Page 1 Service Workshop Manual Jetta 2005 ➤ Bora 2006 ➤ Electrical System Edition 05.2005 Service Department. Technical Information...
Page 2 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...
Page 3: Table Of Contents
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Contents 27 - Starter, current supply, CC ......... .
Page 4 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 11.1 Activating and deactivating cruise control system ....... . 149 90 - Instruments, GCI .
Page 5 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing gas discharge light control unit ......198 Headlight range control unit J431 .
Page 6 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing glove compartment light switch E26 ..... . 242 Removing and installing switches and instruments illumination regulator E20 .
Page 7 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing relay carrier with safety cut-out on left of dash panel ..285 Removing and installing relay carrier on onboard supply control unit, on left of dash panel .
Page 8: Jetta 2005 ➤ , Bora
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Contents...
Page 9: Starter, Current Supply, Cc
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 27 – Starter, current supply, CC 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 10: Warning Notices And Safety Regulations
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 These batteries are often equipped with a magic eye. The magic eye provides information concerning the level of the electrolyte and the charge state of the battery. 1.2.3 Absorbent glass mat (AGM) battery Maintenance-free battery with a contained electrolyte.
Page 11 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 WARNING ♦ Untrained personal e.g. apprentices, trainees etc. may only work on batteries when supervised by a vehicle me‐ chanic/foreman or vehicle electrician/foreman. ♦ Acid is highly corrosive. There is a considerable danger of acid burns if personal do not handle batteries correctly.
Page 12: Battery Terminal Connection
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 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.
Page 13: Checking Battery
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Checking battery WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 Caution To prevent damage to the battery and vehicle, the following should be observed concerning types of battery ⇒...
Page 14: Checking Battery With Magic Eye
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 en the clamps to the torque specified in this workshop manual. If the clamps are not correctly seated and tightened, the wiring could burn, which could result in electrical system malfunc‐...
Page 15: Checking Low Maintenance Battery
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Checking low maintenance battery WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 This battery is “low maintenance” this means the electrolyte level must be checked and occasionally topped-up with distilled water as required.
Page 16 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Battery filler bottle -VAS 5045/- Caution ♦ When filling up with undistilled water or electrolyte the bat‐ tery will be damaged. Top up with distilled water only.
Page 17 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Commercially available hydrometer – Check the electrolyte level of the battery ⇒ page 7 – Switch off the ignition and all electrical consumers. – If fitted, remove the protective foil on the cell sealing plug.
Page 18: Check No Load Voltage Of Battery
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Check no load voltage of battery WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 The no load voltage test is used to determine the capacity of the battery.
Page 19: Battery Tester With Printer Vas 5097 A
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Measured value Measure to be performed No load voltage ≥ 12.5 V No load voltage is OK, perform a battery load test ⇒ page 10 No load voltage < 12.5 V Charge battery ⇒...
Page 20 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 2.6.1 Description of battery tester with printer -VAS 5097 A- Battery tester with printer -VAS 5097 A- 1 - Green LED, “unit operating” 2 - Red LED, “unit reverse-polarity connected”...
Page 21 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Connect black terminal “-” of unit to negative terminal. Note Ensure test clamps have a good contact! – Select point of connection of test terminals with selection switch ⇒...
Page 22: Evaluating Test Result
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Low-temperature test current in A EN/ SAE ⇒ 802 - 819 545 - 554 ⇒ 470 - 479 820 - 837 555 - 564 ⇒ 480 - 489...
Page 23: Charging Battery
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Charging 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 24 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 3.1.2 Charging battery with battery charger - VAS 5095 A- WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 Special tools and workshop equipment required ♦...
Page 25 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 3.1.3 Charging totally discharged battery with battery charger -VAS 5095 A- WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 The charger unit automatically recognises totally discharged bat‐...
Page 26 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Switch off the ignition and all electrical consumers. – Set support mode/normal mode change-over switch to ⇒ page 15 “support mode”. – Connect red terminal clamp “+” of charger unit to positive ter‐...
Page 27: Battery Charger Vas 5900
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Battery charger -VAS 5900- WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 This chapter describes the basic functions of the battery charger -VAS 5900- .
Page 28 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Battery charger -VAS 5900- Note The battery must have a temperature of at least 10 °C. ♦ If the battery has cell sealing plugs, do not open them while ♦...
Page 29 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 At a charge condition of 100 % all bars appear in display. Note In the battery type “standard charge” the parallel use of con‐ ♦ sumers while charging is possible. The charging period will be longer.
Page 30 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Caution When charging always set the battery charger to the correct type of battery ⇒ Operating instructions for battery charger - VAS 5900- ! “Service charge” must only be used for: ♦...
Page 31 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 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.
Page 32 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Caution ♦ The terminal polarity protection in operating mode “charg‐ ing totally discharged batteries/support mode” is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals.
Page 33 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Set battery to respective operating mode with INFO In the display the symbol -1- for “service charge for wet batteries” or the symbol -2- for “service charge for gel/absorbent glass mat batteries”...
Page 34 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Caution ♦ The terminal polarity protection in operating mode “charg‐ ing totally discharged batteries/support mode” is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals.
Page 35: Totally Discharged Batteries
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 The battery charger starts with support mode. – Exchange battery ⇒ page 31 – Press . The support mode is terminated. START / STOP – Disconnect black terminal clamp “-” of charger unit from neg‐...
Page 36 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note Batteries that have not been used for a long time e.g. vehicles ♦ that have been stored, will self-discharge. In totally discharged batteries, the electrolyte is comprised al‐...
Page 37: Disconnecting And Reconnecting Batteries
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Disconnecting and reconnecting bat‐ teries WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 Disconnecting battery Note By disconnecting the battery earth wire (open circuit), safety ♦...
Page 38 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Torque wrench -V.A.G 1331- Note After connecting the battery and switching the ignition on the ESP and TCS warning lamp -K155- lights up permanently. The warn‐ ing lamp goes out automatically if a distance of 15 to 20 km/h is driven straight ahead.
Page 39: Removing And Installing Battery
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing battery WARNING Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 Models with a petrol engine Special tools and workshop equipment required ♦...
Page 40: Models With A Diesel Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Fold handles -arrows- upwards and take battery out. Installing: Caution A loosely fitted battery creates the following dangers: ♦ Shortened service life due to damage from vibration (dan‐...
Page 41 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Spring-type clip pliers -VAS 5024A- Removing: – Disconnect the battery ⇒ page 29 For vehicles with a 1.9 l TDI engine: – Pull engine cover upwards -arrows A- and forwards -arrow B-.
Page 42 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew air filter housing securing bolt -arrow-. – Unlock lugs -arrows- and take cover off. – Pull hose -arrow- off air filter housing and take hose out.
Page 43 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing bolt -1- and remove battery holder -2-. – Fold handles -arrows- upwards and take battery out. Installing: Caution A loosely fitted battery creates the following dangers: ♦...
Page 44: Torque Settings: Battery
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Torque settings: battery Threaded connections Torque settings Battery clamp to battery terminal 6 Nm Additional clamp to battery terminal 6 Nm clamp Securing bolt of battery holder M8x35...
Page 45: Starter
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Starter Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Checking starter -B- – Connect the vehicle diagnosis, testing and information system -VAS 5051A- to ⇒...
Page 46: Removing And Installing Starter, Automatic Gearbox
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing starter, auto‐ matic gearbox 7.2.1 Vehicles with 1.6 l injection engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...
Page 47 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull air filter housing on right side upwards off rubber mounting -arrow-. – Remove air filter housing from vehicle. – Push down protective cap in -direction of arrow- from solenoid switch.
