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Volkswagen 2004 Jetta Introduction Manual - Engines
Summary of 2004 Jetta
Page 1
Self-study program course number 891403 the new jetta new model introduction.
Page 2
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 a...
Page 3: Table of Contents
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...
Page 5: Introduction
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 f...
Page 6: Introduction
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 • desig...
Page 7: Introduction
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.
Page 8: Introduction
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...
Page 9: Introduction
5 introduction 1 2 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.
Page 10: Body
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 ...
Page 11: Body
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 proces...
Page 12: Body
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 ...
Page 13: Body
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.
Page 14: Body
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- reflectiv...
Page 15: 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 ter...
Page 16: Body
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 all...
Page 17: Body
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.
Page 18: Body
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 m...
Page 19: Body
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 bracke...
Page 20: Body
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 pas...
Page 21: Body
17 body 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. S318_101 s318_207 a red indicator showing means that the back...
Page 22: Body
18 body s318_103 s318_105 s891403_47 adjustable temperature outlet storage areas the new jetta features numerous convenient storage areas. Front storage vehicles equipped with air conditioning can cool the front passengerside storage compartment. Overhead storage there is a standard open storage com...
Page 23: Body
19 body s891403_53 s318_081 s318_155 rear fold-out cup holder rear vent adjustable temperature outlet center console storage a new jetta storage option includes an air- conditioned storage compartment in the center console and fold-out cup holders for the rear seats. Trunk storage a sliding cover pr...
Page 24: Passenger Safety
20 passenger safety s318_153 s891403_24 s318_125 s318_153 airbag control module j234 receives data from the sensors and controls airbag deployment. Lateral acceleration sensors, located in the rear wheel housing, detect side impacts. Side curtain airbag with gas distributor tube two longitudinal acc...
Page 25: Passenger Safety
21 passenger safety passengerside two-stage airbag advanced airbag system curtain airbag front seatbelt pretensioner side airbag side airbag side impact pressure sensors front impact sensors driverside two-stage airbag seatbelt engagement detector switch rear side impact sensors rear seatbelt preten...
Page 26: Passenger Safety
22 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. Passenger air bag off advanced airbag system the new jetta ...
Page 27: Passenger Safety
23 passenger safety active front seat head restraints the new jetta is equipped with active head restraints on the front seat. During a collision, as the occupant is pressed back into the seat, the head restraint is activated and moves forward and down to minimize head and neck injuries. At the same...
Page 28: Passenger Safety
24 passenger safety rear side (head) airbags these airbags are available as an option for the outer rear seats. They are located in the side bolsters. Seat belts the front seatbelts are equipped with pyrotechnic tensioners and belt force limiters. The front seatbelts also have adjustable belt guides...
Page 29: Passenger Safety
25 passenger safety side airbag crash sensors the driverside airbag crash sensor g179 and the front passengerside airbag crash sensor g180 replace the conventional acceleration sensors for side impact detection. These new pressure sensors provide faster detection of side impacts in the door area. Se...
Page 30: Engines
26 engines engine code type displacement firing order bore stroke valves per cylinder compression ratio max. Output max. Torque fuel exhaust gas treatment emissions standard bgp 5-cylinder in-line engine 151 cu. In. (2480cc) 1-2-4-5-3 3.25 in. (82.5mm) 3.65 in. (92.8mm) 4 10:1 150 hp (110 kw) at 5,0...
Page 31: Engines
27 engines engine block the 2.5l engine block design is similar to previous models with an improved lubrication system. Engine crankshaft the crankshaft is made of forged steel with bearing and connecting rod surfaces like the 2.0l engine and includes the timing gear. The five connecting rod locatio...
Page 32: Engines
28 engines dual overhead cam head the a5 engine has dual overhead camshafts with a continuously adjusting intake cam. The head design is based on the v10 lamborghini engine. Retard chamber advance chamber assembled camshaft (lower weight) roller cam follower s891403_123 s891403_131 s891403_135.
Page 33: Engines
29 engines timing chains the 2.5l engine uses timing chains to improve durability and extend service periods. The timing chain arrangement also drives the oil pump and the vacuum pump through its intermediate cog wheel. Intake camshaft exhaust camshaft vacuum pump oil pump crankshaft s891403_124.
Page 34: Engines
30 engines intake manifold the intake manifold on the 2.5l a5 engine is made of plastic. The intake manifold assembly includes the throttle body, fuel regulator, akf valve and the pressure and throttle sensor assembly. Exhaust manifold a feature of the 2.5l exhaust manifold is its isolated air-flow ...
