Volkswagen Jetta (A5) Service Manual: 2005-2010 - Excerpt

24-16

Fuel Injection–Gasoline

Fuel Injection Components (2.5L) 

FUEL INJECTION COMPONENTS (2.5L) Component overview (2.5L) 1. Fuel Fuel inje inject ctor ors s • Cylinder #1 (N30) • Cylinder #2 (N31) • Cylinder #3 (N32) • Cylinder #4 (N33) • Cylinder #5 (N83)

N24-10302

2. Camshaft Camshaft position position sensor sensor (G40) (G40) 3. 81-pin 81-pin ECM ECM harnes harness s connec connecto torr • Switch ignition OFF before disconnecting or connecting. 4. Motronic Motronic engine engine control control module module (ECM) (J623) 5. 40-pin 40-pin ECM ECM harnes harness s connec connecto torr • Switch ignition OFF before disconnecting or connecting. 6. Secondar Secondary y air air injection injection solenoid solenoid valve (N112) • See 26 Exhaust System. System. 7. Engine Engine coola coolant nt tempe temperat rature ure (ECT) sensor (G62) 8. Evapo Evaporat rative ive emiss emission ion (EVA (EVAP) P) canister purge regulator valve (N80) • Arrow points in direction of flow. 9. Ignition Ignition coils coils with with power power outpu outputt stages • Use ignition coil puller T40039 for removal. See Spark plugs, replacing in 03 Maintenance. Maintenance . 10. Mass air flow (MAF) sensor sensor (G70) • With intake air temperature (IAT) sensor (G42) 11. E-box in engine compartment compartment • Secondary air injection pump relay (J299) • Fuel pump relay (J17) • Power supply relay (terminal 30, B+) (J317) • Power supply relay (terminal 15) (J329) 12. Engine speed speed (rpm) sensor sensor (G28) • Mounted to control housing cover

13. Throttle valve control control module (J338) • See Throttle valve, removing and installing (2.5L) in this repair group. 14. Camshaft adjustment valve (N205) 15. Secondary air injection injection pump motor (V101) • See 26 Exhaust System. System. 16. Knock sensor sensor 1 (G61) 17. Knock sensor sensor 2 (G66) 18. 6-pin harness harness connector connector • Black connector • For oxygen sensor before catalytic converter and oxygen sensor heater • On bulkhead at left 19. Oxygen sensor sensor (G39) before catalytic converter • In exhaust manifold

20. 4-pin harness harness connector connector • Only for engine code BGQ, CBUA • Black connector • For oxygen sensor in center of catalytic converter and oxygen sensor heater 21. Oxygen sensor sensor in center center of catalytic converter (G465) • Only for engine code BGQ, CBUA 22. 4-pin harness harness connector connector • Brown connector • For oxygen sensor behind catalytic converter and oxygen sensor heater 1 23. Oxygen sensor sensor behind behind catalytic converter (G130)

Fuel Fuel In Inje ject ctio ion– n–Ga Gaso soliline ne

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Fuel Injection Components (2.5L)  Component locations (2.5L) For more component location information, including fuses and relays, see 97 Fuses, Relays, Component Locations .

VJ0697022a

Underneath engine, lower engine compartment sound absorber panels removed: 1. Radiator outlet hose coolant temperature sensor (G83) 2. Engine cooling fan electric connector block 3. Engine speed sensor (G28) and connector

At front of engine (engine removed from vehicle for clarity): 1. Manifold absolute pressure (MAP) sensor (G71) 2. Engine oil pressure sensor (F1) 3. Secondary air pump (V101) VJ0697020

Engine coolant temperature (ECT) sensor ( arrow) arrow) on bottom left of radiator at hose connection.

