VOLKSWAGEN JETTA 2005 (04) PDF Document

Before carrying out further work on the VOLKSWAGEN JETTA 2005 engine, disconnect the battery earth strap. First, check whether a coded radio is fitted and obtain the anti-theft code if necessary. The engine is removed downwards together with the gearbox. Renew all cable ties which are opened or cut open when removing the engine, and refit them in the same position when installing the engine.

When doing any repair work, especially in the engine compartment of the VOLKSWAGEN JETTA 2005, pay attention to the cramped conditions:

• All wirings (e.g. for fuel, hydraulic system, coolant and refrigerant liquid, brake liquid, vacuum) and electrical wirings must be installed in the original way.
• Ensure that there is sufficient clearance to all moving or hot components.

With the ignition switched off, disconnect the earth strap from the battery. Remove the engine cover by pulling it upwards abruptly at the front (arrows A) and then pulling it forwards out of the rear fastening (arrow B).

For VOLKSWAGEN JETTA 2005 vehicles with engine codes BKC, BXE, remove the air filter housing with air mass meter and connecting pipe. Disconnect connector -2- on the air mass meter -G70-. Pull breather hose -1- and air duct hoses -3- and -5- off. Unscrew bolt -4- and take off the air filter housing.

For VOLKSWAGEN JETTA 2005 vehicles with a diesel particulate filter, separate the following connectors (on the bulkhead): Connector for charge pressure regulation solenoid valve -N75-, Connector for bank 1 exhaust gas temperature sender 2 -G448-, Connector for bank 1 exhaust gas temperature sender 1 -G235-, and Connector for Lambda probe -G39-.

Before working on the Mechatronic unit of the VOLKSWAGEN JETTA 2005, touch an earthed object, such as a water pipe or a lifting platform. Do not touch connectors directly. Turn the bayonet connection -1- of the connector to the left and pull the connector off the gearbox.

Release retaining clip -A- off and remove upwards. Pull retaining clip -B- off upwards. Remove the selector lever cable from the selector shaft lever and place it on the top. For vehicles with a manual gearbox, unclip circlips -1- and -2- from both selector cables, then pull off the selector cable end-pieces from the gearbox selector lever and relay lever.

Clamp off the pressure line going to the slave cylinder with hose clamps for diameters up to Ø 25 mm -3094-. Remove the pressure line -1- out of the hose coupling by pulling the retaining clip upwards -arrow-. A caution states: Do not press the clutch pedal after removing the slave cylinder on the VOLKSWAGEN JETTA 2005.

The torque settings for the engine assembly mounting on the VOLKSWAGEN JETTA 2005 are:

Renew bolts for all specifications.

The torque settings for the gearbox assembly mounting on the VOLKSWAGEN JETTA 2005 are:

Renew bolts for all specifications.

The torque settings for the pendulum support on the VOLKSWAGEN JETTA 2005 are:

Renew bolts for both specifications. For removing: First remove bolt -B- then bolts -A-. For installing: First tighten bolts -A- then bolt -B-.

To check the engine oil level on the VOLKSWAGEN JETTA 2005, the engine oil temperature must be at least 60°C, and the vehicle must be level (horizontal). Wait a few minutes after switching off the engine to allow the oil to flow back into the sump.

Test procedure:

• Pull out the dipstick, wipe it off with a clean cloth, and insert it again onto the stop.
• Pull out the dipstick again and read off the oil level.

Markings on oil dipstick:

• 1 – Max. mark
• 2 – Min. mark
• a – Area above grooved section up to max. mark: Do not top up with engine oil!
• b – Oil level in grooved section: Can be topped up with engine oil.
• c – Area from min. mark up to grooved section: Must be topped up, max. 0.5 l of engine oil!

For VOLKSWAGEN JETTA 2005 vehicles with engine codes BKC and BXE:

• With oil filter change: 3.8 l.
• Without oil filter change: 3.3 l.

Top up to the max. marking if necessary.

For VOLKSWAGEN JETTA 2005 vehicles with engine codes BLS and BRM:

• With oil filter change: 4.3 l.
• Without oil filter change: 3.8 l.

Top up to the max. marking if necessary.

