A5_Jetta_Quick_Ref_Spec_Book.pdf

2005–2007

Volkswagen

Jetta

A5 Platform

Quick Reference

Specification Book

2005–2007 A5 Jetta

Quick Reference Specification Book

Table of Contents

General Information ...................................................... 1

Decimal and Metric Equivalents ...........................................1

Tightening Torque .................................................................2

Warnings and Cautions ........................................................4

Maintenance .........................................................................9

Vehicle Identiication................................................... 10

VIN on Lower Edge of Front Window ....................................10

VIN on Longmember Extension.............................................10

VIN on Suspension Strut Mount ............................................ 11

VIN Decoder .......................................................................... 11

Type Plate – Location ............................................................14

Vehicle Data Sticker ..............................................................14

Sales Codes ................................................................. 15

Engine ................................................................................15

Engine Codes ........................................................................15

Transmission ......................................................................15

Transmission Codes ..............................................................15

Vehicle Lifting .............................................................. 15

Lifting the Vehicle Using Vehicle Hoist and Workshop

Trolley Jack - Front..........................................................15

Lifting the Vehicle Using Vehicle Hoist and Workshop

Trolley Jack – Rear .........................................................16

Engine Mechanical, Fuel Injection & Ignition ........... 17

General, Technical Data .....................................................17

Engine Number – Location –1.9L BRM .................................17

Engine Number – Location – 2.0L BPY .................................17

Engine Number – Location – 2.5L BGP, BGQ .......................18

Engine Data ..........................................................................18

Engine – Removing and Installing – 2.0L BPY, 2.5L

BGP/BGQ, 1.9L BRM .........................................................20

2.0L BPY, 2.5L BGP/BGQ - Engine – Tightening Torques ....20

1.9L BRM - Engine – Tightening Torques .............................20

2.0L BPY, 2.5L BGP/BGQ, 1.9L BRM- Assembly

Mountings – Tightening Torques .....................................20

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Crankshaft/Cylinder Block – 4-Cylinder – 2V TDI PD

Engine –1.9L - BRM ...........................................................21

Toothed Belt Drive – Tightening Torques ..............................21

Ribbed Belt Drive – Tightening Torques ...............................21

Crankcase – Tightening Torques ..........................................21

Sealing Flanges and Flywheel – Tightening Torques ............21

Crankshaft – Tightening Torques ...........................................22

Crankshaft Dimensions .........................................................22

Piston and Connecting Rod – Tightening Torques ................22

Piston Position at TDC...........................................................22

Piston and Cylinder Dimensions............................................23

Piston Ring End Gaps ...........................................................23

Piston Ring Clearance...........................................................23

Crankshaft/Cylinder Block – 4-Cylinder – 4V Turbo

Engine – 2.0L - BPY ...........................................................24

Assembly Attachments Mounting – Tightening Torques .......24

Accessory Assembly Bracket – Tightening Sequence...........25

Sealing Flange – Tightening Torques ....................................25

Flywheel/Drive Plate – Tightening Torques ...........................25

Crankshaft Assembly – Tightening Torques ..........................25

Crankshaft Dimensions .........................................................26

Identiication on Crankshaft Bearing, Top ..............................26

Piston and Connecting Rod – Tightening Torques ................26

Piston Ring End Gaps ...........................................................27

Piston Ring Clearance...........................................................27

Piston and Cylinder Dimensions............................................27

Crankshaft/Cylinder Block – 5-Cylinder – 4V Engine –

2.5L – BGP/BGQ ................................................................27

Assembly Attachments Mounting – Tightening Torques .......28

Drive Chain – Tightening Torques .........................................28

Brake Booster Vacuum Pump – Tightening Torques .............28

Sealing Flanges and Flywheel Drive Plate – Tightening

Torques ...........................................................................29

Crankshaft Assembly – Tightening Torques ..........................29

Crankshaft Dimensions – (Dimensions in mm) .....................29

Identiication of Top Crankshaft Bearing Shells .....................30

Piston and Connecting Rod – Tightening Torques ................30

Piston Ring End Gaps ...........................................................30

Piston Ring Clearance...........................................................31

Piston and Cylinder Dimensions............................................31

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Cylinder Head - 1.9L Engine - BRM ..................................31

