2005 Volkswagen Golf Mk4 Download Service & Repair Manual

2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform) 21 - TURBOCHARGER, G-CHARGER TURBOCHARGER Turbocharger The following table provides quick links to all chapters in this section. For all Turbocharger, G-Charger component locations, refer to --> 21 - TURBOCHARGER, G - CHARGER . For all Turbocharger, G-Charger system removal/installation procedures and torque specifications, refer to --> 21 - TURBOCHARGER, G - CHARGER . Check the Technical Bulletins for information that may supersede any information included in this article. Safety Precautions --> Safety Precautions --> Clean Working Conditions --> General Information --> Wastegate Bypass Regulator Valve, Checking --> Charge Air Pressure Sensor, Checking NOTE:  All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through VW.  Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool.  The manufacturers test box Adapter - 68 Pin VAG1598/18 is available for purchase or rental. CAUTION: Observe the following for all installations, especially in engine compartment due to lack of room:  Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform) 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

If special testing equipment is required during road test, note the following: Clean Working Conditions When working on turbocharger, carefully observe the following Rules of Cleanliness:  Thoroughly clean all connections and the surrounding area before disconnecting.  Place parts that have been removed on a clean surface and cover. Use lint-free cloths only!  Carefully cover over opened components or seal, if repairs are not carried out immediately.  Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (in tool boxes etc.)  Transport and protective packaging and sealing caps are to be removed only immediately prior to installation.  During repairs, clean oil from connections and hose ends.  When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary. General Information  Charge air system must be properly sealed.  Always replace self-locking nuts.  Charge air hoses and pipes as well as their connections must be free of oil and grease before reinstalling.  Do not assemble charge air hoses and lines with lubricants containing oils, only coat with water (without additives) if necessary.  Note installation marks on hoses and components.  All hose connections for charge air system are secured by spring-type clamps or by connector couplings. wiring so that the original path is followed.  Watch for sufficient clearance to all moving or hot components. CAUTION:  Test equipment must always be secured to the rear seat and operated from there by a second person.  If test and measuring equipment is operated from the passenger seat, the person seated there could be injured in the event of an accident involving deployment of the passenger-side airbag. CAUTION: The use of nails, paper clips, or another unauthorized materials to back- probe electrical harness connectors is strictly prohibited and may cause damage to the electrical harness connectors, terminal ends or damage to a component. Use only the manufacturers test lead kit or an equivalent aftermarket test lead kit for back-probing all electrical harness connectors. 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

 Install only approved clamps for securing hose connections Electronic Parts Catalog "ETKA".  Spring clamp pliers or Hose clamp pliers are recommended for installing spring clamps.  For connector couplings, always note the following points:  Disengage connector coupling by pulling securing clip - arrow -.  Disconnect hose and pipe without the assistance of tools. Fig. 1: Identifying Hose/Tube Retaining Tabs Courtesy of VOLKSWAGEN UNITED STATES, INC.  When assembling, make sure the retaining tabs - A - are engaged securely.  Before screwing on oil supply line, fill turbocharger with engine oil at filler tube.  After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger. Wastegate Bypass Regulator Valve, Checking Special tools, testers and auxiliary items required  Multimeter.  Wiring diagram. Test requirements  The Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248 fuses OK.  Battery voltage at least 12.5 volts.  All electrical consumers such as, lights and rear window defroster, switched off.  On vehicles with automatic transmission, selector lever in position "P" or "N".  A/C switched off.  Ground (GND) connections between engine/transmission/chassis OK. 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

 Ignition switched off. Test procedure  Perform a preliminary check to verify the customers complaint. Refer to --> General Diagnosis . Start diagnosis  Disconnect the Wastegate Bypass Regulator Valve N75 electrical harness connector. Checking internal resistance Fig. 2: Checking The Turbocharger Recirculating Valve N249 Terminals 1 To 2 For Resistance Courtesy of VOLKSWAGEN UNITED STATES, INC.  Using a multimeter , check the Wastegate Bypass Regulator Valve N75 - 1 - terminals 1 to 2 for resistance. Specified value: 20 to 30 ohms (at approx. 20 ° C) If the specification was not obtained:  Replace the Wastegate Bypass Regulator Valve N75. If the specification is obtained: Checking Voltage supply 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

Fig. 3: 2 - Pin Electrical Harness Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.  Using a multimeter , check the Wastegate Bypass Regulator Valve N75 electrical harness connector terminal 1 to Ground (GND).  Operate the starter briefly. Specified value: battery voltage.  Switch the ignition off. If the specification was not obtained:  Check the wiring for a short circuit to Battery positive (+) or an open circuit.  Check the electrical harness connector for damage, corrosion, loose or broken terminals.  If necessary, repair the wiring connection. If no malfunction is found in the wiring: If the manufacturers test box is being used, perform the following step.  Install the test box. Refer to --> 68 - Pin Test Box Adapter, VAG1598/19, Installing . If the manufacturers test box is not being used, perform the following step.  Remove the Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248. Refer to --> Diesel Direct Fuel Injection ECM, Replacing . Wastegate Bypass Regulator Valve N75 electrical harness connector terminal Measure to 1 Engine Ground (GND) 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

