Volkswagen VW Bora 1998-2005 Service Repair Manual

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Basic Information Identification Make: Volkswagen Model: Bora Model Alias: Jetta (A4 Platform - North America) Model Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Platform Code: A4...

Type: Cars

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Sku: 427897

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Description

Basic Information
Identification
Make:	Volkswagen
Model:	Bora
Model Alias:	Jetta (A4 Platform - North America)
Model Years Covered:	1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Codes
Platform Code:	A4 (PQ34)

Introduction
Market Position
Positioning:	The Volkswagen Bora (Jetta A4 in North America) was positioned as a compact to mid-size sedan, known for its solid build quality, refined driving dynamics, and European styling within its segment. It competed against vehicles like the Honda Civic, Toyota Corolla, Ford Focus, and Chevrolet Cavalier.
Competitive Analysis
Strengths Compared To Competitors:	Often praised for its superior chassis tuning, more upscale interior appointments than many competitors, and a wider range of refined engine options, including diesel variants in some markets. Its solid German engineering was a significant selling point.
Key Features
Design Philosophy:	Understated, clean lines reflecting Volkswagen's design language of the era, emphasizing practicality and German build quality.

Manual Details
Coverage Areas
Coverage Scope:	All Models, Engines, Trim Levels, and Transmission Types
Page Count
Estimated Page Count:	Extensive (Detailed factory service manual, typically 1000+ pages)
Manual Type
Type:	Factory Service and Repair Workshop Manual
Language
Language:	English
Format
Format:	PDF

Manual Coverage
Systems Covered
Powertrain:	Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:	Clutch, manual transmission, automatic transmission, drive shafts, axles, differentials
Chassis:	Suspension (front and rear), steering system, braking system (including ABS), wheels and tires
Electrical:	Battery, charging system, starting system, lighting, instruments, gauges, fuses, relays, body electronics, comfort systems
Body:	Body construction, exterior panels, interior trim, doors, windows, seats, HVAC system, safety restraints (airbags, seatbelts)
Procedures Included
Maintenance:	Scheduled maintenance (oil changes, filter replacements, inspections), fluid checks and changes, component lubrication
Repair:	Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs
Troubleshooting:	Diagnostic procedures, fault code interpretation, symptom-based troubleshooting guides for electrical and mechanical issues
Diagnostics:	On-board diagnostics (OBD-II) information, diagnostic trouble codes (DTCs) and their meanings, guided troubleshooting trees
Specifications:	Torque specifications for fasteners, fluid capacities, tolerances, electrical resistance values, diagnostic parameters
Engine Repair:	Engine removal and installation, cylinder head removal and installation, piston and connecting rod service, crankshaft service, valve timing adjustment, oil pump replacement, oil cooler service.
Transmission Repair:	Manual transmission disassembly and assembly, clutch replacement, automatic transmission service (fluid change, filter replacement), torque converter replacement, shift mechanism adjustment.
Brake Repair:	Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS component testing and replacement, bleeding the brake system.
Suspension And Steering:	Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, power steering pump and rack service.
Electrical Diagnostics:	Wiring diagrams for all circuits, fuse and relay identification, troubleshooting starter and charging systems, diagnosing lighting and accessory faults, instrument cluster diagnostics, ECU pinouts.
Body And Trim:	Door panel removal, window regulator repair, mirror replacement, bumper removal and installation, interior trim piece replacement, headliner repair.
Technical Depth
Depth:	Comprehensive factory-level detail, suitable for experienced mechanics and advanced DIYers. Covers complete disassembly and reassembly of all vehicle systems.

Manual Specifications
File Format
File Type:	PDF
Print Quality
Printable:	Printable without restriction
Binding Type
Binding:	N/A (Digital Download)
Paper Type
Paper Quality:	N/A (Digital Download)
Requirements
Software Requirements:	Adobe PDF Reader
Delivery
Delivery Method:	Instant Digital Download

Engine Specifications
Primary Engine
Typical Engine Options:	1.6L (AWH, AVU, BFQ), 1.8L (AGN, APG, AUM, AUQ - including Turbocharged variants), 2.0L (AEH, APK, AQY, AZJ, AZM), 1.9L TDI (ALH, AHF, ASV, ATD, AXR - naturally aspirated and turbocharged diesel), 2.3L VR5 (AGZ, AQN), 2.8L VR6 (AAA, AQP, AQP)
Performance
Engine Output Range:	Approximately 90 hp (1.9 TDI) to 204 hp (2.8 VR6).
Fuel System
Fuel Delivery:	Multi-point Fuel Injection (MPI) or Direct Injection (GDI) for some later gasoline engines; Direct Injection for TDI models.
Engine Codes
Common Gasoline Codes:	1.6L: AWH, AVU, BFQ; 1.8T: AUM, AUQ; 2.0L: AEH, APK, AQY, AZJ, AZM; VR5: AGZ, AQN; VR6: AAA, AQP
Common Diesel Codes:	1.9 TDI: ALH, AHF, ASV, ATD, AXR
Engine Management
ECU Type:	Bosch Motronic, Siemens VDO, and other relevant ECUs depending on engine and model year.

