Volkswagen Jetta 2004 User Manual
The new Jetta
New Model Introduction
Self-Study Program
Course Number 891403
Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 12/2004
Course Number 891403
©2004 Volkswagen of America, Inc.
All rights reserved. All information contained
in this manual is based on the latest
information available at the time of printing
and is subject to the copyright and other
intellectual property rights of Volkswagen of
America, Inc., its affiliated companies and its
licensors. All rights are reserved to make
changes at any time without notice. No part
of this document may be reproduced,
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the publisher.
All requests for permission to copy and
redistribute information should be referred
to Volkswagen of America, Inc.
Always check Technical Bulletins and the latest
electronic repair information for information
that may supersede any information included
in this booklet.
Trademarks: All brand names and product
names used in this manual are trade names,
service marks, trademarks, or registered
trademarks; and are the property of their
respective owners.
Table of Contents
Introduction ................................................................................1
Course Introduction, The New Jetta
Body ............................................................................................6
Chassis Construction, Exterior Parts, Windows, Hood Latch
Cable, New Door Design, Seat Design Features, Storage
Areas
Passenger Safety ......................................................................20
Overview, Two-Stage Airbags, Advanced Airbag System,
Active Front Seat Head Restraints, Rear Side Head Airbags,
Side Airbag Crash Sensors
Engines......................................................................................26
2.5L/150 HP 5-Cylinder Engine with 4-Valves per Cylinder,
2.0L/200 HP 4-Cylinder Turbo FSI Engine with 4-Valves per
Cylinder, 1.9L/105 HP TDI Engine with 2-Valve Technology,
Pedal Assembly
Automatic Transmission...........................................................52
6-Speed Direct Shift Gearbox (DSG) 02E, 6-Speed Automatic
Transmission 09G
Suspension ...............................................................................54
Suspension Features
Electrical System ......................................................................56
Fuse and Relay Locations, CAN Networking Concept, Air
Conditioning Systems
Heating and Air Conditioning .................................................62
Introduction, Air Distribution System, Overview of the Dual
Zone Climatronic/Climatic System, Sensors, Actuators
Radio and Navigation ..............................................................75
Radio and Navigation Systems
Service.......................................................................................77
Special Tools, New Special Tools
This Self-Study Program covers the design and operation of
the new Jetta!
This Self-Study Program is not a Repair Manual. This
information will not be updated.
For testing, adjustment and repair procedures, always refer
to the latest electronic service information.
New!
Important/Note!
i
Course Introduction
Introduction
The new Jetta continues its success story
of the past 30 years. The new Jetta
introduces new features that combine
appearance with comfort and modern
technology, resulting in a vehicle that
provides the ultimate value in its class.
Attention to detail, increased horsepower,
added safety features and subtle quality
improvements set the new Jetta apart from
the competition.
The new Jetta is built at Volkswagen's
Puebla, Mexico plant. This plant began
operation in 1964, manufacturing the old
style Beetle. Currently, the Puebla plant
employs approximately 14,000 people and
also produces the New Beetle, among
other vehicles.
New Jetta features include:
• Elegant design
• Superior quality
•Excellent handling dynamics
• Comprehensive safety package
• Innovative drivetrain technology
•Improved economy
• Spacious interior
• Customer focused innovations
Additional self-study programs relating to the new Jetta include:
• SSP 851503: 6-Speed Automatic Transmission 09G/09K/09M
• SSP 851403: The Direct Shift Gearbox 02E
• SSP 892403: The Electro-Mechanical Power-Assisted Steering
• SSP 873403: The new Jetta–Electrical System Design and Function
• SSP 861403: The new Jetta–Steering and Suspension
1
Introduction
The New Jetta
The new Jetta sets new standards for its
class in many areas, including:
• Safety
• Quality
• Design
• Handling
•Roominess
• Drivetrain
•Many storage locations such as
the overhead console
•Premium sound system
•Electro-mechanical
power steering
• 2.5L 150 HP 5-Cylinder Engine
with 4-Valves per Cylinder
• Optional Bi-Xenon headlights
• ABS/ESP MK 60
2
Other Features
•Rain sensing windshield wipers
• Optional rear distance warning system
Introduction
• Dual zone climate control
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•Two piece tail light design
•Four link independent suspension
• Customer personalization via the
multi-function indicator (MFI) switch lever
3
Introduction
Te c hnical Specifications
The figure shows the dimensions of the
front-wheel drive new Jetta.