Finding metal shavings or a large quantity of small metal particles during engine repair on the VOLKSWAGEN JETTA 2005 could indicate that the crankshaft bearings or conrod bearings are damaged. To prevent further damage, perform the following repairs: Thoroughly clean oil passages, replace the oil cooler, and renew the oil filter element.

The torque specification for the crankshaft toothed belt pulley on the VOLKSWAGEN JETTA 2005 is 120 Nm + 90° (1/4 turn) further. Renew the component. Use counter-hold tool -3099- to loosen and tighten. Do not additionally oil or grease the thread and shoulder. Turning further can be done in several stages.

Piston projection at TDC on the VOLKSWAGEN JETTA 2005 must be measured when installing new pistons or a short engine. Turn the engine clockwise to measure piston projection at TDC. Install the appropriate cylinder head gasket depending upon piston projection, according to the following table:

Cylinder head gasket identification:

• Part No = -arrow 1-
• Production control code = -arrow 2- (disregard)
• Holes = -arrow 3-

The piston and cylinder dimensions for the basic dimension honing on the VOLKSWAGEN JETTA 2005 (Dimensions in mm) are:

The letter codes on the lower sealing surface of the cylinder block indicate the thickness of the bearing shell to be fitted at each location for the upper crankshaft bearing shells on the VOLKSWAGEN JETTA 2005:

Note: Arrow points in direction of travel. If the coloured marks are no longer legible, use blue bearing shells. Crankshaft lower bearing shells with “yellow” colour mark are always supplied as spare parts.

When installing an exchange cylinder head with a fitted camshaft on the VOLKSWAGEN JETTA 2005, the contact surfaces between the bucket tappets and the cam must be oiled before installing the cylinder head cover. The plastic protectors fitted to protect the open valves must not be removed until immediately before fitting the cylinder head. If the cylinder head is renewed, all the coolant in the system must also be renewed. Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide. Do not rework valve seats; only lapping in of valves is permitted. Wait about 30 minutes after installing the camshafts before starting the engine; hydraulic compensation elements must settle (otherwise valves will strike pistons). After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. Always renew gaskets and seals.

If ceramic glow plugs are fitted on the VOLKSWAGEN JETTA 2005, before removing, check idling speed smooth running control using Vehicle diagnosis, testing and information system -VAS 5051B-. The compression test is warranted only if one or more cylinders stand out in this idling speed check.

Test procedure:

• Remove all glow plugs or ceramic glow plugs using jointed extension and socket -3220-. Tightening torque: 15 Nm.
• Screw in adapter -V.A.G 1381/12- in place of glow plugs or ceramic glow plugs.
• Check compression using compression tester -V.A.G 1763-. Operate starter until tester shows no further pressure increase.

Compression pressures for the VOLKSWAGEN JETTA 2005:

• New: 25…31 bar, wear limit: 19 bar.
• Maximum permissible difference between all cylinders: 5 bar.

Interrogate the engine control unit fault memory.

To check the axial clearance of the camshaft on the VOLKSWAGEN JETTA 2005, check with bucket tappets removed and with the first, third, and last bearing caps fitted. The wear limit is max. 0.15 mm.

The valve dimensions for the VOLKSWAGEN JETTA 2005 are (in mm):

Note: Inlet and exhaust valves must not be machined. Only lapping-in is permitted.

When working on the fuel supply and injection systems of the VOLKSWAGEN JETTA 2005, pay careful attention to the following “6 rules” for cleanliness:

• Thoroughly clean all unions and adjacent areas before disconnecting.
• Place removed parts on a clean surface and cover. Do not use fluffy cloths!
• Carefully cover opened components or seal if repairs cannot be carried out immediately.
• Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes, etc.).
• When the system is open: do not work with compressed air if this can be avoided. Do not move the vehicle unless absolutely necessary.
• Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.

When doing any repair work on the fuel supply system of the VOLKSWAGEN JETTA 2005, pay attention to the following due to the cramped conditions:

• All wirings (e.g. for fuel, hydraulic system, coolant and refrigerant liquid, brake liquid, vacuum) and electrical wirings must be installed in the original way.
• Ensure that there is sufficient clearance to all moving or hot components.
• The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
• The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen the connection to release the pressure!
• Wear eye and hand protection when performing any type of repair work on the fuel system!

