expand_more1.9 TDI with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
expand_moreAt the gearbox
M10
59 lbf⋅ft59 lbf⋅ft80 N⋅m
M8
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
expand_moreBi-hexagon nuts
First stage
221.27 lbf⋅ft221.27 lbf⋅ft300 N⋅m
Replace nuts.
Second stage
360° detach
Third stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Fourth stage
30°30°30°
expand_moreHexagon head screws
First stage
177.01 lbf⋅ft177.01 lbf⋅ft240 N⋅m
Replace screws.
Second stage
90°90°90°
Third stage
180° detach
Fourth stage
177.01 lbf⋅ft177.01 lbf⋅ft240 N⋅m
Fifth stage
90°90°90°
expand_moreAll other modifications
expand_moreBi-hexagon nuts
First stage
147.51 lbf⋅ft147.51 lbf⋅ft200 N⋅m
Replace nuts.
Second stage
180° detach
Fourth stage
60°60°60°
expand_morePropeller shaft
M8
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M10
51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
expand_moreRear axle drive shaft
M8
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M10
51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
expand_moreClutch
Clutch master cylinder
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace nuts.
expand_moreClutch pressure plate
1.6 FSI with gasoline straight-4 1.6 L 109 HP engine (2002.1–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_more1.8 4motion with gasoline straight-4 1.8 L 123 HP engine (1999.2–2005.5)
Dual-mass flywheel
9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Gradually tighten screws crosswise.
Otherwise
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_more1.8 T with gasoline straight-4 1.8 L 148 HP at 5700 RPM, 210 N⋅m at 1750 RPM engine (2000.5–2005.5)
Dual-mass flywheel
9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Gradually tighten screws crosswise.
Otherwise
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_more1.8 T with gasoline straight-4 1.8 L 177 HP at 5500 RPM, 235 N⋅m at 1950 RPM engine (2002.3–2005.5)
Dual-mass flywheel
9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Gradually tighten screws crosswise.
Otherwise
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_more1.8 with gasoline straight-4 1.8 L 123 HP engine (1998.10–2005.5)
Dual-mass flywheel
9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Gradually tighten screws crosswise.
Otherwise
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
Dual-mass flywheel
16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Gradually tighten screws crosswise.
Otherwise
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
1.9 TDI with diesel straight-4 1.9 L 89 HP at 3750 RPM, 210 N⋅m at 1900 RPM engine (1998.10–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
1.9 TDI with diesel straight-4 1.9 L 89 HP at 4000 RPM, 210 N⋅m at 1900 RPM engine (1998.10–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_more2.3 V5 4motion with gasoline V5 2.3 L 168 HP, 220 N⋅m at 3300 RPM engine (2000.10–2005.5)
expand_moreDual-mass flywheel
M6
9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Gradually tighten screws crosswise.
M7
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
Otherwise
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
2.8 V6 4motion with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (1999.3–2005.5)
16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Gradually tighten screws crosswise.
expand_moreAll other modifications
expand_moreM10
First stage
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Use new screws.
Second stage
90°90°90°
M7
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.
expand_moreClutch slave cylinder
1.8 4motion with gasoline straight-4 1.8 L 123 HP engine (1999.2–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
expand_more1.8 T with gasoline straight-4 1.8 L 177 HP at 5500 RPM, 235 N⋅m at 1950 RPM engine (2002.3–2005.5)
With metal concentric slave cylinder
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Use new screws.
With plastic concentric slave cylinder
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Use new screws.
1.9 TDI 4motion with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
With metal concentric slave cylinder
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Use new screws.
With plastic concentric slave cylinder
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Use new screws.
1.9 TDI with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
1.9 TDI with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
1.9 TDI with diesel straight-4 1.9 L 99 HP at 4000 RPM, 240 N⋅m at 1800 RPM engine (2000.9–2005.5)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
1.9 TDI with diesel straight-4 1.9 L 99 HP engine (2000.9–2005.5)
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
2.0 4motion with gasoline straight-4 2.0 L 114 HP at 5400 RPM, 172 N⋅m at 3200 RPM engine (2000.4–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.0 4motion with gasoline straight-4 2.0 L 114 HP engine (2000.4–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
2.3 V5 with gasoline V5 2.3 L 168 HP, 220 N⋅m at 3300 RPM engine (2000.10–2005.5)
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
expand_more2.8 V6 4motion with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (1999.3–2005.5)
With metal concentric slave cylinder
8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Use new screws.
With plastic concentric slave cylinder
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Use new screws.
All other modifications
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreDifferential
Differential oil control screws
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Differential oil drain plug
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Rear axle differential oil control screws
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreGear shifting
Gear rod
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gearbox shift lever
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace nuts.
