97 - Wiring: 1 Vehicle Diagnosis, Testing and Infor Mation Systems

Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005
97 – Wiring
1 Vehicle Diagnosis, Testing and Infor‐
mation Systems
WARNING
♦ During testing or measuring operations using a vehicle di‐

agnosis information system, there is a risk of serious or
even fatal injury!
♦ If the vehicle diagnosis information system is lodged in the
activity area of an airbag during a testing or measuring
operation, a triggered airbag can result in serious or even
fatal injury! gen AG
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♦ During testing and measuring
db
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mation system fromautone
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♦ All working instructions described, such as modifications, cod‐
h re
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ing etc. can be carried out using the vehicle diagnosis, testing
spec
and information system -VAS 5051A- and the vehicle diagno‐
urposes, in part or in wh
sis and service information system -VAS 5052- .
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♦ All working instructions can be found in “guided fault finding”
and “guided functions”.
♦ Additional information: rrectness o
⇒ Self-study programme No. 202 ; Vehicle Diagnosis, Testing

cial p
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and Information System VAS 5051

form
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⇒ Self-study programme No. 256 ; VAS 5052

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⇒ Self-study programme No. 294 ; Online connection of the VAS

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– Connecting Vehicle Diagnosis, Testing and Information Sys‐

um
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tem -VAS 5051A- ⇒ page 281 .

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– Connecting vehicle Diagnosis, Testing and Information Sys‐
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1.1 Connecting vehicle Diagnosis, Testing
Prote AG.
and Information System -VAS 5051A-
Note
Observe the latest operating instructions for vehicle diagnosis,

testing and information system -VAS 5051A- , which are dis‐
played after selecting the “Administration” and “Operating Man‐
ual” buttons.
Special tools and workshop equipment required
1. Vehicle Diagnosis, Testing and Information Systems 281

Jetta 2005 ➤ , Bora 2006 ➤
♦ Vehicle Diagnosis, Testing and Information System -VAS

5051A-
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♦ Diagnosis lead -VAS 5051/6A- (5 m)
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♦ Diagnosis lead -VAS 5051/5A- (3 m)

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Only these leads are to be used for diagnosis, as they are the only Cop py
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and/or CAN communication.
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Connecting Vehicle Diagnosis, Testing and Information System -
VAS 5051A- :
– Apply handbrake.
– On vehicles with automatic gearbox, move selector lever to
position “P” or “N”.
– On vehicles with manual gearbox, move gear stick to neutral
position.
– With the ignition switched off, connect vehicle diagnosis, test‐
ing and information system -VAS 5051A- using diagnostic lead
-VAS 5051/6A- to diagnostic interface -arrow- in vehicle.
– Switch ignition on.
– Switch off all electrical consumers.
Note
Any additional vehicle diagnosis, measuring and information sys‐

tems and/or vehicle diagnosis and service information systems
are connected in the sequence described above.
282 Rep. Gr.97 - Wiring

Jetta 2005 ➤ , Bora 2006 ➤
2 Removing and installing fuse holder
2.1 Removing and installing fuse holder on

left of dash panel
♦ Removal wedge -VAS 3409-
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When removing and aut installing components in visual area (con‐ e or
h
ac
nectors, covers,sstrims etc.) apply a commercial adhesive tape
where a lever tool is applied ( removal wedge -VAS 3409- , srew‐
ce
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driver).
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Caution
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Disconnecting and connecting the battery as described in the

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Workshop Manual ⇒ page 29 .

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Removing:
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– Disconnect the battery ⇒ page 29 .

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– Remove storage compartment on driver side ⇒ General body

repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
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2. Removing and installing fuse holder 283

Jetta 2005 ➤ , Bora 2006 ➤
– Remove lateral cover -1- out of the dash panel, by inserting

the removal wedge -VAS 3409- or a screwdriver in the recess
-2- and lever off cover -1- in -direction of arrow-.
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– Take fuse assignment card -1- out of fuse holder -2-.
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– Remove securing bolts -arrows- and take fuse holder -1- out
or
as far it is possible (depending on cable length).
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Installing:
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Install in reverse order of removal.

