Campaign - Engine Wiring Harness Inspection/Update
Group: 97Number: 05-02
Date: June 3, 2005
Models:
New Jetta, (U.S.), Eng. Code BGP, BGQ 2005
New Jetta (Canada), ENG. Code BGP, BGQ 2006
Subject:
Replace Engine Harness (B4)
Instructions:
Perform this procedure on all applicable vehicles within the Limited New Vehicle Warranty
Tip:
This Technical Bulletin is in effect for 12 months from date of publication as listed above. After that date, this Technical Bulletin will expire and no longer be in effect.
Condition
Inspection and/or Update of engine wiring harness.
Production
Service
^ For this repair ONLY, a Helpline repair contact number is not required except, if after repair and setting readiness code, other DTCs are stored. For this exception and all other repairs, follow the applicable Warranty Policy regarding Helpline repair contact numbers.
Requirements:
Vehicle must meet ALL of the following criteria.
1. Procedure is valid only for vehicles that show the B4 code in the OTIS View Campaign inquiry screen on the day of repair (As shown).
2. Vehicle must be within the Limited New Vehicle Warranty.
3. Procedure must be performed within the allotted time frame stated in this Technical Bulletin.
Parts Ordering:
Reference Material Information Screen, in Parts on Command, for ordering instructions.
Tip:
Procedure must also be performed on applicable vehicles in Dealer inventory.
Procedure:
Identify correct wiring harness by accessing wiring harness label and checking manufacturing date. If manufacturing date is after December 9, 2004, no further action required. Return vehicle to pre-inspection condition.
- Lift up on front cowl panel and remove rear hood seal.
- Remove air guide fasteners and lift up on front of air guide.
- Access and unclip the front wiring harness retaining clip.
- Access harness until label is visible.
- View the harness manufacturing date on label:
If date indicated is greater then or equal to 09.12.04 (Date, Month, Year), no further action is required. Return vehicle to pre-inspection condition.
^ If date indicated is before 09.12.04 (Date, Month. year), replace the wiring harness with the attached procedure.
Tip:
To aid in proper harness routing, it is recommended that digital photo's of harness routing be taken before harness removal, or an identical vehicle be available for comparison.
- Remove engine cover with MAF -G70-.
- Remove battery and battery box. See Repair Manual Group 27, Starter, Generator, Cruise control, Battery, removing and installing.
- Remove wiper arms. See Repair Manual Group 92 - Windshield wiper and washer system, Wiper arms, removing and installing.
- Remove upper and lower cowl covers to expose Engine Control Module (ECM) -J220-.
- Remove ECM -j220-, See Repair Manual Group 24, Fuel injection system, Motronic Engine Control Module (ECM) -J220- removing and installing.
- Remove air intake tube from Throttle Control module -J338-.
- Remove clips (arrows) to allow removal of harness from guide channel located on left side of engine compartment under battery box.
- Disconnect harness from ECM -J220-.
- Remove Electronic Box (E-Box) cover. See Repair Manual Group 97, Electronics boxes (E-Boxes), E-Box in engine Compartment, left side, removing and installing.
- Remove power supply cable (second from left) indicated by arrow.
- Remove Evaporative purge hose (arrow) from top of throttle control module -J338-.
- Disconnect MAP sensor -G71- and throttle control module -J338- connectors.
- With vehicle on hoist, remove noise insulation panel under engine.
- Disconnect engine speed sensor next to oil filter and oil pressure sender -F1- located in upper oil filter housing.
- Remove steel bar in front of injector rail.
- Unclip injector harness from steel bar.
- Disconnect injectors, Evaporative Purge valve -N80-, Cam Position sensor -G40- and Cam Adjustment solenoid.
Disconnect Knock sensors -G61- and -G66-, Coolant Temperature sensor 0G62 and ground wire (arrow).
- Partially lift up ignition coils2, 3, 4 and 5 using special tool T40039 to enable removal of connectors. See Repair Manual Group 01 Maintenance spark plugs, replacing.
- Disconnect all ignition coils.
- Disconnect Secondary Air Injection solenoid valve -N112-.
- Remove old engine harness.
- Install new engine wiring harness Part No: 1K5 972 619 standard transmission, Part No: 1K5 972 619-A automatic transmission and all components in reverse order of removal.
Tip:
Part numbers listed in this bulletin are for reference only. always check with your parts Dept. for the latest parts information.
After engine harness installation is complete:
On Vehicle Diagnostic, testing, and information system VAS 5051/5052:
- Select "Guided Functions" Select "44 - Power Steering"
- Select "Steering angle sensor -G85- basic setting".
Tip:
It is normal for the K155 (ASRIESP control lamp), K161 (power steering indicator lamp) and K47 (ABS warning lamp) to be illuminated at this time until G85 basic setting is complete.
- Refer to Repair Manual Jetta '05, Group 27, Electrical equipment, "Battery disconnecting and reconnecting". Carry out steps in "Battery reconnecting". carry out any Guided Fault Finding (GFF) test plans related only to documented customer complaints.
Tip:
- Do not carry out test plans at this time for DTCs if present in ECM -J220-.
On Vehicle Diagnostic, testing / and information system VAS 5051/5052:
- Select "Guided Functions".
- Select "01 - Motronic engine control"
- Select "generate reaniness code"
Tip:
If the readiness code is OK, GFF will not allow you to generate a readiness code.