Transmission
Standard
Standard Transmission:	5-speed Manual Transmission (e.g., 02A, 02J)
Optional
Optional Transmission:	4-speed Automatic Transmission (e.g., 01M) or 5-speed Tiptronic Automatic Transmission
Features
Automatic Features:	Tiptronic functionality allowing manual gear selection for more engaging driving.

Dimensions
Exterior
Wheelbase:	Approx. 2513 mm (98.9 inches)
Length:	Approx. 4509 mm (177.5 inches)
Width:	Approx. 1735 mm (68.3 inches)
Height:	Approx. 1444 mm (56.8 inches)
Cargo
Trunk Capacity:	Approx. 455 liters (16.1 cubic feet)
Weights
Curb Weight Range:	Approximately 1270 kg (2800 lbs) to 1470 kg (3240 lbs) depending on engine and equipment.
Wheel Bolt Pattern:	5x100 mm
Center Bore:	57.1 mm

Safety Features
Ratings
Euro Ncap Rating:	Achieved a 4-star Euro NCAP rating for occupant protection.
Active Features
Brake System:	Front: Ventilated Discs; Rear: Solid Discs. Anti-lock Braking System (ABS) standard on most models.
Traction Control:	Optional Traction Control System (ASR/EDL).
Passive Features
Airbags:	Standard front airbags. Optional side airbags.
Seatbelts:	Three-point seatbelts with pre-tensioners for front occupants.

Technology Features
Infotainment
Audio Systems:	Factory radio/cassette players, optional CD players, and premium sound systems from brands like Gamma or Delta.
Driver Assistance
Cruise Control:	Available on many models, typically operated via steering column stalk.
Parking Sensors:	Optional rear parking sensors (Park Distance Control) available on later models.
Connectivity
Phone Integration:	Optional Bluetooth preparation or integrated phone systems on higher trims.
Comfort Features
Climate Control:	Manual air conditioning or optional Climatronic automatic climate control.

Maintenance
Service Intervals
Oil Change Interval:	Typically every 10,000 miles (16,000 km) or 12 months, whichever comes first (refer to manual for specific engine/oil type).
Timing Belt Replacement:	Recommended every 60,000 to 100,000 miles (96,000 to 160,000 km) depending on engine and belt material (critical for interference engines).
Fluid Specifications
Engine Oil:	Refer to manual for specific API or ACEA specifications and viscosity grades (e.g., 5W-40, 5W-30, depending on engine and climate). VW 500 00, VW 501 01, VW 502 00, VW 505 00, VW 505 01 (for TDI).
Coolant:	G12 or G12+ (Pink) Antifreeze/Coolant Concentrate (Ethylene Glycol based).
Brake Fluid:	DOT 4
Transmission Fluid Manual:	VW G 052 171 A2 (for 5-speed manual), G 052 512 A2 (for 6-speed manual) or equivalent SAE 75W-90 synthetic gear oil.
Transmission Fluid Automatic:	G 052 162 A2 (ATF) or equivalent specification for 4-speed automatic (e.g., Dexron III).
Known Issues
Common Problems:	Ignition coil failure, mass airflow sensor (MAF) issues, ABS sensor failures, coolant flange leaks (especially on 1.8T), door lock module failures, window regulator failures, oil leaks from crank seals or oil pan gasket.
Tdi Specific Issues:	N75 valve (boost control solenoid) failure, variable geometry turbocharger (VGT) sticking, glow plug issues, EGR valve problems.

Vehicle History
Brand Heritage
Volkswagen Philosophy:	Volkswagen, a brand with a long history of producing reliable, well-engineered vehicles, continued its tradition with the Bora, aiming to offer a premium compact car experience.
Model Evolution
A4 Platform:	The Bora (Jetta A4) was part of Volkswagen's A4 platform, which also underpinned the Golf Mk4, New Beetle, and Audi TT. This shared platform provided economies of scale and consistent engineering.
Production
Production Period:	1998-2005
Manufacturing Locations:	Primarily Germany (Wolfsburg), but also produced in Mexico, South Africa, China, and other locations globally.

Awards & Recognition
Recognitions
General Reputation:	While specific 'awards' are not always documented for individual model years in this range, the Bora (Jetta A4) generally received praise for its solid build, refined ride, and competent handling, often being considered a more premium option in its class.