Page 48 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove lower securing bolt of starter -arrow-. – Unscrew securing nut -1- from upper starter securing bolt. – Remove wiring retainer -2-. – Remove upper securing bolt of starter -arrow-.
Page 49 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing: – Disconnect the battery ⇒ page 29 – Push down protective cap in -direction of arrow- from solenoid switch.
Page 50 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing nut -1- from lower starter securing bolt. – Remove wiring retainer -2-. – Remove lower securing bolt of starter -arrow-. – Unscrew securing nut -1- from upper starter securing bolt.
Page 51 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – 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 52 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -arrow-. – Unclip vacuum hose from its mounting -arrow-. – Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024- .
Page 53 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew air filter housing securing bolt -arrow-. – Pull air filter housing on right side upwards off rubber mounting -arrow-. – Loosen spring-type clip -1- using spring type clip pliers -VAS 5024- .
Page 54 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove air filter housing from vehicle. – Push down protective cap in -direction of arrow- from solenoid switch. – Unscrew positive wire -1- and disconnect connector from ter‐...
Page 55 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing nut -1- from upper starter securing bolt. – Remove wiring retainer -2-. – Remove upper securing bolt of starter -arrow-. – Unscrew earth wire securing nut -1- and place earth wire -2- to one side.
Page 56 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.2.4 Vehicles with 2,5 l injection engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 57 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Separate connector -1-, release spring-type clip -2- with spring type clip pliers -VAS 5024- and pull off vacuum hose -3-. – Pull air filter housing upwards out of brackets and remove.
Page 58 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove lower securing bolt of starter -arrow-. – Unscrew nut -1- from upper starter securing bolt. – Remove wiring retainer -2-. – Remove upper securing bolt of starter -arrow-.
Page 59 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.2.5 Vehicles with 1.9 l TDI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 60 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -1- and loosen spring type clip -2- with spring type clip pliers -VAS 5024- . – Pull the vacuum hose -arrow- off air filter housing.
Page 61 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull hose -arrow- off air filter housing and take hose out. – Pull air filter housing upwards out of brackets and remove. – Push down protective cap -direction of arrow- from solenoid switch.
Page 62 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove lower securing bolt of starter -arrow-. – Unscrew nut -1- from upper starter securing bolt. – Remove wiring retainer -2-. – Remove upper securing bolt of starter -arrow-.
Page 63 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.2.6 Vehicles with 2.0 l SDI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 64 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release spring-type clip -1- using spring type clip pliers -VAS 5024- and disconnect connector -2-. – Remove securing bolt -3-. – Pull vacuum hose off -arrow-. – Pull air filter housing on right side upwards off rubber mounting -arrow-.
Page 65 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Unscrew earth wire from starter securing bolt -arrow-. – Unscrew starter securing bolt -arrow-.
Page 66: Removing And Installing Starter, Automated Shift Gearboxes
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew starter securing bolt -arrow-. – Remove starter from vehicle downwards. Installing: Installation is carried out in the reverse order. When installing, note the following: – Tighten threaded connections to specified torque settings ⇒...
Page 67 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release spring-type clip -1- using spring type clip pliers -VAS 5024- and remove securing bolt -2-. – Release hose -3- and pull it off the air filter housing.
Page 68 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew earth wire from starter securing bolt -arrow-. – Unscrew starter securing bolt -arrow-. – Remove noise insulation ⇒ General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .
Page 69 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.3.2 Vehicles with 2,0 l FSI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 70 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unclip vacuum hose from its mounting -arrow-. – Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024- . – Pull hose -1- off air filter housing.
Page 71 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull air filter housing on right side upwards off rubber mounting -arrow-. – Loosen spring-type clip -1- using spring type clip pliers -VAS 5024- . – Pull hose -2- off pipe union.
Page 72 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Unscrew securing nut -1- from upper starter securing bolt. – Remove wiring retainer -2-.
Page 73 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing nut -1- from lower starter securing bolt. – Remove wiring retainer -2-. – Remove lower securing bolt of starter -arrow-. – Remove starter from vehicle downwards.
Page 74 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.3.3 Vehicles with 2.0 l FSI turbo engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 75 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -arrow-. – Loosen spring-type clips -1- using spring type clip pliers -VAS 5024- . – Pull engine cover off upwards -arrows-. – Push down protective cap in -direction of arrow- from solenoid switch.
Page 76 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Remove upper securing bolt of starter -arrow-. – Remove lower securing bolt of starter -arrow-.
Page 77 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.3.4 Vehicles with 1.9 l TDI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 78 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -1- and loosen spring type clip -2- with spring type clip pliers -VAS 5024- . – Pull the vacuum hose -arrow- off air filter housing.
Page 79 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull hose -arrow- off air filter housing and take hose out. – Pull air filter housing upwards out of brackets and remove. – Push down protective cap -direction of arrow- from solenoid switch.
Page 80 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove lower securing bolt of starter -arrow-. – Remove starter from vehicle upwards. Installing: Installation is carried out in the reverse order. When installing, note the following: –...
Page 81 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull engine cover off upwards -arrows-. – Separate connector -1-, release spring-type clip -2- with spring type clip pliers -VAS 5024- and pull off vacuum hose -3-.
Page 82 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull hose -arrow- off air filter housing and take hose out. – Pull air filter housing upwards out of brackets and remove. – Push down protective cap in -direction of arrow- from solenoid switch.
Page 83 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove upper securing bolt of starter -arrow-. – Remove lower securing bolt of starter -arrow-. – Remove starter from vehicle upwards. Installing: Installation is carried out in the reverse order. When installing, note the following: –...
Page 84: Removing And Installing Starter, Manual Gearbox
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing starter, manual gearbox 7.4.1 Vehicles with 1.6 l engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...
Page 85 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Unscrew earth wire from starter securing bolt -arrow-. – Unscrew starter securing bolt -arrow-.
Page 86 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew starter securing bolt -arrow-. – Remove starter. Installing: Installation is carried out in the reverse order. When installing, note the following: – Tighten threaded connections to specified torque settings ⇒...
Page 87 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Disconnect the battery ⇒ page 29 – Disconnect connector -arrow-. – Unclip vacuum hose from its mounting -arrow-. – Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024- .
Page 88 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew air filter housing securing bolt -arrow-. – Pull air filter housing on right side upwards off rubber mounting -arrow-. – Loosen spring-type clip -1- using spring type clip pliers -VAS 5024- .
Page 89 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove air filter housing from vehicle. – Push down protective cap in -direction of arrow- from solenoid switch. – Unscrew positive wire -1- and disconnect connector from ter‐...
Page 90 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing nut -1- from lower starter securing bolt. – Remove wiring retainer -2-. – Unscrew starter securing bolt -arrow-. – Remove starter from vehicle downwards. Installing: Installation is carried out in the reverse order.
Page 91 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.4.3 Vehicles with 2.0 l FSI turbo engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 92 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -arrow-. – Loosen spring-type clips -1- using spring type clip pliers -VAS 5024 A- . – Pull engine cover off upwards -arrows-. – Push down protective cap in -direction of arrow- from solenoid switch.
Page 93 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Unscrew earth wire from starter securing bolt -arrow-. – Unscrew starter securing bolt -arrow-.
Page 94 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew starter securing bolt -arrow-. – Remove starter from vehicle downwards. Installing: Installation is carried out in the reverse order. When installing, note the following: – Tighten threaded connections to specified torque settings ⇒...
Page 95 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull engine cover off upwards -arrows-. – Separate connector -1-, release spring-type clip -2- with spring type clip pliers -VAS 5024- and pull off vacuum hose -3-.
