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Self-Study Program Course Number 891403 The new Jetta New Model Introduction
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Self-Study ProgramCourse Number 891403
The new JettaNew Model Introduction
Volkswagen of America, Inc.Volkswagen AcademyPrinted in U.S.A.Printed 12/2004Course Number 891403
©2004 Volkswagen of America, Inc.
All rights reserved. All information containedin this manual is based on the latestinformation available at the time of printingand is subject to the copyright and otherintellectual property rights of Volkswagen ofAmerica, Inc., its affiliated companies and itslicensors. All rights are reserved to makechanges at any time without notice. No partof this document may be reproduced,stored in a retrieval system, or transmitted inany form or by any means, electronic,mechanical, photocopying, recording orotherwise, nor may these materials bemodified or reposted to other sites withoutthe prior expressed written permission ofthe publisher.
All requests for permission to copy andredistribute information should be referredto Volkswagen of America, Inc.
Always check Technical Bulletins and the latestelectronic repair information for informationthat may supersede any information includedin this booklet.
Trademarks: All brand names and productnames used in this manual are trade names,service marks, trademarks, or registeredtrademarks; and are the property of theirrespective owners.
i
Table of Contents
This Self-Study Program covers the design and operation ofthe new Jetta!
This Self-Study Program is not a Repair Manual. Thisinformation will not be updated.
For testing, adjustment and repair procedures, always referto the latest electronic service information.
Important/Note!
New!
Introduction ................................................................................1Course Introduction, The New Jetta
Body ............................................................................................6Chassis Construction, Exterior Parts, Windows, Hood LatchCable, New Door Design, Seat Design Features, StorageAreas
Passenger Safety ......................................................................20Overview, Two-Stage Airbags, Advanced Airbag System,Active Front Seat Head Restraints, Rear Side Head Airbags,Side Airbag Crash Sensors
Engines......................................................................................262.5L/150 HP 5-Cylinder Engine with 4-Valves per Cylinder,2.0L/200 HP 4-Cylinder Turbo FSI Engine with 4-Valves perCylinder, 1.9L/105 HP TDI Engine with 2-Valve Technology,Pedal Assembly
Automatic Transmission...........................................................526-Speed Direct Shift Gearbox (DSG) 02E, 6-Speed AutomaticTransmission 09G
Suspension ...............................................................................54Suspension Features
Electrical System ......................................................................56Fuse and Relay Locations, CAN Networking Concept, AirConditioning Systems
Heating and Air Conditioning .................................................62Introduction, Air Distribution System, Overview of the DualZone Climatronic/Climatic System, Sensors, Actuators
Radio and Navigation ..............................................................75Radio and Navigation Systems
Service.......................................................................................77Special 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 storyof the past 30 years. The new Jettaintroduces new features that combineappearance with comfort and moderntechnology, resulting in a vehicle thatprovides the ultimate value in its class.Attention to detail, increased horsepower,added safety features and subtle qualityimprovements set the new Jetta apart fromthe competition.
The new Jetta is built at Volkswagen'sPuebla, Mexico plant. This plant beganoperation in 1964, manufacturing the oldstyle Beetle. Currently, the Puebla plantemploys approximately 14,000 people andalso produces the New Beetle, amongother 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 asthe overhead console
• Electro-mechanicalpower steering
• 2.5L 150 HP 5-Cylinder Enginewith 4-Valves per Cylinder
The New Jetta
The new Jetta sets new standards for itsclass 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 themulti-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)
LengthWidthHeightWheelbase
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 widthRear track widthMaximum 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 thefront-wheel drive new Jetta.
Weights and Exterior Dimensions
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S891403_15
S891403_02
S891403_01
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)
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S891403_12
6
Body
Key:Red = Side Impact ZoneYellow = Occupant CellBlue = Frame Structure
Chassis Construction
Static and Dynamic Rigidity
The new Jetta sets new standards for staticand dynamic rigidity by the application oflightweight design principles.
