Volkswagen 2004 Jetta Introduction Manual Download

Page: 31 / 86

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 locations are
equally positioned at 72

Oil Filter
Bypass
Passage

Oil Filter
Passage

Three Oil Return Check Valves
(Open Above 43.5 psi)

Four Open Oil Return Passages

S891403_133

S891403_134

S891403_132

Summary of Contents for 2004 Jetta

Page 1: ...Self Study Program Course Number 891403 The new Jetta New Model Introduction...

Page 2: ...duced 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 w...

Page 3: ...tive 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 Valv...

Page 4: ......

Page 5: ...mfort 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...

Page 6: ...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...

Page 7: ...trol 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...

Page 8: ...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 5...

Page 9: ...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: ...tensive 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 technolog...

Page 11: ...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...

Page 12: ...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 be...

Page 13: ...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: ...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...

Page 15: ...inted 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 termin...

Page 16: ...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 ca...

Page 17: ...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: ...18_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 el...

Page 19: ...e 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 modu...

Page 20: ...ystem 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 S891...

Page 21: ...ocked in position S318_209 The pass through door is locked in position S318_211 A red indicator showing means that the pass through door is not locked in position An optional feature of the front pass...

Page 22: ...areas Front Storage Vehicles equipped with air conditioning can cool the front passengerside storage compartment Overhead Storage There is a standard open storage compartment in the overhead console...

Page 23: ...r console and fold out cup holders for the rear seats Trunk Storage A sliding cover provides access to a side compartment for storing small objects Removal of the sliding cover allows parallel storage...

Page 24: ...Pressure Sensors G179 and G180 in the front doors detect sudden changes in air pressure during a side impact Overview The new Jetta provides the following protection systems devices Standard protectio...

Page 25: ...Rear Seatbelt Pretensioners The driver and passenger airbags provide two stage deployment The front passenger airbag is activated or deactivated automatically via the Advanced Airbag System Side curta...

Page 26: ...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...

Page 27: ...s pressed back into the seat the head restraint is activated and moves forward and down to minimize head and neck injuries At the same time that the head restraint is activated the lumbar support move...

Page 28: ...tbelts also have adjustable belt guides to improve passenger comfort The rear outer seats on vehicles equipped with rear side head airbags also have belt tensioners and belt force limiters Retractors...

Page 29: ...outer body panels These sensors react to changes in air pressure in the door cavity Air is directed via an inflow duct to a plate The components on the plate react to rapid changes in air pressure th...

Page 30: ...ter SULEV ULEV2 2 5L 150 HP 5 Cylinder Engine with 4 Valves per Cylinder The 2 5L 150 HP engine has 5 cylinders and 4 valves per cylinder driven by DOHC This engine is all new for the new Jetta and of...

Page 31: ...kshaft 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 locations are equally positioned at 72 Oil Filter Bypa...

Page 32: ...ne 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...

Page 33: ...iming 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 Camsh...

Page 34: ...dy 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 design The exhaust manifold features a protec...

Page 35: ...s 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 driven by the timing chain and provides power assi...

Page 36: ...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 N112 V101 Z1...

Page 37: ...ck on the flywheel end The seal is made of heat resistant and nonwearing polytetrafluoroethylene PTFE plastic The engine speed sensor is a Hall effect sensor mounted in the crankshaft seal housing and...

Page 38: ...culation Emissions standard TBD 4 cylinder in line engine 121 cu in 1984cc 1 3 4 2 3 25 in 82 5mm 3 65 in 92 8mm 4 10 5 1 200 HP 147 kW at 5 000 rpm 207 ft lb 280 Nm at 1 800 to 4 700 rpm Bosch Motron...

Page 39: ...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 specifica...

Page 40: ...d pressure regulator with pressure control on the raw oil side close to the oil pump integrated in the balancer shaft housing Higher strength die cast housing Balancer shafts mounted in the aluminium...

Page 41: ...ft chain drive The crank oscillation angle of the turbo engine is 2 Bow springs have been integrated into the sprocket wheel hub They decouple the input shaft of the balancer shaft module from the cra...

