Volkswagen 2004 Jetta Reference manual

Self-Study Program
Course Number 891403
The new Jetta
New Model Introduction

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,
stored in a retrieval system, or transmitted in
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the prior expressed written permission of
the publisher.
All requests for permission to copy and
redistribute information should be referred
to Volkswagen of America, Inc.
Always checkTechnical 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.

i
Table of Contents
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.
Important/Note!
New!
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
AutomaticTransmission...........................................................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

1
Introduction
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
Course 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

2
Introduction
•Premium sound system
•Many storage locations such as
the overhead console
•Electro-mechanical
power steering
•2.5L 150 HP 5-Cylinder Engine
with 4-Valves per Cylinder
The New Jetta
The new Jetta sets new standards for its
class in many areas, including:
•Safety
•Quality
•Design
•Handling
•Roominess
•Drivetrain
•Optional Bi-Xenon headlights
•ABS/ESP MK 60

3
Introduction
•Dual zone climate control
Other Features
•Rain sensing windshield wipers
•Optional rear distance warning system
•Two piece tail light design
S891403_102
•Four link independent suspension
•Customer personalization via the
multi-function indicator (MFI) switch lever

4
Introduction
34.6 in.
(880mm)
101.5 in.
(2578mm)
42.7 in.
(1084mm)
178.1 in.
(4523mm)
178.1 in. (4,523mm)
69.1 in. (1,755mm)
57.5 in. (1,461mm)
101.5 in. (2,578mm)
Length
Width
Height
Wheelbase
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)
Front track width
Rear track width
Maximum weight
Empty weight
*varies depending on model
60.4 in.
(1,533mm)
57.5 in.
(1,461mm)
59.7 in.
(1,517mm)
69.1 in.
(1,755mm)
Technical Specifications
The figure shows the dimensions of the
front-wheel drive new Jetta.
Weights and Exterior Dimensions
S891403_16
S891403_15
S891403_02
S891403_01

5
Introduction
12
Interior Dimensions
1 Front seat headroom
2 Back seat headroom
*varies depending on model
37.4 to 38.4 in.
(949 to 975mm)
37.0 to 37.2 in.
(941 to 945mm)
S891403_03
S891403_12

6
Body
Key:
Red = Side Impact Zone
Yellow = Occupant Cell
Blue = Frame Structure
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 WeldTechnology
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.

7
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.
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.
B-pillar
Outer Body Side
Panel Inner Body Side Panel
(tailored blank)
S318_066
Hot formed panels
S891403_19
S891403_17
S891403_18
Additional side impact
protection in doors

8
Body
Exterior Parts
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.
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.
Bi-Xenon headlights are available as an
option on some models.
Impact-Absorbing Foam
S318_289
S891403_115

9
Body
Exterior Rearview Mirrors
Turn signals are integral to the exterior
rearview mirrors.
Tail Lights
The new Jetta has two-part tail lights.
S891403_26
S891403_116
S891403_117

10
Body
Windows
Ceramic Coating as Third Sun Visor
Clear Area for
Rain/Light Sensors
Drip
Molding Area
Drip Molding
Area
Area Below
the Hood
Sash for Plenum Chamber Cover
S318_003
Clear Area for VIN Plate
Windshield
Label
Sealing Lip
Windshield
The windshield is available with an infrared-
reflective 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.
The windows on the new Jetta are green-
tinted 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.

11
Body
Rear Window
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
Antenna
Terminal
Heater Element
Terminal
S318_005
Heater Element
Terminal
Signals are relayed simultaneously from
these terminals to the radio and the
diversity switching box. Using both antenna
signals significantly reduces interference.
Be sure to order the correct rear
window when replacing to assure
all electrical terminals are
present.

12
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.
S318_251
S318_253
S318_255
Disconnect point (closed)
Disconnect point (open)
Bowden cable disconnected
S891403_47

13
Body
Emergency Release Mechanism
Removing the interior trunk trim allows
access to the locking linkage for emergency
release of the trunk.
S891403_104
S891403_46

14
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.
S318_257
Side Impact Bar
Door Outer
Panel
Door Inner Section
Mounting Rail
Cover Strip
Mounting Rail
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.

15
Body
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.
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.
S318_203
Mounting
Rails
Door Outer Panel
Side Impact Bars
Window
Regulator
Module
Driver’s Side Airbag Crash
Sensor G179
Door Handle
Bracket
Door Lock
S318_205

16
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.
Active Head
Restraint System
S318_060
4-Way Lumbar
Support
S891403_119
S891403_118
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
S891403_94
Height Adjustment
4-Way Lumbar Support
Power Backrest