Volkswagen 2004 Jetta Manuel de référence

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

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

any form or by any means, electronic,

mechanical, photocopying, recording or

otherwise, nor may these materials be

modified or reposted to other sites without

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.

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

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

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

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

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

Introduction

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

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.

Table des matières

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