The Jetta TDI A4, or MkIV Jetta, was known as the Bora in most places outside of North America. Like the previous generation Jetta, it shares its platform with the Golf, in this case the MkIV Golf, or Golf A4.
In the model years of 2004-2005 the Jetta TDI was powered by a 1.9 liter turbocharged direct injection diesel with a more modern injection system. Designed as a collaboration between Bosch and Volkswagen AG, this system was termed “Pumpe Düse, or “PD”, as each individual injector had its own high pressure fuel pump.
Engine
Engine Code: BEW
Horsepower: 100 @ 4000 RPM
Torque: 177 lb/ft @1800 RPM
Injection Pump Type: PD, “Pumpe Düse”, Unit Injectors (Unit Injector on Wikipedia)
The vehicle uses three fuel pumps in total: a very low pressure in-tank “lift” pump that pushes fuel from the tank to the engine bay; a standard rotary style pump attached to the camshaft which sent higher pressure fuel to the injectors; each individual injector set the final fuel pressure depending on load and engine speed.
These PD injectors also had a fully electronic injection timing using piezo technology.
The stock turbocharger was the KP39, manufactured by Borg-Warner. These were slightly problematic with owners that choose to have their car performance-chipped as the KP39 was prone to have “boost creep” issues.
Transmission
The 2004-2005 MkIV Jetta TDI BEW was available with either a 5-speed manual transmission or a 5-speed automatic, referred to as the “Tiptronic” transmission as it had the ability to switch gears manually by shifting the select lever to the right.
The 5-speed manual was equipped with a dual-mass flywheel and clutch design. The clutch was hydraulically operated with a slave cylinder operating a lever to disengage the clutch. The dual-mass flywheel design is prone to failure, so most owners opt to replace their dual-mass design with the more durable single-mass flywheel from the G60/VR6.
The automatic “Tiptronic” transmission proved much stronger and reliable than the 4-speed unit it replaced. However, one gaping flaw was that the transmission filter element was not replaceable without removing the transmission from the car. This discouraged most owners from doing a proper filter and fluid change, opting rather just to replace the fluid. The effects of this seemed negligible as the transmissions operated for hundreds of thousands of miles.
Maintenance
See the Complete BEW TDI Service Schedule
Oil & Oil Filter Change: 10,000 Miles
VW Oil Requirement: VW/AUDI 505.01 5w40 or 5w30
Timing Belt Interval: The BEW engine originally used a timing belt interval of 100,000 miles. Later on, Volkswagen revised the interval to 80,000 miles, presumably due to the extra strain that the injection system put on the timing belt components. There is some debate as to which cars this revision applies to as there was a seemingly insignificant VIN split in the announcement.
Common Replacement Parts for 2004-2005 Jetta TDI – Sponsored By IDParts.com
Oil Change Kit
Engine Filter Pack
505.01 Approved Oils
Timing Belt Replacement Kit
Clutch Replacement Kit
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