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Jetta 2005 ➤ , Bora 2006 ➤
3 Removing and installing relay carrier
3.1 Removing and installing relay carrier

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Removing:
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– Unscrew bolts -arrows- of the bracket.
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– Pull relays -arrows- out of the relay carrier.
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Note
The relay number depends on vehicle equipment.
– Clip locking lugs in -direction of arrow- outwards and then

press the connector -1- through the relay carrier.
3. Removing and installing relay carrier 285

Jetta 2005 ➤ , Bora 2006 ➤
– Unlock locking lug -1- of relay carrier in -direction of arrow- and

take relay carrier off.
Installing:
Installation is performed in the reverse order of installation; when
doing this, note the following:
– Clip connectors into the relay carrier first.
– Fit relay carrier -2- into guide -1- and engage relay carrier.
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3.2 Removing and installing relay carrier on
onboard supply control unit, on left of
dash panel
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♦ The onboard supply control unit -J519- and the
aut relay carrier
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attached to the onboard supply control unit, on left of dash ss c
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panel form one unit and cannot be separated.

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♦ If the onboard supply control unit -J519- is to be replaced, first

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carry out the procedure

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⇒ “5.1.2 Coding onboard supply control unit J519 ”,

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page 293 to read out the stored codes.

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spec
Removing:
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– Switch off ignition and all electrical consumers and pull out
ignition key.
rrectness of i
– Remove cover, footwell, on driver side ⇒ General body re‐

pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
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Jetta 2005 ➤ , Bora 2006 ➤
– Move locking bar -1- of the relay carrier connectors on onboard

supply control unit, on left of dash panel in
-direction of arrow A-.
– Move locking bar -2- of the connectors of the on onboard sup‐
ply control unit -J519- in -direction of arrow B-.
Note
The connectors of the onboardAG. Volksupply

swagen control unit -J519- and the
relay carrier on onboardagensupply controlAunit, eson
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may only be pulled
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– Remove
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all connectors of the onboard supply
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J519- and the relay carrier on onboard supply control unit, on
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The connector number depends on vehicle equipment.
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– Unclip onboard supply control unit -J519- and relay carrier on
onboard supply control unit, on left of dash panel out of the
locking device -arrows C-.
– Pull onboard supply control unit -J519- and relay carrier on rrectness of i
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onboard supply control unit, on left of dash panel downwards

and in opposite direction of travel out of the bracket.
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Installing:
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The locking bars may only be set to “CLOSE” when all connectors
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3. Removing and installing relay carrier 287

Jetta 2005 ➤ , Bora 2006 ➤
4 Electronics boxes agen

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4.1 Removing and installing electronics box ho eo
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Removing:
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– Release clips -1- in -direction of arrow- and take cover of elec‐
tronics box -2- off upwards.
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– Remove hexagon nuts -1-.

– Open -arrows- covers -2- of cable guides on electronics box.
– Remove wiring from stud connections.
– Unclip wiring from cable guides.

Jetta 2005 ➤ , Bora 2006 ➤
– Remove central securing screw -arrow- from electronics box

-1-.
Note
When the central securing screw -arrow-, the electronics box -1-
is pushed upwards off the electronics box mounting.
– Pull electronics box -1- upwards off electronics box mounting.
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Note
For removal of the flat contact housing -1-, the air filter (on vehi‐
cles with diesel engine only), the battery and the battery console
must be removed.
– Remove air filter housing, if necessary.

– Remove battery ⇒ page 29 .
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– Remove securing bolts -arrows- of battery console -1-.

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– Take battery console -1- out of vehicle.

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4. Electronics boxes 289

Jetta 2005 ➤ , Bora 2006 ➤
– Press tabs apart on bracket of electronics box -arrows B- and

slide flat contact housing -1- sidewards -arrow A- out of brack‐
et of electronics box.
– Press tabs apart on bracket of electronics box -arrows C- and
slide flat contact housing -2- forwards -arrow D- out of bracket
of electronics box.
– Unscrew securing nuts -arrows- of bracket from electronics
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box -1-.
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Whether the additional relayaut carrier is installed depends on the
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– Pull bracket of electronics box -1-, upwards off studs as far as

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relay carrier cables allow.

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– Unclip relay carrier -1- sideways out of bracket of electronics

box -2-.
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– Take bracket of electronics box -2- out of vehicle.