Page 35: Engines
31 engines engine cover/air filter housing the engine cover on the 2.5l engine includes the intake air filter and part of the system that delivers heated intake air to the engine. The engine cover’s configuration also lowers engine noise. Vacuum pump the 2.5l engine’s vacuum pump is mechanically dri...
Page 36: Engines
32 engines engine control system–input/output diagram g71 g28 g40 g79 g185 g187 g188 g61 g66 g83 g62 f f47 g70 g42 g476 g39 g130 g465 additional signals vel. Cruise climate dfm alternator pwm ventilators k j519, j533, j527, j234, j104, j285, j217 additional signals ventilators v144 pump ldp j299 n11...
Page 37: Engines
33 engines s318_051 crankshaft seal flange engine speed sensor wheel engine speed sensor s318_049 north pole crankshaft seal flange with integrated engine speed sensor wheel the crankshaft seal flange with integrated engine speed sensor wheel is a new feature. The crankshaft seal flange seals the cy...
Page 38: Engines
34 engines technical data s891403_71 torque (ft. Lb.) horsepo w e r s891403_91 236 207 177 148 118 89 59 30 1000 3000 5000 7000 218 190 163 136 109 82 54 27 engine speed [rpm] torque and power s891403_90 engine code type displacement firing order bore stroke valves per cylinder compression ratio max...
Page 39: Engines
35 engines crankshaft the crankshaft has been modified to meet the tougher demands of the turbo fsi engine. This results in higher strength components and less engine noise. The main bearing flanges and journals have been enlarged for more strength. This meets specifications even with the .25 in. (6...
Page 40: Engines
36 engines engine balancer shaft the balancer shaft gear used in the engine features the following: • separate gear and imbalance masses to improve balancing • oil pump with wider gear • clean oil controlled pressure regulator with pressure control on the raw oil side close to the oil pump, integrat...
Page 41: Engines
37 engines final drive sprocket high torsional irregularities from the crankshaft of the turbo engine at low rpms results in greater chain forces in the balancer shaft chain drive. The crank oscillation angle of the turbo engine is 2°. Bow springs have been integrated into the sprocket wheel hub. Th...
Page 42: Engines
38 engines the new crankshaft torsional cancellation (ctc) toothed belt sprocket reduces camshaft vibration and the forces acting on the toothed belt. Function the toothed belt sprocket is positioned on the crankshaft at tdc of cylinder 1, as shown below. When the cycle begins, forces acting on the ...
Page 43: Engines
39 engines cylinder head the cylinder head features the following: • sodium-filled exhaust valves • intake valves with reinforced seats • roller rocker fingers strengthened while reducing cam and roller land width • identical valve springs are used for both intake and exhaust valves intake port geom...
Page 44: Engines
40 engines crankcase ventilation a constant vacuum is maintained in the crankcase through separate ventilation of the crankcase and cylinder head. The crankcase breather is connected to the intake manifold. The crankcase blow-by gases flow into the cylinder head through the primary oil separator in ...
Page 45: Engines
41 engines exhaust turbocharger/manifold module to conserve space and improve performance and serviceability, the exhaust manifold and turbine housing have been combined into a single module. Special emphasis was placed on easy removal and installation of the exhaust manifold and the close-coupled c...
Page 46: Engines
42 engines a clamping flange on the cylinder head allows easy removal and installation of the exhaust turbocharger/manifold module. The terminal block does not require removal. The exhaust manifold is split. A divider in the manifold ensures a steady flow of exhaust gases to the turbine. The ports o...
Page 47: Engines
43 engines charge air ducting and boost pressure control the boost pressure and intake pressure are converted to control pressure by the pulse width modulated wastegate bypass regulator valve n75. Control pressure acts on the pressure unit that actuates the wastegate flap. The wastegate flap opens a...
Page 48: Engines
44 engines overrun air divert control if the throttle valve closes when the engine is in overrun, back pressure develops in the turbo housing. Back pressure reduces the speed of the turbine, which reduces boost pressure and increases turbo lag. To avoid this, the turbocharger recirculating valve n24...
Page 49: Engines
45 engines cooling system to prevent carbon build-up on the turbine shaft in the turbocharger, an auxiliary water pump provides additional water circulation for up to 15 minutes after the engine is shut off hot. The pump forces the lower temperature coolant against the normal direction of flow. The ...
Page 50: Engines
46 engines tumble flaps at different engine rpms, tumble flaps are activated to enhance the air/fuel mixture. The tumble flaps are actuated: • to improve cold engine idling • to improve charge efficiency at start-up • in overrun mode acf system with double non-return valve throttle valve actuator in...