Page 96 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew earth wire from starter securing bolt -arrow-. – Unscrew starter securing bolt -arrow-. – Remove noise insulation ⇒ General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation .
Page 97 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.4.5 Vehicles with 1.9 l TDI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 98 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -1- and loosen spring type clip -2- with spring type clip pliers -VAS 5024- . – Pull the vacuum hose -arrow- off air filter housing.
Page 99 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull hose -arrow- off air filter housing and take hose out. – Pull air filter housing upwards out of brackets and remove. – Push down protective cap -direction of arrow- from solenoid switch.
Page 100 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew starter securing bolt -arrow-. – Remove noise insulation ⇒ General Body Repairs, Exterior; Rep. Gr. 50 ; Body front; Noise insulation . – Unscrew nut -1- from lower starter securing bolt.
Page 101 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 7.4.6 Vehicles with 2.0 l SDI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spring-type clip pliers -VAS...
Page 102 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release spring-type clip -1- using spring type clip pliers -VAS 5024- and disconnect connector -2-. – Remove securing bolt -3-. – Pull vacuum hose off -arrow-. – Pull air filter housing on right side upwards off rubber mounting -arrow-.
Page 103 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Unscrew earth wire from starter securing bolt -arrow-. – Unscrew starter securing bolt -arrow-.
Page 104 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew starter securing bolt -arrow-. – Remove starter. Installing: Installation is carried out in the reverse order. When installing, note the following: – Tighten threaded connections to specified torque settings ⇒...
Page 105: Torque Settings: Starter
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Torque settings: starter Threaded connections Torque settings Starters on automatic, manual gearboxes 75 Nm Starter on automated shift gearboxes 60 Nm Earthing wire to starter securing bolt 15 Nm...
Page 106: Alternator
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Alternator Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Fastening B+ wire to alternator Caution If the B+ wire is not secured with the prescribed torque the following may occur: ♦...
Page 107: Check Alternator C
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Check alternator -C- – Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A- ⇒ page 281 Select “guided fault finding” in Vehicle Diagnosis, Testing and In‐ formation System -VAS 5051A- .
Page 108 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ❑ 2 Nm 13 - Voltage regulator ❑ Removing and installing voltage regulator ⇒ page 142 14 - Alternator ❑ Removing and installing alternator ⇒ page 100 15 - Poly V-belt ❑...
Page 109 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull engine cover off upwards -arrows-. – Disconnect connector of DF wiring -1- and pull protective cap -2- off. – Unscrew B+ wiring -arrow- off alternator. Caution Mark top and direction of rotation of poly V-belt before remov‐...
Page 110 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unclip coolant hose from hose retainer -1- and remove secur‐ ing nut -2-. – Unbolt securing bolts -arrow-. – Take hose retainer together with tensioning element out of the vehicle.
Page 111 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-. – Position wiring bracket -arrow- on rear of generator at 3 o'clock.
Page 112: Alternator, 1.6 L Fsi Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Alternator, 1.6 l FSI engine 9.5.1 Assembly overview 1 - Hexagon bolt ❑ 40 Nm 2 - Washer 3 - Idler roller 4 - Washer 5 - Valve gear casing 6 - Hexagon head collared nut ❑...
Page 113 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ❑ 20 Nm + 1/4 turn (90°) further 21 - Spacer sleeve 9.5.2 Removing and installing alternator, 1.6 l FSI engine Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦...
Page 114 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove wiring bracket -1- and pull protective cap -2- off. – Disconnect connector of DF wiring -1- and pull B+ wiring -2- off alternator. Caution Mark top and direction of rotation of poly V-belt before remov‐...
Page 115 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-. – Position wiring bracket -arrow- on rear of generator at 9 o'clock.
Page 116: Alternator, 2.0 L Fsi Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Alternator, 2.0 l FSI engine 9.6.1 Assembly overview 1 - Hexagon head collared bolts ❑ M8x90 ❑ 23 Nm 2 - Hexagon head collared bolts ❑ M8x50 ❑ 23 Nm...
Page 117 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.6.2 Removing and installing alternator, 2,0 l FSI engine Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Special tools and workshop equipment required ♦...
Page 118 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull engine cover off upwards -arrows-. – Disconnect connector -arrow-. – Unclip vacuum hose from its mounting -arrow-. – Loosen spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024 A- .
Page 119 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Open retainer -arrow- on front side of air filter housing and take hose -1- off. – Unscrew air filter housing securing bolt -arrow-. – Pull air filter housing on right side upwards off rubber mounting -arrow-.
Page 120 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Separate connector -arrow- on rear of air filter housing. – Remove air filter housing from vehicle. – Remove upper intake manifold. – Disconnect connector of DF wiring -1- and pull protective cap -2- off.
Page 121 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Lock tensioning element with retaining pin -T10060 A- . – Remove ribbed belt. – Remove securing bolts of tensioning element -arrows-. – Take tensioning element together with lifting eye -1- out of the vehicle.
Page 122 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-. – Position wiring bracket -arrow- on rear of generator at 12 o'clock.
Page 123: Alternator, 2.0 L Fsi Turbo Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Models with air conditioning system: Tensioning roller Ribbed belt pulley - Alternator Ribbed belt pulley - Air conditioner compressor Poly V-belt Ribbed belt pulley - Crankshaft Alternator, 2.0 l FSI turbo engine 9.7.1...
Page 124 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 12 - Voltage regulator ❑ Removing and installing voltage regulator ⇒ page 142 13 - Alternator ❑ Removing and installing alternator ⇒ page 116 14 - Poly V-belt ❑...
Page 125 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Disconnect the battery ⇒ page 29 – Unbolt securing bolts -arrow-. – Disconnect connector -arrow-. – Loosen spring-type clips -1- using spring type clip pliers -VAS 5024 A- .
Page 126 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note All hoses of the charge air system are secured with hose clips ♦ or with quick release couplings. When using quick release couplings the following points must be observed: Unlock connection by pulling the securing clamp -arrow-.
Page 127 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release poly V-belt by turning the tensioning element with an open jaw spanner AF 16 in -direction of arrow- and lock ten‐ sioning element with retaining pin -T10060 A- .
Page 128 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew B+ wiring -arrow- off alternator. – Unscrew wiring bracket -arrow- from alternator. – Take alternator out of the vehicle. Installing: Installation is carried out in the reverse order. When installing,...
Page 129 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note ♦ All hoses of the charge air system are secured with hose clips or with quick release couplings. When using quick release couplings the following points must be observed: Fit hose/tube without assistance of tools.
Page 130: Alternator 2.5 L Injection Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Alternator 2.5 l injection engine 9.8.1 Assembly overview 1 - Compact bracket ❑ For alternator and air conditioner compressor 2 - Multi-point socket head bolt M8x60 ❑ 25 Nm...
Page 131 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Torque wrench -V.A.G 1331- ♦ Locking pin -T10060 A- – Disconnect the battery ⇒ page 29 – Take the engine cover off upwards and forwards. – Bring lock carrier into service position ⇒ General body repairs, exterior;...
Page 132 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew B+ wiring -arrow- off alternator. Caution Mark top and direction of rotation of poly V-belt before remov‐ ing. When installing observe direction of rotation marked on removal.
Page 133 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Position wiring bracket -arrow- on rear of generator at 9 o'clock. – Tighten threaded connections to specified torque settings ⇒ page 145 Caution Observe instructions on connecting battery terminals ⇒...
Page 134: Alternator, 1.9 L Tdi Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Alternator, 1.9 l TDI engine 9.9.1 Assembly overview 1 - Hexagon head collared bolts ❑ M8x45 ❑ 20 Nm 2 - Tensioning element for poly V-belt 3 - Hexagon head collared bolts ❑...