Fenders, doors and side panels are all madeof high strength steel.
Laser Weld Technology
The assembly plant in Puebla, Mexicomakes extensive use of laser weldingtechnology to produce the new Jettachassis. The increased use of laser weldshas resulted in significant improvements inchassis strength and rigidity.
Laser weld technology not only improvesmanufacturing efficiency, it also improvesthe quality of the chassis by increasing thewelded surface while reducing thedeformation of the sheet metal caused bythe necessary heat and pressure ofprevious welding methods.
The chart below provides a comparison ofincreased manufacturing technology on thenew Jetta A5 compared to the previousJetta A4.
7
Body
B-pillar
The new Jetta’s B-pillar consists of threehot formed panels that provide improvedpassenger protection in the event of aside-impact collision.
Hot Formed Panels
The B-pillar and adjacent portion of thebody in the direction of the A-pillar are heattreated during the forming process toincrease strength. These hot formed panelsare stronger and weigh less than the panelson previous models.
B-pillar
Outer Body SidePanel Inner Body Side Panel
(tailored blank)
S318_066
Hot formed panelsS891403_19
S891403_17
S891403_18
Additional side impactprotection in doors
8
Body
Exterior Parts
Front Bumper
By integrating an impact-absorbing foamelement into the front bumper behind thefront spoiler, the risk of injury topedestrians is reduced. This deformablefoam element allows compression of thefront bumper during impact.
Headlights
The Jetta headlights feature clear glass. Theturn signals are located below the low andhigh beam headlights to improve theirvisibility to other drivers.
Bi-Xenon headlights are available as anoption on some models.
Impact-Absorbing Foam
S318_289
S891403_115
9
Body
Exterior Rearview Mirrors
Turn signals are integral to the exteriorrearview mirrors.
Tail Lights
The new Jetta has two-part tail lights.
S891403_26
S891403_116S891403_117
10
Body
Windows
Ceramic Coating as Third Sun Visor
Clear Area forRain/Light SensorsDrip
Molding Area
Drip MoldingArea
Area Belowthe Hood
Sash for Plenum Chamber Cover
S318_003
Clear Area for VIN Plate
WindshieldLabel
Sealing Lip
Windshield
The windshield is available with an infrared-reflective metal vapor deposition coating.This coating reflects most of the sun’s heatgenerating infrared rays. Conventionalreflective glass shields a vehicle’s interiorfrom far less solar radiation by absorption.
Always set the windshield on itsside. Otherwise, the sash at thebottom and/or the sealing lip atthe top can become damaged.
The windows on the new Jetta are green-tinted glass (blue-tinted glass will beavailable at a later date). The thickness ofthe window glass depends on its location:the windshield is .17 inches (4.4mm), thefront side windows are .14 inches (3.5mm)and all other windows are .12 inches(3.15mm). All fixed windows are bonded tothe body.
11
Body
Rear Window
Replacement rear windows are producedwith integral diversity antennas. Diversityantennas connect to the diversity switchingbox by two terminals on the window.
Heater element with additional printed conductors foroptimizing the rear window antennas
Antenna Terminal
AntennaTerminal
Heater ElementTerminal
S318_005
Heater ElementTerminal
Signals are relayed simultaneously fromthese terminals to the radio and thediversity switching box. Using both antennasignals significantly reduces interference.
Be sure to order the correct rearwindow when replacing to assureall electrical terminals arepresent.
12
Body
Hood Latch Cable
The hood latch cable (bowden cable) forreleasing the hood latch from inside thepassenger compartment is located in aprotected area in the engine compartment.The hood latch cable disconnect point islocated under the hood behind thedriverside headlight assembly. This allowsfront end service without removing thecable from the vehicles interior.
S318_251
S318_253
S318_255
Disconnect point (closed)
Disconnect point (open)
Bowden cable disconnected
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13
Body
Emergency Release Mechanism
Removing the interior trunk trim allowsaccess to the locking linkage for emergencyrelease of the trunk.
