The new Jetta
New Model Introduction
Self-Study Program
Course Number 891403
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 publisher.
All requests for permission to copy and
redistribute information should be referred
to Volkswagen of America, Inc.
Always check Technical 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
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
Automatic Transmission ...........................................................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 New!
Zone Climatronic/Climatic System, Sensors, Actuators
Radio and Navigation ..............................................................75
Radio and Navigation Systems
Service .......................................................................................77
Special Tools, New Special Tools
Important/Note!
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.
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Introduction
Course Introduction
The new Jetta continues its success story New Jetta features include:
of the past 30 years. The new Jetta • Elegant design
introduces new features that combine
• Superior quality
appearance with comfort and modern
technology, resulting in a vehicle that • Excellent handling dynamics
provides the ultimate value in its class. • Comprehensive safety package
Attention to detail, increased horsepower,
• Innovative drivetrain technology
added safety features and subtle quality
improvements set the new Jetta apart from • Improved economy
the competition. • Spacious interior
The new Jetta is built at Volkswagen's • Customer focused innovations
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.
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
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Introduction
The New Jetta
The new Jetta sets new standards for its
class in many areas, including:
• Safety
• Quality
• Design
• Handling
• Roominess
• Drivetrain
• 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
• Optional Bi-Xenon headlights
• ABS/ESP MK 60
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Introduction
Other Features
• Rain sensing windshield wipers
• Optional rear distance warning system
• Dual zone climate control
• Two piece tail light design
• Four link independent suspension
• Customer personalization via the
multi-function indicator (MFI) switch lever
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3
Volkswagen Service Training 891403 The New Jetta Introduction
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Introduction
Technical Specifications
The figure shows the dimensions of the
front-wheel drive new Jetta.
Weights and Exterior Dimensions
34.6 in. 101.5 in. 42.7 in.
(880mm) (2578mm) (1084mm)
178.1 in.
(4523mm) S891403_16
57.5 in.
(1,461mm)
60.4 in. 59.7 in.
(1,533mm) (1,517mm)
S891403_15
69.1 in.
(1,755mm)
Length 178.1 in. (4,523mm) Front track width 60.4 in. (1,533mm)
Width 69.1 in. (1,755mm) Rear track width 59.7 in. (1,517mm)
Height 57.5 in. (1,461mm) Maximum weight 4,057 to 4,321 lb.*
Wheelbase 101.5 in. (2,578mm) (1,840 to 1,960 kg)
S891403_01 Empty weight 3,016 to 3,331 lb.*
(1,368 to 1,511 kg)
*varies depending on model
S891403_02
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