Before beginning work when removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank on the VOLKSWAGEN JETTA 2005, observe the following:

• Place an extraction hose close to the sender opening in the fuel tank to extract escaping fuel fumes and switch on the exhaust extraction system. If no exhaust extraction system is available, a radial fan with a displacement greater than 15 m³/h can be used providing that the motor is not in the air flow.
• Prevent skin contact with fuel! Wear fuel-resistant gloves!

With the EPC system on the VOLKSWAGEN JETTA 2005, the throttle valve is not operated by a cable; there is no mechanical connection between the accelerator pedal and the throttle valve. The position of the accelerator pedal is transmitted to the engine control unit by two accelerator pedal position senders (variable resistors together in one housing) connected to the accelerator pedal. This position (driver’s requirement) is a main input value for the engine control unit. The throttle valve is actuated by a servomotor (throttle valve positioner) in the throttle valve control part over the full range of engine speeds and load conditions. The engine control unit can open or close the throttle valve independently of the accelerator pedal position sender when the engine is running (under load), which results in significantly improved consumption and exhaust emission values under certain load conditions.

To check the function and voltage supply of the fuel pump on the VOLKSWAGEN JETTA 2005, ensure fuses are OK, battery voltage is at least 11.5 V, and all electrical consumers (e.g., lights and rear window heating) are switched off.

Procedure:

• Switch on the ignition. The fuel pump must be heard to run briefly (it runs very quietly).

If the fuel pump does not run:

• Remove the seat bench. Remove cover -1- from the fuel delivery unit (arrow -2- points in direction of travel). Pull off connector -1-. Connect the voltage tester -V.A.G 1527 B- to the outer contacts of the connector using auxiliary cables from the auxiliary measuring set -V.A.G 1594C-. Switch the ignition on. If the LED lights up briefly (voltage supply OK.), remove the fuel delivery unit. Check that the electrical wires between the flange and fuel pump are connected and for continuity. If no open circuit can be found, renew the fuel delivery unit. If the LED does not light up briefly, locate and eliminate the open circuit using the current flow diagram.

To measure the current draw of the fuel pump on the VOLKSWAGEN JETTA 2005, remove the seat bench. Remove cover -1- from the fuel delivery unit (arrow -2- points in direction of travel). Connect the current clamp -A- of the Vehicle diagnosis, testing and information system -VAS 5051B- to the cable -B- to contact 1 of the 5-pin connector. Start the engine and run at idling speed. The specification for the current draw of the fuel pump is max. 7.5 Ampere.

If the measured values lie outside the specifications, renew the fuel delivery unit.

When working on the turbocharger of the VOLKSWAGEN JETTA 2005, pay careful attention to the following rules of cleanliness:

• Thoroughly clean all joints and surrounding areas before dismantling.
• Place removed parts on a clean surface and cover. Use lint-free cloths only!
• Carefully cover opened components or seal if repairs cannot be carried out immediately.
• Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes, etc.).
• When the system is open: do not work with compressed air if this can be avoided. Do not move the vehicle unless absolutely necessary.

To check the charge air system for leaks on the VOLKSWAGEN JETTA 2005, use the Charge air system tester -V.A.G 1687- and Adapter -V.A.G 1687/1-. Remove intake hose -1- from the air filter and connect adapter -V.A.G 1687/1- in the intake hose -1- and secure with a clip.

Prepare the charge air system tester -V.A.G 1687- as follows:

• Unscrew the pressure regulating valve -2- completely and close valves -3- and -4-. The knob of the pressure regulating valve -2- must be pulled upwards to turn it.
• Connect the charge air system tester -V.A.G 1687- to adapter -V.A.G 1687/1- as shown.
• Connect the compressed air hose -1- (compressed air source) to the charge air system tester -V.A.G 1687-. If there is water in the sight glass, drain at water drain screw -6-.
• Open valve -3-.
• Adjust the pressure to 0.5 bar with the pressure regulating valve -2-. Caution: The pressure must not exceed 0.5 bar! If the pressure is too high this can cause damage to the engine.
• Open valve -4- and wait until the test circuit is filled. If necessary, readjust the pressure to 0.5 bar.
• Close valve -3- to retain pressure and observe the pressure drop over a period of 1 minute.

If the pressure does not drop, the tandem pump can be reused. If the pressure drops, the tandem pump must be renewed.