Volkswagen Jetta / Bora: Electrical System Manual - part 45

♦

Repair points must not be subjected to pulling or bending

forces.

♦

If the damaged section is longer than 20 mm, a new piece of

corrugated pipe must be used and the procedure described

below must be performed twice.

– 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.

Jetta 2005 ➤ , Bora 2006 ➤

5. Hose repair    

177

Torque settings: Windscreen wash/wipe system

Threaded connections

 

Torque settings

Wiper motor to wiper frame

M6

8 Nm

Motor crank arm to wiper motor shaft

M8

18 Nm

Wiper frame to body

M6

8 Nm

Windscreen wiper arms to wiper motor

shaft

M8

20 Nm

Windscreen washer system and headlight

washer system reservoir

M6

8 Nm

Pop-up spray jet cylinder front bumper

cover

 

4.5 Nm

Jetta 2005 ➤ , Bora 2006 ➤

178

1

Headlight

Note

♦

Before working on headlights, always switch off the headlights

and remove the ignition key.

♦

When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system is first under‐

stood.

♦

Additional information:

⇒  Operating instructions
In the vehicle there are fitted headlights of three different manu‐

facturers:
♦ AL (Automotive Lighting)
♦ Hella
Removal and installation of the headlights and its attachments is

the same, only the removing and installing of the actuator motors

are different.
Fault detection and fault display:
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 informa‐

tion system -VAS 5051A- in “guided fault finding” mode.

1.1

Assembly overview, Headlight

Note

In the overview there are shown the three control motors of the

different headlight manufacturers because their removal and in‐

stallation is different.

Jetta 2005 ➤ , Bora 2006 ➤

1. Headlight    

179

❑ 4 Nm

2 - Adjustment bushes

❑ Correcting installation

position of headlight

⇒ page 182

3 - Left headlight main beam

bulb -M30- or right headlight

main beam bulb -M32-

❑ Bulb H7U 12 V, 55 W
❑ Renewing 

⇒ page 185

4 - Left side light bulb -M1- or

right side light bulb -M3-

❑ Bulb 12 V, W 5 W
❑ Renewing 

⇒ page 187

5 - Cover cap
6 - Front left turn signal bulb -

M5- or front right turn signal

bulb -M7-

❑ Bulb 12 V, PY 21 W
❑ Renewing 

⇒ page 188

7 - Bulb holder with grip ele‐

ment

❑ For front left turn signal

bulb -M5- or front right

turn signal bulb -M7-

8 - Body section
9 - Cover cap
10 - Bulb holder with grip ele‐

ment

❑ For left headlight dipped

beam bulb -M29- or right headlight dipped beam bulb -M31-

11 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31-

❑ Bulb H7 12 V, 55 W
❑ Renewing 

⇒ page 184

12 - Headlights

❑ Removing and installing 

⇒ page 181

❑ Correcting installation position of headlight 

⇒ page 182

❑ Servicing headlight securing lugs 

⇒ page 188

Jetta 2005 ➤ , Bora 2006 ➤

180