Volkswagn JETTA VW BORA 2002-2007 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Volkswagen Model: Jetta / Bora Model Variant: Jetta (A4 platform), Bora (European market equivalent) Product Name: Volkswagn JETTA VW BORA 2002-2007 Workshop Service Repair Manual Generation Platform: A4 (Typ 1J for Jetta, 1J for Bora) Codes Chassis Code Jettavw: 1J Chassis Code Boravw: 1J 👋 Introduction Market Position Target Audience: Professional mechanics and DIY enthusiasts seeking comprehensive repair guidance. Competitive Analysis Value Proposition: Offers dealer-level technical information at a fraction of the cost of official subscriptions or printed manuals, with the convenience of instant digital access. Key Features Accessibility: Immediate download, no shipping delays, readable on any PDF-compatible device. Longevity: Permanent storage on hard drive, unaffected by disc degradation. Usability: Searchable text (typical of PDF manuals), bookmarked chapters for quick reference. 📋 Manual Details Coverage Areas Model Years: 2002, 2003, 2004, 2005, 2006, 2007 Market Regions: Global (North America - Jetta, Europe - Bora/Jetta) Page Count Number Of Pages: More than 1200 Manual Type Type: Workshop Service Repair Manual Purpose: Professional repair, maintenance, diagnostics, and troubleshooting Language Language: English (implied by technical terms and target audience) Format File Format: PDF Delivery Method: Digital Download (ZIP archive) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (petrol/diesel), engine reconditioning, fuel system (petrol/diesel), exhaust system, cooling system, lubrication system, charging, starting, ignition system, manual transmission, automatic transmission, clutch system. Chassis: Suspension, steering system, wheel alignment, wheel and tire, half shaft and CV joints, disc and parking brake, hydraulic brakes, anti-lock brake system (ABS). Body And Interior: Body repair, bumper system, door system, window system, wheel housing, heating and air conditioning, accessories. Electrical: Charging, starting, ignition system, wiring diagram, safety system. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections. Repair: Component removal, installation, adjustment, and overhaul. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), system analysis. Reconditioning: Engine rebuild procedures, component overhaul. Technical Depth Level: Comprehensive, from basic maintenance to complex engine and transmission overhauls. Diagrams: High definition diagrams, schematics, and illustrations. Formatting: Well-structured content with bookmarks for easy navigation. 📊 Manual Specifications File Format Primary Format: PDF Required Reader: Adobe Acrobat Reader (free download) Compression: ZIP archive (requires WinZip or WinRAR for extraction) Print Quality Printability: Ready to print Resolution: High Definition (for diagrams and text) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Compatibility Operating Systems: All Windows versions, All Mac versions ⚙️ Engine Specifications Primary Engine Engine Options: 1.8L I4 Petrol, 2.0L I4 Petrol, 2.0L I4 Diesel, 2.5L I5 Petrol, 2.8L VR6 24-Valve Petrol. Performance Horsepower Range: Varies by engine: approx. 115-170 hp for 1.8L/2.0L petrol, 100-150 hp for 2.0L diesel, 170-180 hp for 2.5L I5, and 201 hp for 2.8L VR6. Torque Range: Varies by engine: approx. 122-170 lb-ft for petrol, 150-190 lb-ft for diesel, 177-184 lb-ft for 2.5L I5, and 199 lb-ft for 2.8L VR6. Fuel System Injection Type: Multi-point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) depending on specific engine variant and market. Common rail direct injection for diesel. Engine Mechanical Petrol Engine Codes Petrol: e.g., AGZ (2.8 VR6), AUM/AUQ (1.8T), AZG/AVH/BBW (2.0 MPI), BHW (2.0 TDI). Engine Mechanical Diesel Engine Codes Diesel: e.g., BHW (2.0 TDI). Emission Control Emission Systems: Catalytic converters, oxygen sensors (Lambda sensors), EGR (Exhaust Gas Recirculation) for some engines, diesel particulate filter (DPF) for TDI variants may be present in later models within this range. 