Weights and Exterior Dimensions
Length
Width
Height
Wheelbase
34.6 in.
(880mm)
60.4 in.
(1,533mm)
69.1 in.
(1,755mm)
178.1 in. (4,523mm)
69.1 in. (1,755mm)
57.5 in. (1,461mm)
101.5 in. (2,578mm)
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101.5 in.
(2578mm)
178.1 in.
(4523mm)
57.5 in.
(1,461mm)
59.7 in.
(1,517mm)
Front track width
Rear track width
Maximum weight
Empty weight
42.7 in.
(1084mm)
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60.4 in. (1,533mm)
59.7 in. (1,517mm)
4,057 to 4,321 lb.*
(1,840 to 1,960 kg)
3,016 to 3,331 lb.*
(1,368 to 1,511 kg)
*varies depending on model
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4
Interior Dimensions
Introduction
12
1 Front seat headroom
2 Back seat headroom
*varies depending on model
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37.4 to 38.4 in.
(949 to 975mm)
37.0 to 37.2 in.
(941 to 945mm)
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5
Body
Chassis Construction
Static and Dynamic Rigidity
The new Jetta sets new standards for static
and dynamic rigidity by the application of
lightweight design principles.
Fenders, doors and side panels are all made
of high strength steel.
Laser Weld Technology
The assembly plant in Puebla, Mexico
makes extensive use of laser welding
technology to produce the new Jetta
chassis. The increased use of laser welds
has resulted in significant improvements in
chassis strength and rigidity.
Laser weld technology not only improves
manufacturing efficiency, it also improves
the quality of the chassis by increasing the
welded surface while reducing the
deformation of the sheet metal caused by
the necessary heat and pressure of
previous welding methods.
The chart below provides a comparison of
increased manufacturing technology on the
new Jetta A5 compared to the previous
Jetta A4.
6
Key:
Red = Side Impact Zone
Yellow = Occupant Cell
Blue = Frame Structure
Body
B-pillar
The new Jetta’s B-pillar consists of three
hot formed panels that provide improved
passenger protection in the event of a
side-impact collision.
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B-pillar
Outer Body Side
Panel
Inner Body Side Panel
(tailored blank)
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Hot Formed Panels
The B-pillar and adjacent portion of the
body in the direction of the A-pillar are heat
treated during the forming process to
increase strength. These hot formed panels
are stronger and weigh less than the panels
on previous models.
Hot formed panels
Additional side impact
protection in doors
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7
Body
Exterior Parts
Impact-Absorbing Foam
S318_289
Headlights
The Jetta headlights feature clear glass. The
turn signals are located below the low and
high beam headlights to improve their
visibility to other drivers.
Front Bumper
By integrating an impact-absorbing foam
element into the front bumper behind the
front spoiler, the risk of injury to
pedestrians is reduced. This deformable
foam element allows compression of the
front bumper during impact.
Bi-Xenon headlights are available as an
option on some models.
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8
Body
Exterior Rearview Mirrors
Turn signals are integral to the exterior
rearview mirrors.
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Tail Lights
The new Jetta has two-part tail lights.
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9
Body
Windows
The windows on the new Jetta are greentinted glass (blue-tinted glass will be
available at a later date). The thickness of
the window glass depends on its location:
the windshield is .17 inches (4.4mm), the
front side windows are .14 inches (3.5mm)
and all other windows are .12 inches
(3.15mm). All fixed windows are bonded to
the body.