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Installing:
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– Tighten threaded connections to specified torque settings

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⇒ page 307 .
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Jetta 2005 ➤ , Bora 2006 ➤
– Mount the cover -2- on the electronics box and push the safety
clip -1- in -direction of arrow- until cover -2- engages.
Note
Then check whether the cover -2- of the electronics box is en‐
gaged correctly.
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4. Electronics boxes 291

Jetta 2005 ➤ , Bora 2006 ➤
5 Control units
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5.1 Onboard supply control unit -J519- ised byV gu
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♦ The onboard supply control unit -J519- and the relay carrier
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attached to the onboard supply control unit, on left of dash
ility
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panel form one unit and cannot be separated.
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♦ Additional information:
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⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions
⇒ Operating instructions
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General description:
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The onboard supply control unit -J519- is responsible for the fol‐
o
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lowing in the vehicle:
inform
mer
♦ Electrical load management
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♦ Exterior light control
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♦ Turn signal control

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♦ Rear window wiper

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♦ Heated rear window . Cop py
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♦ Terminal control py by
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♦ Surround lighting
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♦ Terminal control
♦ Dimmers, instrument lighting
♦ Fuel pump presupply
♦ Alternator stand-by
♦ Horn
The following functions can be adapted:
♦ Deleting learning values and setting standard adaptation val‐
ues
♦ Adjusting period for coming home function (depending on
equipment)
♦ Adjusting period for leaving home function (depending on
equipment)
♦ Adjusting rear window heating “On time”
♦ Switching on and off footwell lighting
♦ Switching on and off motorway signaling
♦ Adjusting load management
♦ Adjusting “activation time” for headlight cleaning system
⇒ page 294

Jetta 2005 ➤ , Bora 2006 ➤
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♦ The above adaptations can only be carried out in conjunction
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with certain equipment configurations.
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♦ The “Motorway signaling”, “comfort signaling”, or “tap signal‐
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ing” means that one touch of the turn signal lever will activate
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the turn signals (1-5 times) (turn signal cycles).
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♦ If the onboard supply control unit -J519- is to be replaced, first
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⇒ “5.1.2 Coding onboard supply control unit J519 ”,
page 293 , so that access can be gained to the codes stored
within.
rrectne
Fault detection and fault display:
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The onboard supply control unit -J519- is equipped with self-di‐
o
cial p
f
agnosis, which is designed to ease fault finding.
inform
mer
For fault finding, use the vehicle diagnosis, testing and informa‐
atio
m
tion system -VAS 5051A- in “guided fault finding” mode.

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5.1.1 Removing and installing onboard supply
thi
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control unit -J519-

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If the onboard supply control unit -J519- is to be replaced, first
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⇒ “5.1.2 Coding onboard supply control unit J519 ”, page 293 ,
so that access can be gained to the codes stored within.
Removing:
The removal of the onboard supply control unit -J519- corre‐
sponds to the removal of the relay carrier on onboard supply
control unit, on left of dash panel ⇒ page 286 .
Installing:
The installation of the onboard supply control unit -J519- corre‐
sponds to the installation of the relay carrier on onboard supply
control unit, on left of dash panel ⇒ page 286 .
5.1.2 Coding onboard supply control unit -

J519-
– Connect Vehicle Diagnosis, Testing and Information System
-VAS 5051A- ⇒ page 281 .
– Select “guided fault finding” in Vehicle Diagnosis, Testing and
Information System -VAS 5051A- .
– Using the “Go to” key, select “Function/component selection”
and the following menu items one after the other:
♦ Body
♦ Electrical System
♦ 01 - On Board Diagnostic capable systems
♦ Onboard supply control unit
♦ Onboard supply control unit functions
♦ Code control unit
5. Control units 293

Jetta 2005 ➤ , Bora 2006 ➤
5.1.3 Modifying headlight cleaning system

The “active time” of the headlight cleaning system can be variably
adjusted to between 0 and 12.75 seconds.
– Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to ⇒ page 281
♦ Body
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♦ Onboard supplyriscontrol
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♦ Onboard supply
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♦ Modifying headlight cleaning system

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5.2 Data bus diagnostic interface -J533-

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Additional information: t to the co

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The diagnosis interface for data bus -J533- (gateway) is a sepa‐

m
rate control unit. It has the following functions in the vehicle:

a
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♦ Responsible for exchange of data between CAN data bus sys‐

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tems “drive train CAN data bus”, “convenience CAN data bus”
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and “Infotainment CAN data bus”

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♦ Converts diagnostic data from CAN data bus systems to COM

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wire and vice versa. In this way, data can also be used by the
Co
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Note
If the data bus diagnostic interface -J533- is to be removed, first

⇒ “5.2.1 Renewing data bus diagnostic interface J533 ”,
page 295 , so that access can be gained to the codes stored
within.