Page 51: Engines
47 engines fuel supply fuel for the 2.0l direct-injection engine is supplied by a demand-controlled fuel pump. This demand control was developed to reduce the demands on the fuel pump and improve fuel economy. The fuel pump maintains system pressure but only supplies as much fuel as the engine requi...
Page 52: Engines
48 engines actuators and sensor diagram mass air flow (maf) sensor g70 charge air pressure sensor g31 manifold absolute pressure (map) sensor g71 engine speed (rpm) sensor g28 camshaft position (cmp) sensor g40 throttle drive angle sensor 1 [for electronic power control (epc)] g187 throttle drive an...
Page 53: Engines
49 engines cruise control on/off fuel level sensor g transfer fuel pump (fp) g6 cylinder 1 fuel injector n30 cylinder 2 fuel injector n31 cylinder 3 fuel injector n32 cylinder 4 fuel injector n33 ignition coil 1 with power output stage n70 ignition coil 2 with power output stage n127 ignition coil 3...
Page 54: Engines
50 engines 1.9l/105 hp tdi engine with 2-valve technology special features: • switchable egr cooler • crankshaft sealing flange with integrated engine speed sender wheel • accelerator pedal module with contactless accelerator pedal position senders • contactless clutch pedal switch s318_033 technica...
Page 55: Engines
51 engines pedal assembly the pedal assembly includes accelerator, brake and clutch control modules. The brake pedal module housing is made of aluminium and sheet steel. The accelerator pedal and the clutch pedal module housings are made of plastic. Pedal position sensors recognize the pedal positio...
Page 56: Automatic Transmission
52 automatic transmission 02e dsg features include: • six forward gears and one reverse gear • normal shift control program “d” and sport shift control program “s” • tiptronic shift control and steering wheel shift control • mechatronics: electronic and hydraulic control modules in a single unit are...
Page 57: Automatic Transmission
53 automatic transmission for additional information on this transmission, please refer to ssp 851503 “the 6-speed automatic transmission 09g”. S318_024 6-speed automatic transmission 09g the 6-speed automatic transmission 09g is transverse mounted, compact, lightweight and electronically controlled...
Page 58: Suspension
54 suspension suspension features the suspension of the new jetta sets the standard in its class. An optimized front axle strut suspension provides state of the art handling characteristics. The new balanced four-link rear axle suspension complements the front suspension with its own superior perfor...
Page 59: Suspension
55 suspension for additional information on the suspension, please refer to ssp 861403, “the new jetta steering and suspension”. • four-link rear suspension • tire pressure monitoring system (delayed introduction) • power brakes • toe and camber adjustments on rear suspension s891403_27.
Page 60: Electrical System
56 electrical system fuse and relay locations mounting locations the electrical system on the new jetta is entirely redesigned. Because the electrical system has been completely reconfigured, the mounting location of fuse and relay centers have changed. The adjacent diagram shows the various fitting...
Page 61: Electrical System
57 electrical system relay carrier below the instrument cluster on the driverside, above the power supply control module relay carrier inside the power supply control module, below the instrument cluster on the driverside s891403_61.
Page 62: Electrical System
58 electrical system key d ignition/starter switch e221 control module in steering wheel g85 steering angle sensor g397 rain/light recognition sensor h8 alarm horn j104 abs control module j136 memory seat/steering column adjustment control module j217 transmission control module (tcm) j220 motronic ...
Page 63: Electrical System
59 electrical system engine control module j220 dsg mechatronics j743 abs cm j104 selector lever cm j587 power steering cm j500 headlamp range cm j431 data bus on board diagnostic interface j533 navigation cm j503/ radio r sat radio digital sound system cm j525 auxiliary heater cm j364* alarm horn h...
Page 64: Electrical System
60 electrical system air conditioning systems dual zone climatronic the new jetta is equipped with a dual zone air conditioning system. The temperature on the driver's and front passenger's sides can be controlled separately to between 60°f (16°c) and 85°f (29.5°c). Pressing the “auto” button for lo...
Page 65: Electrical System
61 electrical system climatic system the climatic system manages the interior of the vehicle as one climate zone. The climatic air conditioner has a combined fresh air/recirculating door that, like the temperature control door, is driven by a control motor. The climatic system uses a flexible shaft ...
Page 66
62 heating and air conditioning interior temperature sensor s891403_63 led indicators front passenger seat heating control driver seat heating control dual zone climatronic system introduction the new jetta’s heating, ventilation and air conditioning systems (hvac) is available in two versions, depe...
Page 67
63 heating and air conditioning climatic system the “ac” button on the climatic system is labelled “econ.” air conditioning is deactivated by pressing the “econ” button. Floating mount installation to ensure a uniform fit, the system control units are installed using floating mounts. This installati...
