VOLKSWAGEN JETTA 2005 (21) PDF Document

Carry out the procedure in sequence as follows for the VOLKSWAGEN JETTA 2005:

1. Visual check.
2. Checking battery with a magic eye or checking a low maintenance battery.
3. Check no load voltage of battery.
4. Perform a battery load test using battery tester with printer -VAS 5097 A-.

The three different color displays possible for the magic eye when checking the battery on the VOLKSWAGEN JETTA 2005 are:

“Green”, battery is charged sufficiently.

“Black”, Battery partly discharged, charge state < 65 % or completely discharged.

“Colourless or yellow”, battery must be renewed.

To prevent damage to the battery terminal clamps and battery terminals on the VOLKSWAGEN JETTA 2005, the following should be observed:

The battery terminal clamps should only be fitted by hand and without using force.

Battery terminals should not be coated with grease.

The battery terminal clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it.

Once the battery terminal clamps have been tightened to the specified torque, the threaded connections should not be tightened any further.

To check the electrolyte level on a low maintenance battery for the VOLKSWAGEN JETTA 2005:

Check electrolyte level on housing via -min./ max.- marking on the battery housing. The electrolyte level is OK when the fluid level is at the max. marking.

If the electrolyte level is below the -max.- marking, replenish with distilled water.

Check electrolyte level in the cells by switching off the ignition and all electrical consumers, removing the protective foil (if fitted) on the cell sealing plug, and removing the cell sealing plugs.

Check the electrolyte level of the battery cells. The electrolyte level is OK when the fluid level is the same height as the plastic peg (which corresponds to the max. marking).

If the electrolyte level is OK: Check the cell sealing plugs and the O-ring seals for damage. Damaged parts must be replaced. Seal the cells with the cell sealing plugs.

If the electrolyte level is under the plastic peg, replenish with distilled water.

The torque settings for the battery threaded connections on the VOLKSWAGEN JETTA 2005 are:

To disconnect the battery for the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

Release catch and take cover off battery box.

First unscrew battery earth clamp -1- from battery negative terminal.

Then unscrew battery positive clamp -2- from battery positive terminal.

To connect the battery for the VOLKSWAGEN JETTA 2005, you should:

Fit battery positive clamp -2- to positive terminal of battery and tighten securing bolt to specified torque setting.

Fit battery earth clamp -1- to negative terminal of battery and tighten securing bolt to specified torque setting.

Carry out the procedures as detailed in the table regarding steps after connecting the battery.

The steps to perform after connecting the battery for the VOLKSWAGEN JETTA 2005 are:

If necessary, the table can be printed out.

The battery charger -VAS 5095 A- for the VOLKSWAGEN JETTA 2005 is suitable for charging:

Wet batteries (genuine VW batteries from 2004 with transparent battery housing and black cover).

Absorbent glass mat batteries (genuine VW batteries from 2004 with black housing).

The battery charger charges without peaks in amperage or voltage. This will not adversely effect the onboard electronics. The battery can remain in the vehicle while it is being charged and need not be disconnected.

The indicators on the Battery charger -VAS 5095 A- for the VOLKSWAGEN JETTA 2005 are:

1 – ON / OFF switch (0 = charger OFF)

2 – Charging current indicator (I > 12 A)

3 – Charging current indicator, battery partially charged > 90 %

4 – Maintaining charge, lights up green when battery is fully charged

5 – Malfunction indicator

6 – Support mode indicator

7 – Support mode/normal mode changer-over switch

8 – Charger cable posts, red terminal “+”, black terminal “-”

9 – Battery type change-over switch (on base of charger unit)

To charge a battery with the battery charger -VAS 5095 A- on the VOLKSWAGEN JETTA 2005:

Check setting for battery type on type of battery switch. Must be set to 2.4 V/C (Volt/Cells).

Connect red terminal clamp “+” of charger unit to positive terminal on battery.

Connect black terminal clamp “-” of charger unit to negative terminal on battery.

Switch on battery charger.

The charging current indicators -2- and -3- light up yellow. When only the light emitting diode (LED) -3- lights up yellow, the battery is partially discharged (approx. 90 %).

If the LED lights up green, the charger has switched to “maintaining charge”. The battery is fully charged.

Switch off charging unit.

Remove charger unit terminals from battery terminals.

To charge a totally discharged battery with the battery charger -VAS 5095 A- on the VOLKSWAGEN JETTA 2005:

The charger unit automatically recognises totally discharged batteries and initiates a gentle charging procedure with a low charging current. The charging current is automatically adapted to suit the charge condition of the battery.

The battery voltage must be at least 0.6 V.

Charge battery.

The charger unit automatically recognises totally discharged batteries.

To charge a battery in support mode with the battery charger -VAS 5095 A- on the VOLKSWAGEN JETTA 2005:

Set support mode/normal mode change-over switch to “support mode”.

Connect red terminal clamp “+” of charger unit to positive terminal of vehicle.

Connect black terminal clamp “-” of charger unit to negative terminal of vehicle.

Check setting for battery type on type of battery switch. Must be set to 2.4 V/C (Volt/Cells).

Switch on battery charger.

The yellow LEDs -6- and -3- light up.

A minimum load of 0.6 A (e.g. parking light) must be switched on, otherwise support mode is not possible.

During the support mode the current draw is limited to 5 A.

Switch on vehicle parking light.

Exchange battery.

Switch off charging unit.

Remove charger unit terminals from battery terminals.

Set support mode/normal mode change-over switch to “normal mode” again.

The battery charger -VAS 5900- for the VOLKSWAGEN JETTA 2005 is suitable for charging:

Wet batteries (genuine VW batteries from 2004 with transparent battery housing and black cover).

Absorbent glass mat batteries (genuine VW batteries from 2004 with black housing).

The components of the Battery charger -VAS 5095 A- for the VOLKSWAGEN JETTA 2005 are:

1 – Display

2 – Adjustment button “Up” ↑

3 – Adjustment button “Down” ↓

4 – START / STOP

5 – INFO

The charging indicators on the Battery charger -VAS 5095 A- for the VOLKSWAGEN JETTA 2005 are:

1 – ON / OFF switch (0 = charger OFF)

2 – Charging current indicator (I > 12 A)

3 – Charging current indicator, battery partially charged > 90 %

4 – Maintaining charge, lights up green when battery is fully charged

5 – Malfunction indicator

6 – Support mode indicator

7 – Support mode/normal mode changer-over switch

8 – Charger cable posts, red terminal “+”, black terminal “-”

9 – Battery type change-over switch (on base of charger unit)

To charge a battery with the battery charger -VAS 5900- on the VOLKSWAGEN JETTA 2005:

Set battery to respective operating mode with INFO.

