided fault finding”
and “guided functions”.
♦ Additional information: rrectness o
f in
atio
n
c
n thi
e
5051
t
sd
iva
o
pr
en
ng
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
♦ Diagnosis lead -VAS 5051/6A- (5 m)
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi Co
Only these leads are to be used for diagnosis, as they are the only Cop py
ones fitted with CAN lines and therefore allowing CAN diagnosis
t. rig
gh ht
yri
and/or CAN communication.
p by
o Vo
by c lksw
cted agen
Prote AG.
Connecting Vehicle Diagnosis, Testing and Information System -
VAS 5051A- :
– Apply handbrake.
– On vehicles with automatic gearbox, move selector lever to
position “P” or “N”.
– On vehicles with manual gearbox, move gear stick to neutral
position.
– With the ignition switched off, connect vehicle diagnosis, test‐
ing and information system -VAS 5051A- using diagnostic lead
-VAS 5051/6A- to diagnostic interface -arrow- in vehicle.
– Switch ignition on.
– Switch off all electrical consumers.
Note
AG. Volkswagen AG d
agen oes
Noteolksw not
y V gu
d b ara
rise nte
o
When removing and aut installing components in visual area (con‐ e or
h
ac
nectors, covers,sstrims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
ce
le
un
pt
driver).
an
d
itte
y li
rm
ab
pe
ility
ot
Caution
wit
, is n
h re
hole
spec
Removing:
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Remove securing bolts -arrows- and take fuse holder -1- out
or
as far it is possible (depending on cable length).
m
m
atio
om
Installing:
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Removing:
h re
hole
spec
– Disconnect the battery ⇒ page 29 .
es, in part or in w
t to the co
– Remove storage compartment on driver side ⇒ General body
repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
– Unscrew bolts -arrows- of the bracket.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
– Pull relays -arrows- out of the relay carrier.
co Vo
by lksw
cted agen
Prote AG.
Note
– Fit relay carrier -2- into guide -1- and engage relay carrier.
pt
an
d
itte
ab
ility
wit
, is n
spec
Removing:
es, in part or in w
t to the co
– Switch off ignition and all electrical consumers and pull out
ignition key.
rrectness of i
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
The connector number depends on vehicle equipment.
hole
spec
es, in part or in w
t to the co
– Unclip onboard supply control unit -J519- and relay carrier on
onboard supply control unit, on left of dash panel out of the
locking device -arrows C-.
– Pull onboard supply control unit -J519- and relay carrier on rrectness of i
l purpos
Installing:
orm
m
thi
te
sd
iva
o
r
Note
rp
cu
o
m
f
en
ng
t.
yi Co
The locking bars may only be set to “CLOSE” when all connectors
Cop py
are fitted “correctly”.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
Caution
erm
ab
ility
ot p
wit
Disconnecting and connecting the battery as described in the
is n
h re
Workshop Manual ⇒ page 29 .
ole,
spec
urposes, in part or in wh
t to the co
Removing:
– Disconnect the battery ⇒ page 29 .
rrectne
– Release clips -1- in -direction of arrow- and take cover of elec‐
tronics box -2- off upwards.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
When the central securing screw -arrow-, the electronics box -1-
is pushed upwards off the electronics box mounting.
Note
For removal of the flat contact housing -1-, the air filter (on vehi‐
cles with diesel engine only), the battery and the battery console
must be removed.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
h re
hole
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Installing:
Installation is performed in the reverse order of installation; when
nform
ercia
at
om
in t
⇒ page 307 .
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Mount the cover -2- on the electronics box and push the safety
clip -1- in -direction of arrow- until cover -2- engages.
Note
Then check whether the cover -2- of the electronics box is en‐
gaged correctly.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5 Control units
AG. Volkswagen AG d
agen oes
olksw not
5.1 Onboard supply control unit -J519- ised byV gu
ara
nte
or eo
h
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
♦ The onboard supply control unit -J519- and the relay carrier
erm
ab
attached to the onboard supply control unit, on left of dash
ility
ot p
panel form one unit and cannot be separated.
wit
is n
h re
♦ Additional information:
ole,
spec
urposes, in part or in wh
t to the co
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
⇒ Operating instructions
rrectne
General description:
ss
The onboard supply control unit -J519- is responsible for the fol‐
o
cial p
f
lowing in the vehicle:
inform
mer
atio
om
n
c
i
or
n thi
e
sd
iva
o
pr
cum
r
en
ng
t.
yi Co
♦ Heated rear window . Cop py
rig
ht ht
rig
♦ Terminal control py by
co Vo
by lksw
cted
♦ Surround lighting
agen
Prote AG.
