volkswagen jetta (a5) service manual: 2005-2010 - excerpt

24-16 Fuel Injection–GasolineFuel Injection Components (2.5L)

N24-10302

FUEL INJECTION COMPONENTS (2.5L)

Component overview (2.5L)

1. Fuel injectors • Cylinder #1 (N30)• Cylinder #2 (N31)• Cylinder #3 (N32)• Cylinder #4 (N33)• Cylinder #5 (N83)

2. Camshaft position sensor (G40)

3. 81-pin ECM harness connector• Switch ignition OFF before

disconnecting or connecting.

4. Motronic engine control module (ECM) (J623)

5. 40-pin ECM harness connector• Switch ignition OFF before

disconnecting or connecting.

6. Secondary air injection solenoid valve (N112)• See 26 Exhaust System.

7. Engine coolant temperature (ECT) sensor (G62)

8. Evaporative emission (EVAP) canister purge regulator valve (N80)• Arrow points in direction of flow.

9. Ignition coils with power output stages• Use ignition coil puller T40039 for

removal. See Spark plugs, replacing in 03 Maintenance.

10. Mass air flow (MAF) sensor (G70)• With intake air temperature (IAT)

sensor (G42)

11. E-box in engine 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 (rpm) sensor (G28) • Mounted to control housing cover

13. Throttle valve control module (J338)• See Throttle valve, removing

and installing (2.5L) in this repair group.

14. Camshaft adjustment valve (N205)

15. Secondary air injection pump motor (V101)• See 26 Exhaust System.

16. Knock sensor 1 (G61)

17. Knock sensor 2 (G66)

18. 6-pin harness connector • Black connector• For oxygen sensor before catalytic

converter and oxygen sensor heater

• On bulkhead at left

19. Oxygen sensor (G39) before catalytic converter• In exhaust manifold

20. 4-pin harness connector • Only for engine code BGQ, CBUA• Black connector• For oxygen sensor in center of

catalytic converter and oxygen sensor heater

21. Oxygen sensor in center of catalytic converter (G465)• Only for engine code BGQ, CBUA

22. 4-pin harness connector • Brown connector• For oxygen sensor behind catalytic

converter and oxygen sensor heater 1

23. Oxygen sensor behind catalytic converter (G130)

Fuel Injection–Gasoline 24-17Fuel Injection Components (2.5L)

VJ0697022a

VJ0697020

0024806a

Component locations (2.5L)

For more component location information, including fuses and relays, see 97 Fuses, Relays, Component Locations.

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)

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


N24-10306

Intake manifold overview (2.5L)

1. Bleeder hose for crankcase ventilation• From cylinder head cover

2. Ventilation hose

3. Evaporative emission (EVAP) canister purge regulator valve (N80)

4. Vacuum 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.

6. Fuel rail

7. Fuel supply line

8. Gasket• Replace with new.• Installation position: flashing faces

up

9. Intake manifold

10. Rubber bushing• Engine codes BGP, BGQ only

11. Intake manifold support

12. Bolt• Tighten to 25 Nm (18 ft-lb)

13. 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• Replace if damaged.

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

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

17. Coolant connections

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

19. Throttle valve 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.

20. Oil seal • Replace if damaged.


VJ0624011

VJ0624012

VJ0624013

M24-0522

M24-0522

4 2

3

1

Intake manifold, removing and installing (2.5L)

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

– Remove engine cover. See 03 Maintenance.

Disconnect vent line (A), breather line (B) and fuel supply line (C). Press in securing ring to disengage lines.

Disconnect harness connectors (A).

– Remove wiring harness (B) from retaining brackets.

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

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

– Remove throttle valve. See Throttle valve, removing and installing (2.5L) in this repair group.

Disconnect harness connector (A) and crankcase ventilation hose (C).

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

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

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

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

WARNING —• To avoid personal injury, be sure the engine is cold before

beginning this procedure.

WARNING —• Before opening the fuel system, wrap shop towels around

connections and loosen connections slowly to release pressure.


M24-0510

M24-0510

T10107A

N24-10305

Loosen intake manifold bolts (arrows) using multipoint socket T10107 A or equivalent. Bolts remain in intake manifold.

– Tilt intake manifold and lift out.

– Plug intake channels in cylinder head using clean rags.

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

– If intake manifold is being replaced, 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).