The data bus diagnostic interface -J533- is equipped with self-
diagnosis, which is designed to ease fault finding.

Jetta 2005 ➤ , Bora 2006 ➤
5.2.1 Renewing data bus diagnostic interface

-J533-
-VAS 5051A- ⇒ page 281 .
♦ Body
♦ Data bus diagnostic interface
♦ Data bus diagnostic interface functions
♦ Renewing data bus diagnostic interface
5.2.2 Removing and installing data bus diag‐
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nostic interface -J533-
Removing:
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Note
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Before removing
rised data bus diagnostic interface -J533-
ara
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sentialutthat the following work procedure
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⇒ “1.1
ss a Renewing dash panel insert”, page 150 is carried c out, so
that access can be gained to the codes stored within.
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ignition key.
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– Remove cover, footwell, on driver side ⇒ General body re‐

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pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

hole
spec
es, in part or in w
– Release connector -1- and pull connector off data bus diag‐
t to the co
nostic interface -J533- -2-.

– Push securing pins -3- together -arrows- and pull out of holes.
rrectness of i
Installing:
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Install in reverse order of removal.

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5.3 Central control unit for convenience sys‐

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op
tem -J393-
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Note
Additional information:

tions

Jetta 2005 ➤ , Bora 2006 ➤
The convenience system central control unit -J393- is responsible
for the following in the vehicle:
♦ Sliding/tilting sunroof control (release instruction)
♦ Power window control (release instruction)
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♦ Central locking control lksw
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♦ Anti-theft alarm system control rised b ara
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♦ Radio-wave receiver aut ra
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♦ Rear lid lock
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♦ Comfort operation
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Some of the above functions can be adapted ⇒ page 298 .
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The convenience system central control unit -J393- is equipped
with self-diagnosis, which is designed to ease fault finding.
t to the co
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5.3.1 Removing and installing convenience
s
system central control unit -J393-
s o
cial p
f inform
Removing:
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atio
om
n
ignition key.
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– Remove glove compartment ⇒ General body repairs, interior;
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o
r
Rep. Gr. 68 ; Compartments, covers and trim; Removing and

p
cum
r
fo
installing glove compartment .
en
ng
t.
yi Co
op
– Pull locking lug -1- off convenience system central control unit C py
ht. rig
-J393- bracket in -direction of arrow- and move the conven‐ rig ht
py by
ience system central control unit -J393- until the recesses
co Vo
by lksw
cted
-2- align with the recesses -3-.
agen
Prote AG.
Note
The connectors may only be unlocked and pulled off if the re‐
cesses -arrows- of the connectors and the bracket align exactly.
– Unlock connectors and pull them off convenience system cen‐

tral control unit -J393- .
Note
The connector number depends on vehicle equipment.

Jetta 2005 ➤ , Bora 2006 ➤
– Unscrew securing nuts -arrows-.

– Take bracket off with convenience system central control unit
-J393- .
Volkswagen AG
– Pull locking lug -1- in -direction of arrow B- and push conven‐ swagen AG. does
ience system central control unit -J393- -2- out of the bracketby
Vol
k not
gu
ara
in -direction of arrow A-. ris
ed
nte
ho eo
ut
Installing: ss
a ra
c
ce
Installation is performed in the reverse order of installation; when e
nl
pt
du
an
itte
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erm
ab
ility
cardiagn.com
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ After installing a new convenience system central control unit

it must be coded ⇒ page 297 .
nform
ercia
♦ The connectors may only be placed and locked if the recesses

m
-arrows- of the connectors and the bracket align exactly.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
5.3.2 Coding convenience system central
gh ht
pyri by
Vo
co
control unit -J393-
by lksw
cted agen
Prote AG.