0024806a

24-18

Fuel Injection–Gasoline

Fuel Injection Components (2.5L)  Intake manifold overview (2.5L) 1. Bleed Bleeder er hose hose ffor or cran crankca kcase se ventilation • From cylinder head cover 2. Vent Ventil ilat atio ion n hos hose e 3. Evapo Evaporat rative ive emiss emission ion (EVA (EVAP) P) canister purge regulator valve (N80)

N24-10306

4. Vacu Vacuum um hose hose • From leak detection pump (V144) 5. Bolt • Tighten to 9 Nm (80 in-lb) • Check tightening torque on 2005 models when performing first spark plug change. See 03 Maintenance. Maintenance . 6. Fuel ra rail 7. Fuel Fuel supp supply ly li line ne 8. Gasket • Replace with new. • Installation position: flashing faces up 9. Inta Intake ke mani manifo fold ld 10. Rubber Rubber bushing bushing • Engine codes BGP, BGQ only

15. Manifold absolute pressure (MAP) sensor (G71)

19. Throttle valve control control module (J338) • Also contains the following electronic power control components: -Throttle drive (G186) -Throttle drive angle sensor 1 (G187) -Throttle drive angle sensor 2 (G188) • During replacement, erase adaptation values and adapt ECM to throttle valve control module using Volkswagen scan tool or equivalent.

16. Screw Screw • Tighten to 3.5 Nm (31 in-lb)

20. Oil seal seal • Replace if damaged.

11. Intake manifold manifold support 12. Bolt Bolt • Tighten to 25 Nm (18 ft-lb) 13. Nut/Bolt Nut/Bolt • BGP, BGQ nut: Tighten to 20 Nm (15 ft-lb) • CBTA, CBUA bolt: Tighten to 16 Nm (12 ft-lb) 14. O-ring O-ring • Replace if damaged.

17. Coolant connections connections 18. Bolt Bolt • Tighten to 6.5 Nm (57 in-lb)

Fuel Fuel In Inje ject ctio ion– n–Ga Gaso soliline ne

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Fuel Injection Components (2.5L)  Intake manifold, removing and installing (2.5L) WARNING  —

 To avoid personal injury, injury, be sure the engine is cold before  beginning this procedure. procedure.

VJ0624011

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Disconnect battery ground strap from battery negative (–) terminal. See 27 Battery, Alternator, Starter. Starter .

–

Remove engine cover. See 03 Maintenance. Maintenance . Disconnect vent line ((A A), breather line (B ( B) and fuel supply line (C ( C). Press in securing ring to disengage lines. WARNING  —

• Before opening the fuel system, system, wrap shop towels around  connections and loosen connections slowly to release  pressure. VJ0624012

Disconnect harness connectors ( A).

–

Remove wiring harness (B ( B) from retaining brackets.

–

Release clamps and retaining ring ( C) out of retainer.

–

Remove two bolts (arrow ( arrow)) and remove retaining bracket.

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Remove throttle valve. See Throttle valve, removing and installing (2.5L) in this repair group. Disconnect harness connector ( A) and crankcase ventilation hose (C).

–

VJ0624013

Pull oil dipstick (1 ( 1) out and press retaining ring ( 4) downward.

1

M24-0522 4

2

3

Remove wiring harness (B ( B) by carefully prying off clips (arrows ( arrows). ).

M24-0522

–

If present, remove nuts ( 3) on intake manifold support.

–

Unscrew guide tube (2 ( 2) at bottom of cylinder block and pull it out.

24-20

Fuel Injection–Gasoline

Fuel Injection Components (2.5L)  Loosen intake manifold bolts ( arrows) arrows) using multipoint socket T10107 A or equivalent. Bolts remain in intake manifold.

T10107A

– M24-0510

Tilt intake manifold and lift out. CAUTION —

• Make sure sure that no bolts fall out.

–

Plug intake channels in cylinder head using clean rags.

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Insert oil dipstick guide tube into cylinder block again and fasten it.

–

If intake manifold is being replaced, remove remove fuel rail with injectors. See Fuel injectors, removing and installing (2.5L) in this repair group.

–

Disconnect vacuum hose for leak detection pump (LDP).

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Remove manifold absolute pressure (MAP) sensor.

