27 - Starter, Current Supply, CC

Service
Workshop Manual
Jetta 2005 ➤
Bora 2006 ➤
Electrical System
Edition 05.2005
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005820

Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
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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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1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Procedure when checking the 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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2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.7 Evaluating test result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.3 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Disconnecting and reconnecting batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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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
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11.1 Activating and deactivating cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Renewing dash panel ainsert
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1.4 Warnings aulamp symbols in dash panel insert . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . .
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2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1 Windscreen wiper 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 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

2.1 Assembly overview of windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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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 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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3.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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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
94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Assembly overview, Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.4 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.5 Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.6 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2 Main headlights with gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.1 Assembly overview - gas discharge headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.2 Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.4 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.5 Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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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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5.1 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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6.2 Removing and installing 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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9.1 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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9.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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9.3 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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9.4 Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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10 Ignition switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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10.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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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
96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1 Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.1 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2 Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.1 Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.2 Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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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...................................................................... 246
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
........................................................................ 249
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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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operated switch to block release of rear lid remote E232 . . . . . . . . . . . . . . . . . . . . . . . . . . 252

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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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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 ➤
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
cardiagn.com
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
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d b unit J345 . . . . . . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . 307
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Contents v
Jetta 2005 ➤ , Bora 2006 ➤
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vi Contents
Jetta 2005 ➤ , Bora 2006 ➤
27 – Starter, current supply, CC

1 Battery
WARNING
Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !
Caution
To prevent damage to the battery and vehicle, the following

should be observed concerning types of battery ⇒ page 1 .
1.1 Fundamentals for batteries
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To ensure long use of the battery, the battery must be checked,
serviced and maintained as per instructions in this Manual.
Apart from supplying energy for starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
to the complete vehicle electrical system.
Note
Observe ⇒ Self-study programme No. 234 ; vehicle batteries .
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1.2.2 Maintenance-free battery

Maintenance-free battery with liquid electrolyte (wet battery).
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These batteries have a cover over the cells instead of cell plugs.
The cover seals the battery after initial filling during production.
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These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.
1.2.3 Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte.
Lead-acid battery where the electrolyte is contained within a mi‐
croscopic glass mat (AGM). The battery is sealed and fitted with
valves.
AGM is the abbreviation for Absorbent Glass Mat.
Note
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Batteries can be dangerous. These dangers can be avoided when
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the warnings on the battery and in the owners/instruction manual
and in ELSA are observed.
2 Rep. Gr.27 - Starter, current supply, CC

Jetta 2005 ➤ , Bora 2006 ➤
WARNING
♦ Untrained personal e.g. apprentices, trainees etc. may

only work on batteries when supervised by a vehicle me‐
chanic/foreman or vehicle electrician/foreman.
♦ Acid is highly corrosive. There is a considerable danger of
acid burns if personal do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.
♦ If electrolyte leaks from a battery it may cause skin burns
and acid corrosion, rusting on the vehicle. This may dam‐
age safety relevant components on the vehicle.
♦ The gas which forms when charging and the gas which
may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
correctly.
♦ It is prohibited to cause sparks through grinding, welding,
cutting operations and use naked lights in the vicinity of
batteries. Smoking is also prohibited. Sparks must also
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prevented through electrostatic discharge, therefore al‐
ways earth through vehicle body etc. before touching
battery.
♦ Only work on batteries in well ventilated and suitable
rooms.
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4. - Disposal: old batteries are classed as hazardous waste. They

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5. - Never dispose of old batteries in household waste system!
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6. - There is a danger of an explosion when working with batteries.

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7. - Follow instructions concerning batteries, in ELSA "electrical
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8. - Battery acid is very caustic, therefore wear eye protection and

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1. Battery 3
Jetta 2005 ➤ , Bora 2006 ➤
1.4 Battery terminal connection
Caution
To prevent damage to the battery terminal clamps and battery

terminals, the following should be observed:
♦ The battery terminal clamps should only be fitted by hand
and without using force.
♦ Battery terminals should not be coated with grease.
♦ The battery terminal clamps should be fitted so that the
battery terminal is either flush with the clamp or protruding
from it.
♦ Once the battery terminal clamps have been tightened to
the specified torque, the threaded connections should not
be tightened any further.
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 .
cardiagn.com
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Jetta 2005 ➤ , Bora 2006 ➤
2 Checking battery
WARNING

tions ⇒ page 2 !
Caution

2.1 Procedure when checking the battery

Carry out procedure in sequence as follows:
AG. Volkswagen AG d
1. Visual check ⇒ page 5 . lksw
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2. Checking battery with a magicised eye ⇒ page 6 or checking
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3. Check no load voltage
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4. Perform a battery load test using battery tester with printer
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It is essential first to check the external condition, the terminals of

the battery and that the battery is seated securely visually before
performing more extensive tests.
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♦ The battery will be damaged if the battery is not secured

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♦ Check battery is securely seated, if necessary tighten se‐ cted agen
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curing bolt to specified torque setting. ⇒ page 36
♦ Whether the battery housing is damaged: Check whether the

battery housing is damaged. Electrolyte can leak out if the
housing is damaged. If battery acid leaks out, serious damage
to the vehicle could be caused. Treat areas of the vehicle af‐
fected by leaked battery acid immediately with acid neutraliser
or a soap solution.
♦ Whether the battery terminals (battery wiring/cable connec‐
tions) are damaged. Check whether the battery terminals (bat‐
tery wire connections) are damaged. The necessary contact
at the terminal clamps cannot be guaranteed if the terminals
are damaged. When connecting clamps to the terminals, tight‐
2. Checking battery 5
Jetta 2005 ➤ , Bora 2006 ➤
en the clamps to the torque specified in this workshop manual.

If the clamps are not correctly seated and tightened, the wiring
could burn, which could result in electrical system malfunc‐
tions. Which will cause malfunctions in the electricalAG. Volsystem.
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The magic eye (condition indicator) provides information on the
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electrolyte level and condition (charge state) of the battery.
Batteries with a magic eye are produced in two versions:
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♦ Low maintenance ⇒ page 1
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♦ Maintenance-free ⇒ page 1
cardiagn.com
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Because the magic eye is located in only one cell, the display
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– Before performing a visual check, tap the magic eye lightly and Cop py
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be more accurate.
Note
♦ Air bubbles can form below the magic eye particularly when
the battery is being charged, including during normal vehicle
operation. These falsify the colour display of the magic eye.
♦ The magic eye can be located at various positions on the bat‐
tery.
Three different colour displays are possible:

♦ “Green”, battery is charged sufficiently.
♦ “Black”, Battery partly discharged, charge state < 65 % or
completely discharged.
♦ “Colourless or yellow”, battery must be renewed.
Note
♦ Charging battery with battery charger -VAS 5095 A-

⇒ page 15 .
♦ Charging battery with battery charger -VAS 5900-
⇒ page 19 .

Jetta 2005 ➤ , Bora 2006 ➤
2.4 Checking low maintenance battery
WARNING AG. Volkswagen AG d

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Danger of injury! Observe warning noticesiseand
d b safety regula‐ ara
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This battery is “low maintenance” this means the electrolyte level
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Check electrolyte level on housing:
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– Check electrolyte level via -min./ max.- marking on the battery
housing.
The electrolyte level is OK when the fluid level is at the max.
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marking.
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If the electrolyte level is below the -max.- marking:
cardiagn.com
– Replenished with distilled water ⇒ page 7 .
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Check electrolyte level in the cells:

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– Switch off the ignition and all electrical consumers.
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The foil with the warning notices must remain on the battery. co Vo
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– Remove cell sealing plugs.

– Check the electrolyte level of the battery cells.
The electrolyte level is OK when the fluid level -1- is the same
height as the plastic peg.
Note
The plastic peg corresponds to the max. marking.
If electrolyte level is OK:

– Check the cell sealing plugs and the O-ring seals for damage.
Damaged parts must be replaced.
– Seal the cells with the cell sealing plugs.
If the electrolyte level is under the plastic peg:
– Replenished with distilled water ⇒ page 7 .
2.4.2 Topping up with distilled water

Special tools and workshop equipment required
Jetta 2005 ➤ , Bora 2006 ➤
♦ Battery filler bottle -VAS 5045/-
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Caution
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♦ When filling up with undistilled water or electrolyte the bat‐
tery will be damaged. Top up with distilled water only.
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♦ The battery may be damaged when the cells are overfilled.
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When topping up use only the battery filling bottle -VAS

5045/- . The construction of the filler neck prevents an
cardiagn.com
overfilling of the battery cells.
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– Check the electrolyte level of the battery ⇒ page 7 .
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The foil with the warning notices must remain on the battery.
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– Remove cell sealing plugs.