Fig. 4: 2 - Pin Electrical Harness Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.  Using a multimeter , check the Wastegate Bypass Regulator Valve N75 electrical harness connector terminal 2 to the Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248 electrical harness connector T60 terminal 29 for an open circuit. Specified value: 1.5 ohms max. If the specification is not obtained:  Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).  Check the electrical harness connector for damage, corrosion, loose or broken terminals.  If necessary, repair the faulty wiring connection. If no malfunction is detected in the wiring and if the voltage supply was OK:  Replace the Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248. Refer to --> Diesel Direct Fuel Injection ECM, Replacing . Final procedures After the repair work, the following work steps must be performed in the following sequence: 1. Check the DTC memory. 2. If necessary, erase the DTC memory. Refer to Diagnostic Mode 04 - Reset/Delete Diagnostic Data . 3. If the DTC memory was erased, generate readiness code. Refer to Readiness Code . End of diagnosis. Wastegate Bypass Regulator Valve N75 electrical harness connector terminal Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248 electrical connector T60 terminal or test box socket 2 29 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

Charge Air Pressure Sensor, Checking Special tools, testers and auxiliary items required  Multimeter.  Wiring diagram.  Comparative turbocharger tester. Test requirements  The Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248 fuses OK.  Battery voltage at least 12.5 volts.  All electrical consumers such as, lights and rear window defroster, switched off.  Vehicles with automatic transmission, shift selector lever into position "P" or "N".  A/C switched off.  Ground (GND) connections between engine/transmission/chassis OK.  Ignition switched off. Test procedure  Perform a preliminary check to verify the customers complaint. Refer to --> General Diagnosis . Start diagnosis  Connect the scan tool.  Switch the ignition on.  Using the scan tool, check the intake manifold pressure PID 11: If the specified value is not obtained: NOTE:  Use only gold-plated terminals when servicing terminals in the electrical harness connector of the Charge Air Pressure Sensor G31. Diagnostic text Specified value Intake Manifold Pressure PID 11 reading within +/- 50mbar of turbocharger tester 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

Fig. 5: Identifying Charge Air Pressure Sensor G31 Electrical Harness Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.  Disconnect the Charge Air Pressure Sensor G31 electrical harness connector - arrow -. Checking wiring If the manufacturers test box is being used, perform the following step.  Install the test box. Refer to --> 68 - Pin Test Box Adapter, VAG1598/19, Installing . If the manufacturers test box is not being used, perform the following step.  Remove the Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248. Refer to --> Diesel Direct Fuel Injection ECM, Replacing . Fig. 6: 4 Pin Harness Connector & Terminals Courtesy of VOLKSWAGEN UNITED STATES, INC.  Using a Multimeter , check the Charge Air Pressure Sensor G31 electrical harness connector terminals to the Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248 electrical harness connector T94 terminals for resistance. 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

Specified value: 1.5 ohms Max. If the specification was not obtained:  Check the wiring for a short circuit to each other, Battery (+), and Ground (GND).  If necessary, repair the faulty wiring connection.  Check the electrical harness connector for damage, corrosion, loose or broken terminals. If no malfunction is detected in the wiring:  Erase the DTC memory. Refer to --> Diagnostic Mode 04 - Reset/Delete Diagnostic Data .  Perform a road test to verify repair. If the DTC does not return: Repair complete, Generate readiness code. Refer to --> Readiness Code .  End diagnosis. If the DTC does return and no malfunction is detected in the wiring:  Replace the Charge Air Pressure Sensor G31  Erase the DTC memory. Refer to --> Diagnostic Mode 04 - Reset/Delete Diagnostic Data .  Perform a road test to verify repair. If the DTC does not return: Repair complete, Generate readiness code. Refer to --> Readiness Code . If the DTC does return and no malfunction is detected in the wiring or the Charge Air Pressure Sensor G31 :  Replace the Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248. Refer to --> Diesel Direct Fuel Injection ECM, Replacing .  Assembly is performed in the reverse of the removal. Final procedures After the repair work, the following work steps must be performed in the following sequence: Charge Air Pressure Sensor G31 electrical harness connector terminals Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) J248 electrical harness connector T94 terminals or test box socket 3 62 4 78 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

1. Check the DTC memory. 2. If necessary, erase the DTC memory. Refer to Diagnostic Mode 04 - Reset/Delete Diagnostic Data . 3. If the DTC memory was erased, generate readiness code. Refer to Readiness Code . End of diagnosis 23 - DIESEL FUEL INJECTION DIESEL DIRECT FUEL INJECTION SYSTEM, SERVICING Diesel Direct Fuel Injection System, Servicing The following table provides quick links to all chapters in this section. For all Diesel fuel injection system component locations, refer to --> - 23 - DIESEL FUEL INJECTION . For all Diesel fuel injection system removal/installation procedures and torque specifications, refer to --> - 23 - DIESEL FUEL INJECTION Check the Technical Bulletins for information that may supersede any information included in this article. Safety Precautions To reduce the risk of personal injury and/or damage to the fuel injection and ignition system. Note the following: --> Safety Precautions --> Clean Working Conditions --> Technical Data NOTE:  All manufacturers special tools as well as common tools may contain a manufacturer specific part number. These tools may be substituted with an equivalent aftermarket tool or are available for purchase through VW.  Manufacturers special tools as well as common tools that contain a manufacturer specific part number may be referenced in the test procedure illustrations showing the tool use or installation. If the manufacturer specific tool is not being used, an equivalent aftermarket tool may be installed in the same manner as the manufacturers special tool.  The manufacturers test box Adapter - 68 Pin VAG1598/18 is available for purchase or rental. CAUTION: Fire hazard! To prevent personal injury, and damage to vehicle components. Remove all objects from the repair area that can ignite Diesel 2007 Volkswagen Jetta 2.0T 2005-2007 ENGINE PERFORMANCE 1.9 Liter 4-Cyl. 2V TDI PD Generic Scan Tool, Engine Code(S): BRM -- Jetta (A5 Platform)

2005 Volkswagen Golf Mk4 Download Service & Repair Manual

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