–

Remainder of installation is reverse of removal.

M24-0510

• Be sure to replace seals between intake intake manifold and cylinder head. • Tighten all bolts for intake intake manifold from inside to outside in a diagonal sequence. Tightening torques Intake ma manifold su support to cy cylinder bl block Intake manifold to cylinder head Manifold absolute pressure sensor to intake manifold Transpor t strap to cylinder head

25 Nm Nm (1 (18 ft ft-lb) lb) 9 Nm (80 in-lb) 3.5 Nm (31 in-lb) 25 Nm (18 ft-lb)

Fuel rail and injectors (2.5L) 1. Fuel rail mounting bolts • Tighten to 3.5 Nm (31 (31 in-lb) N24-10305

2. Fuel rail 3. Fuel supply line 4. O-ring • Replace Replace with with new. • Moisten with with clean engine oil. oil. 5. Retaining clip • Make sure clip is correctly correctly seated on fuel injector and fuel distributor. 6. Fuel injector • Cylinder Cylinder #1 #1 (N30) (N30) • Cylinder Cylinder #2 #2 (N31) (N31) • Cylinder Cylinder #3 #3 (N32) (N32) • Cylinder Cylinder #4 #4 (N33) (N33) • Cylinder Cylinder #5 #5 (N83) (N83) 7. Intake manifold 8. Protective cap 9. Breather valve

Fuel Fuel In Inje ject ctio ion– n–Ga Gaso soliline ne

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Fuel Injection Components (2.5L)  Fuel injectors, removing and installing (2.5L)

VJ0624011

–

Disconnect battery ground strap from battery negative (–) terminal.

–

Remove engine cover. See 03 Maintenance. Maintenance . Disconnect vent line ((A A), breather line (B ( B) and fuel supply line (C ( C). Press in securing ring to disengage lines. WARNING  —

• Before opening the fuel system, system, wrap shop towels around  connections and loosen connections slowly to release  pressure.

Disconnect harness connectors ( A).

VJ0624012

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Remove wiring harness (B ( B) from retaining bracket.

–

Pull clamps and retaining ring ( C) out of retainer.

–

Remove two bolts (arrow ( arrow)) and remove transport strap.

–

Remove fuel rail mounting bolts and pull fuel rail with injectors uniformly out of intake manifold.

–

Plug openings in intake manifold or cover it.

–

Pull off retaining clip for each fuel injector. Remove fuel injectors from fuel rail.

–

When installing, coat new fuel injector O-rings lightly with clean motor oil. Press fuel injectors into fuel rail so that tabs ( 1) and (2 ( 2) face each other.

M24-0514

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Push retaining clip (3 ( 3) into groove of fuel injector, as shown.

–

Position shoulder (4 ( 4) correctly in cutout of retaining clip on both sides.

–

After assembly, verify that all fuel injectors are securely seated.

–

Set fuel rail with secured fuel injectors onto intake manifold manifold and uniformly press it into place.

–

Install fuel rail mounting bolts and tighten to specification. Tightening torque Fuel rail to intake manifold

3.5 Nm (31 in-lb)

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Install remaining components and harness connectors in reverse order of removal.

–

Connect battery, see 27 Battery, Alternator, Starter. Starter.

–

If fuel injectors were replaced, erase adaptation values and adapt engine control module using Volkswagen scan tool or equivalent.

24-22

Fuel Injection–Gasoline

Fuel Injection Components (2.5L)  Throttle valve, removing and installing (2.5L) NOTE  —

• The throttle valve valve is also referred to as throttle valve valve control  module (J338).

0024819

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Remove engine cover. See 03 Maintenance. Maintenance . Disconnect secondary air injection hoses ( lower arrows) arrows) from intake air duct (1 ( 1).

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Release spring clamp (upper ( upper arrow) arrow) and remove intake air duct ( 1).

Unscrew (arrows (arrows)) and remove intake air connection at engine hood lock carrier.