– Replenish with distilled water using battery filling bottle -VAS
5045/- . When the max. level is reached the flow is interrupted
automatically.
– Check the cell sealing plugs and the O-ring seals for damage.
– Seal the cells with the cell sealing plugs.
– Check no load voltage of battery ⇒ page 10 .
– Perform battery load/discharge test ⇒ page 12 .
2.4.3 Check electrolyte density


Jetta 2005 ➤ , Bora 2006 ➤
♦ Commercially available hydrometer
– Check the electrolyte level of the battery ⇒ page 7 .
cardiagn.com
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The foil with the warning notices must remain on the battery.
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– Remove cell sealing plugs. au
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– Draw electrolyte off a cell using a hydrometer until the float
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The electrolyte density is determined by the float position in the
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Electrolyte density Charge Voltage
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1.28 g/cm3 100 % 12,7 V
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1,21 g/cm3 60 % 12,3 V
1,18 g/cm3 40 % 12,1 V rrectness of i
1,10 g/cm3 0% 11,7 V

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– Seal the cells with the cell sealing plugs. cted agen
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Jetta 2005 ➤ , Bora 2006 ➤
2.5 Check no load voltage of battery
WARNING
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Danger of injury! Observe warning notices
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The no load voltage test is used to determine the capacity of the
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The battery must not be charged or discharged for at least 2 hours
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No load voltage Charge Condition of battery
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11,70 V 0% Discharged, no capacity. Heavily discharged.
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⇒ page 27 .
cardiagn.com
12,20 V 50 % Over a period of time sulphate crystals build-up which can
nf
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only be reversed using a considerable amount of energy.
or
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12,35 V 65 % ♦ On batteries with a magic eye, the display will change

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♦ Hand multimeter -V.A.G 1526 B-
– Switch off ignition and all electrical consumers and pull out
ignition key.
– Disconnect negative terminal on battery ⇒ page 29 .
– Wait at least 2 hours. The battery must not be charged or dis‐
charged within this period.
– Check battery no load voltage with hand multimeter -V.A.G
1526 B- .

Jetta 2005 ➤ , Bora 2006 ➤
Measured value Measure to be performed

No load voltage ≥ 12.5 V No load voltage is OK, perform
a battery load test ⇒ page 10 .
No load voltage < 12.5 V Charge battery ⇒ page 15 .
If the battery has been recharged as a result of the no load test,
proceed as follows:
– Wait at least 2 hours. The battery must not be charged or dis‐
charged within this period.
– Check battery no load voltage again with hand multimeter -
V.A.G 1526 B- .
If after the loading process the battery no load voltage is < 12.5 V,
renew battery ⇒ page 31 .
2.6 Battery tester with printer -VAS 5097 A-
WARNING

tions ⇒ page 2 !
cardiagn.com
It is not necessary to remove or disconnect battery when using
battery tester with printer -VAS 5097 A- .
Battery tester with battery tester with printer -VAS 5097 A- can be
used to test 12 V starter batteries according to
♦ 80 - 499 A A low-temperature test current according to DIN
(Deutsche Industrie Norm (German Industrial Standard))1)
♦ 95 - 574 A A low-temperature test current according to IEC
(International Engineering Consortium)
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♦ 136 - 855 A VAollow-temperature
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For test purposes the battery is loaded with a current which is

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♦ Observe the ⇒ Instruction Manual for battery tester with printer

-VAS 5097 A- or sticker ⇒ Brief instructions for battery tester
with printer -VAS 5097 A- stuck on the unit or table Low-tem‐
rrectness of i
perature current. ⇒ page 13

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♦ Observe battery manufacture's handling instructions!

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Jetta 2005 ➤ , Bora 2006 ➤
2.6.1 Description of battery tester with printer

-VAS 5097 A-
Battery tester with printer -VAS 5097 A-
1 - Green LED, “unit operating”
2 - Red LED, “unit reverse-polarity connected”
3 - Red LED, “battery cannot be tested”, recharge battery.
4 - Start tester
5 - Low-temperature current selection switch
6 - ON/OFF and functions switch
7 - Selection switch (battery tester to pick-off point on battery/
external test point in engine compartment) AG. Volkswagen
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8 - Button to advance paper Volks ot g
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with printer -VAS 5097 A-
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WARNING
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tions ⇒ page 2 !
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♦ Battery tester with printer -VAS 5097 A-

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Perform battery load test:
– 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.

Jetta 2005 ➤ , Bora 2006 ➤
– Connect black terminal “-” of unit to negative terminal.
Note
Ensure test clamps have a good contact!
– Select point of connection of test terminals with selection

switch ⇒ page 12 .
1- Connected directly to battery.
2- Connected to external test points in engine compartment.
– Check that the figures given on the battery are correct for the
settings on the battery tester.
– Press start test button ⇒ page 12 .
The green LED lights up ⇒ page 12 . The test program runs
through automatically. The test result is printed out by the printer
⇒ page 14 .
– Switch off unit ⇒ page 12 .
cardiagn.com
– Remove test terminals.
Note
♦ The test is completed after about 20 seconds.

♦ The result of the test is printed out by the printer.
♦ Perform test once only. Repeating the test falsifies the results.
2.6.3 Table: low-temperature test current

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Low-temperature
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EN/ SAE ed IEC
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136 - 17 tho 95 - 124 ⇒ eo
80 - 104
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178 - 219 ss 125 - 154 ⇒ 105 - 129
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220 - 261 155 - 184 ⇒ 130 - 154

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262 - 303 185 - 214 ⇒ 155 - 179

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304 - 345 215 - 244 ⇒ 180 - 204

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388 - 429 275 - 304 ⇒ 230 - 254

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430 - 471 305 - 334 ⇒ 255 - 279

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472 - 513 335 - 364 ⇒ 280 - 304

514 - 555 365 - 394 ⇒ 305 -329
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556 - 597 395 - 424 ⇒ 330 - 354

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598 - 639 425 - 454 ⇒ 355 - 379

640 - 657 455 - 464 ⇒ 380 - 389
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658 - 675 465 - 474 ⇒ 390 - 399

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694 - 711 485 - 494 ⇒ 410 - 419

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Jetta 2005 ➤ , Bora 2006 ➤
Low-temperature test current in A

EN/ SAE IEC ⇒ DIN
802 - 819 545 - 554 ⇒ 470 - 479
820 - 837 555 - 564 ⇒ 480 - 489
838 - 855 565 - 574 ⇒ 490 - 4992)
2) Batteries with a low-temperature test current of 520 A according to DIN can be tested using setting for 499A according to DIN.
2.7 Evaluating test result

Because of the high load on the battery during this test (a high
current flows) the battery voltage drops.
♦ If the battery is OK the voltage value only lowers to the mini‐
mum voltage.
♦ If the battery is defective or has a low charge the battery volt‐
age quickly drops below the minimum voltage.
♦ This low voltage value remains over a long period and the
voltage only increases again slowly after the test has been
cardiagn.com
completed.
2.7.1 Comments concerning test print out

1- Measuring range set on tester.
2- Diagram -arrow- indicates battery condition.
3- Test result.
4- Battery voltage during load test.
AG. Volkswagen AG d
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5- Vehicle data and date. VoMust
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♦ The print out is required for warranty purposes.

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2.7.2 Assessing test results

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Battery tester print out Measure to be performed

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Starting power very good Battery OK

Start output good Battery OK
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Starting power sufficient Charge battery ⇒ page 15

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AG. Volkswagen AG d Jetta 2005 ➤ , Bora 2006 ➤
agen
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Caution
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3.1 Battery charger -VAS 5095 A-

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This chapter describes the basic functions of the battery charger
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-VAS 5095 A- . For additional information refer to ⇒ Operating
c
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instructions for battery charger -VAS 5095 A- .
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♦ Observe battery manufacture's handling instructions!
3.1.1 Description of battery charger -VAS

5095 A-
Battery charger -VAS 5095- is suitable for charging
♦ Wet batteries (genuine VW batteries from 2004 with transpar‐
ent battery housing and black cover).
♦ Absorbent glass mat batteries (genuine VW batteries from
2004 with black housing).
The battery charger charges without peaks in amperage or volt‐
age. This will not adversely effect the onboard electronics. The
battery can remain in the vehicle while it is being charged and
need not be disconnected.
Battery charger -VAS 5095 A-
1 - ON / OFF switch (0 = charger OFF)
2 - Charging current indicator (I > 12 A)
3 - Charging current indicator, battery partially charged > 90 %
4 - Maintaining charge, lights up green when battery is fully charg‐
ed
5 - Malfunction indicator
6 - Support mode indicator
7 - Support mode/normal mode changer-over switch
8 - Charger cable posts, red terminal “+”, black terminal “-”
9 - Battery type change-over switch (on base of charger unit)
3. Charging battery 15
Jetta 2005 ➤ , Bora 2006 ➤
3.1.2 Charging battery with battery charger -

VAS 5095 A-
WARNING

tions ⇒ page 2 !

♦ Battery charger -VAS 5095 A-
cardiagn.com
Caution AG. Volkswagen AG d
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Always set battery type 2.4 V/C (Volt/Cells) when ycharging!
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t to the co

– Check setting for battery type on type of battery switch
rrectness of i
⇒ page 15 . Must be set to 2.4 V/C (Volt/Cells).

l purpos
– Connect red terminal clamp “+” of charger unit to positive ter‐

minal on battery.
nform
ercia
– Connect black terminal clamp “-” of charger unit to negative

m
at
terminal on battery.
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– Switch on battery charger ⇒ page 15 .

or
his
ate
The charging current indicators ⇒ page 15 -2- and -3- light up

do
priv
yellow. When only the light emitting diode (LED) -3- lights up yel‐
um
for
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low, battery is partially discharged (approx. 90 %).

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If the LED lights up green ⇒ page 15 -4- the charger has switched
. C rig
ht ht
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to "maintaining charge". The battery is fully charged. py by
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– Switch off charging unit ⇒ page 15 . Prote AG.
– Remove charger unit terminals from battery terminals.