Cylinder Head – Tightening Torques .....................................31

Cylinder Head Cover – Tightening Sequence .......................31

Cylinder Head – Tightening Sequence ..................................32

Compression Pressures ........................................................32

Cylinder Head - 2.0L Engine - BPY ...................................32

Cylinder Head – Tightening Torques .....................................32

Cylinder Head – Tightening Sequence ..................................33

Cylinder Head (Valve) Cover – Tightening Sequence ..........33

Cylinder Head (Valve) Cover – Tightening Torques...............33

Compression Pressures ........................................................33

Cylinder Head - 2.5L Engine – BGP/BGQ .........................34

Cylinder Head – Tightening Torques .....................................34

Cylinder Head – Removal Sequence ....................................35

Cylinder Head – Tightening Sequence ..................................35

Cylinder Head Cover – Tightening Sequence .......................36

Cylinder Head Cover – Tightening Torques ...........................36

Compression Pressures ........................................................36

Valvetrain - 1.9L Engine – BRM.........................................36

Valvetrain – Tightening Torques.............................................36

Valve Dimensions ..................................................................37

Valvetrain - 2.0L Engine – BPY .........................................37

Valvetrain – Tightening Torques.............................................37

Valve Dimensions ..................................................................38

Camshaft - Tightening Sequence ..........................................38

Camshaft - Tightening Torques..............................................38

Valvetrain - 2.5L Engine – BGP/BGQ ................................39

Valvetrain – Tightening Torques.............................................39

Valve Dimensions ..................................................................39

Camshaft Guide Frame Sealant Bead Width ........................40

Camshaft – Tightening Sequence .........................................40

Camshaft – Tightening Torques .............................................40

Engine Lubrication – 1.9L BRM ..........................................41

Lubrication System Components – Tightening Torques ........41

Oil Filter Bracket – Tightening Torques..................................41

Engine Lubrication – 2.0L BPY...........................................42

Lubrication System Components – Tightening Torques ........42

Oil Filter Bracket – Tightening Torques..................................42

Engine Lubrication – 2.5L BGP/BGQ .................................43

Lubrication System Components – Tightening Torques ........43

Oil Filter Bracket – Tightening Torques..................................43

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iii

Engine Cooling – 1.9L BRM ...............................................43

Cooling System Components (Body Side) – Tightening

Torques ...........................................................................43

Cooling System Components (Engine Side) – Tightening

Torques ...........................................................................44

Recommended Coolant Mixture Ratios.................................44

Coolant Fan V7 and Coolant Fan 2 V177 – Tightening

Torques ...........................................................................44

Radiator – Tightening Torques..............................................44

Engine Cooling – 2.0L BPY ................................................44

Cooling System Components (on Engine) – Tightening

Torques ...........................................................................44

Cooling System Components (on Body) –

Tightening Torques..........................................................45

Coolant Pump V50 – Tightening Torques ..............................45

Coolant Pump – Tightening Torques .....................................45

Recommended Coolant Mixture Ratios.................................45

Engine Cooling – 2.5L BGP/BGQ.......................................45

Cooling System Components (on Engine) – Tightening

Torques ...........................................................................45

Cooling System Components (on Body) –

Tightening Torques..........................................................46

Recommended Coolant Mixture Ratios.................................46

Fuel Storage and Supply – 1.9L BRM ................................46

Fuel Supply System – Tightening Torques ............................46

Fuel Storage and Supply – 2.0L BPY, 2.5L BGP/BGQ .......46

Fuel Pump – Tightening Torques ...........................................46

Fuel Tank – Tightening Torques.............................................47

Accelerator Pedal Module – Tightening Torques ...................47

EVAP Canister System – Tightening Torques........................47

Fuel Injection – Tightening Torques .......................................47

Turbocharger – 1.9L BRM ..................................................48

Turbocharger – Tightening Torques.......................................48

Charge Air Cooler Components – Tightening Torques ..........48

Diesel Fuel Injection – 1.9L BRM .......................................49

Diesel Direct Fuel Injection System – Tightening Torques ....49

Turbocharger – 2.0L BPY ...................................................50

Turbocharger – Tightening Torques.......................................50

Charge Air Cooler – Tightening Torques................................51

Noise Booster – Tightening Torques......................................51

A5 Jetta Quick Reference Book

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November 2006

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