Page 135 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.9.2 Removing and installing alternator, 1.9 l TDI engine Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Removing: Special tools and workshop equipment required ♦...
Page 136 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note All hoses of the charge air system are secured with hose clips ♦ or with quick release couplings. When using quick release couplings the following points must be observed: Unlock connection by pulling the securing clamp -arrow-.
Page 137 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew charge air pipe securing bolt -arrow-. – Disconnect connector of charge air pipe -arrow-. – Take charge air pipe out upwards. – Disconnect connector of DF wiring -1- and pull protective cap -2- off.
Page 138 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release poly V-belt by turning the tensioning device with an open-ended spanner AF 16 in -direction of arrow-. – Lock tensioning element with retaining pin -T10060 A- .
Page 139 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Drive threaded sleeves -A- out of the alternator housing for approx. 4 mm in -direction of arrow-. – Position wiring bracket -arrow- on rear of generator at 9 o'clock.
Page 140 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.9.3 Ribbed belt routing, 1.9 l TDI engine Models without air conditioning system: Tensioning roller Ribbed belt pulley - Alternator Poly V-belt Ribbed belt pulley - Crankshaft Models with air conditioning system:...
Page 141: Alternator, 2,0 L Tdi Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.10 Alternator, 2,0 l TDI engine 9.10.1 Assembly overview 1 - Hexagon head collared bolts ❑ M8x45 ❑ 20 Nm 2 - Tensioning element for poly V-belt 3 - Hexagon head collared bolts ❑...
Page 142 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Locking pin -T10060 A- – Disconnect the battery ⇒ page 29 – Pull engine cover off upwards -arrows-.
Page 143 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unbolt securing bolts -arrow-. – Disconnect connector of DF wiring -1- and pull protective cap -2- off. – Unscrew B+ wiring -arrow- off alternator. – Pull fuel filter off the retainer and place to side (fuel hoses re‐...
Page 144 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Lock tensioning element with retaining pin -T10060 A- . – Remove ribbed belt. – Remove alternator securing bolts -arrows-. – Unscrew wiring bracket -arrow- from alternator. – Remove alternator.
Page 145: Removing And Installing Ribbed Belt (Poly V-Belt) Pulley On Alternator
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Position wiring bracket -arrow- on rear of generator at 9 o'clock. – Tighten threaded connections to specified torque settings ⇒ page 145 Caution Observe instructions on connecting battery terminals ⇒...
Page 146 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Socket -VAS 3310- ♦ Torque wrench -V.A.G 1332- Removing: – Take off alternator ⇒ page 98 – Fit alternator in a vice on fitting points. – Use socket -VAS 3310- to remove ribbed belt (poly V-belt) pulley securing nut from alternator shaft.
Page 147 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Adapter -VAS 3400- ♦ Torque wrench -V.A.G 1332- Removing: – Take off alternator ⇒ page 98 – Fit alternator in a vice on fitting points. – Take protective cap off ribbed belt (poly V-belt) pulley with freewheel.
Page 148 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Insert a socket M10 -1- in the alternator shaft. – Loosen threaded joint by turning to right and counter-hold with ring spanner. – Hold the ribbed belt (poly V-belt) pulley with a freewheel with the hand and turn the drive shaft of the alternator until the rib‐...
Page 149 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.11.3 Removing and installing a ribbed belt (poly V-belt) pulley with freewheel, manufacturer: Valeo Special tools and workshop equipment required ♦ Adapter -VAS 3400- ♦ Torque wrench -V.A.G 1332- ♦...
Page 150: Voltage Regulator For Alternator
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Fit TORX key -V.A.G 1603/1- into alternator shaft. – Loosen threaded joint by turning to right and counter-hold with ring spanner. – Hold the ribbed belt (poly V-belt) pulley with a freewheel with the hand and turn the drive shaft of the alternator until the rib‐...
Page 151 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Torque screwdriver -V.A.G 1624- Removing: – Remove alternator. – Remove securing bolt and nuts -arrows- and take protective cap off alternator. – Remove securing bolts for voltage regulator -arrows-.
Page 152 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Remove alternator. – Remove spring clips -arrows- and take protective cap off al‐ ternator. – Remove securing bolts for voltage regulator -arrows-. – Remove voltage regulator from alternator.
Page 153: Torque Settings: Alternator
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Torque settings: alternator 10.1 General torque settings for all vehicles Threaded connections Torque settings B+ wire to alternator 15 Nm Cable holder to alternator 3,2 Nm Voltage regulator to alternator...
Page 154: 2.0 L Fsi Turbo Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 10.2.2 Tightening sequence for compact brack‐ et, models with air conditioning system Tightening sequence for compact bracket to cylinder block Procedure – Place compact bracket on cylinder block.
Page 155: 1.9 L And 2.0 L Tdi Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 10.3.2 Tightening sequence for compact brack‐ et, models with air conditioning system Tightening sequence for compact bracket to cylinder block Procedure – Place compact bracket on cylinder block.
Page 156: 2.5 L Injection Engine
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 10.4.2 Tightening sequence for compact brack‐ Tightening sequence for compact bracket to cylinder block Procedure – Place compact bracket on cylinder block. Note Observe dowel sleeve between compact bracket and cylinder ♦...
Page 157: Cruise Control System (Ccs)
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 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”.
Page 158: Instruments, Gci
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 90 – Instruments, GCI Dash panel insert General description: Integrated in the dash panel insert are the following components: ♦ Control unit with display in dash panel insert -J285- ♦...
Page 159: Removing And Installing Dash Panel Insert
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Vehicle Diagnosis, Testing and Information System -VAS 5051A- ♦ Diagnosis lead -VAS 5051/6A- – Connect the vehicle diagnosis, testing and information system -VAS 5051A- to ⇒ page 281 –...
Page 160: Description Of Reverse Side Of Dash Panel Insert
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove the upper part of the steering column trim ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim; Removing and installing steering column switch trim .
Page 161 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 1 - Electric On Board Diagno‐ sis (EOBD) 2 - Engine malfunction (EPC) ❑ Warning lamp is fitted only on vehicles with petrol engine. 3 - Immobilizer 4 - Battery charge...
Page 162: Service Interval Display
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Service interval display Resetting service interval display ⇒ Maintenance ; Booklet 20.1 Rep. Gr.90 - Instruments, GCI...
Page 163: Windscreen Wash/Wipe System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 92 – Windscreen wash/wipe system Windscreen wiper system Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Note Additional information: ⇒ Operating instructions...
Page 164: Removing And Installing The Windscreen Wiper System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Diagnosis lead -VAS 5051/6A- The windscreen wiper system is equipped with an APP function (alternating park position system). With the APP function, the wiper arm is moved up slightly once it has reached the lowest position.
Page 165 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Puller -T10130- ♦ Removal lever -80-200- 1.2.1 Removing windscreen wiper system – Deactivating APP function ⇒ page 155 –...
Page 166 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 1.2.2 Removing wiper arm – Lever off the protective cap -arrows- using a screwdriver. – Loosen the hexagon nut -arrows-, without removing it com‐ pletely. – Position legs of puller -T10130- -2- under wiper arm-4- as shown in the figure.
Page 167 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 1.2.4 Removing air cowling – Remove securing screws -1- and securing nut -2- from air cowling -3-. – Take air cowling -3- out of vehicle. 1.2.5 Removing wiper frame with linkage and wiper motor –...
Page 168: Removing And Installing Wiper Arms
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 1.2.7 Installing wiper motor in wiper frame – Insert wiper motor with control unit in wiper frame and secure it in place with the securing bolts -arrows-. – Tighten threaded connections to specified torque settings ⇒...