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S891403_46
14
Body
New Door Design
The doors on the new Jetta consist of anouter panel with two mounting rails and aninner section for mounting hardware. Thedoor’s outer panel is bonded to themounting rails that are bolted to the innersection.
S318_257
Side Impact Bar
Door OuterPanel
Door Inner Section
Mounting Rail
Cover Strip
Mounting Rail
Cover Strip
Removal of the outer door panel allowsaccess to some of the door’s innerhardware and electronics, the windowmotor is accessed through the inside. Also,in the event of door damage, the outerpanel can be removed for repair orreplacement.
Check the current service repairinformation for instructions onouter door panel removal.
15
Body
Mounting Rails
The mounting rails are permanently bondedto the outer panel with adhesive. Thisensures an accurate fit when the outerpanel is bolted to the door's inner section.
Internal Door Components
Removing the outer panel allows easyaccess to the side impact bars, door handlebracket, door lock, side airbag crash sensorand the window regulator module.
S318_203
MountingRails
Door Outer Panel
Side Impact Bars
WindowRegulatorModule
Driver’s Side Airbag CrashSensor G179
Door HandleBracket
Door Lock
S318_205
16
Body
Seat Design Features
Front Seats
The front seats on the new Jetta areequipped with an active head restraintsystem. Options include: a mechanical2-way lumbar support or an electrical 4-waylumbar support.
The active head restraint system is amechanical system that moves the driverand passenger head restraints upward andforward in the event of a rear end collision.
Active HeadRestraint System
S318_060
4-Way LumbarSupport
S891403_119
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1. Through-Loading Front Passenger Seat2. Rear Loading Door3. Active Head Restraints4. 4-Way Lumbar Support5. Power Backrest6. Complete Power Seat, Optional
S891403_94
Height Adjustment
4-Way Lumbar Support
Power Backrest
17
Body
Rear Seats
The rear seat cushion extends across thefull width of the interior. The backrest issplit 60/40 and can be folded down. Thebackrests lock using a rotary latch. A redindicator shows if the backrests are lockedor not.
S318_101
S318_207A red indicator showingmeans that the backrestis not locked in position.
S318_209
The pass-through door is lockedin position.
S318_211A red indicator showing meansthat the pass-through door is notlocked in position.
An optional feature of the front passengerseat allows it to be folded flat for loadingand hauling of long items by using the fulllength of the interior.
On vehicles equipped with thepass-through option for the rear seat, thearmrest and the door located behind it canbe folded forward to allow transport of longitems such as skis or golf bags.
18
Body
S318_103
S318_105 S891403_47
AdjustableTemperatureOutlet
Storage Areas
The new Jetta features numerousconvenient storage areas.
Front Storage
Vehicles equipped with air conditioning cancool the front passengerside storagecompartment.
Overhead Storage
There is a standard open storagecompartment in the overhead console ofthe new Jetta.
Door Storage
Storage compartments, and a cup holderfor 1.6 quart (1.5 liter) bottles are located inthe door panels.
19
Body
S891403_53
S318_081
S318_155
Rear Fold-OutCup Holder
Rear Vent
AdjustableTemperatureOutlet
Center Console Storage
A new Jetta storage option includes an air-conditioned storage compartment in thecenter console and fold-out cup holders forthe rear seats.
Trunk Storage
A sliding cover provides access to a sidecompartment for storing small objects.Removal of the sliding cover allows parallelstorage of larger items such as a golf bag.
Spare Tire Area Storage
The new Jetta is equipped with a full-sizeemergency spare tire. There are additionalstorage areas near the spare tire location.
StorageCompartmentDoor
20
Passenger Safety
S318_153
S891403_24
S318_125
S318_153
Airbag ControlModule J234receives data fromthe sensors andcontrols airbagdeployment.
Lateral accelerationsensors, located inthe rear wheelhousing, detectside impacts.