0024820

Disconnect harness connector ( 1) and vent hose (2 ( 2) from throttle valve.

– 0024821

Remove throttle valve mounting bolts ( arrows) arrows) and pull throttle valve away from intake manifold. CAUTION —

• Plug intake manifold port using a clean rag. rag.

Pinch off coolant hoses with hose clamps 3094 or equivalent. Pull coolant hoses (arrows ( arrows)) off throttle valve. 3094

– M24-0517

Installation is reverse of removal. Replace seal for throttle valve control module if damaged. Tightening torque Throttle valve to intake manifold

M24-0517

6.5 Nm (58 in-lb)

–

Make sure secondary air hoses are securely connected to intake air duct.

–

If throttle valve control module is replaced, erase adaptation values and adapt ECM to throttle valve control module using Volkswagen scan tool or equivalent.

established 1950 Automotive Reference™

BentleyPublishers .com

Volkswagen Jetta (A5) Service Manual: 2005-2010 1.9L and 2.0L diesel, 2.0L and 2.5L gasoline including TDI, GLI and SportWagen Price: $129.95 Bentley Stock No: VJ10 Publication Date: 2009.dec.18 ISBN: 978-0-83 978-0-8376-1616-2 76-1616-2 Softcover, 8 3/8 in. x 11 in. Case quantity: 5 1352 pages 2484 technical photos and illustrations including 991 electrical wiring diagrams

The Volkswagen Jetta (A5) Service Manual: 2005-2010 is a definitive reference source of technical automotive repair and maintenance information for Volkswagen Jetta models built on the “A5” platform.The platform. The do-it-yoursel Volkswagen owner will fnd this manual indispensable as a source o detailed maintenance and repair inormation.

Includes 32 page full color Volkswagen A5 platform Jetta familiarization section

Technical Features

Bentley technical editors working on a 2005 Jetta.

• Covers Jetta models 2005-2010 based on the A5 platorm. • Maintenance procedures rom oil changes to belt replacement. • Engine and cylinder head service, including timing belt replacement. • Removal and installation o Motronic (gasoline) and diesel uel injection system components, including Pumpe Düse (PD) and common rail diesel. • Emission control tests, repairs and adjustments, including exhaust gas recirculation and secondary air injection system. • Drivetrain maintenance, troubleshooting, adjustment and repair,, including clutch, gearshit linkage, and drive axles. repair • Suspension component replacement including ront struts, rear shocks, coil springs, wheel bearings and wheels. • Heating and air-conditioning repair, repair, including A/C component replacement or Climatronic and Climatic systems. • Body adjustment and repairs including ront and rear doors, enders, ront radiator support and sunroo. • Wiring schematics with use/relay locations including an easy-to- use illustrated component locator section. • Volkswagen Volkswagen OBD II diagnostic trouble codes, SAE-defned OBD II P-codes, as well as basic scan tool operation. • Comprehensive Volkswagen Volkswagen actory tolerances, wear limits, adjustments, and tightening torques.

Tensioner being rotated  Tensioner to remove ribbed belt. 03 Maintenance

Detailed brake pad and  rotor service procedure. 46 Brakes–Mechanic Brakes–Mechanical al

Engines covered • 1.9L TDI PD diesel (engine code: BRM) • 2.0L TDI common rail (engine code: CBEA, CJAA) • 2.0L FS I turbo gasoline (engine code: BPY) • 2.0L TSI turbo gasoline (engine code: CBFA, CCTA) • 2.5L gasoline (engine code: BGP, BGQ, CBTA, CBUA)

Transmissions covered • 0A4 5-speed manual • 02Q 6-speed manual • 09G 6-speed automatic automatic • 02E 6-speed DSG

Bentley Publishers, 1734 1734 Massachusetts Avenue, Cambridge, MA 02138-180 4 USA Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235 http://www.bentleypublis http://www .bentleypublishers.com/contact-sales hers.com/contact-sales bentley_vj10_new.product.announcement.pdf