Jetta 2005 ➤ , Bora 2006 ➤
3.1.3 Charging totally discharged battery with

battery charger -VAS 5095 A-
WARNING

tions ⇒ page 2 ! en AG. V
olkswagen AG
wag does
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The charger unit automatically recognises totally tho discharged bat‐
ris nte
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teries and initiates a gentle charging procedureau with a low charg‐ ra
c
ss
ing current. The charging current is automatically adapted to suit
ce
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the charge condition of the battery.
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Note
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♦ Observe notes in chapter ⇒ page 27 .
ole,
spec
urposes, in part or in wh
♦ The battery voltage must be at least 0.6 V.
t to the co
cardiagn.com
– 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
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sd
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fo
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When in support mode the battery charger -VAS 5095 A- replaces
ng
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a defective vehicle battery whilst it is being exchanged. The on‐ Cop py
board supply remains intact. The vehicles electrical equipment
t. rig
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(e.g. electric windows) can be used. cop Vo
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Prote
AG.
♦ Battery charger -VAS 5095 A-
Caution
♦ Always set battery type 2.4 V/C (Volt/Cells) when in sup‐

port mode! This applies for all batteries.
♦ The battery charger -VAS 5095 A- terminal clamps must
remain in contact with the battery terminal clamps whilst
the battery is being exchanged.
Jetta 2005 ➤ , Bora 2006 ➤

– Set support mode/normal mode change-over switch to
⇒ page 15 “support mode”.
minal of vehicle.
terminal of vehicle.
– Check setting for battery type on type of battery switch
⇒ page 15 . Must be set to 2.4 V/C (Volt/Cells).
– Switch on battery charger ⇒ page 15 .
The yellow LEDs ⇒ page 15 -6- and -3- light up.
AG. Volkswagen AG d
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Note by Vol not
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♦ A minimum load of 0.6 A (e.g. parking light) must be switched
auth
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on, otherwise support mode is not possible. ss c
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♦ During the support mode the current draw is limited to 5 A.
an
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– Switch on vehicle parking light.
ility
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– Exchange battery ⇒ page 31 .
h re
ole,
spec
– Switch off charging unit ⇒ page 15 .
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
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thi
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tions ⇒ page 2 !
iv
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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
♦ When a battery is being charged in the buffer mode and a

consumer draws current from the battery, the battery charger
-VAS 5095 A- automatically compensates the charge.
♦ The buffer mode can be continued for an unlimited period.
♦ The battery is always ready for use.
♦ Observe battery manufacture's maintenance instructions!

Jetta 2005 ➤ , Bora 2006 ➤
3.2 Battery charger -VAS 5900-
WARNING

tions ⇒ page 2 !
This chapter describes the basic functions of the battery charger

-VAS 5900- . For additional information refer to ⇒ Operating in‐
structions for battery charger -VAS 5900- .
Note
AG. Volkswagen AG d
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♦ Observe battery manufacture's handlingssinstructions!
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3.2.1 Description of battery charger -VAS
an
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5900-
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Battery charger -VAS 5900- is suitable for charging
h re
hole
spec
♦ Wet batteries (genuine VW batteries from 2004 with transpar‐
es, in part or in w
ent battery housing and black cover).
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
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3 - Adjustment button “Down” ↓

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4 - START / STOP
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3.2.2 Charging battery with battery charger -
yi Co
Cop py
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VAS 5900-
rig
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Vo
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Prote AG.
WARNING

tions ⇒ page 2 !
AG. Volkswagen AG d
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Jetta 2005 ➤ , Bora oris 2006 ➤ nte
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th
Electrical System
s au - Edition 05.2005 ra
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♦ Battery charger -VAS 5900-
an
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pe
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spec
es, in part or in w
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Note
com
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♦ If the battery has cell sealing plugs, do not open them while
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C py
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– Switch off the ignition and all electrical consumers. rig ht
py by
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– 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.
At a charge condition of approx. 80 - 85 % the charger unit

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

Jetta 2005 ➤ , Bora 2006 ➤
At a charge condition of 100 % all bars appear in display.
Note
♦ In the battery type “standard charge” the parallel use of con‐

sumers while charging is possible. The charging period will be
longer.
♦ The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100 % charge the battery should remain connected for this
period.
Possible faults and fault rectification:

1- Displayed battery voltage is not as per nominal voltage:
– Press respective button “Up” ↑ or “Down” ↓ until charging
sequence starts.
2- Displayed battery voltage is not as per nominal voltage –
charging sequence already started: en AG. V
olkswagen AG
ag does
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– Press START / STOP twice. Vol
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– Press respective button “Up” ↑ or or
“Down” ↓uthuntil charging eo
ra
sequence starts again. ss a c
ce
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un
3- Battery charger does not detect a battery, when battery volt‐
pt
an
d
age is less than 2 V:

itte
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Display remains unchanged.
ility
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The battery type and ampere hours (Ah) as set is displayed.
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
tive terminal on battery.
nform
– Pull charger unit plug out power supply socket.
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3.2.3 Charging battery in service mode with
ion in
r
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battery charger -VAS 5900-

thi
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WARNING
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Cop py
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Danger of injury! Observe warning notices and safety regula‐ yri
gh by
ht
tions ⇒ page 2 ! cop Vo
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cted agen
Prote AG.
Caution
The operating mode “service charge” is not permitted on VW

vehicles as the voltage peaks will damage the onboard elec‐
tronics.
If there is a requirement to use “service charge” the battery
must be disconnected from the onboard supply.
Jetta 2005 ➤ , Bora 2006 ➤
Caution
When charging always set the battery charger to the correct

type of battery ⇒ Operating instructions for battery charger -
VAS 5900- !
“Service charge” must only be used for:
♦ Wet batteries, where distilled water can be replenished.
♦ Gel/absorbent glass mat batteries.
Do not use operating mode “service charge” with maintenance-
free wet batteries ⇒ page 1 .
The operating mode “service charge (SERV)” is only used on

suspect defective batteries (e.g. sulphation). The battery will be
charged to maximum specific gravity and the plates will be reac‐
tivated (dissipation of sulphur layer).
cardiagn.com
AG. Volkswagen AG d
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nl
pt
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ab
ility
ot p
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Note
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Connect charger unit plug to power supply. The last selected

nform
ercia

m
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
batteries” will appear.

do
priv
cum
or

f
en
ng
t.
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Cop py
ht. rig
– Connect red terminal clamp “+” to positive terminal on battery. rig ht
py by
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– 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.

AG. Volkswagen AG d
agen oes Jetta 2005 ➤ , Bora 2006 ➤
olksw not
V
d by gu
ara Electrical System - Edition 05.2005
rise nte
tho eo
At a charge
ss au
condition of approx. 80 - 85 % the charger unit
ra
c
switches to the “final charge” mode. The fourth bar appears in
ce
e
nl
display -1-. The battery is ready for use.
pt
du
an
itte
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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
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
– Press START / STOP twice.

o
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or c
thi
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t
sd
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sequence starts.
o
r
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3- Battery charger does not detect a battery, when battery volt‐

t.
yi Co
age is less than 2 V:
Cop py
t. rig
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Display remains unchanged. p by
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cted agen
The operating mode and ampere hours (Ah) as set is displayed.
Prote AG.

– Press START / STOP .
ative terminal on battery.
3.2.4 Charging totally discharged battery with

WARNING

tions ⇒ page 2 !
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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Jetta 2005 ➤ , Bora 2006 ➤ horis nte
eo
Electrical System - Edition 05.2005 aut ra
ss c
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e
nl
pt
du
an
itte
Caution
y li
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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
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ion
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or
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Batteries with a voltage of less than 2 Volt will not be recognised

a
do
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automatically by battery charger -VAS 5900- .

p
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en
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op
cardiagn.com
C py
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rig ht
py by
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Prote AG.
Note



Jetta 2005 ➤ , Bora 2006 ➤

In the display the symbol -1- for “service charge for wet batteries”
or the symbol -2- for “service charge for gel/absorbent glass mat
batteries” will appear.
– Connect red terminal clamp “+” to positive terminal on battery.
– Connect black terminal clamp “-” to negative terminal on bat‐
tery.
– Press START / STOP for approx. 5 seconds. The menu
““charging totally discharged batteries/support mode” will be
activated.
– Press respective button “Up” ↑ or “Down” ↓ to set the respec‐
tive battery voltage (6 V, 12 V or 24 V).
Note
If a button is not pressed within 5 seconds the charger will return
cardiagn.com
to the main menu (select operating mode).
– Confirm the selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".
– Check polarity of charger unit cables.
– Confirm polarity of charger unit cables with START / STOP .
Charger will start charging sequence for totally discharged bat‐
tery.
gen AG
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d a oes
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– Press START /d bSTOP
yV . gu
ara
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ris
– Disconnect au
thoblack terminal clamp “-” of charger unit from eneg‐
or
ac
ative terminal
ss on battery.
ce
e
nl

pt
du
an
itte

y li
erm
ab

ility
ot p
wit
, is n
h re
3.2.5 Charging battery in support mode with

hole
spec

es, in part or in w
t to the co
WARNING
rrectness of i

l purpos
tions ⇒ page 2 !
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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o
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m
f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Jetta 2005 ➤ , Bora 2006 ➤
Caution
♦ The terminal polarity protection in operating mode “charg‐

ing totally discharged batteries/support mode” is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.
♦ When charging in support mode always set the battery
charger to the correct type of battery ⇒ Operating instruc‐
tions for battery charger -VAS 5900- !
♦ Do not press START / STOP button when charger unit
cables are connected incorrectly. The charger unit may be
damaged.
When in support mode the battery charger -VAS 5900- replaces

a defective vehicle battery whilst it is being
wage
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Volkswagen AGThe on‐
does
board supply remains intact. The yV
o vehicles electrical equipment
lks not
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(e.g. electric windows) canisebe
d used.
b ara
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Special tools and workshop
sa
ut equipment required or
ac
s
ce
le
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itte
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ility
ot p
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spec
t to the co
rrectness o
cial p
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nform
mer

atio
m

o
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c
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– Press START / STOP for approx. 5 seconds. The menu

te
sd
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““charging totally discharged batteries/support mode” will be

i
o
pr
cum
activated.
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– 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
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cted agen
Prote AG.
Note
If a button is not pressed within 5 seconds the charger will return

to the main menu (select operating mode).
– Confirm the selected battery voltage with START / STOP .

minal of vehicle.
Then follows the enquiry for "is charger cable terminal polarity
correct".
– Check polarity of charger unit cables.
– Confirm polarity of charger unit cables with START / STOP .