-VAS 5051A- ⇒ page 281 .
♦ Body
♦ General Body Repairs
♦ Comfort system
♦ Comfort system central control unit functions
♦ J393 - Coding convenience system central control unit

Jetta 2005 ➤ , Bora 2006 ➤
5.3.3 Adapting convenience system central

control unit -J393-
The following functions can be adapted:
♦ Activating and deactivating “single door opening”
♦ Activating and deactivating “automatic locking above >15 Km/
h”
♦ Activating and deactivating “automatic unlocking when ignition
key is removed”
♦ Activating and deactivating “country settings for intelligent
alarm horn”
♦ Activating and deactivating “battery monitoring system (soun‐
der)” AG. Volkswagen AG d
agen oes
lksw not
♦ Activating and deactivating “comfort operation via radio re‐by V o gu
ara
mote control unit” rised
nte
ho eo
ut
♦ Activating and deactivating “anti-theft alarm system
ss a - alarm ra
c
delay when driver's door is opened”
ce
le
un
pt
an
d
♦ “Sensitivity of tilt angle sensor”
cardiagn.com
itte
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erm
ab
♦ “Sensitivity of interior monitoring system”
ility
ot p
wit
is n
h re
-VAS 5051A- ⇒ page 281 .
ole,
spec
t to the co
rrectne
♦ Body
ss o
cial p
f inform
mer
atio
m
♦ Comfort system
o
n
c
i
or
n
thi
te
sd
iva
♦ J393 - Adapting convenience system central control unit o

pr
cum
r
fo
en
ng
5.3.4 Convenience system central control unit

t.
yi Co
op py
-J393- - Read alarm sources of anti-theft
t. C rig
gh ht
pyri by
alarm system
o Vo
by c lksw
cted agen
Prote AG.
-VAS 5051A- ⇒ page 281 .
♦ Body
♦ Comfort system
♦ J393 - Read alarm sources of anti-theft alarm system

Jetta 2005 ➤ , Bora 2006 ➤
5.4 Trailer detector control unit -J345-

The trailer detector control unit -J345- -arrow- is located behind
the left side trim in the luggage compartment.
Note
Additional information:

tions
Note
♦ The Golf currently features only control units manufactured by

Westfalia.
♦ To check the control unit use plug socket tester -V.A.G 1537/
cardiagn.com
. Volkswagen AG
gen AG
A- olks
wa does
not
⇒ “5.4.3 Final control diagnosis trailer detector controleunit
db
yV gu
ara
J345 ”, page 301 . tho
ris nte
eo
au ra
c
ss
The trailer detector control unit -J345- etects from a power draw
ce
e
nl
pt
of minimum 5 W4) the “trailer operation” and transfers this infor‐
du
an
itte
mation to various control units via the CAN databus.
y li
erm
ab
ility
The trailer detector control unit -J345- is supplied with information
ot p
wit
(light control) from the onboard supply control unit -J519- and
, is n
h re
convenience system central control unit -J393- via the CAN.
hole
spec
4) At least the turn signal and brake light must be switched on, in order to detect
es, in part or in w
“trailer operation”.
t to the co
The trailer detector control unit -J345- is equipped with self-diag‐
rrectness of i
nosis, which is designed to ease fault finding.
l purpos
nform
mercia
5.4.1 Removing and installing trailer detector at

om
ion
control unit -J345-

c
in t
or
his
ate
do
riv

p
cum
for
♦ Torque wrench -V.A.G 1783-

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 ➤
Removing:
ignition key.
– Remove left side panel trim in luggage compartment ⇒ Gen‐
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐
ling load and luggage compartment trim; Trim, luggage
compartment, sidewards .
– Release connectors -2- and pull off trailer detector control unit
-J345- .
Note
The connector number on the trailer detector control unit -J345-

shown in the figure depends on vehicle equipment and may vary.
– Remove securing bolts -1- and take trailer detector control unit
-J345- with the bracket out of the vehicle.
cardiagn.com
– Remove securing bolts -arrows- and take trailer detector con‐
trol unit -J345- off bracket.
Installing:
doing this, note the following: . Volkswag AG en AG
w agen does
– Tighten threaded connections to specified
yV
olks torque settings not
gu
⇒ page 307 . ise
d b ara
nte
r
ho eo
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
After installing a new trailer detector control unit -J345- it must be

erm
ab
coded ⇒ page 300 .