Page 169: Adjusting Wiper Blade Park Position
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Place wiper arm in approximate park position on wiper arm shaft and tighten securing nut -arrows- by hand. – Adjust windscreen wiper blade park position ⇒ page 161...
Page 170: Removing And Installing Aerodynamic Wipers
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Driver's side: Distance -A- between wiper blade and upper edge of plenum chamber cover should be 10 mm. – If necessary, adjust wiper blade park position by moving wiper arm.
Page 171: Removing And Installing Rain And Light Detector Sensor G397
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Turn wiper blade -1- on wiper arm onto limit stop -arrow A-. – Pull wiper blade -1- off axis of wiper arm -arrow B-. Installing: – Slide wiper blade onto axis of wiper arm.
Page 172 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Using removal wedge -3409- , lever rain and light detector sensor -G397- -1- out of retainer -2-. Note When removing, ensure to remove the complete rain and light detector sensor -G397- and not only the upper shell of the sensor.
Page 173: Windscreen Washer System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Windscreen washer system Note Additional information: ⇒ Operating instructions Assembly overview of windscreen washer system 1 - Y-piece ❑ Distribution of wash wa‐ ter line to windscreen spray jets...
Page 174: Removing And Installing Reservoir For Windscreen And Headlight Washer Systems
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing reservoir for windscreen and headlight washer sys‐ tems The reservoir for windscreen and headlight washer systems has three parts. The individual parts are connected together. To en‐...
Page 175 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Connecting pipe -1- and filler neck -2- must be fitted together so that the guides -arrows- grip into one another. 2.2.2 Removing and installing reservoir for windscreen and headlight washer sys‐...
Page 176: Removing And Installing Washer Pump V5
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unbolt securing bolts -arrows- and take reservoir out of vehi‐ cle. Installing: Installation is carried out in the reverse order. When installing, note the following: – Tighten threaded connections to specified torque settings ⇒...
Page 177: Removing And Installing Windscreen Washer Spray Jets
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing windscreen washer spray jets Removing: – Push spray jets upwards -arrow A- and pull out of bonnet from rear -arrow B-. – Pull hose -1- off spray jet and disconnect connector -2-.
Page 178: Headlight Washer System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Headlight washer system Note Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating instructions General description: Every fifth time the front windscreen washer system is activated the headlights are also washed if the windscreen wiper lever on the steering wheel is pulled for at least 1.5 seconds - provided...
Page 179: Assembly Overview - Headlight Washer System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Assembly overview - headlight washer system 1 - Washer spray jet assembly with right spray jets ❑ Removing and installing spray jet assembly ⇒ page 173 ❑ Adjusting spray jets ⇒...
Page 180: Removing And Installing Pop-Up Spray Jet Cylinder
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Remove front bumper cover ⇒ Body Repairs, exterior; Rep. Gr. 63 ; Front bumper .
Page 181: Removing And Installing Spray Jet Assembly
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing spray jet as‐ sembly Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Pull spray jet with cover cap -1- onto stop out of bumper cover.
Page 182: Wash Water Line Hose Couplings
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Wash water line hose couplings The following hose coupling types are used to connect the hoses to pumps and spray jets and/or as points of separation: Windscreen and rear window washer system –...
Page 183: Headlight Washer System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Headlight washer system – To loosen the connection -1- push the lock ring -arrow- and pull off the hose connection. – To secure the connection, push and hold the lock ring -arrow- and push on the hose connection.
Page 184: Hose Repair
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Hose repair A new repair concept has been developed for repair work on wash system hoses. Various connectors, special EPDM hoses (ethyl‐ ene propylene diene monomer) and heat-shrink hose are availa‐...
Page 185 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note Repair points must not be subjected to pulling or bending ♦ forces. If the damaged section is longer than 20 mm, a new piece of ♦ corrugated pipe must be used and the procedure described below must be performed twice.
Page 186: Torque Settings: Windscreen Wash/Wipe System
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Torque settings: Windscreen wash/wipe system Threaded connections Torque settings Wiper motor to wiper frame 8 Nm Motor crank arm to wiper motor shaft 18 Nm Wiper frame to body...
Page 187: Lights, Lamps, Switches - Outside
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 94 – Lights, lamps, switches - outside Headlight Note Before working on headlights, always switch off the headlights ♦ and remove the ignition key. When dealing with complaints, it is absolutely essential that ♦...
Page 188: Jetta 2005 ➤ , Bora
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 1 - Securing bolts ❑ 4 Nm 2 - Adjustment bushes ❑ Correcting installation position of headlight ⇒ page 182 3 - Left headlight main beam bulb -M30- or right headlight main beam bulb -M32- ❑...
Page 189: Removing And Installing Headlights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing headlights 1.2.1 Removing headlights Note It is not necessary to disconnect the battery earth strap. ♦ The diagrams show how the left headlight is removed and in‐...
Page 190: Adjusting Headlight Installation Position
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing screw -arrow- on lower right headlight. 1.2.2 Installing headlights Installation is performed in the reverse order of installation; when doing this, note the following: – Tighten all securing bolts to specified torque setting ⇒...
Page 191 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing screw -arrow- on upper headlight. – Unscrew securing screw -arrow- on lower left headlight. – Unscrew securing screw -arrow- on lower right headlight. – Adjust shutlines to body by pushing in or pulling out alignment bush -arrow- on lower left or lower right headlight.
Page 192: Renewing Headlight Bulbs
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Renewing headlight bulbs 1.4.1 Renewing dipped beam headlight bulb Note The diagrams show renewal of the dipped beam headlight bulb for the left headlight. Removing: – Switch off ignition and all electrical consumers and pull out ignition key.
Page 193 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Place headlight dipped beam bulb -1- in the bulb holder that the pin on the dipped beam headlight bulb lies in the recess -arrow- of bulb holder -2-.
Page 194 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull off cover cap -1-. – Pull off multi-pin connector -2-. – Press spring retaining clip -2- in -direction of arrow- under the locking lugs-1- and fold spring retaining clip -2- upwards.
Page 195 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Place the headlight main beam bulb -1- in the recesses -arrows- on the headlight. – Check function of headlight. – Check headlight setting and adjust headlight as necessary ⇒...
Page 196: Servicing Headlight Securing Lugs
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull side light bulb -2- in -direction of arrow- out of the bulb holder -1-. Installing: Note When installing cap, ensure that it is seated correctly. The in‐...
Page 197: Adjusting Headlights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Adjusting headlights Adjusting headlights ⇒ Maintenance ; Booklet 20.1 . 1. Headlight...
Page 198: Main Headlights With Gas Discharge Bulbs
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Main headlights with gas discharge bulbs Note Before working on gas discharge headlights, always switch off ♦ the headlights and remove the ignition key. The automatic headlight range control on headlights with gas ♦...
Page 199: Assembly Overview - Gas Discharge Headlights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Assembly overview - gas discharge headlights Note After any measures which could affect the headlight setting, the headlight must be checked and if necessary adjusted ⇒ Maintenance ; Booklet 20.1 .
Page 200: Removing And Installing Headlights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 12 - Rear left vehicle level sender -G76- ❑ Removing and installing ⇒ page 201 ❑ Checking ⇒ page 203 13 - Adjustment bush ❑ Correcting installation position of headlight ⇒...
Page 201 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Turn cover cap -1- in -direction of arrow- and remove. – Pull off connector -1-. Note The connector is ejected automatically when the gas discharge bulb starter unit -N195- is removed.
Page 202 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Carefully pull gas discharge bulb -1- out of mounting. Installing: Note Do not touch bulb glass when fitting a gas discharge lamp ♦ bulb . Fingers leave traces of grease on the glass, which when switching the gas discharge lamp bulb on, evaporate and cause the glass to cloud over.