Jetta 2005 ➤ , Bora 2006 ➤
The battery charger starts with support mode.

– Exchange battery ⇒ page 31 .
– Press START / STOP . The support mode is terminated.
ative terminal of vehicle.
– Disconnect red terminal clamp “+” of charger unit from positive
3.2.6 Charging battery in maintenance mode

with battery charger -VAS 5900-
WARNING

tions ⇒ page 2 !
AG. Volkswagen AG d
agen oes
olksw not
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When the battery isisefully charged the battery charger -VAS ar5900-
cardiagn.com
d b
an
switches to maintenance
uthor
mode. tee
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– Proceed as for charging battery ⇒ page 19 .
s
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nl
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At a charge condition of 100 % all bars appear in display. an

itte
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erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ When a battery is being charged in the buffer mode and a

spec
consumer draws current from the battery, the battery charger

es, in part or in w
t to the co
-VAS 5900- automatically compensates the charge.

♦ The maintenance mode can be continued for an unlimited pe‐
riod.
rrectness of i
♦ The battery is always ready for use.

l purpos
♦ Observe battery manufacture's maintenance instructions!

nform
mercia
at
3.3 Totally discharged batteries

om
ion
c
in t
or
his
ate
WARNING
do
priv
cum
for
en
g

n
t.
yi Co
op
tions ⇒ page 2 ! C py
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rig ht
py by
co Vo
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cted agen
A battery is designated “totally discharged” when the "no load" Prote AG.
voltage is less than 12.2 V.
Caution
♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.
Jetta 2005 ➤ , Bora 2006 ➤
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
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♦ 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
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le
un
pt
an
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itte
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– Charge battery.
ility
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wit
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Charging battery with battery charger -VAS 5095 A- ⇒ page 15 .
h re
ole,
cardiagn.com
Charging battery with battery charger -VAS 5900- ⇒ page 19 .
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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fo
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t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
4 Disconnecting and reconnecting bat‐

teries
WARNING

tions ⇒ page 2 !
4.1 Disconnecting battery
Note
♦ By disconnecting the battery earth wire (open circuit), safety

is ensured when carrying out work on the electrical system.
♦ The battery positive wire need only be disconnected for re‐
moval of the battery.
cardiagn.com
– Release catch -arrow- and take cover off battery box.
– First unscrew battery earth clamp -1- from battery negative
terminal.
AG. Volkswagen AG d
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– Then
ss unscrew battery positive clamp -2- from batteryc positive
terminal.
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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
4.2 Connecting battery

nform
ercia
Caution
m
at
om
ion
c
in t
Observe instructions on connecting battery terminals

or
his
e
⇒ page 4 .
at
do
priv
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for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
4. Disconnecting and reconnecting batteries 29

Jetta 2005 ➤ , Bora 2006 ➤
♦ Torque wrench -V.A.G 1331-
Note
After connecting the battery and switching the ignition on the ESP
and TCS warning lamp -K155- lights up permanently. The warn‐
ing lamp goes out automatically if a distance of 15 to 20 km/h is
driven straight ahead. This activates the steering angle sender -
G85- again.
cardiagn.com
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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
tighten securing bolt to specified torque setting ⇒ page 36 .
wit
, is n
h re
– Fit battery earth clamp -1- to negative terminal of battery and
hole
tighten securing bolt to specified torque setting ⇒ page 36 . spec

es, in part or in w
t to the co
– Carry out the procedures as detailed in the table.
Steps after connecting battery
rrectness of i
Procedures Performed
l purpos
Switch ignition on and off again

using ignition key
nf
ercia
Read fault memory: ⇒ Guided

orm
fault finding using VAS 5051A .

m
atio
m
Clock: Check time on clock and

o
n in
or c
change as necessary.
thi
te
sd
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Electric windows: Open all

iv
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electric windows fully and close

o
m
f
en
ng
again.
t.
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op py
Functional check: of all electri‐ t. C rig
gh ht
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Jetta 2005 ➤ , Bora 2006 ➤
5 Removing and installing battery
WARNING

tions ⇒ page 2 !
5.1 Models with a petrol engine

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– Disconnect the battery ⇒ page 29 .

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– Unscrew securing bolt -1- and remove battery holder -2-.
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5. Removing and installing battery 31

Jetta 2005 ➤ , Bora 2006 ➤
– Fold handles -arrows- upwards and take battery out.

Installing:
Caution
A loosely fitted battery creates the following dangers:

♦ Shortened service life due to damage from vibration (dan‐
ger of explosion).
♦ The cells in the battery will be damaged if the battery is
not secured correctly.
♦ Damage to battery housing by. Vclamping bracket (possi‐
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– Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024A- .
– Pull the vacuum hose -arrow- off air filter housing.

Jetta 2005 ➤ , Bora 2006 ➤
– Unscrew air filter housing securing bolt -arrow-.
– Unlock lugs -arrows- and take cover off.
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– Pull panel of battery box out upwards in direction of arrow.
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Jetta 2005 ➤ , Bora 2006 ➤
– Unscrew securing bolt -1- and remove battery holder -2-.
AG. Volkswagen AG d
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Installing:
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A loosely fitted battery creates the following dangers:
♦ Shortened service life due to damage from vibration (dan‐
rrectness of i
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♦ The cells in the battery will be damaged if the battery is

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– After installing, check that battery is seated securely.
Caution


Jetta 2005 ➤ , Bora 2006 ➤ agen
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6 Torque settings: battery
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
7 Starter
Caution

7.1 Checking starter -B-

– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐
formation System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Body
♦ Electrical System
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AG. Volkswagen AG d
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7. Starter 37
Jetta 2005 ➤ , Bora 2006 ➤
7.2 Removing and installing starter, auto‐

matic gearbox
7.2.1 Vehicles with 1.6 l injection engine

equipment required
♦ Torque wrench -V.A.G
1331-
1332-
♦ Spring-type clip pliers -VAS
5024-
cardiagn.com
AG. Volkswagen AG d
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– Release hose -3- and pull it off the air filter housing.
ss o
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Rep. Gr.27 - Starter, current supply, CC
AG.
Jetta 2005 ➤ , Bora 2006 ➤
– Pull air filter housing on right side upwards off rubber mounting
-arrow-.
– Remove air filter housing from vehicle.
AG. Volkswagen AG d
agen oes
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– Push down protective cap orisin -direction of arrow- from solenoid
ed
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spec
t to the co
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– Unscrew positive wire -1- and disconnect connector from ter‐
minal 50 -2-.
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– Remove noise insulation ⇒ General Body Repairs, Exterior;
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Rep. Gr. 50 ; Body front; Noise insulation .
form
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– Unscrew securing nut -1- from lower starter securing bolt.
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– Remove wiring retainer -2-.
7. Starter 39
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
Electrical System - Edition 05.2005 lksw
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– Remove lower securing bolt of starter
horis -arrow-. nte
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– 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:
⇒ page 97 .
7.2.2 Vehicles with 1.6 l FSI engine


Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
♦ Torque wrench -V.A.G 1332- lksw
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du
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ility
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Removing:
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– Push down protective cap in -direction of arrow- from solenoid

switch.
nform
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c
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priv
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for
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minal 50 -2-.
7. Starter 41
Jetta 2005 ➤ , Bora 2006 ➤

– Remove lower securing bolt of starter -arrow-.
AG. Volkswagen AG d
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
to one side.
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Removing:
7. Starter 43
Jetta 2005 ➤ , Bora 2006 ➤
– Disconnect connector -arrow-.
– Unclip vacuum hose from its mounting -arrow-.
cardiagn.com
AG. Volkswagen AG d
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– Open retainer -arrow- on front side of air filter housing and take
form
mer
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t.
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Cop py
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rig ht
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
-arrow-.
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– Loosen spring-type clip -1- using spring typethoclip
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Prote AG.
7. Starter 45
Jetta 2005 ➤ , Bora 2006 ➤

switch.

minal 50 -2-. agen
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– Remove noise insulation ⇒ General Body Repairs, Exterior; d by V gu
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Cop py
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Jetta 2005 ➤ , Bora 2006 ➤

– Remove upper securing bolt of starter -arrow-. agen

AG. Volkswagen AG d
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⇒ page 97 .
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
7. Starter 47
Jetta 2005 ➤ , Bora 2006 ➤
7.2.4 Vehicles with 2,5 l injection engine

equipment required
1331-
1332-
AG. Volkswagen AG d
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♦ Spring-type clip pliers -VAS olksw
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
– Pull engine cover off upwards -arrows-.

Jetta 2005 ➤ , Bora 2006 ➤
– Separate connector -1-, release spring-type clip -2- with spring

type clip pliers -VAS 5024- and pull off vacuum hose -3-.
– Push down protective cap -direction of arrow- from solenoid

switch.
lkswage es n
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wit
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spec

t to the co
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cial p
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mer
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– Unscrew nut -1- from lower starter securing bolt.

c
i
or
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te

sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.
7. Starter 49
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
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aut ra
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ce
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nl
pt
du
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ility
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nf
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Installing: pyri by
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Installation is carried out in the reverse order. When installing, Prote AG.
note the following:
⇒ page 97 .