ility
ot p
wit
, is n
h re
hole
5.4.2 Coding trailer detector control unit -

spec
es, in part or in w
J345-
t to the co

-VAS 5051A- ⇒ page 281 .
rrectness of i

l purpos

nf
ercia

rm
m
atio
m
♦ Body
o
n in
or c

thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
♦ Trailer detector
t.
yi Co
Cop py
♦ Function
t. rig
gh ht
pyri by
Vo
o
♦ Coding trailer detector control unit
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes Jetta 2005 ➤ , Bora 2006 ➤
olksw not
V
ed by gu
ara Electrical System - Edition 05.2005
ris nte
tho e or
5.4.3 Final control diagnosis trailer detector
ss
au ac
ce
le
control unit -J345-
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
♦ The trailer detector control unit -J345- detects from a power
hole
spec
draw of minimum 5 W 4) the “trailer operation”.
es, in part or in w
t to the co
♦ To check use plug socket tester -V.A.G 1537/A- .
rrectness of i
♦ Plug socket tester -V.A.G 1537/A- 5)
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
cardiagn.com
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5) After a few minutes the plug socket tester -V.A.G 1537/A- gets to hot and
switches off automatically. After a cooling period the plug socket tester -V.A.G
1537/A- works again perfectly.
– Connect the plug socket tester -V.A.G 1537/A- .

-VAS 5051A- ⇒ page 281 .
♦ Body
♦ Trailer detector
♦ Function
♦ Trailer detector control unit - Final control diagnosis

Jetta 2005 ➤ , Bora 2006 ➤
6 Wiring harness and connector re‐

pairs
6.1 Safety instructions
Caution
For repair work on airbag and seat belt tensioner wiring har‐
nesses, only contacts, connectors and wiring designed specif‐
ically for this purpose may be used ⇒ Parts catalogue (ETKA)!
♦ Observe country-specific regulations.

♦ Observe vehicle stickers indicating high voltage components.
Before carrying out repairs, discharge residual voltage.
♦ Wires from airbag and belt tensioner wiring harness must only
be repaired using wiring harness repair set -V.A.Gw1978-
agen .
AG. Volkswagen AG d
oe
olks s no
cardiagn.com
t gu
⇒ Operating instructions wiring harness repair
ed
bset
y V -V.A.G 1978- ara
is nte
or
⇒ General body repairs interior; Rep. Gr.
au 69
th eo
ra
ss c
6.2 General notes concerning repairs to ve‐
ce
e
nl
pt
du
an
hicle electrical system
itte
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erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Observe current notes (also notes concerning removing and
rrectness of i
installing components) in workshop manuals and in the Tech‐
nical Service Handbook.
l purpos
♦ Yellow wiring and sections of wiring harness wrapped in yellow

nform
tape indicate a prior repair.

mercia
⇒ Operating instructions wiring harness repair set -V.A.G 1978-

at
om
ion
c
♦ Before beginning repairs to a wiring harness, first rectify the

in t
or
his
cause of the damage, e.g. sharp edges on a body part, de‐

ate
do
riv
fective electrical consumer, corrosion.

p
cum
for
♦ Disconnecting the battery earth strap (open circuit) provides a

en
ng
t.
yi
safe working environment for repairs to the electrical system.
Co
Cop py
The battery positive wire need only be disconnected for re‐ ht. rig
rig ht
moval of the battery.
py by
co Vo
by lksw
cted agen
♦ If possible, do not loosen any earth wires from the body (dan‐
Prote AG.
ger of corrosion).
6.3 Notes on repairs to wiring harness and

connectors
Supplementary notes on repair of CAN bus wiring ⇒ page 303
♦ Soldering is not permitted for repairs to vehicle wiring.
♦ Never repair any heat-shrink connections. If necessary, lay
wiring parallel to the defective wiring.
♦ Onboard supply wiring harnesses and connectors may only
be repaired using wiring harness repair set -V.A.G 1978- .