Sealing Lip
Drip
Molding Area
Ceramic Coating as Third Sun Visor
Windshield
The windshield is available with an infraredreflective metal vapor deposition coating.
This coating reflects most of the sun’s heat
generating infrared rays. Conventional
reflective glass shields a vehicle’s interior
from far less solar radiation by absorption.
Always set the windshield on its
side. Otherwise, the sash at the
bottom and/or the sealing lip at
the top can become damaged.
Clear Area for
Rain/Light Sensors
Windshield
Label
Area Below
the Hood
Drip Molding
Area
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Clear Area for VIN Plate
Sash for Plenum Chamber Cover
10
Rear Window
Body
Replacement rear windows are produced
with integral diversity antennas. Diversity
antennas connect to the diversity switching
box by two terminals on the window.
Heater element with additional printed conductors for
optimizing the rear window antennas
Antenna Terminal
Signals are relayed simultaneously from
these terminals to the radio and the
diversity switching box. Using both antenna
signals significantly reduces interference.
Antenna
Terminal
S318_005
Heater Element
Terminal
Be sure to order the correct rear
window when replacing to assure
all electrical terminals are
present.
Heater Element
Terminal
11
Body
Hood Latch Cable
The hood latch cable (bowden cable) for
releasing the hood latch from inside the
passenger compartment is located in a
protected area in the engine compartment.
The hood latch cable disconnect point is
located under the hood behind the
driverside headlight assembly. This allows
front end service without removing the
cable from the vehicles interior.
Disconnect point (closed)
Disconnect point (open)
Bowden cable disconnected
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12
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Emergency Release Mechanism
Removing the interior trunk trim allows
access to the locking linkage for emergency
release of the trunk.
Body
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13
Body
New Door Design
The doors on the new Jetta consist of an
outer panel with two mounting rails and an
inner section for mounting hardware. The
door’s outer panel is bonded to the
mounting rails that are bolted to the inner
section.
Cover Strip
Removal of the outer door panel allows
access to some of the door’s inner
hardware and electronics, the window
motor is accessed through the inside. Also,
in the event of door damage, the outer
panel can be removed for repair or
replacement.
Check the current service repair
information for instructions on
outer door panel removal.
Door Inner Section
Door Outer
Panel
Mounting Rail
Cover Strip
Mounting Rail
Side Impact Bar
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14
Mounting Rails
The mounting rails are permanently bonded
to the outer panel with adhesive. This
ensures an accurate fit when the outer
panel is bolted to the door's inner section.
Body
Mounting
Rails
Internal Door Components
Removing the outer panel allows easy
access to the side impact bars, door handle
bracket, door lock, side airbag crash sensor
and the window regulator module.
Door Outer Panel
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Door Handle
Bracket
Window
Regulator
Module
Side Impact Bars
Door Lock
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Driver’s Side Airbag Crash
Sensor G179
15
Body
Seat Design Features
Front Seats
The front seats on the new Jetta are
equipped with an active head restraint
system. Options include: a mechanical
2-way lumbar support or an electrical 4-way
lumbar support.
The active head restraint system is a
mechanical system that moves the driver
and passenger head restraints upward and
forward in the event of a rear end collision.
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1. T hrough-Loading Front Passenger Seat
2. Rear Loading Door
3. Active Head Restraints
4. 4-Way Lumbar Support
5. Power Backrest
6. Complete Power Seat, Optional
Power Backrest
4-Way Lumbar Support
Active Head
Restraint System
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Height Adjustment
4-Way Lumbar
Support
S318_060
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16
Body
An optional feature of the front passenger
seat allows it to be folded flat for loading
and hauling of long items by using the full
length of the interior.
S318_101
Rear Seats
The rear seat cushion extends across the
full width of the interior. The backrest is
split 60/40 and can be folded down. The
backrests lock using a rotary latch. A red
indicator shows if the backrests are locked
or not.
On vehicles equipped with the
pass-through option for the rear seat, the
armrest and the door located behind it can
be folded forward to allow transport of long
items such as skis or golf bags.