In the display the symbol -1- for “standard charge for wet batteries” or the symbol -2- for “standard charge for gel/absorbent glass mat batteries” will appear.

Set battery capacity (Ah) of battery for charging using respective button “Up” ↑ or “Down” ↓.

Connect red terminal clamp “+” to positive terminal on battery.

Connect black terminal clamp “-” to negative terminal on battery.

The charger unit recognises the voltage required for the connected battery (6 V, 12 V or 24 V) and initiates the charging sequence.

At a charge condition of approx. 80 – 85 % the charger unit switches to the “final charge” mode. The fourth bar appears in display -1-. The battery is ready for use.

To end the battery charging sequence when using the battery charger -VAS 5900- on the VOLKSWAGEN JETTA 2005:

Press START / STOP.

Disconnect black terminal clamp “-” of charger unit from negative terminal on battery.

Disconnect red terminal clamp “+” of charger unit from negative terminal on battery.

Pull charger unit plug out power supply socket.

To check the battery no load voltage of the VOLKSWAGEN JETTA 2005:

The battery must not be charged or discharged for at least 2 hours before making the measurements.

Switch off ignition and all electrical consumers and pull out ignition key.

Disconnect negative terminal on battery.

Wait at least 2 hours. The battery must not be charged or discharged within this period.

Check battery no load voltage with hand multimeter -V.A.G 1526 B-.

The measured values and corresponding measures to be performed for the no load voltage test on the VOLKSWAGEN JETTA 2005 battery are:

If the battery has been recharged as a result of the no load test, proceed as follows:

Wait at least 2 hours. The battery must not be charged or discharged within this period.

Check battery no load voltage again with hand multimeter -V.A.G 1526 B-.

If after the loading process the battery no load voltage is < 12.5 V, renew battery.

The assembly overview components for the alternator on a 1.6 l injection engine for the VOLKSWAGEN JETTA 2005 are:

To remove the ribbed belt (poly V-belt) on the 1.6 l injection engine for the VOLKSWAGEN JETTA 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.

Mark direction of rotation of poly V-belt.

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-.

Remove ribbed belt.

To remove the alternator on a 1.6 l injection engine for the VOLKSWAGEN JETTA 2005:

Unclip coolant hose from hose retainer -1- and remove securing nut -2-.

Unbolt securing bolts -arrow-.

Take hose retainer together with tensioning element out of the vehicle.

Remove alternator securing bolts -arrows-.

Unscrew wiring bracket -arrow- from alternator.

Remove alternator.

The ribbed belt routing models on the 1.6 l FSI engine for the VOLKSWAGEN JETTA 2005 are:

Models without air conditioning system:

1. Ribbed belt (poly V-belt) pulley – Coolant pump
2. Tensioning roller
3. Ribbed belt (poly V-belt) pulley – Alternator
4. Poly V-belt
5. Ribbed belt (poly V-belt) pulley – Crankshaft

Models with air conditioning system:

1. Ribbed belt (poly V-belt) pulley – Coolant pump
2. Idler roller
3. Ribbed belt (poly V-belt) pulley – Alternator
4. Tensioning roller
5. Ribbed belt (poly V-belt) pulley – Air conditioner compressor
6. Poly V-belt
7. Ribbed belt (poly V-belt) pulley – Crankshaft

The assembly overview components for the alternator on a 2.0 l FSI engine for the VOLKSWAGEN JETTA 2005 are:

To remove the alternator on a 2.0 l FSI engine for the VOLKSWAGEN JETTA 2005:

Remove wiring bracket -1- and pull protective cap -2- off.

Disconnect connector of DF wiring -1- and pull B+ wiring -2- off alternator.

Mark direction of rotation of poly V-belt.

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-.

Remove ribbed belt.

Remove air conditioner compressor.

Remove lower securing bolt of alternator -arrow-.

Remove alternator from vehicle downwards.

The ribbed belt routing models on the 2.0 l FSI engine for the VOLKSWAGEN JETTA 2005 are:

Models without air conditioning system:

1. Tensioning roller
2. Ribbed belt pulley – Alternator
3. Poly V-belt
4. Ribbed belt pulley – Crankshaft

Models with air conditioning system:

1. Tensioning roller
2. Ribbed belt pulley – Alternator
3. Ribbed belt pulley – Air conditioner compressor
4. Tensioning roller
5. Ribbed belt pulley – Crankshaft

The assembly overview components for the alternator on a 1.9 l TDI engine for the VOLKSWAGEN JETTA 2005 are:

To remove the alternator on a 1.9 l TDI engine for the VOLKSWAGEN JETTA 2005:

Disconnect the battery.

Pull engine cover upwards -arrows A- and forwards -arrow B-.

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.

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.

Pull air filter housing upwards out of brackets and remove.

Push down protective cap -direction of arrow- from solenoid switch.

Unscrew positive wire -1- and disconnect connector from terminal 50 -2-.

Unscrew earth wire from starter securing bolt -arrow-.

Unscrew starter securing bolt -arrow-.

Remove noise insulation.

Unscrew nut -1- from lower starter securing bolt.

Remove wiring retainer -2-.

Unscrew starter securing bolt -arrow-.

Remove starter from vehicle upwards.

To remove the alternator on a 2.0 l TDI engine for the VOLKSWAGEN JETTA 2005:

Unbolt securing bolts -arrow-.

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-.

Pull hose -1- off air filter housing.

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-.

Unscrew positive wire -1- and disconnect connector from terminal 50 -2-.

Unscrew earth wire from starter securing bolt -arrow-.

Unscrew starter securing bolt -arrow-.

Remove noise insulation.

Unscrew securing nut -1- from lower starter securing bolt.

Remove wiring retainer -2-.

Unscrew starter securing bolt -arrow-.

Remove starter from vehicle downwards.

To remove the starter on the 2.0 l FSI turbo engine for the VOLKSWAGEN JETTA 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.

Unscrew positive wire -1- and disconnect connector from terminal 50 -2-.

Unclip hose -1- from hose retainer -2-.

Remove upper securing bolt of starter -arrow-.

Remove lower securing bolt of starter -arrow-.

Remove starter from vehicle upwards.