Jetta 2005 ➤ , Bora 2006 ➤
⇒ Operating instructions wiring harness repair set -V.A.G 1978-

. Volkswagen AG
a gen AG d
♦ Perform wiring harness repairs Vol only with yellow wires. Mark
ksw
oes
not
gu
repair locations with yellow
ed b tape.
y ara
n is tee
or
♦ Shielded wires mustautnot
h
be repaired. In case of damage, they or
ac
must be entirely replaced.
ss
ce
e
nl
pt
du
6.4 Supplementary notes on repair of CAN
an
itte
y li
bus wiring
erm
ab
ility
ot p
wit
♦ An unshielded two-wire line -1- and -2- with a cross section of
, is n
h re
0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
hole
spec
♦ The colour codes of the CAN bus wiring can be gleaned from
es, in part or in w
t to the co
the following table:
Drivetrain CAN, high orange/black
rrectness of i
Convenience CAN, high orange/green
l purpos
Infotainment CAN, high orange/violet

CAN Low wire (all) orange/brown
nf
ercia
or
♦ Perform wiring harness repairs only with yellow wires. Mark
m
m
cardiagn.com
atio
repair locations with yellow tape.
om
n in
or c
♦ When repairs are performed, both bus wires must have the
thi
te
same length. When wires -1- and -2- are twisted together, the
sd
iva
o
twist spacing should be A=20 mm.
r
rp
cu
o
m
f
en
ng
♦ No section of wiring greater than B=50 mm, e.g. in the vicinity

t.
yi Co
op
of heat-shrink sleeves -arrow-, should not be twisted. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Wiring harness and connector repairs 303

Jetta 2005 ➤ , Bora 2006 ➤
6.5 Wiring harness repair set -V.A.G 1978-
- Repairs to wiring harnesses

and connectors of the onboard
electrical supply system
should only be carried out us‐
ing wiring harness repair set -
V.A.G 1978- .
- Included with the wiring har‐
ness repair set -V.A.G 1978- is
a set of operating instructions,
which provides comprehen‐
sive information on how to con‐
duct repairs.
- Further information, e.g. re‐
moval and installation of parts
and components, appears in
the relevant workshop manual.
cardiagn.com
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Jetta 2005 ➤ , Bora 2006 ➤
olkswagen AG
en AG. V
7 Renewal
yV
olks
wag of aerial wiring
does
not
gu
b ara
ed
A new repair
ho
ris concept has been developed for repairnte
work
eo on aer‐
ial wires.
s aut Now connecting wires in different lengths and r a various
c
adapter
s cables are available as replacement parts instead of a
ce
e
complete aerial wire.

nl
pt
du
an
itte
y li
7.1 General description
erm
ab
ility
ot p
♦ Aerial wires must not be repaired, but if repair is required, they
wit
, is n
must be replaced only by connecting wires and adapter cables
h re
hole
offered as genuine parts.
spec
es, in part or in w
♦ Replacement parts can be found in the electronic parts cata‐
t to the co
logue: Special catalogue; Electrical connections; Genuine ac‐
cessories; Subgroup 35 from illustration No. 035-20.
rrectness of i
♦ These genuine parts are suitable for all aerial wires and wire
diameters which may need to be replaced.
l purpos
♦ No provision has been made for replacement of individual

aerial connectors in the event of repair.
nf
ercia
orm
♦ The wires can be used retroactively for all VW models, with all
m
atio
m
cardiagn.com
installed aerial wire diameters.
o
n in
or c
♦ All adapter and connection wires are suitable for all transmitter thi
te
sd
a
and receiver signals.

iv
o
r
rp
cu
o
♦ This repair method can also be used for testing or retrofitting.

f
en
ng
t.
yi Co
op
7.2 Assembly overview - an aerial wire
C py
ht. rig
rig ht
py by
o Vo
Example: Aerial wire between radio and aerial is defective. The
by c lksw
cted agen
following wires are required for the repair:
Prote AG.
1- Adapter cable, to radio connection. Length approx. 30 cm.

2- Connecting wire, available in different lengths.
3- Adapter cable, to aerial connection. Length approx. 30 cm.
7.3 Installing a new aerial wire
Note
Note that the total length of an aerial wire, depending on vehicle

equipment level, can be divided into sections by aerial diversity
control unit, traffic information control unit or aerial amplifier. Only
the defective section of aerial wire must be replaced.
– Pull defective aerial wire connections off units.