🔧 Transmission Standard Manual Transmission Options: 5-speed Manual, 6-speed Manual (for some performance variants). Optional Automatic Transmission Options: 4-speed Automatic (e.g., 01M), 5-speed Automatic Tiptronic (e.g., 01V for VR6). Features Tiptronic Functionality: Selectable manual gear changes available on Tiptronic automatic transmissions. Fluid Specifications Manual Transmission Fluid: G 052 171 A2 (API GL-4 75W-90 synthetic oil) or equivalent. Automatic Transmission Fluid: G 052 162 A2 (ATF Dexron III or equivalent for 01M) or G 055 025 (for 01V Tiptronic). 📐 Dimensions Exterior Length: Approximately 4627 mm (182.2 in) for Jetta, 4409 mm (173.6 in) for Bora. Width: Approximately 1735 mm (68.3 in). Height: Approximately 1444 mm (56.9 in). Weights Curb Weight Range: Approx. 1300 kg (2866 lbs) to 1500 kg (3307 lbs) depending on engine and equipment. Gross Vehicle Weight Rating: Typically around 1900-2000 kg. 🛡️ Safety Features Ratings NHTSA Ratings: Generally good for its time, but specific ratings varied by year and test criteria. Earlier models might not have the same level of rollover protection as later generations. Active Features ABS: Standard on most models, Anti-lock Braking System. Traction Control: Optional or standard on higher trims (ASR - Antriebsschlupfregelung). Passive Features Airbags: Front airbags standard, side airbags and curtain airbags often optional or standard on higher trims. Seatbelts: Three-point inertia reel seatbelts with pre-tensioners. 💡 Technology Features Infotainment Audio System: Factory head units with AM/FM radio, CD player, and optional CD changer. Speaker configurations vary by trim level. Driver Assistance Cruise Control: Standard or optional depending...
Jetta (A4 platform), Bora (European market equivalent)
Product Name:
Volkswagn JETTA VW BORA 2002-2007 Workshop Service Repair Manual
Generation
Platform:
A4 (Typ 1J for Jetta, 1J for Bora)
Codes
Chassis Code Jettavw:
1J
Chassis Code Boravw:
1J
👋 Introduction
Market Position
Target Audience:
Professional mechanics and DIY enthusiasts seeking comprehensive repair guidance.
Competitive Analysis
Value Proposition:
Offers dealer-level technical information at a fraction of the cost of official subscriptions or printed manuals, with the convenience of instant digital access.
Key Features
Accessibility:
Immediate download, no shipping delays, readable on any PDF-compatible device.
Longevity:
Permanent storage on hard drive, unaffected by disc degradation.
Usability:
Searchable text (typical of PDF manuals), bookmarked chapters for quick reference.
📋 Manual Details
Coverage Areas
Model Years:
2002, 2003, 2004, 2005, 2006, 2007
Market Regions:
Global (North America - Jetta, Europe - Bora/Jetta)
Page Count
Number Of Pages:
More than 1200
Manual Type
Type:
Workshop Service Repair Manual
Purpose:
Professional repair, maintenance, diagnostics, and troubleshooting
Language
Language:
English (implied by technical terms and target audience)
Varies by engine: approx. 115-170 hp for 1.8L/2.0L petrol, 100-150 hp for 2.0L diesel, 170-180 hp for 2.5L I5, and 201 hp for 2.8L VR6.
Torque Range:
Varies by engine: approx. 122-170 lb-ft for petrol, 150-190 lb-ft for diesel, 177-184 lb-ft for 2.5L I5, and 199 lb-ft for 2.8L VR6.
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) depending on specific engine variant and market. Common rail direct injection for diesel.
Catalytic converters, oxygen sensors (Lambda sensors), EGR (Exhaust Gas Recirculation) for some engines, diesel particulate filter (DPF) for TDI variants may be present in later models within this range.
🔧 Transmission
Standard
Manual Transmission Options:
5-speed Manual, 6-speed Manual (for some performance variants).