The torque settings for the starter on the VOLKSWAGEN JETTA 2005 are:

The general torque settings for the alternator on the VOLKSWAGEN JETTA 2005 are:

To check the ribbed belt (poly V-belt) on the VOLKSWAGEN JETTA 2005:

Crank engine at vibration damper/belt pulley using a socket.

Fit ribbed belt (poly V-belt).

Check for:

Sub-surface cracks (cracks, core ruptures, cross sectional breaks)

Layer separation (top layer, draw strands)

Chassis breakout

Fraying of cord strands

Flank wear (material wear, frayed flanks, flank brittleness (glassy flanks), surface cracks)

Traces of oil and grease

It is essential to renew poly V-belt if faults are found. This will avoid possible break-downs or operating problems.

To check the alternator -C- on the VOLKSWAGEN JETTA 2005:

Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 27 – Starter, current supply
• Electrical components
• C – Alternator

The ribbed belt routing models on the 1.9 l TDI engine for the VOLKSWAGEN JETTA 2005 are:

Models without air conditioning system:

1. Tensioning roller
2. Ribbed belt pulley – Alternator
3. Poly V-belt
4. Ribbed belt pulley – Crankshaft

Models with air conditioning system:

1. Tensioning roller
2. Ribbed belt pulley – Alternator
3. Ribbed belt pulley – Air conditioner compressor
4. Poly V-belt
5. Ribbed belt pulley – Crankshaft

To remove the air filter housing on the 1.9 l TDI engine for the VOLKSWAGEN JETTA 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.

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.

Pull air filter housing upwards out of brackets and remove.

To remove the starter on the 2.0 l SDI engine for the VOLKSWAGEN JETTA 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-.

Remove air filter housing from vehicle.

Push down protective cap -direction of arrow- from solenoid switch.

Unscrew positive wire -1- and disconnect connector from terminal 50 -2-.

Unscrew earth wire from starter securing bolt -arrow-.

Unscrew starter securing bolt -arrow-.

Remove noise insulation.

Unscrew securing nut -1- from lower starter securing bolt.

Remove wiring retainer -2-.

Unscrew starter securing bolt -arrow-.

Remove starter from vehicle downwards.

To deactivate the APP function of wiper motors on the VOLKSWAGEN JETTA 2005:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 01 – On Board Diagnostic capable systems
• Onboard supply control unit
• Onboard supply control unit functions
• Control unit functions for wiper electronics

The steps to remove the wiper arm on the VOLKSWAGEN JETTA 2005 are:

Lever off the protective cap -arrows- using a screwdriver.

Loosen the hexagon nut -arrows-, without removing it completely.

Position legs of puller -T10130- -2- under wiper arm-4- as shown in the figure.

Turn thrust bolt -1- of puller -T10130- clockwise until it comes into contact with the wiper shaft. The hexagon nut -3- previously loosened on the wiper arm serves as a means of centring and guiding the thrust bolt -1-.

Turn thrust bolt -1- of puller -T10130- clockwise using 6 mm spanner until wiper arm -4- is released from the shaft.

The steps for removing the plenum chamber cover on the VOLKSWAGEN JETTA 2005 are:

Unclip plenum chamber cover -1-, starting from side, off top of windscreen frame -arrow-.

If the spray field is not uniform because the spray jet is soiled on the VOLKSWAGEN JETTA 2005, remove the spray jet and clean in opposite direction of spray with water. In the following it is allowed to blow the spray jets in opposite direction of spray with compressed air. Do not use objects to clean the spray jets.

To bleed the headlight washer system on the VOLKSWAGEN JETTA 2005 to guarantee sound functioning, the headlight washer system must be bled following assembly work or when operated for the first time:

Fill reservoir for windscreen and headlight washer systems.

Start the engine.

Switch “ON” the headlight.

Operate headlight washer system several times (3-5 times, 3 seconds each time).

Repeat this bleeding procedure until the pop-up cylinders and spray jets are functioning soundly.

The torque settings for the windscreen wash/wipe system on the VOLKSWAGEN JETTA 2005 are:

The torque settings for exterior lights, bulbs, and switches on the VOLKSWAGEN JETTA 2005 are:

The torque settings for fog lights on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the tail light in the side panel on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the tail light in the tailgate on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the vehicle level sender on the VOLKSWAGEN JETTA 2005 are:

The components integrated into the light switch -E1- on the VOLKSWAGEN JETTA 2005 are:

Fog light switch -E7-

Rear fog light switch -E18-

Light switch illumination bulb -L9-

The components integrated into the driver side door lock on the VOLKSWAGEN JETTA 2005 are (depending on equipment):

Driver door contact switch -F2-

Driver side central locking lock unit -F220-

Driver door central locking motor -V56-

Driver door central locking deadlock function motor -V161-

The components integrated into the passenger side door lock on the VOLKSWAGEN JETTA 2005 are (depending on equipment):

Front passenger door contact switch -F3-

Front passenger side central locking lock unit -F221-

Front passenger seat central locking motor -V57-

Front passenger door central locking deadlock function motor -V162-

The components integrated into the switch module for the driver side window lift (4 doors) on the VOLKSWAGEN JETTA 2005 are:

Front left window regulator switch -E40-

Rear left window regulator switch, in door -E53-

Rear right window regulator switch, in door -E55-

Front right window regulator switch in driver door -E81-

Childproof lock button -E318-

Button illumination bulb -L76-

The components integrated into the switch module for the driver side window lift (2 doors) on the VOLKSWAGEN JETTA 2005 are:

Front left window regulator switch -E40-

Front right window regulator switch in driver door -E81-

Button illumination bulb -L76-

The components integrated into the rear left door lock on the VOLKSWAGEN JETTA 2005 are (depending on equipment):

Rear left door contact switch -F10-

Rear left central locking lock unit -F222-

Rear left door central locking motor, lock -V214-

Rear left door central locking deadlock function motor -V163-

The components integrated into the rear right door lock on the VOLKSWAGEN JETTA 2005 are (depending on equipment):

Rear right door contact switch -F11-

Rear right central locking lock unit -F223-

Rear right door central locking motor, lock -V215-

Rear right door central deadlock function locking motor -V164-

The components integrated in the rear interior light and reading light with ATAS on the VOLKSWAGEN JETTA 2005 are:

Rear left footwell light -W45-

Rear left reading light -W11-

Rear right reading light -W12-

Anti-theft alarm ultrasonic sensor -G209-

The components integrated in the rear interior light and reading light without ATAS on the VOLKSWAGEN JETTA 2005 are:

Rear left footwell light -W45-

Rear left reading light -W11-

Rear right reading light -W12-

To remove the interior light using removal wedge -VAS 3409- on the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

Carefully lever lens for interior light out using removal wedge -VAS 3409- or screwdriver -arrow-.

