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
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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.