Selectable manual gear changes available on Tiptronic automatic transmissions.
Fluid Specifications
Manual Transmission Fluid:
G 052 171 A2 (API GL-4 75W-90 synthetic oil) or equivalent.
Automatic Transmission Fluid:
G 052 162 A2 (ATF Dexron III or equivalent for 01M) or G 055 025 (for 01V Tiptronic).
📐 Dimensions
Exterior
Length:
Approximately 4627 mm (182.2 in) for Jetta, 4409 mm (173.6 in) for Bora.
Width:
Approximately 1735 mm (68.3 in).
Height:
Approximately 1444 mm (56.9 in).
Weights
Curb Weight Range:
Approx. 1300 kg (2866 lbs) to 1500 kg (3307 lbs) depending on engine and equipment.
Gross Vehicle Weight Rating:
Typically around 1900-2000 kg.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Generally good for its time, but specific ratings varied by year and test criteria. Earlier models might not have the same level of rollover protection as later generations.
Active Features
ABS:
Standard on most models, Anti-lock Braking System.
Traction Control:
Optional or standard on higher trims (ASR - Antriebsschlupfregelung).
Passive Features
Airbags:
Front airbags standard, side airbags and curtain airbags often optional or standard on higher trims.
Seatbelts:
Three-point inertia reel seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory head units with AM/FM radio, CD player, and optional CD changer. Speaker configurations vary by trim level.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Electronic Stability Control:
ESP (Elektronisches Stabilitätsprogramm) was available as an option on some models.
Connectivity
Auxiliary Input:
Rarely standard on base models; may require aftermarket adapter installation for audio input.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles (15,000 km) or 12 months, whichever comes first, using synthetic oil. Consult manual for specific engine recommendations.
Timing Belt Replacement:
For 1.8T and 2.0L petrol engines, often recommended around 60,000-80,000 miles (100,000-130,000 km) or 5-7 years. VR6 engines may have timing chains.
Brake Fluid Flush:
Recommended every 2 years.
Fluid Specifications
Engine Oil Specification:
VW 502.00 or 505.00 approved synthetic oil, typically 5W-40 or 0W-40 depending on climate. Always check manual for specific engine requirements.
Coolant Specification:
G12 or G12+ (Purple) coolant, a silicate-free long-life antifreeze/coolant. Never mix with G11 (Blue).
Power Steering Fluid:
G 002 000 (Pentosin CHF 11 S or equivalent).
Known Issues
Ignition Coils:
Coil-on-plug ignition systems (especially on 1.8T) are prone to failure, causing misfires.
ABS Sensors:
Wheel speed sensors for the ABS system can fail, leading to ABS warning lights.
Window Regulators:
Plastic components in window regulator mechanisms can break.
Egr Valve:
EGR valves can become clogged and fail, particularly on diesel models.
Mass Air Flow Sensor:
Mass Air Flow (MAF) sensors can become dirty or fail, affecting engine performance and fuel economy.
📚 Vehicle History
Brand Heritage
Volkswagen Heritage:
Volkswagen, a German automotive manufacturer with a long history of producing reliable and popular vehicles, known for its engineering and build quality.
Model Evolution
Jetta Bora A4 Generation:
This generation (A4 platform) represented a significant evolution in design and technology for the Jetta/Bora, moving towards a more modern and aerodynamic aesthetic compared to its predecessors.
Production
Production Period:
The A4 platform Jetta/Bora was produced globally from 1999 to 2005 for the initial run, with facelifted versions and extended production in some markets continuing into 2007.
Manufacturing Locations:
Primary manufacturing in Wolfsburg, Germany, with significant production also occurring in Mexico (for North American market Jettas) and other global facilities.
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Consumer Reports often provided mixed reviews for this generation, with some praise for ride quality and engines but concerns about reliability in certain areas.
Ieda Awards:
The Jetta and Bora were generally well-received in their respective markets for their driving dynamics and upscale interior feel for their segment.
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