Press contact -1- of light to side -arrow- and remove festoon bulb -2- with the contact from the interior light.

Pull contact -arrow- off defective festoon bulb.

Unbolt securing bolts -arrow-.

Take the interior light out of the headliner console.

Remove connectors -arrows-.

To remove the sunroof switch -E8- on the VOLKSWAGEN JETTA 2005:

Remove interior light.

Disconnect connector -arrow-.

Release locking lugs -arrows- and remove switch from the installation frame.

To remove the TCS and ESP button -E256- on the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

Take bellow carefully off centre console -arrows-.

Unbolt securing bolts -arrow-.

Take mounting frame with ashtray out of the centre console.

Remove connectors -arrows-.

To remove the alarm horn -H12- on the VOLKSWAGEN JETTA 2005:

Switch off ignition and all electrical consumers and pull out ignition key.

Remove front right wheel housing liner.

Drill out both pop rivets -arrows- using drill -VAS 5134- and ∅ 6 mm twist drill.

Pull alarm horn -H12- -1- in -direction of arrow- out of the aperture in the bodywork.

Pull connector off -2-.

To check the trailer detector control unit -J345- on the VOLKSWAGEN JETTA 2005:

Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• General Body Repairs
• 01 – On Board Diagnostic capable systems
• Trailer detector
• Function
• Trailer detector control unit – Final control diagnosis

To remove the electronics box on the left in the engine compartment on the VOLKSWAGEN JETTA 2005:

Disconnect the battery.

Release clips -1- in -direction of arrow- and take cover of electronics box -2- off upwards.

Remove hexagon nuts -1-.

Open -arrows- covers -2- of cable guides on electronics box.

Remove wiring from stud connections.

Unclip wiring from cable guides.

Remove central securing screw -arrow- from electronics box -1-.

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

Remove air filter housing, if necessary.

Remove battery.

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

Take battery console -1- out of vehicle.

To install the electronics box on the left in the engine compartment on the VOLKSWAGEN JETTA 2005:

Mount the cover -2- on the electronics box and push the safety clip -1- in -direction of arrow- until cover -2- engages.

Then check whether the cover -2- of the electronics box is engaged correctly.

The onboard supply control unit -J519- for the VOLKSWAGEN JETTA 2005 is responsible for the following in the vehicle:

Electrical load management

Exterior light control

Turn signal control

Rear window wiper

Heated rear window

Terminal control

Surround lighting

Terminal control

Dimmers, instrument lighting

Fuel pump presupply

Alternator stand-by

Horn

The functions that can be adapted on the onboard supply control unit -J519- for the VOLKSWAGEN JETTA 2005 are:

Deleting learning values and setting standard adaptation values

Adjusting period for coming home function (depending on equipment)

Adjusting period for leaving home function (depending on equipment)

Adjusting rear window heating “On time”

Switching on and off footwell lighting

Switching on and off motorway signaling

Adjusting load management

Adjusting “activation time” for headlight cleaning system

To code the onboard supply control unit -J519- on the VOLKSWAGEN JETTA 2005:

Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 01 – On Board Diagnostic capable systems
• Onboard supply control unit
• Onboard supply control unit functions
• Code control unit

To modify the headlight cleaning system on the VOLKSWAGEN JETTA 2005:

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-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 01 – On Board Diagnostic capable systems
• Onboard supply control unit
• Onboard supply control unit functions
• Modifying headlight cleaning system

The functions of the diagnosis interface for data bus -J533- (gateway) in the vehicle for the VOLKSWAGEN JETTA 2005 are:

Responsible for exchange of data between CAN data bus systems “drive train CAN data bus”, “convenience CAN data bus” and “Infotainment CAN data bus”

Converts diagnostic data from CAN data bus systems to COM wire and vice versa. In this way, data can also be used by the the vehicle diagnosis, testing and information system -VAS 5051A-

To remove the data bus diagnostic interface -J533- on the VOLKSWAGEN JETTA 2005:

Before removing data bus diagnostic interface -J533- , it is essential that the work procedure “Renewing dash panel insert” is carried out, so that access can be gained to the codes stored within.

Switch off ignition and all electrical consumers and pull out ignition key.

Remove cover, footwell, on driver side.

Release connector -1- and pull connector off data bus diagnostic interface -J533- -2-.

Push securing pins -3- together -arrows- and pull out of holes.

Installation is in reverse order of removal.

The convenience system central control unit -J393- for the VOLKSWAGEN JETTA 2005 is responsible for the following in the vehicle:

Sliding/tilting sunroof control (release instruction)

Power window control (release instruction)

Central locking control

Anti-theft alarm system control

Radio-wave receiver

Rear lid lock

Comfort operation

The functions that can be adapted on the convenience system central control unit -J393- for the VOLKSWAGEN JETTA 2005 are:

Activating and deactivating “single door opening”

Activating and deactivating “automatic locking above >15 Km/h”

Activating and deactivating “automatic unlocking when ignition key is removed”

Activating and deactivating “country settings for intelligent alarm horn”

Activating and deactivating “battery monitoring system (sounder)”

Activating and deactivating “comfort operation via radio remote control unit”

Activating and deactivating “anti-theft alarm system – alarm delay when driver’s door is opened”

“Sensitivity of tilt angle sensor”

“Sensitivity of interior monitoring system”

To code the convenience system central control unit -J393- on the VOLKSWAGEN JETTA 2005:

Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• General Body Repairs
• 01 – On Board Diagnostic capable systems
• Comfort system
• Comfort system central control unit functions
• J393 – Coding convenience system central control unit

To read alarm sources of the anti-theft alarm system using the convenience system central control unit -J393- on the VOLKSWAGEN JETTA 2005:

Connect Vehicle Diagnosis, Testing and Information System -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• General Body Repairs
• 01 – On Board Diagnostic capable systems
• Comfort system
• Comfort system central control unit functions
• J393 – Read alarm sources of anti-theft alarm system

To check the vehicle level sender on the VOLKSWAGEN JETTA 2005:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Running gear
• Brake system
• 01 – Mark 60/Mark 70 systems, capable of self-diagnosis
• Anti-lock braking system ABS/EDL/TCS/ESP Mark 60
• Function
• Basic setting steering angle sensor (00778-3132) -G85-

Before working on headlights on the VOLKSWAGEN JETTA 2005, always switch off the headlights and remove the ignition key.