– Determine the routing of the defective aerial wire in vehicle
and measure the total length of the aerial connecting wire to
be replaced.
7. Renewal of aerial wiring 305

Jetta 2005 ➤ , Bora 2006 ➤
The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-.
– To determine the length of connecting wire required, subtract
60 cm from the measured total length of aerial connecting wire
-2-. n AG. Volkswagen A ge G do
swa es n
– Procure the required adapter cables -1- and -3- band y V connect‐
olk ot g
ua
ing wire -2- at the calculated length as genuine
ris
edparts from the ran
tee
parts catalogue (ETKA). ut
ho or
a ac
ss
– Cut off connectors of defective aerial wire.
ce
le
un
pt
an
The remainder of the defective aerial wire remains in the vehicle. d
itte
y li
erm
ab
– Connect adapter cables -1- and -3- to equipment in vehicle.
ility
ot p
wit
– Route and secure connecting wire -2- parallel to the old aerial
is n
h re
wire.
ole,
spec
t to the co
Note
Do not kink or excessively bend aerial wires! The bending radius
rrectne
cardiagn.com
must not be below 50 mm.
ss
– Connect connecting wire to adapter cables.
o
cial p
f inform
– Perform a functional check.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

8.1 Torque settings: Electronics box in left
side of engine compartment
Threaded connections Torque settings

Securing nuts -1- M5 (AF 8) 4 Nm
Securing nuts -1- M6 (AF 10) 6 Nm
cardiagn.com
8.2 Torque settings trailer detector control unit -J345-
Threaded connections Torque settings
Securing bolts bracket to body 2 Nm
Securing bolts control unit to bracket 2 Nm
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8. Torque settings: Cables 307

97 - Wiring: 1 Vehicle Diagnosis, Testing and Infor Mation Systems

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97 - Wiring: 1 Vehicle Diagnosis, Testing and Infor Mation Systems

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Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

♦ During testing or measuring operations using a vehicle di‐

♦ All working instructions described, such as modifications, cod‐

sis and service information system -VAS 5052- .

⇒ Self-study programme No. 202 ; Vehicle Diagnosis, Testing

and Information System VAS 5051

⇒ Self-study programme No. 256 ; VAS 5052

⇒ Self-study programme No. 294 ; Online connection of the VAS

– Connecting Vehicle Diagnosis, Testing and Information Sys‐

tem -VAS 5051A- ⇒ page 281 .

and Information System -VAS 5051A-

Observe the latest operating instructions for vehicle diagnosis,

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information Systems 281

♦ Vehicle Diagnosis, Testing and Information System -VAS

♦ Diagnosis lead -VAS 5051/5A- (3 m)

Any additional vehicle diagnosis, measuring and information sys‐

282 Rep. Gr.97 - Wiring

2 Removing and installing fuse holder

2.1 Removing and installing fuse holder on

Disconnecting and connecting the battery as described in the

Workshop Manual ⇒ page 29 .

– Disconnect the battery ⇒ page 29 .

– Remove storage compartment on driver side ⇒ General body

2. Removing and installing fuse holder 283

– Remove lateral cover -1- out of the dash panel, by inserting

– Take fuse assignment card -1- out of fuse holder -2-.

Install in reverse order of removal.

284 Rep. Gr.97 - Wiring

3 Removing and installing relay carrier

3.1 Removing and installing relay carrier

Disconnecting and connecting the battery as described in the

Workshop Manual ⇒ page 29 .

The relay number depends on vehicle equipment.

– Clip locking lugs in -direction of arrow- outwards and then

3. Removing and installing relay carrier 285

– Unlock locking lug -1- of relay carrier in -direction of arrow- and

panel form one unit and cannot be separated.

♦ If the onboard supply control unit -J519- is to be replaced, first

carry out the procedure

⇒ “5.1.2 Coding onboard supply control unit J519 ”,

page 293 to read out the stored codes.

– Remove cover, footwell, on driver side ⇒ General body re‐

– Remove storage compartment on driver side ⇒ General body

286 Rep. Gr.97 - Wiring

– Move locking bar -1- of the relay carrier connectors on onboard

The connectors of the onboardAG. Volksupply

left of dash panel.

onboard supply control unit, on left of dash panel downwards

Installation is performed in the reverse order of installation; when

doing this, note the following:

3. Removing and installing relay carrier 287

4 Electronics boxes agen

– Remove hexagon nuts -1-.

288 Rep. Gr.97 - Wiring

– Remove central securing screw -arrow- from electronics box

– Pull electronics box -1- upwards off electronics box mounting.

– Remove air filter housing, if necessary.

– Remove securing bolts -arrows- of battery console -1-.

– Take battery console -1- out of vehicle.

4. Electronics boxes 289

– Press tabs apart on bracket of electronics box -arrows B- and