Page 203 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull connector off -arrow-. – Press spring retaining clip -2- in -direction of arrow- under the locking lugs-1- and fold spring retaining clip -2- upwards. – Take main beam bulb -1- out of headlight.
Page 204 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 2.4.3 Renewing side light bulb Note The following diagrams show renewal of the side light bulb for the left headlight. Removing: – Switch off ignition and all electrical consumers and pull out ignition key.
Page 205 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 2.4.4 Renewing front turn signal bulb Note The following diagrams show renewal of the turn signal bulb for the left headlight. Removing: – Switch off ignition and all electrical consumers and pull out ignition key.
Page 206: Removing And Installing Headlight Range Control Motor
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing headlight range control motor Information was not available when it was time of going to press. Removing and installing gas discharge light control unit Note The left gas discharge light control unit -J343- or the right gas discharge light control unit -J344- are not capable of self-diagno‐...
Page 207 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srew‐...
Page 208 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing bolt -arrow- and take control unit for head‐ light range control -J431- -1- of bracket -2-. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: –...
Page 209: Vehicle Level Sender
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Automatic headlight range control ♦ Automatic headlight range control functions ♦ Coding automatic headlight range control Note If the control unit for headlight range control -J431- has been co‐...
Page 210 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove securing nut -1-. – Unscrew securing bolt -2- and remove front left vehicle level sender -G78- -3-. Installing: Installation is carried out in the reverse order. When installing, note the following: –...
Page 211 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew the five securing bolts -1- and remove rear left vehi‐ cle sender -G76- -2-. Installing: Installation is carried out in the reverse order. When installing, note the following: –...
Page 212: Servicing Headlight Securing Lugs
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Servicing headlight securing lugs Information on servicing headlight securing lugs was not available when it was time of going to press. 2.10 Adjusting headlights Adjusting headlights with gas discharge lamp ⇒ Maintenance ;...
Page 213: Fog Lights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Fog lights Fault detection and fault display: The onboard supply control unit has a self-diagnosis function, which makes fault finding on the fog lights easier. For fault finding, use the vehicle diagnosis, testing and informa‐...
Page 214: Removing And Installing Fog Light Bulb
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Remove bolt -2-. – Unclip cover cap -2- off locking device. – Unbolt securing bolts -arrow-.
Page 215: Adjusting Fog Lights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Turn bulb holder -1- in -direction of arrow- and take out of fog light. The bulb for the fog light is permanently attached to the bulb holder and cannot be renewed separately.
Page 216: Removing And Installing Side Marker In Front Bumper
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing side marker in front bumper Removing and installing front side mark‐ Removing Note Removal and installation of front side marker on left and right are identical.
Page 217: Mirror Turn Signal Bulb And Entry Light In Exterior Mirror
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Mirror turn signal bulb and entry light in exterior mirror Note Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions General description: The exterior mirror turn signal bulbs are located in the housing of the exterior mirror.
Page 218: Removing And Installing Entry Light In Exterior Mirror
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing entry light in ex‐ terior mirror The driver side entry light in exterior mirror -W52- or the front passenger side entry light in exterior mirror -W53- is installed in the housing of the left or right exterior mirror.
Page 219 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull bulb carrier -2- in -direction of arrow- out of entry light housing -1-. Renew bulb: – Pull bulb -1- in -direction of arrow- out of the carrier -2-.
Page 220: Tail Lights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Tail lights Assembly overview - tail light in side panel Torque settings ⇒ page 238 1 - Securing nuts 2 - Left brake and tail light bulb -M21- or right brake and tail...
Page 221: Removing And Installing Tail Light Bulb Carrier In Side Panel
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull connector -1- off. – Remove securing nuts -2- on tail light in side panel. – Remove tail light. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: –...
Page 222: Assembly Overview - Tail Light In Tailgate
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Assembly overview - tail light in tailgate Torque settings ⇒ page 238 1 - Securing nuts 2 - Bulb carrier ❑ Removing and installing ⇒ page 215 3 - Left reversing light bulb -...
Page 223: Removing And Installing Tail Light Bulb Carrier In Tailgate
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull connector -2- off. – Remove securing nuts -1- on tail light in tailgate. – Remove tail light. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: –...
Page 224 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unclip the two retaining tabs -in direction of arrow- and take bulb carrier -1- out. Installing: Install in reverse order of removal. Rep. Gr.94 - Lights, lamps, switches - outside...
Page 225: Number Plate Lights
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Number plate lights Removing and installing number plate light -X- Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Remove securing bolts -arrows- of number plate light -X- .
Page 226: Additional Brake Light
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Additional brake light Removing and installing high level brake light bulb -M25- Note In the event of damage, the complete high level brake light -M25- unit must be renewed.
Page 227: Steering Column Switch
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Steering column switch Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Note After installing a new steering column electronics control unit ♦...
Page 228: Assembly Overview - Steering Column Switch
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Assembly overview - steering column switch 1 - Turn signal switch ❑ Removing and installing ⇒ page 224 ❑ The “turn signal switch” comprises of the follow‐ ing components turn...
Page 229 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note When removing the steering column switch, observe that no metal shavings/swarf enter the steering column switch when drilling out the shear head bolts. Removing: For removal of the complete steering column switch, inc. base module, the switch is dismantled and the steering lock housing is also removed.
Page 230 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Unscrew bolt -1-. – Insert a thin rod, e.g. of ∅ 2.5 mm -2- approx. 45 mm in the hole -arrow 1- in steering column electronics control unit - J527- to release the locking tab -arrow 2-.
Page 231 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.2.2 Removing and installing coil connector for airbag and reset ring with slip ring - F138- Removing: Note The coil connector should not be moved out of the central position during removal and the road wheels should be in the “straight...
Page 232 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.2.3 Removing and installing steering angle sensor -G85- Removing: – Pull the steering angle sender -G85- -1- backwards and away from the steering column switch -arrow-. Installing: Install in reverse order of removal.
Page 233 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.2.5 Removing and installing windscreen wiper switch -E- Removing: Note For reasons of clarity, the steering column switch is shown in the removed state. – Release retaining clips -arrows- using 1.0 mm feeler gauge -1- and take windscreen wiper switch -E- off backwards.
Page 234 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.2.6 Removing and installing base module of steering column switch Note To remove the base module of the steering column switch -2- -, the shear head bolts of the steering lock housing must be drilled out.
Page 235: Steering Column Electronics Control Unit J527
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull steering lock housing and base module of steering column switch -2- to rear off steering column. – Take steering lock housing off base module of steering column switch.
Page 236: Steering Angle Sender G85
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Steering wheel electronics final control diagnosis Steering angle sender -G85- Removing and installing steering angle sender -G85- ⇒ page 224 9.4.1 Basic setting steering angle sender - G85- –...
Page 237: Ignition Switch And Lock Cylinder
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Ignition switch and lock cylinder 10.1 Removing and installing steering lock housing Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Note To remove steering lock housing it is necessary to remove the steering column switch base first.
Page 238 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove coil spring for airbag/coil connector with slip ring - F138- ⇒ page 223 – Remove steering angle sender -G85- ⇒ page 224 Note For reasons of clarity, the diagram is shown without turn signal ♦...
Page 239: Removing And Installing Ignition Switch
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Installing: Note For reasons of clarity, the ignition key is not shown in the following diagram. – Insert ignition key in lock cylinder -1- and turn to position “Drive”.
Page 240 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Insert ignition key in lock cylinder and turn to position “Drive”. Note Insert ignition key in lock cylinder and turn to position “Drive”. Position of key in lock cylinder: 1 - Position “Stop”...