Side Curtain Airbag withGas Distributor Tube
Two Longitudinal AccelerationSensors (Early Crash Sensors)G251, located in the front ofthe vehicle, detect impact andimpact intensity.
Pressure Sensors G179and G180 in the frontdoors detect suddenchanges in air pressureduring a side impact.
Overview
The new Jetta provides the followingprotection systems/devices.
Standard protection equipment includes:• Driver and front passenger two-stage
airbags
• Front seat side curtain airbags
• Front and rear side (head) airbags
• 3-point seat belts on all seats
• Front seat belt tensioners and belt forcelimiters
• Front seat active head restraint system.
Optional protection equipment includes:• Rear passenger side (head) airbags in
combination with belt tensioners andbelt force limiters on the outer rearseats.
21
Passenger Safety
PassengersideTwo-StageAirbag
AdvancedAirbagSystem
CurtainAirbag
Front SeatbeltPretensioner
SideAirbagSide
Airbag
Side ImpactPressureSensors
FrontImpactSensors
DriversideTwo-StageAirbag
SeatbeltEngagementDetectorSwitch
Rear SideImpactSensors
Rear SeatbeltPretensioners
The driver and passenger airbags providetwo-stage deployment. The front passengerairbag is activated or deactivatedautomatically via the Advanced AirbagSystem.
Side curtain airbags cover the window areafrom the A-pillar to the C-pillar. In the eventof a crash, a pressurized gas cylinderprovides uniform inflation of the curtainairbags.
The rear outer seats are equipped with childseat anchors as standard equipment.
S891403_92AirbagControlModule
22
Passenger Safety
Two-Stage Airbags
The airbag system reacts to unique crashconditions by deploying the driverside andpassengerside airbags in two stages,depending on the size of the front seatoccupants and the severity of the impact.
PASSENGER
AIR BAG OFF
Advanced Airbag System
The new Jetta is equipped with theAdvanced Airbag System. This system is astandard feature for the front passengerseat. Based on occupant weight andseatbelt tension, the system signals thecontrol module to deploy the airbag in oneof two stages. In a slow speed collision, thetwo-stage airbag and the Advanced AirbagSystem work together to activate only thefirst stage. This provides the best protectionfor a small adult. The “Passenger AirbagOFF” light is illuminated when thepassenger seat is unoccupied.
Seat Belt Sensor
Bladder
Hose
PressureSensor
Protection
Felt
ElectronicControl Module
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23
Passenger Safety
Active Front Seat Head Restraints
The new Jetta is equipped with active headrestraints on the front seat. During acollision, as the occupant is pressed backinto the seat, the head restraint is activatedand moves forward and down to minimizehead and neck injuries. At the same timethat the head restraint is activated, thelumbar support moves forward to provideadditional protection from injury. This is acompletely mechanical system thatrequires no electronics.
S891403_98
Movementof HeadRestraints
24
Passenger Safety
Rear Side (Head) Airbags
These airbags are available as an option forthe outer rear seats. They are located in theside bolsters.
Seat Belts
The front seatbelts are equipped withpyrotechnic tensioners and belt forcelimiters. The front seatbelts also haveadjustable belt guides to improvepassenger comfort.
The rear outer seats on vehicles equippedwith rear side head airbags also have belttensioners and belt force limiters.Retractors are attached to the body toimprove passenger shoulder comfort.
The rear center seat has a three-pointseatbelt with a retractor integrated in thebackrest.
S318_016
S318_213
Airbag Module
Rear Side Cushion
The driverside seatbelt is located in the B-pillar.
25
Passenger Safety
Side Airbag Crash Sensors
The Driverside Airbag Crash Sensor G179and the Front Passengerside Airbag CrashSensor G180 replace the conventionalacceleration sensors for side impactdetection.
These new pressure sensors provide fasterdetection of side impacts in the door area.