♦ Terminal control
♦ Dimmers, instrument lighting
♦ Fuel pump presupply
♦ Alternator stand-by
♦ Horn
The following functions can be adapted:
♦ Deleting learning values and setting standard adaptation val‐
ues
♦ Adjusting period for coming home function (depending on
equipment)
♦ Adjusting period for leaving home function (depending on
equipment)
♦ Adjusting rear window heating “On time”
♦ Switching on and off footwell lighting
♦ Switching on and off motorway signaling
♦ Adjusting load management
♦ Adjusting “activation time” for headlight cleaning system
⇒ page 294
ce
le
un
pt
with certain equipment configurations.
an
d
itte
y li
♦ The “Motorway signaling”, “comfort signaling”, or “tap signal‐
erm
ab
ility
ing” means that one touch of the turn signal lever will activate
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
⇒ “5.1.2 Coding onboard supply control unit J519 ”,
page 293 , so that access can be gained to the codes stored
within.
rrectne
Fault detection and fault display:
ss
The onboard supply control unit -J519- is equipped with self-di‐
o
cial p
f
agnosis, which is designed to ease fault finding.
inform
mer
For fault finding, use the vehicle diagnosis, testing and informa‐
atio
m
n
c
i
or
n
5.1.1 Removing and installing onboard supply
thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
If the onboard supply control unit -J519- is to be replaced, first
cted agen
Prote AG.
carry out the procedure
⇒ “5.1.2 Coding onboard supply control unit J519 ”, page 293 ,
so that access can be gained to the codes stored within.
Removing:
The removal of the onboard supply control unit -J519- corre‐
sponds to the removal of the relay carrier on onboard supply
control unit, on left of dash panel ⇒ page 286 .
Installing:
The installation of the onboard supply control unit -J519- corre‐
sponds to the installation of the relay carrier on onboard supply
control unit, on left of dash panel ⇒ page 286 .
ce
le
pt
an
d
itte
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
⇒ Operating instructions
l purpos
General description:
nform
ercia
tion in
thi
tems “drive train CAN data bus”, “convenience CAN data bus”
s
iva
do
cum
fo
t.
yi
wire and vice versa. In this way, data can also be used by the
Co
Cop py
the vehicle diagnosis, testing and information system -VAS
t. rig
gh ht
yri
5051A- p by
co Vo
by lksw
cted agen
Prote AG.
Note
agen
Note
AG. Volkswagen AG d
oes
olksw not
V gu
by
Before removing
rised data bus diagnostic interface -J533-
ara
nte , it is es‐
sentialutthat the following work procedure
ho eo
ra
⇒ “1.1
ss a Renewing dash panel insert”, page 150 is carried c out, so
that access can be gained to the codes stored within.
ce
e
nl
pt
du
an
itte
y li
– Switch off ignition and all electrical consumers and pull out
erm
ab
ignition key.
ility
ot p
wit
, is n
spec
es, in part or in w
– Release connector -1- and pull connector off data bus diag‐
t to the co
Installing:
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
t.
yi Co
op
tem -J393-
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Additional information:
⇒ Operating instructions
General description:
The convenience system central control unit -J393- is responsible
for the following in the vehicle:
♦ Sliding/tilting sunroof control (release instruction)
♦ Power window control (release instruction)
AG. Volkswagen AG d
♦ Central locking control lksw
agen oes
not
o
yV gu
♦ Anti-theft alarm system control rised b ara
nte
ho eo
♦ Radio-wave receiver aut ra
ss c
ce
le
♦ Rear lid lock
un
pt
an
d
itte
♦ Comfort operation
y li
erm
ab
ility
Some of the above functions can be adapted ⇒ page 298 .
ot p
wit
is n
h re
ole,
spec
The convenience system central control unit -J393- is equipped
urposes, in part or in wh
t to the co
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
rrectne
5.3.1 Removing and installing convenience
s
system central control unit -J393-
s o
cial p
f inform
Removing:
mer
atio
– Switch off ignition and all electrical consumers and pull out
om
n
ignition key.
c
i
or
n thi
te
sd
iva
o
r
cum
r
fo
en
ng
t.
yi Co
op
– Pull locking lug -1- off convenience system central control unit C py
ht. rig
-J393- bracket in -direction of arrow- and move the conven‐ rig ht
py by
ience system central control unit -J393- until the recesses
co Vo
by lksw
cted
-2- align with the recesses -3-.
agen
Prote AG.
Note
The connectors may only be unlocked and pulled off if the re‐
cesses -arrows- of the connectors and the bracket align exactly.
Note
Volkswagen AG
– Pull locking lug -1- in -direction of arrow B- and push conven‐ swagen AG. does
ience system central control unit -J393- -2- out of the bracketby
Vol
k not
gu
ara
in -direction of arrow A-. ris
ed
nte
ho eo
ut
Installing: ss
a ra
c
ce
Installation is performed in the reverse order of installation; when e
nl
pt
du
an
doing this, note the following:
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
5.3.2 Coding convenience system central
gh ht
pyri by
Vo
co
control unit -J393-
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
y li
erm
ab
♦ “Sensitivity of interior monitoring system”
ility
ot p
wit
is n
h re
-VAS 5051A- ⇒ page 281 .