Page 68
64 heating and air conditioning functions of the systems in overview components dual zone climatronic climatic pollen filter with activated charcoal air recirculation control air flow control temperature control central footwell control defrost control left vent temperature sensor g150 right vent te...
Page 69
65 heating and air conditioning • the rear passenger area is vented by a single air duct leading to the left and right footwells. The dual zone climatronic air ducts in the instrument panel provide indirect ventilation through vents in the top of the instrument panel. Air distribution system the air...
Page 70
66 heating and air conditioning the main difference between the climatronic and climatic systems is the method used to control air distribution. The dual zone climatronic system has an additional fresh air door, which closes at speeds above 60 mph (97 kph). This provides constant fresh air flow at d...
Page 71
67 heating and air conditioning storage box cooling all vehicles are equipped with a cooled glovebox storage compartment located in the front passenger side area. The storage compartment is cooled directly by air from the evaporator. The cooling level is adjusted manually by turning an adjustable no...
Page 72
68 heating and air conditioning overview of the dual zone climatronic/climatic system fresh air intake duct temperature sensor g89* left footwell vent temperature sensor g261 right footwell vent temperature sensor g262* left vent temperature sensor g150 right vent temperature sensor g151* high press...
Page 73
69 heating and air conditioning defrost door motor v107* fresh/recirculating air door motor v154 left temperature door motor v158 right temperature door motor v159* central air door motor v70* air flow door motor v71* a/c compressor regulator valve n280 fresh air blower v2 with integrated fresh air ...
Page 74
70 heating and air conditioning function diagram - air conditioning systems input signal output signal positive ground can-bus g89 fresh air intake duct temperature sensor g261 left footwell vent temperature sensor g262 right footwell vent temperature sensor g263 evaporator vent temperature sensor g...
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71 heating and air conditioning n280 a/c compressor regulator valve g65 high pressure sensor v2 fresh air blower j533 data bus on board diagnostic interface v154 fresh/recirculating air door motor g143 recirculation door control motor position sensor v158 left temperature door motor g220 left temper...
Page 76
72 heating and air conditioning signal line to the control unit sensors interior temperature sensor function the interior temperature sensor replaces the instrument panel interior temperature sensor g56 with ventilation motor. It is an integral part of the control unit. The new sensor measures: • su...
Page 77
73 heating and air conditioning for additional information please refer to the following: ssp 881203 “hvac theory and operation” ssp 894303 “the phaeton heating and air conditioning system” ssp 899303 “the touareg heating/air conditioning system” construction the interior temperature sensor is not v...
Page 78
74 heating and air conditioning actuators fresh air blower and integrated fresh air blower controller v2 the dual zone climatronic system has a fresh air blower with an integrated controller. The fresh air blower is accessible from the front passenger footwell. Fresh air blower controller activation...
Page 79: Radio and Navigation
75 radio and navigation rcd 500 radio system (premium 7) the premium radio in the new jetta is the rcd 500 with the following features: • four loudspeaker channels (each 20 w) • rds fm/am • display of stored stations and rds names • mp3 compatible • fm-2 tuner • control by multi-function steering wh...
Page 80: Radio and Navigation
76 radio and navigation mfd 2 radio dvd navigation system (delayed introduction) the mfd 2 radio dvd navigation system operates similarly to the radio navigation system in the touareg. Features include: • multi-color display (mcd) • dynamic traffic guidance • four loudspeaker channels (each 20 w) • ...
Page 81: Service
77 service s318_052 s318_267 straightening bracket set vas 6240 special tools alignment bracket set vas 6240 and supplementary set vas 6240/2 are required service tools for new jetta frame and chassis alignment and straightening. New required equipment: • alignment bracket set vas 6240 • supplementa...
Page 82: Service
78 service tool number diagram application t10237 t10236 t10238 (1) t10240 (2) v.A.G. 1598 (1) v.A.G. 1598/47 (2) door setting tool rear door removal tool accelerator pedal module release tool (1) left-hand drive (2) right-hand drive dual zone climatronic, climatic and heating and ventilation system...
Page 83: Notes
79 notes.
Page 84: Knowledge Assessment
80 knowledge assessment an on-line knowledge assessment (exam) is available for this self-study program. The knowledge assessment may or may not be required for certification. You can find this knowledge assessment at: www.Vwwebsource.Com from the vwwebsource.Com homepage: – click on the certificati...
Page 86
Volkswagen of america, inc. 3800 hamlin road auburn hills, mi 48326 printed in u.S.A. December, 2004.