Sensor Function
The side airbag crash sensors are located inthe front doors between the inner andouter body panels. These sensors react tochanges in air pressure in the door cavity.Air is directed via an inflow duct to a plate.The components on the plate react to rapidchanges in air pressure that occur during acrash.
Sensor Signal
The sensor continuously monitors airpressure in the door cavity. If the sensordetects a rise in air pressure above apredetermined value, it sends a signal tothe airbag control module.
Sensor Failure
If the sensor fails, the airbag warning lamp,located in the instrument cluster, will comeon.
S318_127
Sealing Compound
Blank
Air Inflow Duct
Contacts
Housing
26
Engines
Engine code TypeDisplacement Firing OrderBore Stroke Valves per cylinderCompression ratio Max. output Max. torque Fuel
Exhaust gas treatmentEmissions standard
BGP5-cylinder in-line engine151 cu. in. (2480cc)1-2-4-5-33.25 in. (82.5mm)3.65 in. (92.8mm)410:1150 HP (110 kW) at 5,000 rpm168 ft. lb. (228 Nm) at 4,000 rpm94 octane (98 RON) unleaded fuel, 91 octane (95 RON) unleaded can be used with reduced performanceCatalytic converter
SULEV ULEV2
2.5L/150 HP 5-Cylinder Enginewith 4-Valves per Cylinder
The 2.5L/150 HP engine has 5 cylinders and4 valves per cylinder driven by DOHC. Thisengine is all new for the new Jetta andoffers high torque, high performance, lowfuel consumption, low emissions and lowmaintenance.
Special Features:• Transverse 5-cylinder design
• Dual overhead cams
• Continuously variable intake cam
• Chain driven cams
• Roller rocker fingers
• No hazardous materials used incomponents
Technical Data Torque and Power
Torq
ue (F
t. L
bs.)
Hor
sepo
wer
184
147
111
74
37
1000 3000 5000 7000
335
268
201
134
67
Engine Speed [rpm]S891403_32
S891403_31
S891403_33
27
Engines
Engine Block
The 2.5L engine block design is similar toprevious models with an improvedlubrication system.
Engine Crankshaft
The crankshaft is made of forged steel withbearing and connecting rod surfaces likethe 2.0L engine and includes the timinggear. The five connecting rod locations areequally positioned at 72°.
Oil FilterBypassPassage
Oil FilterPassage
Three Oil Return Check Valves(Open Above 43.5 psi)
Four Open Oil Return Passages
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28
Engines
Dual Overhead Cam Head
The A5 engine has dual overheadcamshafts with a continuously adjustingintake cam. The head design is based onthe V10 Lamborghini engine.
RetardChamber
AdvanceChamber
AssembledCamshaft(Lower Weight)
Roller CamFollower
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S891403_131
S891403_135
29
Engines
Timing Chains
The 2.5L engine uses timing chains toimprove durability and extend serviceperiods. The timing chain arrangement alsodrives the oil pump and the vacuum pumpthrough its intermediate cog wheel.
IntakeCamshaft
ExhaustCamshaft
VacuumPump
OilPump
Crankshaft
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30
Engines
Intake Manifold
The intake manifold on the 2.5L A5 engineis made of plastic. The intake manifoldassembly includes the throttle body, fuelregulator, AKF valve and the pressure andthrottle sensor assembly.
Exhaust Manifold
A feature of the 2.5L exhaust manifold is itsisolated air-flow design. The exhaustmanifold features a protective plate thatserves as a source for heated intake air.
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S891403_127
S891403_128
Heated Air tothe Intake System
Protective Plate
31
Engines
Engine Cover/Air Filter Housing
The engine cover on the 2.5L engineincludes the intake air filter and part of thesystem that delivers heated intake air to theengine. The engine cover’s configurationalso lowers engine noise.
Vacuum Pump
The 2.5L engine’s vacuum pump ismechanically driven by the timing chain andprovides power assist to the vehicle’s brakesystem. The pump is driven via its cogwheel assembly.