ole,
spec
urposes, in part or in wh
t to the co
Information System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
rrectne
♦ Body
ss o
♦ General Body Repairs
cial p
f inform
♦ 01 - On Board Diagnostic capable systems
mer
atio
m
♦ Comfort system
o
n
c
i
or
n
♦ Comfort system central control unit functions
thi
te
sd
iva
cum
r
fo
en
ng
Note
Additional information:
Note
ce
e
nl
pt
of minimum 5 W4) the “trailer operation” and transfers this infor‐
du
an
itte
y li
erm
ab
ility
The trailer detector control unit -J345- is supplied with information
ot p
wit
(light control) from the onboard supply control unit -J519- and
, is n
h re
convenience system central control unit -J393- via the CAN.
hole
spec
4) At least the turn signal and brake light must be switched on, in order to detect
es, in part or in w
“trailer operation”.
t to the co
Fault detection and fault display:
The trailer detector control unit -J345- is equipped with self-diag‐
rrectness of i
nosis, which is designed to ease fault finding.
l purpos
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
nform
mercia
ion
in t
or
his
ate
do
riv
cum
for
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing:
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Remove left side panel trim in luggage compartment ⇒ Gen‐
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐
ling load and luggage compartment trim; Trim, luggage
compartment, sidewards .
– Release connectors -2- and pull off trailer detector control unit
-J345- .
Note
– Remove securing bolts -1- and take trailer detector control unit
-J345- with the bracket out of the vehicle.
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J345-
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♦ Body
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♦ Trailer detector
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♦ Function
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♦ Coding trailer detector control unit
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control unit -J345-
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Note
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♦ The trailer detector control unit -J345- detects from a power
hole
spec
draw of minimum 5 W 4) the “trailer operation”.
es, in part or in w
t to the co
♦ To check use plug socket tester -V.A.G 1537/A- .
rrectness of i
♦ Plug socket tester -V.A.G 1537/A- 5)
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t. rig
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5) After a few minutes the plug socket tester -V.A.G 1537/A- gets to hot and
switches off automatically. After a cooling period the plug socket tester -V.A.G
1537/A- works again perfectly.
Caution
For repair work on airbag and seat belt tensioner wiring har‐
nesses, only contacts, connectors and wiring designed specif‐
ically for this purpose may be used ⇒ Parts catalogue (ETKA)!
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nl
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hicle electrical system
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Caution
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Disconnecting and connecting the battery as described in the
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♦ Observe current notes (also notes concerning removing and
rrectness of i
installing components) in workshop manuals and in the Tech‐
nical Service Handbook.
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cum
for
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safe working environment for repairs to the electrical system.
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Cop py
The battery positive wire need only be disconnected for re‐ ht. rig
rig ht
moval of the battery.
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♦ If possible, do not loosen any earth wires from the body (dan‐
Prote AG.
ger of corrosion).
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bus wiring
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ility
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♦ An unshielded two-wire line -1- and -2- with a cross section of
, is n
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0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
hole
spec
♦ The colour codes of the CAN bus wiring can be gleaned from
es, in part or in w
t to the co
the following table:
Drivetrain CAN, high orange/black
rrectness of i
Convenience CAN, high orange/green
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ercia
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♦ Perform wiring harness repairs only with yellow wires. Mark
m
m
atio
repair locations with yellow tape.
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♦ When repairs are performed, both bus wires must have the
thi
te
same length. When wires -1- and -2- are twisted together, the
sd
iva
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twist spacing should be A=20 mm.
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AG. Volkswagen AG d
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olkswagen AG
en AG. V
7 Renewal
yV
olks
wag of aerial wiring
does
not
gu
b ara
ed
A new repair
ho
ris concept has been developed for repairnte
work
eo on aer‐
ial wires.
s aut Now connecting wires in different lengths and r a various
c
adapter
s cables are available as replacement parts instead of a
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7.1 General description
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logue: Special catalogue; Electrical connections; Genuine ac‐
cessories; Subgroup 35 from illustration No. 035-20.
rrectness of i
♦ These genuine parts are suitable for all aerial wires and wire
diameters which may need to be replaced.
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nf
ercia
orm
♦ The wires can be used retroactively for all VW models, with all
m
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♦ All adapter and connection wires are suitable for all transmitter thi
te
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7.2 Assembly overview - an aerial wire
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Example: Aerial wire between radio and aerial is defective. The
by c lksw
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following wires are required for the repair:
Prote AG.
Note
The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-.
– To determine the length of connecting wire required, subtract
60 cm from the measured total length of aerial connecting wire
-2-. n AG. Volkswagen A ge G do
swa es n
– Procure the required adapter cables -1- and -3- band y V connect‐
olk ot g
ua
ing wire -2- at the calculated length as genuine
ris
edparts from the ran
tee
parts catalogue (ETKA). ut
ho or
a ac
ss
– Cut off connectors of defective aerial wire.
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le
un
pt
an
The remainder of the defective aerial wire remains in the vehicle. d
itte
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ab
– Connect adapter cables -1- and -3- to equipment in vehicle.
ility
ot p
wit
– Route and secure connecting wire -2- parallel to the old aerial
is n
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wire.
ole,
spec
urposes, in part or in wh
t to the co
Note
rrectne
must not be below 50 mm.
ss
– Connect connecting wire to adapter cables.
o
cial p
f inform
– Perform a functional check.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
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d
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rm
ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.