Jetta 2005 ➤ , Bora 2006 ➤
7.2.5 Vehicles with 1.9 l TDI engine

equipment required
1331- AG. Volkswagen AG d
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lksw not
♦ Torque wrench -V.A.G byV
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c
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priv
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for
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Removing:
-arrow B-.
7. Starter 51
Jetta 2005 ➤ , Bora 2006 ➤
spring type clip pliers -VAS 5024- .
lkswage es n
o ot g
byV ua
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ir se tee
o
cardiagn.com
th or
au ac
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nl
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du
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Vo
co lksw
by
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤

switch.
cardiagn.com
minal 50 -2-.
AG. Volkswagen AG d
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
7. Starter 53
Jetta 2005 ➤ , Bora 2006 ➤
– Unscrew nut -1- from upper starter securing bolt.

AG. Volkswagen AG d
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olksw not
V gu
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by ara
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Jetta 2005 ➤ , Bora 2006 ➤
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Jetta 2005 ➤ , Bora 2006 ➤

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Jetta 2005 ➤ , Bora 2006 ➤

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Jetta 2005 ➤ , Bora 2006 ➤
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Jetta 2005 ➤ , Bora 2006 ➤

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equipment required
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7. Starter 69
Jetta 2005 ➤ , Bora 2006 ➤
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Jetta 2005 ➤ , Bora 2006 ➤

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Jetta 2005 ➤ , Bora 2006 ➤

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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Starter 81
Jetta 2005 ➤ , Bora 2006 ➤


Installing:
note the following:
cardiagn.com
⇒ page 97 .
AG. Volkswagen AG d
agen oes
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nl
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c
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do
priv
cum
for
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
7.4.3 Vehicles with 2.0 l FSI turbo engine

equipment required
1331-
1332-
5024-
cardiagn.com
lkswage es n
o ot g
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tho
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du
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Removing:
rrectness of i

l purpos

nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Starter 83
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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un
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– Loosen spring-type clips -1- using spring type clip pliers -VAS
itte
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erm
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n
c
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sd
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pr
cum
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fo
en
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

switch.

Jetta 2005 ➤ , Bora 2006 ➤
– Unscrew positive wire -1- and disconnect connector from ter‐ AG. Volkswagen AG d
minal 50 -2-. lksw
agen oes
n o ot g
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tho or
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nl
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du
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ility
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spec
es, in part or in w
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nform
mercia
at
cardiagn.com
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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– 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
lksw
cted agen
Prote AG.

7. Starter 85
Jetta 2005 ➤ , Bora 2006 ➤

Installing:
note the following:
⇒ page 97 .
7.4.4 Vehicles with 2.5 l engine

equipment required
1331-
cardiagn.com
1332- AG. Volkswagen AG d
agen oes
olksw not
♦ Spring-type clip pliers -VAS d by V gu
ara
5024- orise nte
eo
th
au ra
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nl
pt
du
an
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nf
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:

Jetta 2005 ➤ , Bora 2006 ➤

cardiagn.com
AG. Volkswagen AG d
– Push down protective cap -direction of arrow-
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agen oes
not
switch. y Vol gu
db e
ara
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au ra
c
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nl
pt
du
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ab
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, is n
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spec
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t to the co

minal 50 -2-.
rrectness of i
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nf
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n in
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thi
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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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
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– Unscrew earth wire oris from starter securing bolt -arrow-. eo
th
au ra
c
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ce
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un
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d
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ab
pe
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spec
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t to the co
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
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do
cardiagn.com
r
rp
cum
fo
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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.

– Remove starter.
Installing:
note the following:
⇒ page 97 .

Jetta 2005 ➤ , Bora 2006 ➤

equipment required
1331-
1332-
5024-
cardiagn.com
AG. Volkswagen AG d
agen oes
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un
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ab
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spec
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Removing:
l purpos

nform
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-arrow B-.
m
a
com
tion in
r
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s
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do
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fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
7. Starter 89
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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cardiagn.com
ce
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nl
pt
du
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spec
es, in part or in w
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nform
mercia
at
om
ion
c
in t
or
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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.

Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
agen oes
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ara
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– Push
ss a down protective cap -direction of arrow- from solenoid
ra
c
switch.
ce
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un
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an
d
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ab
ility
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wit
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spec
cardiagn.com
t to the co
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ss o
minal 50 -2-.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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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 ➤

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
an
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ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
cardiagn.com
rrectness of i
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nform
ercia

m
at
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io
– Remove starter.
n
c
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e
Installing:
at
do
priv
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um
for
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note the following:
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t.
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op py
– Tighten threaded connections to specified torque settings t. C rig
gh ht
⇒ page 97 . pyri by
Vo
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by
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
7.4.6 Vehicles with 2.0 l SDI engine

equipment required
♦ Torque wrench -V.A.G AG. Volkswagen AG d
1331- lksw
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not
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♦ Torque wrench -V.A.G rised b ara
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pt
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nf
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Removing:
-arrow B-.
7. Starter 93
Jetta 2005 ➤ , Bora 2006 ➤
5024- and disconnect connector -2-.
– Pull vacuum hose off -arrow-.
cardiagn.com
AG. Volkswagen AG d
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du
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-arrow-.
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spec
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nform
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switch.
m
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c
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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.

Jetta 2005 ➤ , Bora 2006 ➤

minal 50 -2-.
lkswage es n
o ot g
byV ua
d ran
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an
d
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spec
cardiagn.com
t to the co
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o
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form
mer
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Starter 95
Jetta 2005 ➤ , Bora 2006 ➤

– Remove starter.
Installing:
note the following:
⇒ page 97 .
cardiagn.com
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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un
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d
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cial p
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mer
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n
c
i
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
8 Torque settings: starter

Starters on automatic, manual gearboxes M12 75 Nm
Starter on automated shift gearboxes M10 60 Nm
Earthing wire to starter securing bolt M8 15 Nm
Wiring retainer on starter securing bolt M8 15 Nm
Positive wire to starter solenoid switch M8 15 Nm
Air filter housing to body 10 Nm
Earthing wire to automatic gearbox M8 15 Nm
cardiagn.com
AG. Volkswagen AG d
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mer
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n
c
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8. Torque settings: starter 97

Jetta 2005 ➤ , Bora 2006 ➤
9 Alternator
Caution

9.1 Fastening B+ wire to alternator
Caution
If the B+ wire is not secured with the prescribed torque the

following may occur:
♦ Battery not charge fully.
♦ Vehicle electrics/electronics fail completely (breakdown). agen
AG. Volkswagen AG d
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V
♦ Danger of fires from sparks. by gu
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or
cardiagn.com
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♦ Damage to electronic components and control units due
aut
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ra
to excessive voltage. ss c
ce
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nl
pt
du
an
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– 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
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
9.2 Checking ribbed belt (poly V-belt)
at
om
ion
c
in t
r
– Crank engine at vibration damper/belt pulley using a socket.

o
his
ate
do
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– Fit ribbed belt (poly V-belt).

p
cum
for
en
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♦ Sub-surface cracks (cracks, core ruptures, cross sectional

n
t.
yi Co
breaks) Cop py
t. rig
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♦ Layer separation (top layer, draw strands) p by
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by c lksw
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♦ chassis breakout Prote AG.
♦ Fraying of cord strands

♦ Flank wear (material wear, frayed flanks, flank brittleness
(glassy flanks), surface cracks)
♦ Traces of oil and grease
Caution
It is essential to renew poly V-belt if faults are found. This will

avoid possible break-downs or operating problems.

Jetta 2005 ➤ , Bora 2006 ➤
Electrical
. Volkswage
System - Edition 05.2005
AG n AG d
agen oes
olksw not
9.3 Check alternator -C- ise
db
yV gu
ara
nte
r
tho eo
– Connect Vehicle Diagnosis, Testing and
s au Information System ra
c
-VAS 5051A- ⇒ page 281 . s
ce
e
nl
pt
du
Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐
an
itte
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formation System -VAS 5051A- .
erm
ab
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wit
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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
9.4 Alternator, 1.6 l injection engine
nf
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m
atio
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9.4.1 Assembly overview
or c
cardiagn.com
thi
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1 - Hexagon head collared bolt
o
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t.
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❑ M8x108
Co
Cop py
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❑ 23 Nm
rig
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pyri by
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co
2 - Hexagon head collared
by lksw
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Prote
bolts
AG.
❑ M8x50
❑ 23 Nm
3 - Bracket
4 - Hexagon head collared nut
❑ M8
bolts
❑ M8x45
❑ 52 Nm
6 - Protective cap
❑ M8
8 - Cross-head screw
❑ M5x21
❑ 4.5 Nm
9 - Hexagon nut, flat
❑ M8
10 - Plain washer
❑ M5
11 - Phillips screws
❑ M4x19
❑ 2 Nm
❑ M4x13
9. Alternator 99
Jetta 2005 ➤ , Bora 2006 ➤
❑ 2 Nm
13 - Voltage regulator
AG. Volkswagen AG d
❑ Removing and installing voltage regulator
ksw
agen ⇒ page 142 oes n
ol ot g
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14 - Alternator ed
b ran
oris tee
❑ Removing and installing
au
th alternator ⇒ page 100 or
ac
ss
15 - Poly V-belt
ce
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nl
pt
du
❑ Checking ⇒ page 98 .
an
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erm
ab
16 - Compact bracket
ility
ot p
❑ For alternator and air conditioner compressor
wit
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❑ Tightening sequence ⇒ page 145
hole
spec
17 - Tensioning element for poly V-belt
es, in part or in w
t to the co
❑ M8x90
rrectness of i
❑ 23 Nm
l purpos
9.4.2 Removing and installing alternator, 1.6 l
nform
ercia
cardiagn.com
injection engine
m
at
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ion
c
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Caution
at
do
priv
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or

f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co
by lksw
cted agen
Prote AG.
♦ Locking pin -T10060 A-
Removing:

Jetta 2005 ➤ , Bora 2006 ➤
– Disconnect connector of DF wiring -1- and pull protective cap

-2- off.
cardiagn.com
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
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erm
ab
ility
Mark top and direction of rotation of poly V-belt before remov‐
ot p
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wit
, is n
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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
– Release poly V-belt by turning the tensioning device with an

open-ended spanner AF 16 in -direction of arrow-.
nf
ercia
– Lock tensioning element with retaining pin -T10060 A- .

orm
m
atio
– Remove ribbed belt.
om
n in
or c
thi
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Vo
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by
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Prote AG.
9. Alternator 101
AG. Volkswagen AG d
agen oes
olksw not
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ara
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Jetta 2005 ➤ , Bora 2006 ➤ aut
h
ra
s c
Electrical System - Edition 05.2005 s
ce
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nl
pt
du
an
– Unclip coolant hose from hose retainer -1- and remove secur‐
itte
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erm
ing nut -2-.
ab
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hole
spec
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nf
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o
rm
m
atio
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– Take hose retainer together with tensioning element out of the o
n in
c
vehicle.
or
thi
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f
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ng
t.
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Cop py
ht. rig
cardiagn.com
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove alternator securing bolts -arrows-.
– Unscrew wiring bracket -arrow- from alternator.

– Remove alternator.
Installing:
note the following:
Caution
♦ When reinstalling used ribbed belts (poly V-belts) observe

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

Jetta 2005 ➤ , Bora 2006 ➤
swage es n
– Drive threadedbysleeves
Volk
-A- out of the alternator ot housing
gu
ara
for
approx. 4 mm ir se in -direction of arrow-.
d
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un
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– Position wiring bracket -arrow- on rear of generator at 3
rrectne
o'clock.
ss
⇒ page 145 .
o
cial p
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mer
Caution
atio
om
n
c
i
or
n
cardiagn.com
thi
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⇒ page 4 .
t
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t.
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Co
Cop py
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– Start the engine and check belt running.
ht
pyri by
Vo
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by
– Switch off the engine.
cted agen
Prote AG.
9.4.3 Ribbed belt routing, 1.6 l injection en‐

gine
Models with air conditioning system:
1- Tensioning roller
2- Ribbed belt pulley - Alternator
3- Ribbed belt pulley - Air conditioner compressor
4- Poly V-belt
5- Ribbed belt pulley - Crankshaft
9. Alternator 103
Jetta 2005 ➤ , Bora 2006 ➤
9.5 Alternator, 1.6 l FSI engine
1 - Hexagon bolt
❑ 40 Nm
2 - Washer
3 - Idler roller
4 - Washer
5 - Valve gear casing
❑ M8 AG. Volkswagen AG d
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7 - Cross-head screw d by
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❑ M5x21 hor eo
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❑ 4.5 Nm ss c
cardiagn.com
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❑ M8
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9 - Plain washer
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❑ 2 Nm
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voltage regulator
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⇒ page 142
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agen
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16 - Hexagon head collared bolts

❑ M8x90
❑ 23 Nm
17 - Hexagon head collared bolts
❑ M8x50
❑ 25 Nm
18 - Tensioning element
19 - Bracket
❑ For tensioning element and air conditioner compressor
❑ M10x50

Jetta 2005 ➤ , Bora 2006 ➤
❑ 20 Nm + 1/4 turn (90°) further
21 - Spacer sleeve

FSI engine
cardiagn.com
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9. Alternator 105
Jetta 2005 ➤ , Bora 2006 ➤
– Remove wiring bracket -1- and pullAGprotective

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agen

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

– Remove alternator from vehicle downwards.
Installing:
note the following:
Caution

♦ Ensure, before installing poly V-belt, that all ancillaries
(alternator, air conditioner compressor, power assisted
steering vane pump) are secured tightly.

Jetta 2005 ➤ , Bora 2006 ➤
– Drive threaded sleeves -A- out of the alternator housing for

approx. 4 mm in -direction of arrow-.

o'clock. en AG. V
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9.5.3 Ribbed belt routing, 1.6 l FSI engine
Models without air conditioning system:
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1- Ribbed belt (poly V-belt) pulley – Coolant pump
l purpos
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3- Ribbed belt (poly V-belt) pulley – Alternator

mercia
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5- Ribbed belt (poly V-belt) pulley - Crankshaft

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2- Idler roller
3- Ribbed belt (poly V-belt) pulley – Alternator
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 ➤
9.6 Alternator, 2.0 l FSI engine

bolts
❑ M8x90
❑ 23 Nm
bolts
❑ M8x50
❑ 23 Nm
3 - Transport bracket
4 - Tensioning element for poly
V-belt
5 - Compact bracket AG. Volkswagen AG d
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❑ M4x13
❑ 2 Nm
❑ Removing and installing voltage regulator ⇒ page 142
15 - Alternator
❑ Removing and installing alternator ⇒ page 109
16 - Poly V-belt

Jetta 2005 ➤ , Bora 2006 ➤
9.6.2 Removing and installing alternator, 2,0 l

FSI engine
Caution

Special tools and workshop AG. Volkswagen AG d

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equipment required by
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♦ Torque wrench -V.A.G hor eo
1331- aut ra
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♦ Locking pin -T10060- or

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c
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Removing:
9. Alternator 109
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
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clip pliers -VAS 5024 A- .

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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
hose -1- off.
AG. Volkswagen AG d
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es, in part or in w
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pyri by
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co lksw
by
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Prote AG.
5024 A- .
9. Alternator 111
Jetta 2005 ➤ , Bora 2006 ➤
– Separate connector -arrow- on rear of air filter housing.

– Remove upper intake manifold.

-2- off.
AG. Volkswagen AG d
agen oes
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– Unscrew B+ wiring -arrow- off alternator.
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belt damage!
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤

– Remove securing bolts of tensioning element -arrows-.

– Take tensioning element together with lifting eye -1- out of the
vehicle.
cardiagn.com
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– Unscrew wiring bracket -arrow- from alternator.

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9. Alternator 113
Jetta 2005 ➤ , Bora 2006 ➤


o'clock.
⇒ page 145 .
Caution
cardiagn.com
the direction of rotation marked on removal! wage
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♦ Ensure, before installing ribbed belt, that all ancillaries
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⇒ page 4 .
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3- Poly V-belt
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Jetta 2005 ➤ , Bora 2006 ➤
AG. VolkswageElectrical
n AG d System - Edition 05.2005
agen oes
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Models with air conditioning system: rised b ara
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4- Poly V-belt
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9.7 Alternator, 2.0 l FSI turbo engine
l purpos
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❑ M8x90 Prote
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agen
❑ 23 Nm
3 - Compact bracket
❑ For alternator and air
conditioner compressor
❑ Tightening sequence
⇒ page 146
bolts
❑ M10x45
❑ 45 Nm
5 - Protective cap
❑ M8
❑ M5x21
❑ 4.5 Nm
❑ M8
9 - Plain washer
❑ M5
❑ M4x19
❑ 2 Nm
❑ M4x13
❑ 2 Nm
9. Alternator 115
Jetta 2005 ➤ , Bora 2006 ➤
13 - Alternator
14 - Poly V-belt
15 - Tensioning element for poly V-belt

turbo FSI engine
Caution

cardiagn.com
equipment required
1331-
♦ Locking pin -T10060- or
locking pin -T10060 A-
5024 A-
AG. Volkswagen AG d
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Cop py
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pyri by
Vo
co lksw
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Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
Removing:
cardiagn.com
AG. Volkswagen AG d
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– Loosen spring-type clips -1- using spring type clip pliers -VAS s
ce
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 117
Jetta 2005 ➤ , Bora 2006 ➤
Note
♦ All hoses of the charge air system are secured with hose clips
or with quick release couplings. When using quick release
couplings the following points must be observed:
♦ Unlock connection by pulling the securing clamp -arrow-.
♦ Pull hose/tube off without assistance of tools.
– Disconnect quick release coupling -arrow-.
cardiagn.com
– Loosen spring-type clip -arrow- using spring type clip pliers -
VAS 5024 A- .
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– Take hose out of the vehicle.

t to the co
– Remove connecting pipe between charge air cooler and tur‐

bocharger.
rrectness of i
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Caution

nform
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at

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n
c
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
– Release poly V-belt by turning the tensioning element with an

open jaw spanner AF 16 in -direction of arrow- and lock ten‐ n AG. Volkswagen A
sioning element with retaining pin -T10060 A- . olks
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– Remove ribbed belt. db ara
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– 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
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Prote AG.

-2- off.
9. Alternator 119
Jetta 2005 ➤ , Bora 2006 ➤
AG. Volkswagen AG d
agen oes
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– Unscrew wiring bracket -arrow- from alternator. by Vol not
gu
d ara
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– Take alternator out of the vehicle. thor eo
au ra
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o'clock.

Jetta 2005 ➤ , Bora 2006 ➤
Note
♦ Fit hose/tube without assistance of tools. agen
AG. Volkswagen AG d
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– Tighten threaded connections to specified torque
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⇒ page 145 .
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9.7.3 Ribbed belt routing, 2.0 l turbo engine
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Cop py
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rig ht
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by lksw
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Prote AG.