Cog WheelAssembly
VacuumPump
S891403_129
S891403_130
S891403_125
32
Engines
Engine Control System–Input/OutputDiagram
G71
G28
G40
G79G185
G187G188
G61G66
G83
G62
FF47
G70G42
G476
G39G130G465
Additional SignalsVel. CruiseClimateDFM AlternatorPWM Ventilators
K
J519, J533, J527, J234, J104, J285, J217 Additional Signals
Ventilators
V144PumpLDP
J299N112
V101
Z19Z29Z30
N33N83
N30N31N32
N205
G186
N292N323
N80
N29N70N127
Relay 167
Relay 458 (87)
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33
Engines
S318_051
CrankshaftSeal Flange
Engine SpeedSensor Wheel
Engine SpeedSensor
S318_049North Pole
Crankshaft Seal Flange with IntegratedEngine Speed Sensor Wheel
The crankshaft seal flange with integratedengine speed sensor wheel is a newfeature. The crankshaft seal flange seals thecylinder block on the flywheel end. The sealis made of heat-resistant and nonwearingpolytetrafluoroethylene (PTFE) plastic.
The engine speed sensor is a Hall effectsensor mounted in the crankshaft sealhousing and consists of a steel ringmounted in rubber. This rubber materialcontains embedded magnetized metalchips that have an alternate north and southpolarity with a large north pole to serve as areference for the engine speed sensor. Thesensor wheel is precisely press-fit into thecrankshaft flange.
South Pole
34
Engines
Technical Data
S891403_71
Torq
ue (F
t. L
b.)
Hor
sepo
wer
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 OrderBore Stroke Valves per cylinderCompression ratio Max. output Max. torque
Engine management Fuel
Exhaust gas recirculation Emissions standard
TBD4-cylinder in-line engine121 cu. in. (1984cc)1-3-4-23.25 in. (82.5mm) 3.65 in. (92.8mm) 410.5:1200 HP (147 kW) at 5,000 rpm207 ft. lb. (280 Nm) at 1,800 to 4,700 rpmBosch Motronic MED 9.194 octane (98 RON) unleaded fuel, 91 octane (95 RON) unleaded can be used with reduced performanceInner EGR
ULEV
2.0L/200 HP 4-Cylinder Turbo FSIEngine with 4-Valves per Cylinder
The 2.0L turbo FSI engine combines theadvantages of direct injection combustionwith exhaust turbo charging technology. Theresult is an extremely responsive engine.
35
Engines
Crankshaft
The crankshaft has been modified to meetthe tougher demands of the turbo FSIengine. This results in higher strengthcomponents and less engine noise.
The main bearing flanges and journals havebeen enlarged for more strength. Thismeets specifications even with the .25 in.(6.4mm) increase in stroke.
Flanges
332_020
36
Engines
Engine Balancer Shaft
The balancer shaft gear used in the enginefeatures the following:• Separate gear and imbalance masses to
improve balancing
• Oil pump with wider gear
• Clean oil controlled pressure regulatorwith pressure control on the raw oil sideclose to the oil pump, integrated in thebalancer shaft housing
• Higher strength die-cast housing
• Balancer shafts mounted in thealuminium housing
• Decoupled final drive sprocket in thebalancer shaft drive gear
Final DriveSprocket
Oil Pump
DriveGear Imbalance
GearsBalancerShaftHousing
BalancerShafts
Crankshaft
IntakeLine
332_021
37
Engines
Final Drive Sprocket
High torsional irregularities from thecrankshaft of the turbo engine at low RPMsresults in greater chain forces in thebalancer shaft chain drive. The crankoscillation angle of the turbo engine is 2°.Bow springs have been integrated into thesprocket wheel hub. They decouple theinput shaft of the balancer shaft modulefrom the crankshaft. This is similar to a dual-mass flywheel.
Cover Disc
HubPlainBearing Sprocket
WheelBow Spring(2x) Friction
Disc
Diamond-CoatedDisc
DiaphragmSpring
332_022
38
Engines
The new Crankshaft Torsional Cancellation(CTC) toothed belt sprocket reducescamshaft vibration and the forces acting onthe toothed belt.