Selector cable linkage
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreGearbox
expand_moreGearbox flange connection at engine
expand_more1.4 16V with gasoline straight-4 1.4 L 74 HP engine (2000.3–2005.5)
M10
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_more1.6 FSI with gasoline straight-4 1.6 L 109 HP engine (2002.1–2005.5)
M10
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_more1.8 4motion with gasoline straight-4 1.8 L 123 HP engine (1999.2–2005.5)
M7
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M10
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_more1.8 T with gasoline straight-4 1.8 L 177 HP at 5500 RPM, 235 N⋅m at 1950 RPM engine (2002.3–2005.5)
M10
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
M7
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_moreM10
With automatic gearbox
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
With manual transmission
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
M7
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
M10
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_more2.8 V6 4motion with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (1999.3–2005.5)
M10
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
expand_moreAll other modifications
M10
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
M12
59 lbf⋅ft59 lbf⋅ft80 N⋅m
Torque converter
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
expand_moreGearbox lubrication
expand_moreGearbox oil drain plug
expand_moreWith automatic gearbox
Overflow pipe
2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
expand_morePlug
09A gearbox
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace sealing rings.
01M gearbox
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.
expand_moreWith manual transmission
expand_more02M gearbox
Hexagon head screws
22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
With Torx screws
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
02J gearbox
22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
expand_moreGearbox oil filler plug
expand_moreWith manual transmission
02J gearbox
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
02K gearbox
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_more02M gearbox
Hexagon head screws
22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Use new seal and screws.
With Torx screws
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Use new seal and screws.
expand_moreOil control plug
expand_moreWith automatic gearbox
09A gearbox
11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace sealing rings.
expand_moreGearbox mounting
expand_moreGearbox mounting
expand_more1.6 FSI with gasoline straight-4 1.6 L 109 HP engine (2002.1–2005.5)
expand_moreAt the bracket
First stage
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Use new screw.
Second stage
45°45°45°
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Use new screw.
Second stage
90°90°90°
expand_more1.8 4motion with gasoline straight-4 1.8 L 123 HP engine (1999.2–2005.5)
Screws at the gearbox bracket
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
M8
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_moreWith manual transmission
Screws at the gearbox bracket
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
Screws at the gearbox bracket
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_more1.9 TDI with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
M8
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_moreWith automatic gearbox at the gearbox bracket
First stage
44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Replace screws.
Second stage
90°90°90°
expand_moreWith manual transmission
Screws at the gearbox bracket
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
expand_more2.3 V5 with gasoline V5 2.3 L 168 HP, 220 N⋅m at 3300 RPM engine (2000.10–2005.5)
Screws at the gearbox bracket
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
M8
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_more2.8 V6 4motion with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (1999.3–2005.5)
Screws at the gearbox bracket
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
expand_moreM8
First stage
14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Replace screws.
Second stage
90°90°90°
expand_moreOn chassis
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_moreAll other modifications
M8
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_moreM10
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
M12
73.76 lbf⋅ft73.76 lbf⋅ft100 N⋅m
expand_moreGearbox support
expand_more1.6 FSI with gasoline straight-4 1.6 L 109 HP engine (2002.1–2005.5)
expand_moreAt the gearbox
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
On chassis
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
expand_more1.8 4motion with gasoline straight-4 1.8 L 123 HP engine (1999.2–2005.5)
expand_moreAt the gearbox
First stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage
90°90°90°
expand_more1.8 T with gasoline straight-4 1.8 L 177 HP at 5500 RPM, 235 N⋅m at 1950 RPM engine (2002.3–2005.5)
expand_moreAt the gearbox
First stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage
90°90°90°
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 129 HP at 4000 RPM, 310 N⋅m at 1900 RPM engine (2000.11–2005.5)
expand_moreAt the gearbox
First stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws.
Second stage
90°90°90°
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
expand_moreAt the gearbox
First stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage
90°90°90°
expand_moreAll other modifications
expand_moreAt the gearbox
First stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage
90°90°90°
expand_moreTransfer case
expand_moreBevel gear mounting
expand_more2.3 V5 4motion with gasoline V5 2.3 L 168 HP, 220 N⋅m at 3300 RPM engine (2000.10–2005.5)
First stage
Tighten by hand
Second stage
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
on the engine block
Third stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
At the gearbox
Fourth stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
on the engine block
expand_more2.8 V6 4motion with gasoline vr-6 2.8 L 201 HP at 6200 RPM, 270 N⋅m at 3200 RPM engine (1999.3–2005.5)
First stage
Tighten by hand
Second stage
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
on the engine block
Third stage
36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
At the gearbox
Fourth stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
on the engine block
expand_moreAll other modifications
First stage
Tighten by hand
Second stage
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
on the engine block
Third stage
18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
At the gearbox
Fourth stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
on the engine block
expand_moreTransfer box bracket
expand_more1.9 TDI 4motion with diesel straight-4 1.9 L 148 HP at 4000 RPM, 320 N⋅m at 1900 RPM engine (2000.5–2005.5)
With hexagon-head screws
33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
expand_moreHexagon head screws
First stage
7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Second stage
29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2005 Volkswagen Bora Sedan user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.
Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.
DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Bora Sedan service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.
Doing basic service for your 2005 Volkswagen Bora Sedan you're not only saving money, but also also improving your technical skills and learning something new.
Volkswagen Bora Sedan First generation model years