To remove the front side marker on the VOLKSWAGEN JETTA 2005:

Remove noise insulation.

Unlock side marker -1- by pressing the locking lug -in direction of arrow-.

Remove bulb holder -2- out of side marker.

After the installation perform functional check.

To renew the side marker bulb on the VOLKSWAGEN JETTA 2005:

Pull side marker bulb -1- in direction of arrow out of the bulb holder -2-.

The torque settings for exterior lights, bulbs, and switches on the VOLKSWAGEN JETTA 2005 are:

The torque settings for fog lights on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the tail light in the side panel on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the tail light in the tailgate on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the vehicle level sender on the VOLKSWAGEN JETTA 2005 are:

The torque settings for cables related to the electronics box in the left side of the engine compartment on the VOLKSWAGEN JETTA 2005 are:

The torque settings for the trailer detector control unit -J345- on the VOLKSWAGEN JETTA 2005 are:

The functions of the cruise control system (CCS) controlled by the engine control unit for the VOLKSWAGEN JETTA 2005 are:

Activating and deactivating cruise control system.

The components integrated in the dash panel insert for the VOLKSWAGEN JETTA 2005 are:

Control unit with display in dash panel insert -J285-

Immobilizer control unit -J362-

Speedometer

Rev counter

Fuel gauge

Coolant temperature gauge

Multi-function display

Warning lamps.

The work sequence “Renewing dash panel insert” for the VOLKSWAGEN JETTA 2005 consists of the following work:

If a new dash panel insert has to be installed in the vehicle, the dash panel insert control unit has to be adapted to the different vehicle equipment and the respective country variant.

To adapt the integrated immobilizer to the engine control unit, the data of the engine control unit must be stored in the exchange dash panel insert.

After installing a new dash panel insert, perform adaption of all vehicle keys.

To remove the dash panel insert on the VOLKSWAGEN JETTA 2005:

Remove the upper part of the steering column trim.

Remove securing bolts -arrows- for dash panel insert.

Pull dash panel insert out of dash panel.

The warning lamp symbols on the dash panel insert for the VOLKSWAGEN JETTA 2005 depend on the vehicle’s equipment, country and engine type. They include:

The procedure for resetting the service interval display on the VOLKSWAGEN JETTA 2005 is found in Maintenance; Booklet 20.1.

The wiper motor control unit -J400- and the wiper motor -V- are joined together as one unit for the windscreen wiper system on the VOLKSWAGEN JETTA 2005.

To remove the wiper blades, the wiper arms should be placed in the “service/winter position”. The “service/winter position” is activated within 10 seconds after ignition is switched off by pressing windscreen wiper lever in “tip wipe”.

The onboard supply control unit -J519- is equipped with self-diagnosis, which is designed to ease fault finding for the windscreen wiper system on the VOLKSWAGEN JETTA 2005.

For fault finding, use the vehicle diagnosis, testing and information system -VAS 5051A- in “guided fault finding” mode.

To deactivate the APP function of wiper motors on the VOLKSWAGEN JETTA 2005:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 01 – On Board Diagnostic capable systems
• Onboard supply control unit
• Onboard supply control unit functions
• Control unit functions for wiper electronics

Note that the APP function cannot be activated, and after 100 cycles of wiper movement, the APP function is activated automatically.

The assembly overview of the windscreen washer system for the VOLKSWAGEN JETTA 2005 includes:

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 either dipped beam or high beam are switched on for the headlight washer system on the VOLKSWAGEN JETTA 2005.

The “active time” of the headlight washer system can be variably adjusted to between 0 and 12.75 seconds.

To guarantee sound functioning, the headlight washer system must be vented following assembly work or when activated for the first time.

The onboard supply control unit -J519- is equipped with self-diagnosis, which is designed to ease fault finding.

For fault finding, use the vehicle diagnosis, testing and information system -VAS 5051A- in “guided fault finding” mode.

The assembly overview of the headlight washer system for the VOLKSWAGEN JETTA 2005 includes:

To remove the spray jet assembly on the headlight washer system for the VOLKSWAGEN JETTA 2005:

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.

Unclip cap -1- from mounting points -arrows- on washer spray jet assembly.

Lever locking hooks -arrow- up slightly and pull out spray jet assembly.

To install, push washer spray jet assembly in pop-up cylinder until it engages, fit cover cap on washer spray jet assembly and allow pop-up cylinder to retract, check cover cap seating, adjust if necessary, bleed headlight washer system, and check/adjust spray jets.

To remove the pop-up spray jet cylinder on the headlight washer system for the VOLKSWAGEN JETTA 2005:

Switch off ignition and all electrical consumers and pull out ignition key.

Pull spray jets with cap -1- out of bumper cover onto stop.

Unclip cap -1- from mounting points -arrows- on washer spray jet assembly.

Remove front bumper cover.

Pull the securing clip -4- off hose connection.

Pull hose connection off pop-up cylinder -2-.

Remove securing bolt -1-.

Unclip pop-up spray jet cylinder -2- from bracket -3-.

To install, ensure the pop-up spray jet cylinder hose is attached to the securing clip on the bracket, tighten threaded connections to specified torque settings, and bleed the headlight washer system.

To bleed the headlight washer system on the VOLKSWAGEN JETTA 2005:

Fill reservoir for windscreen and headlight washer systems.

Start the engine.

Switch “ON” the headlight.

Operate headlight washer system several times (3-5 times, 3 seconds each time).

Repeat this bleeding procedure until the pop-up cylinders and spray jets are functioning soundly.

The following hose coupling types are used for the Wash water line hose couplings on the VOLKSWAGEN JETTA 2005:

For Windscreen and rear window washer system: Pull the two coupling sections apart (no securing device) to loosen the connection. To secure the connection, push the two coupling sections together, until you hear and feel them engage. Or, to loosen the connection, rotate the lock ring -1- by 90° -arrow- and pull off the hose connection. To secure the connection, push on the hose connection and rotate the lock ring -1- -arrow- until it engages. Or, to loosen the connection, pull up the lock ring -1- by approx. 1 mm -arrow- and pull off the hose connection. To secure the connection, push on the hose connection and push in the lock ring -1- until it engages.

For 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. Check that the securing clip has correctly engaged by depressing and trying to pull off without the clip.

A new repair concept for the VOLKSWAGEN JETTA 2005 involves connectors, special EPDM hoses (ethylene propylene diene monomer) and heat-shrink hose available as spare parts. Replacement parts are available for repair of both smooth and corrugated pipes.