4- Poly V-belt
9. Alternator 121
Jetta 2005 ➤ , Bora 2006 ➤
9.8 Alternator 2.5 l injection engine
1 - Compact bracket
wage
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Vol t gu
2 - Multi-point socket ed head bolt
by ara
M8x60 oris nte
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❑ 25 Nm au ra
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nl
3 - Multi-point socket head bolt
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M8x30
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es, in part or in w
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❑ Qty. 4
cardiagn.com
5 - Protective cap for alternator
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6 - Phillips screws
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❑ M4x20
❑ 2 Nm
nf
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7 - Protective cap for carbon

rm
m
brushes
atio
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voltage regulator
r
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⇒ page 142
f
en
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9 - Alternator C py
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❑ Removing and installing py by
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alternator ⇒ page 127
by c lksw
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Prote AG.
10 - Poly V-belt
bolts M8x90
❑ 25 Nm
❑ Qty. 2
9.8.2 Removing and installing alternator, 2.5l

engine
Caution

Removing:

Jetta 2005 ➤ , Bora 2006 ➤
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
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– Disconnect the battery ⇒ page 29 . aut ra
ss c
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– Take the engine cover off upwards and forwards.

un
pt
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d
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– Bring lock carrier into service position ⇒ General body repairs,
y li
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ab
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ility
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is n
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9. Alternator 123
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Caution
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l purpos
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Prote AG.
– Unscrew wiring bracket from alternator -arrow-.

– Take alternator out upwards.
Installing:
note the following:
Caution


approx. 4 mm in direction of arrow.

Jetta 2005 ➤ , Bora 2006 ➤
– Position wiring bracket -arrow- on rear of wgenerator

agen
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es, in part or in w
t to the co
rrectness of i
l purpos
9.8.3 Ribbed belt routing, 2.5l engine

nf
ercia
orm
1- Upper idler roller
m
atio
m
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o
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c
2- Belt pulley - Alternator

or
thi
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3- Lower idler roller

iv
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4- Poly V-belt for alternator and coolant pump
f
en
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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.
8- Tensioning roller for air conditioner compressor poly V-belt

9- Tensioning roller for alternator poly V-belt and coolant pump
10 - Belt pulley - Coolant pump
9. Alternator 125
Jetta 2005 ➤ , Bora 2006 ➤
9.9 Alternator, 1.9 l TDI engine

AG. Volkswagen AG d
agen oes
ksw
9.9.1 Assembly overview ol not
y V gu
d b ara
rise nte
tho eo
au ra
c
1 - Hexagon head collared ss
ce
le
bolts
un
pt
an
d
itte
❑ M8x45
y li
erm
ab
❑ 20 Nm
ility
ot p
wit
is n
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V-belt
ole,
spec
t to the co
bolts
❑ M8x90
rrectne
❑ 20 Nm
4 - Compact bracket
ss
o
cial p
f
in
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form
mer
❑ Tightening sequence
atio
⇒ page 148
om
n
c
i
or
n
thi
te
bolts
sd
iva
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pr
c
❑ M10x65
um
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❑ 40 Nm
t.
yi Co
Cop py
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6 - Hexagon head collared yri
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ht
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❑ 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
12 - Alternator
13 - Poly V-belt

Jetta 2005 ➤ , Bora 2006 ➤

TDI engine
Caution

Removing:
cardiagn.com
lkswage es n
o ot g
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du
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rrectness of i
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ion
c
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or
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ate
do
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for
en
ng
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yi Co
Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 127
Jetta 2005 ➤ , Bora 2006 ➤
Note
♦ Unlock connection by pulling the securing clamp -arrow-.
♦ Pull hose/tube off without assistance of tools.
– Disconnect connectors -1-.

– Unclip fuel hoses -2- and take charge air hose out.
AG. Volkswagen AG d
agen oes
olksw not
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byV gu
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ho eo
aut ra
ss c
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pt
du
an
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– Pull vacuum hose -1- off.
ab
ility
ot p
– Disconnect connector -2-.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Unbolt securing bolt -arrow-.

at
om
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c

in t
or
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e

at
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.

Jetta 2005 ➤ , Bora 2006 ➤
– Unscrew charge air pipe securing bolt -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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ce
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nl
pt
du
an
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ab
ility
ot p
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– 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
cardiagn.com
nf
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m
atio
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n in
or c
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r
rp
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

belt damage!
9. Alternator 129
Jetta 2005 ➤ , Bora 2006 ➤


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
le
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un
pt
an
d
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ility
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nform
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com
tion in
r
te o
thi
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iva
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– Unscrew wiring bracket from alternator -arrow-.

rp
cum
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en
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Cop py
t. rig
Installing: opyri
gh by
Vo
ht
c
by lksw
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Prote
note the following:
AG.
Caution


Jetta 2005 ➤ , Bora 2006 ➤


o'clock.
cardiagn.com
Note
♦ Fit hose/tube without assistance of tools.
G. Volkswage nA n AG d
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♦ Check for secure fit of they Vlugs
olks -arrow-. not
gu
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– Tighten threadedauconnections
th to specified torque settings ra
⇒ page 145 . ss c
ce
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Caution
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wit
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⇒ page 4 .
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es, in part or in w
t to the co

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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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9. Alternator 131
Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005 agen
AG. Volkswagen AG d
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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
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un
pt
an
d
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ab
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3- Poly V-belt
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4- Ribbed belt pulley - Crankshaft ole,
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4- Poly V-belt
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
9.10 Alternator, 2,0 l TDI engine

bolts
❑ M8x45
❑ 20 Nm
V-belt
bolts
❑ M8x90
❑ 20 Nm
4 - Compact bracket
cardiagn.com
❑ Tightening sequence agen
AG. Volkswagen AG d
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⇒ page 148 olksw not
V gu
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5 - Hexagon head collared horis nte
eo
bolts s aut ra
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s
❑ M10x65
ce
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nl
pt
du
❑ 40 Nm
an
itte
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erm
ab
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
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ercia

voltage regulator
m
at
om
⇒ page 142
ion
c
in t
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10 - Alternator
his
ate
do
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p
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11 - Poly V-belt
en
ng
t.
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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 ➤
Removing:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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es, in part or in w
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io

n
c
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or
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cum
for
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull vacuum hoses off -arrow-.

Jetta 2005 ➤ , Bora 2006 ➤
. Volkswage
AG n AG d
agen oes
olksw not
– Unbolt securing bolts -arrow-. db
yV gu
ara
rise nte
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s au ra
c
s
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nl
pt
du
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-2- off.
l purpos
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ion
c
in t
or
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his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
– Pull fuel filter off the retainer and place to side (fuel hoses re‐
main connected).
Caution

belt damage!

9. Alternator 135
Jetta 2005 ➤ , Bora 2006 ➤

cardiagn.com
– Unscrew wiring bracket s-arrow-
wage
n AGfrom
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wagen AG
does
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note the following:

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Caution
ot p
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ercia

m
at
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ion
c
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t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤

o'clock.
⇒ page 145 .
Caution

⇒ page 4 .

9.10.3 Ribbed belt routing, 2,0 l TDI engine

cardiagn.com
2- Ribbed belt pulley - Alternator n AG. Volkswagen AG do
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4- Poly V-belt
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9.11 Removing and installing ribbed belt

p
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for
(poly V-belt) pulley on alternator

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Cop py
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9.11.1 Removing and installing a ribbed belt
c by lksw
cted agen
Prote AG.
(poly V-belt) pulley with no freewheel
9. Alternator 137
Jetta 2005 ➤ , Bora 2006 ➤
♦ Socket -VAS 3310-
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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Removing: ss c
ce
e
nl
pt
du
– Take off alternator ⇒ page 98 .
an
itte
y li
erm
– Fit alternator in a vice on fitting points.
ab
ility
ot p
– Use socket -VAS 3310- to remove ribbed belt (poly V-belt)
wit
, is n
pulley securing nut from alternator shaft.
h re
hole
spec
Installing:
es, in part or in w
t to the co
rrectness of i
⇒ page 145 .
l purpos
nform
mercia
at
om
ion
c
in t
9.11.2 Removing and installing a ribbed belt

or
his
ate
(poly V-belt) pulley with freewheel, man‐

do
priv
cum
or
ufacturer: Bosch
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
♦ Adapter -VAS 3400-
cardiagn.com
Removing:
– 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
with a freewheel of the alternator with a ring spanner AF 17.

ot
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
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 ➤
– Insert a socket M10 -1- in the alternator shaft.

– Loosen threaded joint by turning to right and counter-hold with
ring spanner.
– Hold the ribbed belt (poly V-belt) pulley with a freewheel with
the hand and turn the drive shaft of the alternator until the rib‐
bed belt (poly V-belt) pulley with a freewheel can be taken off.
Installing:
note the following:
– At first screw the ribbed belt (poly V-belt) pulley with a free‐
wheel on the drive shaft of the alternator by hand to limit stop.
The torque wrench -V.A.G 1332- must be rearranged before in‐
stalling the ribbed belt (poly V-belt) pulley with a freewheel as
follows:
– Release socket -1- and pull off grip -2-. agen

AG. Volkswagen AG d
oes
cardiagn.com
olksw not
V
– Turn the torque wrench grip -2- through
ed by 180 degrees and re‐ gu
ara
insert socket drive. horis nte
eo
aut ra
– Set torque wrench directions of rotation on socket to left.
s c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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es, in part or in w
t to the co
– Insert a socket M10 -1- in the alternator shaft.

rrectness of i
– Counter-hold adapter -VAS 3400- with ring spanner, AF 17.