– Remove manifold absolute pressure (MAP) sensor.

– Remainder of installation is reverse of removal.

• Be sure to replace seals between intake manifold and cylinder head.

• Tighten all bolts for intake manifold from inside to outside in a diagonal sequence.

Fuel rail and injectors (2.5L)

1. Fuel rail mounting bolts• Tighten to 3.5 Nm (31 in-lb)

2. Fuel rail

3. Fuel supply line

4. O-ring• Replace with new.• Moisten with clean engine oil.

5. Retaining clip• Make sure clip is correctly seated on fuel injector and fuel

distributor.

6. Fuel injector• Cylinder #1 (N30)• Cylinder #2 (N31)• Cylinder #3 (N32)• Cylinder #4 (N33)• Cylinder #5 (N83)

7. Intake manifold

8. Protective cap

9. Breather valve

CAUTION—• Make sure that no bolts fall out.

Tightening torques

Intake manifold support to cylinder block 25 Nm (18 ft-lb)

Intake manifold to cylinder head 9 Nm (80 in-lb)

Manifold absolute pressure sensor to intake manifold

3.5 Nm (31 in-lb)

Transport strap to cylinder head 25 Nm (18 ft-lb)


VJ0624011

VJ0624012

M24-0514

Fuel injectors, removing and installing (2.5L)

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


Disconnect vent line (A), breather line (B) and fuel supply line (C). Press in securing ring to disengage lines.

Disconnect harness connectors (A).

– Remove wiring harness (B) from retaining bracket.

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

– Remove two bolts (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) face each other.

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

– Position shoulder (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 and uniformly press it into place.

– Install fuel rail mounting bolts and tighten to specification.

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

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

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

WARNING —• Before opening the fuel system, wrap shop towels around

connections and loosen connections slowly to release pressure.

Tightening torque

Fuel rail to intake manifold 3.5 Nm (31 in-lb)


0024819

0024820

0024821

M24-0517

M24-0517

3094

Throttle valve, removing and installing (2.5L)

NOTE —

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


Disconnect secondary air injection hoses (lower arrows) from intake air duct (1).

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

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

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

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

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

– Installation is reverse of removal. Replace seal for throttle valve control module if damaged.

– 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.

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

Tightening torque

Throttle valve to intake manifold 6.5 Nm (58 in-lb)

established 1950Automotive Reference™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

Volkswagen Jetta (A5)Service Manual: 2005-20101.9L and 2.0L diesel, 2.0L and 2.5L gasolineincluding TDI, GLI and SportWagen

Price: $129.95Bentley Stock No: VJ10Publication Date: 2009.dec.18ISBN: 978-0-8376-1616-2Softcover, 8 3/8 in. x 11 in.Case quantity: 51352 pages 2484 technical photos and illustrations including 991 electrical wiring diagrams Includes 32 page full color Volkswagen A5 platform Jetta familiarization sectionThe 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 do-it-yourself Volkswagen owner will find this manual indispensable as a source of detailed maintenance and repair information.

Technical Features• Covers Jetta models 2005-2010 based on the A5 platform.• Maintenance procedures from oil changes to belt

replacement.• Engine and cylinder head service, including timing belt

replacement.• Removal and installation of Motronic (gasoline) and diesel

fuel 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, gearshift linkage, and drive axles.

• Suspension component replacement including front struts, rear shocks, coil springs, wheel bearings and wheels.

• Heating and air-conditioning repair, including A/C component replacement for Climatronic and Climatic systems.

• Body adjustment and repairs including front and rear doors, fenders, front radiator support and sunroof.

• Wiring schematics with fuse/relay locations including an easy-to- use illustrated component locator section.

• Volkswagen OBD II diagnostic trouble codes, SAE-defined OBD II P-codes, as well as basic scan tool operation.

• Comprehensive Volkswagen factory tolerances, wear limits, adjustments, and tightening torques.

BentleyPublishers.com

Tensioner being rotated to remove ribbed belt.03 Maintenance

bentley_vj10_new.product.announcement.pdf

Bentley technical editors working on a 2005 Jetta.

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

Engines covered• 1.9L TDI PD diesel (engine code: BRM)• 2.0L TDI common rail (engine code: CBEA, CJAA)• 2.0L FSI 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• 02E 6-speed DSG

volkswagen jetta (a5) service manual: 2005-2010 - excerpt

Documents