To repair a smooth pipe with a diameter of 5×1 mm or 6×1 mm using EPDM hose on the VOLKSWAGEN JETTA 2005:

Cut damaged section at right angles out of smooth pipe which is to be repaired.

Select the appropriate EPDM hose -2- and cable ties according to the parts catalogue (ETKA).

Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe can each be pushed about 10 mm into the EPDM hose -2-.

Secure the repair joints with cable ties -1-.

To repair a corrugated pipe on the VOLKSWAGEN JETTA 2005:

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.

Cut damaged section at right angles out of corrugated pipe which is to be repaired.

Select the appropriate connectors -2- and -3- as well as the appropriate heat-shrink hose according to the parts catalogue (ETKA).

Heat end of corrugated pipe -1-.

Push connector -2- into corrugated pipe -2- -arrow A-.

Heat end of corrugated pipe -4-.

Push connector -3- into corrugated pipe -4- -arrow B-.

Cut heat-shrink hose so that ends of corrugated pipe are each covered by about 20 mm -dimension x- of heat-shrink hose.

Push heat-shrink hose over corrugated pipe, join connectors and secure repair joints with heat-shrink hose.

Repair points must not be subjected to pulling or bending forces.

Before working on headlights on the VOLKSWAGEN JETTA 2005, always switch off the headlights and remove the ignition key.

When dealing with complaints, it is absolutely essential that the function and operation of the lighting system is first understood.

The vehicle is fitted with headlights from three different manufacturers: AL (Automotive Lighting) and Hella.

Removal and installation of the headlights and its attachments is the same; only the removing and installing of the actuator motors are different.

The onboard supply control unit has a self-diagnosis function, which makes fault finding on the headlights easier.

For fault finding, use the vehicle diagnosis, testing and information system -VAS 5051A- in “guided fault finding” mode.

The assembly overview for the headlight on the VOLKSWAGEN JETTA 2005 includes:

To remove headlights on the VOLKSWAGEN JETTA 2005:

Switch off ignition and all electrical consumers and pull out ignition key.

Release multi-pin connector -arrow- and pull off multi-pin connector.

Remove front bumper.

Unscrew securing screw -arrow- on upper headlight.

Unscrew securing screw -arrow- on lower left headlight.

Unscrew securing screw -arrow- on lower right headlight.

To install headlights on the VOLKSWAGEN JETTA 2005:

Installation is performed in the reverse order of installation. Tighten all securing bolts to specified torque setting.

Check headlight installation position is central, i.e. shutlines are equal around headlight. If the shutlines around the headlight are uneven, the installation position must be adjusted.

Check function of headlight. If a headlight is removed, it should always be adjusted.

Check headlight setting and adjust headlight as necessary.

To adjust the headlight installation position on the VOLKSWAGEN JETTA 2005:

The front bumper must not be removed.

Switch off ignition and all electrical consumers and pull out ignition key.

Remove radiator.

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.

Tighten threaded connections to specified torque settings.

Check and, if necessary, readjust headlight to ensure gaps are even all round.

Install radiator.

Check function of headlight. If a headlight is removed or adapted to the body it should always be adjusted after installing or adapting it. Check headlight setting and adjust headlight as necessary.

To renew the dipped beam headlight bulb for the left headlight on the VOLKSWAGEN JETTA 2005:

Switch off ignition and all electrical consumers and pull out ignition key.

Turn cover cap -1- in -direction of arrow- and remove.

Turn bulb holder with dipped beam headlight bulb -1- in -direction of arrow- and remove from headlight.

Pull dipped beam headlight bulb -2- in -direction of arrow- out of bulb holder -1-.

When installing cap, ensure that it is seated correctly. The ingress of water will lead to permanent damage of the headlight.

Do not touch bulb glass when fitting bulbs. Fingers leave traces of grease on the glass, which evaporate when the bulb is switched on and cause the glass to cloud over.

Place headlight dipped beam bulb -1- in the bulb holder that the pin on the dipped beam headlight bulb lies in the recess -arrow- of bulb holder -2-.

Place bulb holder with dipped beam headlight bulb -1- in headlight and turn bulb holder with dipped beam headlight bulb in -direction of arrow-.

Place cover cap -1- in headlight recess and tighten in -direction of arrow-.

Check function of headlight.

Check headlight setting and adjust headlight as necessary.

To renew the front turn signal bulb for the left headlight on the VOLKSWAGEN JETTA 2005:

Switch off ignition and all electrical consumers and pull out ignition key.

Turn off cover cap -1-.

Pull, depending on the cable length, the bulb holder -1- with the front turn signal bulb in -direction of arrow- and take them out of the reflector.

Push front turn signal bulb -2- into bulb holder -1- and turn front turn signal bulb -2- in -direction of arrow-.

Pull front turn signal bulb -2- out of the bulb holder -1-.

When installing cap, ensure that it is seated correctly. The ingress of water will lead to permanent damage of the headlight.

Do not touch bulb glass when fitting bulbs. Fingers leave traces of grease on the glass, which evaporate when the bulb is switched on and cause the glass to cloud over.

Check function of headlight.

Check headlight setting and adjust headlight as necessary.

Before working on gas discharge headlights on the VOLKSWAGEN JETTA 2005, always switch off the headlights and remove the ignition key.

The automatic headlight range control on headlights with gas discharge bulbs is equipped with self-diagnosis.

When dealing with complaints, it is absolutely essential that the function and operation of the lighting system is first understood.

The automatic headlight range adjustment (HRA) and onboard supply control unit have a self-diagnosis function, which makes fault finding on the headlights using gas discharge lamps easier.

For fault finding, use the vehicle diagnosis, testing and information system -VAS 5051A- in “guided fault finding” mode.

The assembly overview for gas discharge headlights on the VOLKSWAGEN JETTA 2005 includes:

To remove the gas discharge light control unit on the VOLKSWAGEN JETTA 2005:

Remove headlight.

Remove securing bolts -arrows- of gas discharge light control unit -1-.

Take off gas discharge light control unit -1- from headlight.

Note that when taking off the gas discharge light control unit the connectors must not be removed. The connector is fitted tightly to the headlight and is automatically disconnected when taking off the gas discharge light control unit.

When installing the gas discharge light control unit secure correct seat of the seal. The ingress of water will lead to permanent damage of the headlight.

Check function of headlight.

Perform basic setting of headlights.

The components integrated in the interior light and reading light (vehicles with no sliding sunroof) on the VOLKSWAGEN JETTA 2005 are:

Front interior light -W1-

Left centre reading light -W39-

Left centre reading light -W40-

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.