– Tighten the ribbed belt (poly V-belt) pulley with a freewheel by
l purpos
turning the alternator drive shaft to left using torque wrench -

V.A.G 1332- .
nf
ercia
or

m
m
atio
⇒ page 145 .
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
9.11.3 Removing and installing a ribbed belt (poly V-belt) pulley with freewheel,
manufacturer: Valeo
wage es n
Special tools and yV
olworkshop
ks ot g
ua
equipment isrequired
ed
b ran
or tee
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♦ Adapter
aut
-VAS 3400- or
ac
ss
ce
le
un
pt
1332-
an
d
itte
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erm
ab
♦ TORX key -V.A.G 1603/1-
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness
cardiagn.com
o
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f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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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 protective cap off ribbed belt (poly V-belt) pulley with
freewheel.
Note
The thread on the alternator shaft is a left-hand thread, i.e. turn

to right when loosening and to left when tightening the threaded
joint.
– Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley
with a freewheel of the alternator with a ring spanner AF 17.
9. Alternator 141
Jetta 2005 ➤ , Bora 2006 ➤
– Fit TORX key -V.A.G 1603/1- into alternator shaft.

– Loosen threaded joint by turning to right and counter-hold with
ring spanner.
– Hold the ribbed belt (poly V-belt) pulley with a freewheel with
the hand and turn the drive shaft of the alternator until the rib‐
bed belt (poly V-belt) pulley with a freewheel can be taken off.
Installing:
note the following:
– At first screw the ribbed belt (poly V-belt) pulley with a free‐
wheel on the drive shaft of the alternator by hand to limit stop.
The torque wrench -V.A.G 1332- must be rearranged before in‐
stalling the ribbed belt (poly V-belt) pulley with a freewheel as
follows:
– Release socket -1- and pull off grip -2-.
cardiagn.com
– Turn the torque wrench grip -2- through 180 degrees and re‐
insert socket drive.
– Set torque wrench direction of rotation on socket to left.
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
– Counter-hold adapter -VAS 3400- with ring spanner, AF 17.

itte
y li
erm
ab
– Tighten the ribbed belt (poly V-belt) pulley with a freewheel by

ility
ot p
turning the alternator drive shaft to left using torque wrench -

wit
, is n
V.A.G 1332- .
h re
hole
spec

es, in part or in w
⇒ page 145 .
t to the co
rrectness of i
l purpos
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orm
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atio
om
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9.12 Voltage regulator for alternator

o
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f
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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.

Jetta 2005 ➤ , Bora 2006 ➤
♦ Torque screwdriver -V.A.G 1624-
Removing:
– Remove securing bolt and nuts -arrows- and take protective
cap off alternator.
cardiagn.com
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
Install in reverse order of removal.

an
d
itte
y li

erm
ab
ility
⇒ page 145 .
ot p
wit
is n
h re
ole,
spec
t to the co
9.12.2 Removing and installing voltage regula‐

rrectne
tor, manufacturer: Valeo

ss

o
cial p
f inform
♦ Torque wrench -V.A.G 1783/-

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.
9. Alternator 143
Jetta 2005 ➤ , Bora 2006 ➤
Removing:
– Remove spring clips -arrows- and take protective cap off al‐
ternator.
– Remove securing bolts for voltage regulator -arrows-.

– Remove voltage regulator from alternator.
Installing:
cardiagn.com
note the following:
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

an
d
itte
⇒ 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
– Push protective cap into guides -arrows- until it audibly en‐

rrectness of i
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.

Jetta 2005 ➤ , Bora 2006 ➤
10 Torque settings: alternator
10.1 General torque settings for all vehicles

B+ wire to alternator M8 15 Nm
Cable holder to alternator M5 3,2 Nm
Voltage regulator to alternator M4 2 Nm
Protective cap to alternator M5 4.5 Nm
Poly V-belt pulley with freewheel to alternator M10 80 Nm
Poly V-belt pulley without freewheel to alternator M10 65 Nm
10.2 1.6 l injection engine and 2.0 l FSI en‐

gine
cardiagn.com
Caution
In order to avoid damage to cylinder block and compact brack‐

et, you must respect the tightening sequence for the compact
bracket.
10.2.1 Torque settings

AG. Volkswagen AG d
Alternator to compact M8 23 Nm lksw
agen oes
not
bracket by
Vo gu
ara
ed
nte
Tensioning element to com‐ M8x50 23 Nm horis
eo
pact bracket aut ra
ss c
Compact bracket to cylin‐ M10x45 52 Nm
ce
e
nl
pt
du
der block
an
itte
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erm
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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
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10. Torque settings: alternator 145

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– Tighten securing bolts of compact bracket in following se‐

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A - Hexagon head collared bolt, M10x45, 52 Nm, locating hole

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B - Hexagon head collared bolt, M10x45, 52 Nm
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Caution
In order to avoid damage to cylinder block and compact brack‐

et, you must respect the tightening sequence for the compact
bracket.

Alternator to compact M8x90 23 Nm
bracket
Tensioning element to com‐ M8x90 23 Nm
pact bracket
der block
Air conditioner compressor M8x100 23 Nm
to compact bracket

Jetta 2005 ➤ , Bora 2006 ➤
10.3.2 Tightening sequence for compact brack‐

et, models with air conditioning system
Procedure
Note
Before tightening to specified torque setting, screw in all bolts by

hand.

quence:
A - Cylinder collar screw, M10x45, 40 Nm, locating hole
B - Cylinder collar screw, M10x45, 40 Nm
C - Cylinder collar screw, M10x45, 40 Nm
cardiagn.com
D - Cylinder collar screw, M10x45, 40 Nm
E - Cylinder collar screw, M10x45, 40 Nm
F - Cylinder collar screw, M10x45, 40 Nm
10.4 1.9 l and 2.0 l TDI engine

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Tensioning element to compact bracket M8 20 Nm

Compact bracket to cylinder block M10 40 Nm
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10. Torque settings: alternator 147

Jetta 2005 ➤ , Bora 2006 ➤
10.4.2 Tightening sequence for compact brack‐

et
Procedure
Note
♦ Observe dowel sleeve between compact bracket and cylinder

block.
♦ Before tightening to specified torque setting, screw in all bolts
by hand.

quence:
A - Hexagon head collared bolt, M10x65, 40 Nm
B - Hexagon head collared bolt, M10x45, 40 Nm
cardiagn.com
C - Hexagon head collared bolt, M10x45, 40 Nm
D - Hexagon head collared bolt, M10x45, 40 Nm
E - Hexagon head collared bolt, M10x65, 40 Nm
F - Hexagon head collared bolt, M10x65, with dowel sleeves 40
Nm
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Alternator to compact M8x90 25 Nm ss
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Tensioning element to com‐ M8x50 23 Nm

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der block
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Note
♦ Observe dowel sleeve between compact bracket and cylinder

rrectness of i
block.
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served.
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Jetta 2005 ➤ , Bora 2006 ➤
11 Cruise control system (CCS)

General description:
The functions of the cruise control system are controlled by the
engine control unit.
There are no additional components, apart from the switch for
CCS -E45- , which is integrated into the “turn signal switch”.
– Removing and installing switch for CCS -E45- (“turn signal
switch”) ⇒ page 224 .
– You can activate and deactivate the cruise control system
⇒ page 149 .
Fault detection and fault display:
Faults on the CCS are output via the engine control unit.
For fault finding, use the vehicle diagnosis, testing and informa‐
tion system -VAS 5051A- in “guided fault finding” mode.
11.1 Activating and deactivating cruise Vol
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– Connect Vehicle Diagnosis, Testing and
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-VAS 5051A- ⇒ page 281 .
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– Select “guided fault finding” in Vehicle Diagnosis, Testing and
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Information System -VAS 5051A- .
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♦ 01 - On Board Diagnostic capable systems
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♦ Function
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♦ Activating and deactivating cruise control system

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11. Cruise control system (CCS) 149

27 - Starter, Current Supply, CC

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Service

Service Department. Technical Information

94 - Lights, lamps, switches - outside

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005820

1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Procedure when checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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

90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

6.2 Removing and installing tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

9.1 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.3 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

9.4 Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

10 Ignition switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

10.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

operated switch to block release of rear lid remote E232 . . . . . . . . . . . . . . . . . . . . . . . . . . 252

27 – Starter, current supply, CC

Danger of injury! Observe warning notices and safety regula‐

To prevent damage to the battery and vehicle, the following

1.1 Fundamentals for batteries

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

1.2 Types of battery AG. Volkswagen AG d

These batteries are recognised by the removable cell plugs.

topped-up with distilled water as required.

eye provides information concerning the level of the electrolyte

and the charge state of the battery.

1.2.2 Maintenance-free battery

Lead-acid battery, where electrolyte need not be topped-up with

1.2.3 Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte.

The battery is sealed and fitted with valves.

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

1.3 Warning notices and safety regulations

1.3.1 Dangers when handling vehicle batter‐

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

♦ Untrained personal e.g. apprentices, trainees etc. may

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

3. - Keep children away from acid and batteries.

4. - Disposal: old batteries are classed as hazardous waste. They

may only be disposed of through a suitable collection centre and

only in accordance with respective legislation.

6. - There is a danger of an explosion when working with batteries.

A highly explosive gas is produced when batteries are charged.

system" and in owner's manual.

8. - Battery acid is very caustic, therefore wear eye protection and

leak out of the gas vents of some batteries.

1.4 Battery terminal connection

To prevent damage to the battery terminal clamps and battery

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

Danger of injury! Observe warning notices and safety regula‐