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The pass-through door is locked
in position.
A red indicator showing
means that the backrest
is not locked in position.
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A red indicator showing means
that the pass-through door is not
locked in position.
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17
Body
Storage Areas
The new Jetta features numerous
convenient storage areas.
Front Storage
Vehicles equipped with air conditioning can
cool the front passengerside storage
compartment.
Adjustable
Temperature
Outlet
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Overhead Storage
There is a standard open storage
compartment in the overhead console of
the new Jetta.
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Door Storage
Storage compartments, and a cup holder
for 1.6 quart (1.5 liter) bottles are located in
the door panels.
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18
Body
Center Console Storage
A new Jetta storage option includes an airconditioned storage compartment in the
center console and fold-out cup holders for
the rear seats.
Adjustable
Temperature
Outlet
Storage
Compartment
Door
S318_081
Rear Vent
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Rear Fold-Out
Cup Holder
Trunk Storage
A sliding cover provides access to a side
compartment for storing small objects.
Removal of the sliding cover allows parallel
storage of larger items such as a golf bag.
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Spare Tire Area Storage
The new Jetta is equipped with a full-size
emergency spare tire. There are additional
storage areas near the spare tire location.
19
Passenger Safety
Overview
The new Jetta provides the following
protection systems/devices.
Standard protection equipment includes:
• Driver and front passenger two-stage
airbags
• Front seat side curtain airbags
• Front and rear side (head) airbags
• 3-point seat belts on all seats
• Front seat belt tensioners and belt force
limiters
• Front seat active head restraint system.
Two Longitudinal Acceleration
Sensors (Early Crash Sensors)
G251, located in the front of
the vehicle, detect impact and
impact intensity.
Optional protection equipment includes:
• Rear passenger side (head) airbags in
combination with belt tensioners and
belt force limiters on the outer rear
seats.
Side Curtain Airbag with
Gas Distributor Tube
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Airbag Control
Module J234
receives data from
the sensors and
controls airbag
deployment.
Pressure Sensors G179
and G180 in the front
doors detect sudden
changes in air pressure
during a side impact.
Lateral acceleration
sensors, located in
the rear wheel
housing, detect
side impacts.
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20
The driver and passenger airbags provide
two-stage deployment. The front passenger
airbag is activated or deactivated
automatically via the Advanced Airbag
System.
Side curtain airbags cover the window area
from the A-pillar to the C-pillar. In the event
of a crash, a pressurized gas cylinder
provides uniform inflation of the curtain
airbags.
The rear outer seats are equipped with child
seat anchors as standard equipment.
Advanced
Airbag
System
Passengerside
Two-Stage
Airbag
Curtain
Airbag
Side
Airbag
Front Seatbelt
Pretensioner
Passenger Safety
Side Impact
Pressure
Sensors
Side
Airbag
Front
Impact
Sensors
Airbag
Control
Module
Driverside
Two-Stage
Airbag
Seatbelt
Engagement
Detector
Switch
Rear Seatbelt
Pretensioners
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Rear Side
Impact
Sensors
21
Passenger Safety
Two-Stage Airbags
The airbag system reacts to unique crash
conditions by deploying the driverside and
passengerside airbags in two stages,
depending on the size of the front seat
occupants and the severity of the impact.
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Advanced Airbag System
The new Jetta is equipped with the
Advanced Airbag System. This system is a
standard feature for the front passenger
seat. Based on occupant weight and
seatbelt tension, the system signals the
control module to deploy the airbag in one
of two stages. In a slow speed collision, the
two-stage airbag and the Advanced Airbag
System work together to activate only the
first stage. This provides the best protection
for a small adult. The “Passenger Airbag
OFF” light is illuminated when the
passenger seat is unoccupied.
PASSENGER
AIR BAG
OFF
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Bladder
Pressure
Sensor
Hose
Protection
Felt
Electronic
Control Module
Seat Belt Sensor
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22
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