To remove the interior light using removal wedge -VAS 3409- on the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

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.

Remove connectors -arrows-.

The components integrated in the interior light and reading light (vehicles with sliding sunroof) on the VOLKSWAGEN JETTA 2005 are:

Front interior light -W1-

Left centre reading light -W39-

Left centre reading light -W40-

Sunroof switch -E8-

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.

To remove the sunroof switch -E8- on the VOLKSWAGEN JETTA 2005:

Remove interior light.

Disconnect connector -arrow-.

Release locking lugs -arrows- and remove switch from the installation frame.

To remove the festoon bulb from the interior light on the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

Carefully lever lens for interior light out using removal wedge -VAS 3409- or screwdriver -arrow-.

Press contact -1- of light to side -arrow- and remove festoon bulb -2- with the contact from the interior light.

Pull contact -arrow- off defective festoon bulb.

Fit the contact to the new festoon bulb (12 V, 10 W).

To turn the bulb holder for the left/right centre reading light on the VOLKSWAGEN JETTA 2005:

Remove interior light.

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.

Renew glas base bulb (12 V, 5 W).

To remove the rear interior and reading light (vehicles without ATAS) on the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

Release locking lugs -arrows- and take trim with lens off interior light and reading light.

Release locking lugs -arrows- and remove interior light and reading light from the headliner.

Disconnect connector -arrow-.

To remove the rear interior and reading light (vehicles with ATAS) on the VOLKSWAGEN JETTA 2005:

If a rear interior and reading light is removed, the ATAS must be deactivated.

Switch off the ignition and all electrical consumers.

Pull the entire complete trim -1- (including lens and reflectors) -arrows- vertically downwards and out from the interior and reading light.

Press both locking tabs -2- in -direction of arrow A- and take the complete interior and reading light -1- in -direction of arrow B- off the headliner.

Unlock connectors -1- and -2- and pull both connectors off.

To remove the rear interior and reading light bulbs (vehicles with ATAS) on the VOLKSWAGEN JETTA 2005:

If a rear interior and reading light bulb is renewed, the ATAS must be deactivated.

Release locking lugs -arrows- and take trim with lens off interior light and reading light.

Pull glass base bulb -1- from the holder.

Renew defective glass base bulb (12 V, 5 W).

To remove the front passenger side illuminated vanity mirror -W14- and driver side illuminated vanity mirror -W20- on the VOLKSWAGEN JETTA 2005:

Switch off the ignition and all electrical consumers.

Lever light carefully out of the roof trim using removal wedge -VAS 3409- or screwdriver -arrow-.

Press contact -1- of light to side -arrow- and remove festoon bulb -2- out of the socket.

Pull contact -arrow- off defective festoon bulb.

Fit the contact to the new festoon bulb (12 V, 10 W).

To remove the garage door operating unit -E284- on the VOLKSWAGEN JETTA 2005:

The garage door operating unit -E284- is located in the sun visor on the driver side. The sun visor and the garage door operating unit -E284- may only be replaced together.

Remove the sun visor on the driver side with garage door operating unit -E284- -1-.

The functions of the ATAS for the VOLKSWAGEN JETTA 2005 are integrated into the central control unit for comfort system -J393-.

The anti-theft alarm system is equipped with self-diagnosis which makes fault finding easier.

For fault finding, use the vehicle diagnosis, testing and information system -VAS 5051A- in “guided fault finding” mode.

Once the anti-theft alarm system has been triggered, the alarm source that has been stored in the convenience system central control unit -J393- can be interrogated.

To activate the anti-theft alarm system on the VOLKSWAGEN JETTA 2005, the system is switched on automatically when the vehicle is locked. The system is then immediately armed. Completely close all windows and doors before locking the vehicle to prevent an unnecessary alarm.

To deactivate the anti-theft alarm system on the VOLKSWAGEN JETTA 2005:

The system is deactivated when the vehicle is unlocked using the radio remote control key or when the ignition is switched on.

To unlock the car mechanically (emergency open), unlock the driver door. The anti-theft alarm system remains active, although no alarm is triggered. Switch ignition on within 15 seconds. If you do not switch on the ignition, the alarm will trigger after 15 seconds.

The anti-theft alarm ultrasonic sensor -G209- on the VOLKSWAGEN JETTA 2005, comprising 4 individual sensors -2-, leads and a control element on the back of the interior and reading light, cannot be replaced individually; the entire rear interior and reading light must be replaced.

The anti-theft alarm system must be deactivated before the sender is removed.

Removing:

Switch off ignition and all electrical consumers and pull out ignition key.

Remove glove compartment.

Unscrew the securing bolts -1- and remove vehicle inclination sender -G384- from the bracket.

Release the connector -2- and pull it away from the vehicle inclination sender -G384- .

Installation is in reverse order of removal.

The alarm horn -H12- on the VOLKSWAGEN JETTA 2005 can be tested using final control diagnosis from convenience system central control unit -J393-.

For repair work on airbag and seat belt tensioner wiring harnesses on the VOLKSWAGEN JETTA 2005, only contacts, connectors and wiring designed specifically for this purpose may be used. Observe country-specific regulations and vehicle stickers indicating high voltage components. Before carrying out repairs, discharge residual voltage. Wires from airbag and belt tensioner wiring harness must only be repaired using wiring harness repair set -V.A.G 1978- .

General notes concerning repairs to the vehicle electrical system on the VOLKSWAGEN JETTA 2005:

Observe current notes (also notes concerning removing and installing components) in workshop manuals and in the Technical Service Handbook.

Yellow wiring and sections of wiring harness wrapped in yellow tape indicate a prior repair.

Before beginning repairs to a wiring harness, first rectify the cause of the damage, e.g. sharp edges on a body part, defective electrical consumer, corrosion.

Disconnecting the battery earth strap (open circuit) provides a safe working environment for repairs to the electrical system. The battery positive wire need only be disconnected for removal of the battery.

If possible, do not loosen any earth wires from the body (danger of corrosion).

Notes on repairs to wiring harness and connectors on the VOLKSWAGEN JETTA 2005:

Soldering is not permitted for repairs to vehicle wiring.

Never repair any heat-shrink connections. If necessary, lay wiring parallel to the defective wiring.

Onboard supply wiring harnesses and connectors may only be repaired using wiring harness repair set -V.A.G 1978- .

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.

Supplementary notes on repair of CAN bus wiring for the VOLKSWAGEN JETTA 2005:

An unshielded two-wire line -1- and -2- with a cross section of 0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.