Page 241: Parking Aid
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Parking aid Note For complaints with the parking aid system it is absolutely es‐ ♦ sential to understand the function and operation of the system. Additional information ⇒ Operating instructions ♦...
Page 242: Assembly Overview - Parking Aid
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 11.1 Assembly overview - parking aid 1 - Parking aid system warning buzzer -H15- ❑ Below the rear shelf ❑ Removing and installing ⇒ page 236 2 - Parking aid control unit - J446- ❑...
Page 243: Removing And Installing Parking Aid Sensor
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove connectors -1- by pressing the locking tabs -arrows- inwards. – Press locking tabs -arrows- of the retainer outwards and take parking aid control unit -1- out of the retainer.
Page 244: Removing And Installing Rear Parking Aid Warning Buzzer H15
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -arrow-. – Release locking lugs -arrows- and pull sender out of bumper cover. Installing: Install in reverse order of removal. 11.4 Removing and installing rear parking aid...
Page 245 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Parking aid functions ♦ Final control diagnosis 11. Parking aid...
Page 246: Torque Settings: Lights, Bulbs, Switches - Exterior
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Torque settings: lights, bulbs, switches - exterior 12.1 Torque settings: headlight Threaded connections Torque settings Upper headlight 4 Nm Lower left headlight 4 Nm Lower right headlight 4 Nm 12.2...
Page 247: Lights, Lamps, Switches - Inside
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 96 – Lights, lamps, switches - inside Lights and switches in engine com‐ partment Note The Jetta or the Bora have no lights in the engine compartment. Removing and installing bonnet contact...
Page 248: Lights And Switches In Dash Panel
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Lights and switches in dash panel Removing and installing light switch - The following components are integrated into the light switch - E1- : ♦ Fog light switch -E7- ♦...
Page 249: Removing And Installing Glove Compartment Light W6
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing glove compart‐ ment light -W6- Special tools and workshop equipment required ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐...
Page 250: Removing And Installing Glove Compartment Light Switch E26
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unlock locking tabs -1- and take thermal protection plate -2- off the lens or the light. – Lever bulb carefully out of the holder. – Renew glas base bulb (12 V, 5 W).
Page 251: Removing And Installing Front Passenger Side Airbag Deactivated Warning Lamp K145
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -arrow-. – Unlock locking lugs -arrows- and take adjuster and regulator out. Installing: Install in reverse order of removal. Removing and installing front passenger side airbag deactivated warning lamp -...
Page 252: Removing And Installing Hazard Warning Light Switch E3
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unlock locking lugs -arrows- and take warning lamp out. Installing: Install in reverse order of removal. Removing and installing hazard warning light switch -E3- Removing: – Switch off the ignition and all electrical consumers.
Page 253 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐ ♦ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srewdriver).
Page 254: Removing And Installing Key Operated Switch To Deactivate Front Passenger Side Airbag E224
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unlock locking tabs -1- and take thermal protection plate -2- off the lens or the light. – Lever bulb carefully out of the holder. – Renew glas base bulb (12 V, 5 W).
Page 255 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove key switch. Installing: Install in reverse order of removal. 2. Lights and switches in dash panel...
Page 256: Lights And Switches In Front Doors
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Lights and switches in front doors Removing and installing window regula‐ tor switch in front passenger door - E107- Note The window regulator switch in front passenger door -E107- fea‐...
Page 257: Removing And Installing Driver Side Interior Locking Button For Central Locking System E308
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note In the event of repair, the complete component must be renewed. Removing: – Remove switch module window lifter, driver side ⇒ page 250 – Unclip installation frame for switch from trim.
Page 258: Components - Front Door Locks
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove interior locking switch from the installation frame. Installing: Install in reverse order of removal. Components - front door locks The following components (depending on equipment) are inte‐...
Page 259 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note When removing and installing components in visual area (con‐ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srew‐...
Page 260: Removing And Installing Remote Release Button For Fuel Filler Flap And Rear Lid E463 And Key Operated Switch To Block Release Of Rear Lid Remote E232
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove connectors -arrows-. – Release locking lugs -arrows- and remove switch from the in‐ stallation frame. Installing: Install in reverse order of removal. Removing and installing remote release...
Page 261 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove switch from the door trim. Installing: Install in reverse order of removal. 3. Lights and switches in front doors...
Page 262: Lights And Switches In Rear Doors
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Lights and switches in rear doors Components - front door locks The following components (depending on equipment) are inte‐ grated into the rear left door lock: ♦ Rear left door contact switch -F10- ♦...
Page 263 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove switch from the in‐ stallation frame. Installing: Install in reverse order of removal. 4. Lights and switches in rear doors...
Page 264: Lights And Switches In Luggage Compartment
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Lights and switches in luggage com‐ partment Removing and installing luggage com‐ partment light -W3- Special tools and workshop equipment required ♦ Removal wedge -VAS 3409- Note The luggage compartment light can be found on the right side ♦...
Page 265: Removing And Installing Rear Lid Lock Unit F256
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Disconnect connector -arrow-. Renew bulb: – Press contact plate -1- of the light outwards and take festoon bulb -2- out of the socket. – Renew festoon bulb (12 V, 10 W).
Page 266: Lights And Switches In Roof Trim
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Lights and switches in roof trim Removing and installing front interior light and reading light (vehicles with no sliding sunroof) The following components are integrated in the interior light and reading light: ♦...
Page 267 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Carefully lever trim out of interior light using removal wedge - VAS 3409- or screwdriver -arrow-. – Unbolt securing bolts -arrow-. – Take the interior light out of the headliner console.
Page 268 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note When removing and installing components in visual area (con‐ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srew‐...
Page 269: Removing And Installing Front Interior Light And Reading Light (Vehicles With Sliding Sunroof)
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Turn bulb holder -arrows- of the defective reading light for 90° to the left. – Take the holder with the bulb out of the reading light. – Pull glas base bulb carefully out of the holder.
Page 270 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srew‐...
Page 271 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove connectors -arrows-. Installing: Install in reverse order of removal. 6.2.2 Removing and installing sunroof switch -E8- Removing: – Remove interior light ⇒ page 261 – Disconnect connector -arrow-.
Page 272 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srew‐...
Page 273: Rear Interior And Reading Light (Vehicles Without Atas)
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Pull contact -arrow- off defective festoon bulb. – Fit the contact to the new festoon bulb (12 V, 10 W). Installing: Install in reverse order of removal.
Page 274 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note The interior light and reading light as well as the switches for the interior light and reading light are connected together and can not be separated. When repairing, renew the complete component.
Page 275: Rear Interior And Reading Light (Vehicles With Atas)
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 6.3.2 Renewing rear interior and reading light bulbs (vehicles without ATAS) Removing: – Release locking lugs -arrows- and take trim with lens off inte‐ rior light and reading light.
Page 276 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 6.4.1 Removing and installing rear interior and reading light (vehicles with ATAS) Note If a rear interior and reading light is removed, the ATAS must ♦ be deactivated ⇒...
Page 277 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 6.4.2 Renewing rear interior and reading light bulbs (vehicles with ATAS) Note If a rear interior and reading light bulb is renewed, the ATAS ♦ must be deactivated ⇒...
Page 278 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐ ♦ nectors, covers, trims etc.) apply a commercial adhesive tape where a lever tool is applied ( removal wedge -VAS 3409- , srewdriver).
Page 279: Removing And Installing Garage Door Operating Unit E284
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Press contact -1- of the light in direction of arrow and take festoon bulb -2- out of the socket. – Renew festoon bulb (12 V, 5 W).