Page 42: ...ackening of the toothed belt Toothed Belt Drive As with all 4 cylinder in line engines the timing gear drives a toothed belt that drives the exhaust camshaft The toothed belt tensioning system has bee...

Page 43: ...ke 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 geometry is...

Page 44: ...trol valve is located on the cylinder head cover If vacuum exist in the intake manifold blow by gases flow directly into the intake manifold If a boost pressure is present in the intake manifold a one...

Page 45: ...ase and ACF ventilation A silencer reduces pressure pulsation noises Boost pressure is controlled by a Wastegate Bypass Regulator Valve N75 A Turbocharger Recirculating Valve N249 prevents overbraking...

Page 46: ...old is split A divider in the manifold ensures a steady flow of exhaust gases to the turbine The ports of cylinders 1 and 4 and cylinders 2 and 3 are separated based on the firing order The divider al...

Page 47: ...flow past the turbine wheel into the exhaust system This control system regulates the turbine speed and sets the maximum boost pressure If the control system fails the boost pressure acts directly on...

Page 48: ...the Turbocharger Recirculating Valve N249 is opened by an electrical actuator This allows the compressed air to flow back to the intake side of the circuit through the turbine This maintains turbine...

Page 49: ...hot The pump forces the lower temperature coolant against the normal direction of flow The coolant flows from the radiator through the turbocharger to the engine block and back to the cooler Connectio...

Page 50: ...ove cold engine idling To improve charge efficiency at start up In overrun mode ACF System with Double Non Return Valve Throttle Valve Actuator Intake Air Temperature Sensor High Pressure Low Pressure...

Page 51: ...modulation Pressure Limiting Valve Low Pressure Fuel Circuit High Pressure Fuel Circuit High Pressure Injector Triple Pump Cam High Pressure Pump Low Fuel Pressure Sensor G410 Fuel Pressure Sensor G2...

Page 52: ...osition Sensor 2 G185 Brake Light Switch F Brake Light Switch F63 Fuel Pressure Sensor G247 Intake Manifold Runner Position Sensor G336 Knock Sensor KS 1 G61 Knock Sensor KS 2 G66 Engine Coolant Tempe...

Page 53: ...Power Control EPC G186 Motronic Engine Control Module ECM Power Supply Relay J271 Engine Component Power Supply Relay J757 Voltage Supply Terminal 15 B Relay J329 Evaporative Emission EVAP Canister P...

Page 54: ...Ft Lbs Horsepower S318_197 295 236 177 118 59 1000 2000 3000 4000 Engine Speed rpm Torque and Power S891403_70 Engine code Type Displacement Bore Stroke Valves per cylinder Compression ratio Max outp...

Page 55: ...deactivates the cruise control system and briefly reduces fuel to the fuel injectors to prevent engine shudder during the resulting gear change For additional information on the accelerator brake and...

Page 56: ...er Oil Cooler Mechatronics Control Modules Multi Plate Clutches S318_002 6 Speed Direct Shift Gearbox DSG 02E The 02E 6 speed gearbox combines the advantages of a manual transmission with those of an...

Page 57: ...the 09G include Maximum torque 229 ft lbs 310 Nm Weight 185 lbs 84kg Length 13 8 in 350mm Torque converter with lockup Automatic and Tiptronic operation Forward and reverse gears have simple planetar...

Page 58: ...erior performance characteristics Electro mechanical power steering provides excellent handling assistance while maintaining road feel This variable assist system also automatically adjusts the level...

Page 59: ...tion 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 adjus...

Page 60: ...ng location of fuse and relay centers have changed The adjacent diagram shows the various fitting locations For additional information on the electrical system please refer to SSP 873403 The new Jetta...

Page 61: ...ystem 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 driver...

Page 62: ...Control Module J503 Radio Navigation Display Control Module J519 Vehicle Electrical System Control Module J525 Digital Sound System Control Module J527 Steering Column Electronic Systems Control Modu...

Page 63: ...ear Door CM J388 Climatronic CM J255 Memory Seat Steering CM J136 Instrument Cluster CM J285 Anti Theft Engine Disable Immobilizer IV CM J334 Vehicle Electrical CM J519 Airbag CM J234 Steering Wheel C...