The colour codes of the CAN bus wiring are:

Perform wiring harness repairs only with yellow wires. Mark repair locations with yellow tape.

When repairs are performed, both bus wires must have the same length. When wires -1- and -2- are twisted together, the twist spacing should be A=20 mm.

No section of wiring greater than B=50 mm, e.g. in the vicinity of heat-shrink sleeves -arrow-, should not be twisted.

For the renewal of aerial wiring for the VOLKSWAGEN JETTA 2005, a new repair concept uses connecting wires in different lengths and various adapter cables as replacement parts instead of a complete aerial wire. Replacement parts can be found in the electronic parts catalogue: Special catalogue; Electrical connections; Genuine accessories; Subgroup 35 from illustration No. 035-20.

These genuine parts are suitable for all aerial wires and wire diameters which may need to be replaced.

This repair method can also be used for testing or retrofitting.

The aerial wire components required for the repair of a defective aerial wire between the radio and aerial on the VOLKSWAGEN JETTA 2005 are:

1. Adapter cable, to radio connection. Length approx. 30 cm.
2. Connecting wire, available in different lengths.
3. Adapter cable, to aerial connection. Length approx. 30 cm.

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 install a new aerial wire on the VOLKSWAGEN JETTA 2005:

Pull defective aerial wire connections off units.

Determine the routing of the defective aerial wire in vehicle and measure the total length of the aerial connecting wire to be replaced.

To determine the length of connecting wire required, subtract 60 cm from the measured total length of aerial connecting wire -2-.

Procure the required adapter cables -1- and -3- and connecting wire -2- at the calculated length as genuine parts from the parts catalogue (ETKA).

Cut off connectors of defective aerial wire. The remainder of the defective aerial wire remains in the vehicle.

Connect adapter cables -1- and -3- to equipment in vehicle.

Route and secure connecting wire -2- parallel to the old aerial wire.

Do not kink or excessively bend aerial wires! The bending radius must not be below 50 mm.

Connect connecting wire to adapter cables.

Perform a functional check.

To remove the steering column electronics control unit -J527- on the VOLKSWAGEN JETTA 2005:

Disconnect the battery.

Remove steering wheel.

Remove steering column trim.

Remove steering column electronics control unit -J527-.

Remove coil spring for airbag/coil connector with slip ring -F138-.

Remove steering angle sender -G85-.

Remove the turn signal light switch -E2-.

Remove windscreen wiper switch -E-.

Disconnect connector -arrow- at reader coil -3-.

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.

To install, place the steering lock housing into the basic for the steering column switch, push base module of steering column switch -2- as far as possible onto steering column, fit connector -arrow- at reader coil -3-, tighten the new shear head bolts -1- to steering column, tighten the new shear head bolts -1- until bolt heads shear off, and install all parts in reverse order of removal.

Note that after new control unit has been installed, it must be coded.

To code the steering column electronics control unit -J527- on the VOLKSWAGEN JETTA 2005:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 01 – On Board Diagnostic capable systems
• Steering wheel electronics
• Steering wheel electronics functions
• Coding control unit for steering wheel electronics

To perform final control diagnosis for the steering column electronics control unit -J527- on the VOLKSWAGEN JETTA 2005:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• Electrical System
• 01 – On Board Diagnostic capable systems
• Steering wheel electronics
• Steering wheel electronics functions

To remove the steering angle sender -G85- on the VOLKSWAGEN JETTA 2005:

Pull the steering angle sender -G85- -1- backwards and away from the steering column switch -arrow-.

Install in reverse order of removal.

To remove the turn signal switch on the VOLKSWAGEN JETTA 2005:

Release retaining clips -arrows- using a 1.0 mm feeler gauge -1- and take “turn signal switch” off backwards.

The “turn signal switch” should be heard to engage upon installation.

To remove the windscreen wiper switch -E- on the VOLKSWAGEN JETTA 2005:

Release retaining clips -arrows- using 1.0 mm feeler gauge -1- and take windscreen wiper switch -E- off backwards.

The windscreen wiper switch -E- should be heard to engage upon installation.

To remove the base module of the steering column switch -2- on the VOLKSWAGEN JETTA 2005:

Disconnect the battery.

Remove steering wheel.

Remove steering column trim.

Remove steering column electronics control unit -J527-.

Remove coil spring for airbag/coil connector with slip ring -F138-.

Remove steering angle sender -G85-.

Remove the turn signal light switch -E2-.

Remove windscreen wiper switch -E-.

Disconnect connector -arrow- at reader coil -3-.

Drill out securing bolts -1- of steering lock housing -3- (Bolts M8 -1-, core diameter 6.8 mm).

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.

To install, place the steering lock housing into the basic for the steering column switch, push base module of steering column switch -2- as far as possible onto steering column, fit connector -arrow- at reader coil -3-, tighten the new shear head bolts -1- to steering column until bolt heads shear off, and install all parts in reverse order of removal.

To check the entire parking aid system on the VOLKSWAGEN JETTA 2005, perform final control diagnosis:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• General Body Repairs
• 01 – On Board Diagnostic capable systems
• Parking aid

To remove connectors -1- by pressing the locking tabs -arrows- inwards on the VOLKSWAGEN JETTA 2005:

Press locking tabs -arrows- of the retainer outwards and take parking aid control unit -1- out of the retainer.

Install in reverse order of removal.

To remove a parking aid sensor on the VOLKSWAGEN JETTA 2005:

Switch off ignition and all electrical consumers and pull out ignition key.

Remove rear bumper cover.

Disconnect connector -arrow-.

Release locking lugs -arrows- and pull sender out of bumper cover.

Install in reverse order of removal.

If the vehicle level sensors are replaced, check the sensor values and carry out basic setting on headlights.

If the values from the vehicle level sensors are outside the specified tolerance, basic headlight setting cannot be carried out.

To remove the rear parking aid warning buzzer -H15- on the VOLKSWAGEN JETTA 2005:

The rear parking aid warning buzzer -H15- is fitted on the rear shelf plate. It is accessible via the luggage compartment.

Pull off connector -1-.

Release securing clips -arows- remove rear parking aid warning buzzer -H15- from retainer.

Install in reverse order of removal.

To perform final control diagnosis of the parking aid system on the VOLKSWAGEN JETTA 2005:

Connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

• Body
• General Body Repairs
• 01 – On Board Diagnostic capable systems
• Parking aid

Parking aid functions

Final control diagnosis