Page 280: Lights And Switches In Centre Console
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Lights and switches in centre console Removing and installing TCS and ESP button -E256- Removing: – Switch off the ignition and all electrical consumers. – Take bellow carefully off centre console -arrows-.
Page 281 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Release locking lugs -arrows- and remove switch from the in‐ stallation frame. Installing: Install in reverse order of removal. 7. Lights and switches in centre console...
Page 282: Horn
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Horn Removing and installing treble tone horn -H2- and bass tone horn -H7- Note The treble tone horn -H2- and the bass tone horn -H7- are ♦ controlled in parallel from the onboard supply control unit - J519- .
Page 283: Immobilizer
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Immobilizer General description: The vehicle is equipped with an immobilizer of the 4th generation. Modifications by comparison with the immobilizer of the 3rd gen‐ eration: ♦ An adaptation of components of other group marks to Volks‐...
Page 284 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 9.3.2 Adapting ignition keys to the immobilizer – Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A- ⇒ page 281 – Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .
Page 285: Anti-Theft Alarm System (Atas)
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Anti-theft alarm system (ATAS) Note Additional information: ⇒ Operating instructions General description: The functions of the ATAS are integrated into the central control unit for comfort system -J393- .
Page 286: Removing And Installing Anti-Theft Alarm Ultrasonic Sensor G209
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 When the ignition is switched on, the electronic immobilizer de‐ tects a valid vehicle key and deactivates the anti-theft alarm system. 10.2 Removing and installing anti-theft alarm ultrasonic sensor -G209- The anti-theft alarm ultrasonic sensor -G209- , comprising 4 indi‐...
Page 287: Alarm Horn H12
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions The central locking and anti-theft alarm system aerial -R47- is laid from the central locking and anti-theft alarm system aerial -J393- to the A-pillar (driver side) in the main wiring loom.
Page 288 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove front right wheel housing liner ⇒ General body re‐ pairs, interior; Rep. Gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner; Removing .
Page 289: Wiring
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 97 – Wiring 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! ♦...
Page 290: Jetta 2005 ➤ , Bora
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ♦ Vehicle Diagnosis, Testing and Information System -VAS 5051A- ♦ Diagnosis lead -VAS 5051/6A- (5 m) ♦ Diagnosis lead -VAS 5051/5A- (3 m) Note Only these leads are to be used for diagnosis, as they are the only ones fitted with CAN lines and therefore allowing CAN diagnosis and/or CAN communication.
Page 291: Removing And Installing Fuse Holder
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing fuse holder Removing and installing fuse holder on left of dash panel Special tools and workshop equipment required ♦ Removal wedge -VAS 3409- Note When removing and installing components in visual area (con‐...
Page 292 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – 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-.
Page 293: Removing And Installing Relay Carrier
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing and installing relay carrier Removing and installing relay carrier with safety cut-out on left of dash panel Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒...
Page 294: Removing And Installing Relay Carrier On Onboard Supply Control Unit, On Left Of Dash Panel
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unlock locking lug -1- of relay carrier in -direction of arrow- and take relay carrier off. Installing: Installation is performed in the reverse order of installation; when doing this, note the following: –...
Page 295 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Move locking bar -1- of the relay carrier connectors on onboard supply control unit, on left of dash panel in -direction of arrow A-. – Move locking bar -2- of the connectors of the on onboard sup‐...
Page 296: Electronics Boxes
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Electronics boxes Removing and installing electronics box on left in engine compartment Caution Disconnecting and connecting the battery as described in the Workshop Manual ⇒ page 29 Removing: –...
Page 297 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Remove central securing screw -arrow- from electronics box -1-. Note When the central securing screw -arrow-, the electronics box -1- is pushed upwards off the electronics box mounting.
Page 298 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Press tabs apart on bracket of electronics box -arrows B- and slide flat contact housing -1- sidewards -arrow A- out of brack‐ et of electronics box. – Press tabs apart on bracket of electronics box -arrows C- and slide flat contact housing -2- forwards -arrow D- out of bracket of electronics box.
Page 299 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Mount the cover -2- on the electronics box and push the safety clip -1- in -direction of arrow- until cover -2- engages. Note Then check whether the cover -2- of the electronics box is en‐...
Page 300: Control Units
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Control units Onboard supply control unit -J519- Note The onboard supply control unit -J519- and the relay carrier ♦ attached to the onboard supply control unit, on left of dash panel form one unit and cannot be separated.
Page 301 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Note The above adaptations can only be carried out in conjunction ♦ with certain equipment configurations. The “Motorway signaling”, “comfort signaling”, or “tap signal‐ ♦ ing” means that one touch of the turn signal lever will activate the turn signals (1-5 times) (turn signal cycles).
Page 302: Data Bus Diagnostic Interface J533
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 5.1.3 Modifying headlight cleaning system The “active time” of the headlight cleaning system can be variably adjusted to between 0 and 12.75 seconds. – Connect the vehicle diagnosis, testing and information system -VAS 5051A- to ⇒...
Page 303: Central Control Unit For Convenience System J393
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 5.2.1 Renewing data bus diagnostic interface -J533- – Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A- ⇒ page 281 – Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .
Page 304 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ⇒ Operating instructions General description: The convenience system central control unit -J393- is responsible for the following in the vehicle: ♦ Sliding/tilting sunroof control (release instruction) ♦ Power window control (release instruction) ♦...
Page 305 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 – Unscrew securing nuts -arrows-. – Take bracket off with convenience system central control unit -J393- . – Pull locking lug -1- in -direction of arrow B- and push conven‐...
Page 306: Convenience System Central Control Unit
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 5.3.3 Adapting convenience system central control unit -J393- The following functions can be adapted: ♦ Activating and deactivating “single door opening” ♦ Activating and deactivating “automatic locking above >15 Km/ h”...
Page 307: Trailer Detector Control Unit J345
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Trailer detector control unit -J345- The trailer detector control unit -J345- -arrow- is located behind the left side trim in the luggage compartment. Note Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐...
Page 308 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Removing: – Switch off ignition and all electrical consumers and pull out ignition key. – Remove left side panel trim in luggage compartment ⇒ Gen‐ eral body repairs, interior; Rep. Gr. 70 ; Removing and instal‐...
Page 309 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 5.4.3 Final control diagnosis trailer detector control unit -J345- Note The trailer detector control unit -J345- detects from a power ♦ draw of minimum 5 W the “trailer operation”.
Page 310: Wiring Harness And Connector Repairs
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Wiring harness and connector re‐ pairs Safety instructions Caution For repair work on airbag and seat belt tensioner wiring har‐ nesses, only contacts, connectors and wiring designed specif‐...
Page 311: Supplementary Notes On Repair Of Can Bus Wiring
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 ⇒ Operating instructions wiring harness repair set -V.A.G 1978- ♦ Perform wiring harness repairs only with yellow wires. Mark repair locations with yellow tape. ♦ Shielded wires must not be repaired. In case of damage, they must be entirely replaced.
Page 312: Wiring Harness Repair Set V.a.g 1978
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 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- .
Page 313: Renewal Of Aerial Wiring
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Renewal of aerial wiring A new repair concept has been developed for repair work on aer‐ ial wires. Now connecting wires in different lengths and various adapter cables are available as replacement parts instead of a complete aerial wire.
Page 314 Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 The total length of aerial connecting wire is the sum of the length of adapter cables required -1- and -3- and the connecting wire -2-. – To determine the length of connecting wire required, subtract 60 cm from the measured total length of aerial connecting wire -2-.
Page 315: Torque Settings: Cables
Jetta 2005 ➤ , Bora 2006 ➤ Electrical System - Edition 05.2005 Torque settings: Cables 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-...

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