Page 64: ...tioner doors on the Dual Zone Climatronic are actuated by six control motors with integrated potentiometers The Dual Zone Climatronic can be operated either automatically or manually To prevent foggin...

Page 65: ...ution doors Temperature requests are relayed to the control module by a potentiometer in the rotary switch The requested temperature setting is achieved by adjusting the position of the temperature do...

Page 66: ...air conditioning systems HVAC is available in two versions depending on the option selected The Dual Zone Climatronic heating and air conditioning system The Climatic heating and air conditioning sys...

Page 67: ...by pressing the ECON button Floating Mount Installation To ensure a uniform fit the system control units are installed using floating mounts This installation method allows perfect alignment with the...

Page 68: ...Intake Duct Temperature Sensor G89 Evaporator Vent Temperature Sensor G263 High Pressure Sensor G65 Fresh Air Blower V2 Sunlight Photosensor 2 G134 Interior temperature sensor Air recirculation mode W...

Page 69: ...the system have been made including The cross sectional area of all air ducts has been increased The air duct to the defrost and instrument panel vents runs through the instrument panel The front sid...

Page 70: ...imatronic uses a fresh flow door and a separate air recirculation door Defrost Door Left FootWell Vent Temperature Sensor G261 Central Door Instrument Panel Footwell Doors Not Visible Defroster Door M...

Page 71: ...ctly by air from the evaporator The cooling level is adjusted manually by turning an adjustable nozzle Adjustable Vent S318_006 Adjustable Vent S318_004 The center console also has an adjustable vent...

Page 72: ...vaporator Vent Temperature Sensor G263 Sunlight Photosensor 2 G134 Defroster Door Control Motor Position Sensor G135 Recirculation Door Motor Position Sensor G143 Central Door Motor Position Sensor G1...

Page 73: ...280 Fresh Air Blower V2 with integrated fresh air blower controller In the Climatic system air flow is not controlled electronically but through series resistors S318_083 Steering Column Electronic Sy...

Page 74: ...G150 Left Vent Temperature Sensor G151 Right Vent Temperature Sensor G134 Sunlight Photosensor 2 J255 Climatronic Control Module V70 Central Air Door Motor G112 Central Door Motor Position Sensor V71...

Page 75: ...Right Temperature Door Motor G221 Right Temperature Door Potentiometer Actuator Term 75 Term 30 Term 15 Term 31 J533 Convenience CAN bus N280 V2 G65 Unventilated Interior Temperature Sensor V154 G143...

Page 76: ...It is an integral part of the control unit The new sensor measures Surface temperature Unit temperature Sunlight penetration S318_141 S318_237 Its advantages over the previous sensor include The senso...

Page 77: ...vented and consists of an integrated thermo optical sensor an NTC element in combination with a photodiode The NTC element measures the temperature and intensity of solar radiation on its surface Thi...

Page 78: ...ia a pulse width modulated signal PWM and can also send back a diagnostic feedback signal A single pulse transmitted in the diagnostic feedback signal indicates no fault to the air conditioner control...

Page 79: ...ellite Radio Sound adaptation capabilities Self diagnosis including speaker diagnosis Transport Mode Add on amplifier capability S891403_120 Radio and Navigation Systems RCD 300 Radio System Base Radi...

Page 80: ...e Multi color display MCD Dynamic traffic guidance Four loudspeaker channels each 20 W RDS FM AM Display of stored stations together with RDS names Control by multi function steering wheel MFS and mul...

Page 81: ...ols 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...

Page 82: ...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 systems troubleshooting tools...

Page 83: ...79 Notes...

Page 84: ...s Knowledge Assessment at www vwwebsource com From the vwwebsource com Homepage Click on the Certification tab Type the course number in the Search box Click Go and wait until the screen refreshes Cli...

Page 85: ......

Page 86: ...Volkswagen of America Inc 3800 Hamlin Road Auburn Hills MI 48326 Printed in U S A December 2004...

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