Function
The toothed belt sprocket is positioned onthe crankshaft at TDC of cylinder 1, asshown below. When the cycle begins,forces acting on the toothed belt arereduced by the elliptical shape of thetoothed belt sprocket. The flat side of thesprocket gear allows a slight slackening ofthe toothed belt.
Toothed Belt Drive
As with all 4-cylinder in-line engines, thetiming gear drives a toothed belt that drivesthe exhaust camshaft.
The toothed belt tensioning system hasbeen modified to meet the demands placedon the toothed belt drive by the turbo,including:• Higher valve spring pressures
• Turbo-related valve timing associatedwith the 42° crank angle adjustmentrange of the continuous variable valvetiming on the intake camshaft
• High-pressure oil pump drive from atriple cam on the intake camshaft
The modification is an elliptical toothed beltsprocket on the crankshaft.
D1
D2
D2>D1
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39
Engines
Cylinder Head
The cylinder head features the following:• Sodium-filled exhaust valves
• Intake valves with reinforced seats
• Roller rocker fingers strengthened whilereducing cam and roller land width
• Identical valve springs are used for bothintake and exhaust valves
Intake port geometry is used to enhancethe tumble effect, reduce knock andimprove running smoothness.
2.0L 4V T-FSI
332_017
40
Engines
Crankcase Ventilation
A constant vacuum is maintained in thecrankcase through separate ventilation ofthe crankcase and cylinder head. Thecrankcase breather is connected to theintake manifold.
The crankcase blow-by gases flow into thecylinder head through the primary oilseparator in the oil filter module. Here theblow-by gases mix with the gases from thecylinder head and flow through a secondseparator to provide additional oilseparation.
Since a turbo engine requires a moresophisticated pressure control system, atwo-stage pressure control valve is locatedon the cylinder head cover. If vacuum existin the intake manifold, blow-by gases flowdirectly into the intake manifold.
If a boost pressure is present in the intakemanifold, a one-way valve in the pressurecontrol valve housing closes and the blow-by gases flow into the cylinder head coverahead of the turbocharger. The system candetect faulty installation of the pressurecontrol valve. Unmetered air is detected bythe reaction of the lambda probe.
Valve Cover
If a boost pressure is present upstream of turbochargerIf a vacuum is present in the intake manifold
ExhaustTurbochargerGas Outlet
IntakeManifoldGas Outlet
CentralCrankcaseGas Inlet
Oil Filter Module
Non-Return Valve Non-Return ValvePressureControl Valve
332_057
41
Engines
Exhaust Turbocharger/Manifold Module
To conserve space and improveperformance and serviceability, the exhaustmanifold and turbine housing have beencombined into a single module. Specialemphasis was placed on easy removal andinstallation of the exhaust manifold and theclose-coupled catalytic converter.
The turbine shaft mount is integrated intothe compressor housing. The air intakeincludes connections for crankcase andACF ventilation. A silencer reducespressure pulsation noises.
Boost pressure is controlled by aWastegate Bypass Regulator Valve N75. ATurbocharger Recirculating Valve N249prevents “overbraking” of the turbine whenthe engine is in overrun with the throttlevalve closed and boost pressure stillpresent. The Wastegate Bypass RegulatorValve N75 and the TurbochargerRecirculating Valve N249 are located on theturbocharger.
Crankcase BreatherConnection
Coolant Inlet FromEngine Block
TurbochargerRecirculating ValveN249
Pressurized Oil Inlet
ACF Connection
Coolant Flow to Radiator orFrom Auxiliary Water Pump
332_024
42
Engines
A clamping flange on the cylinder headallows easy removal and installation of theexhaust turbocharger/manifold module. Theterminal block does not require removal.
The exhaust manifold is split. A divider inthe manifold ensures a steady flow ofexhaust gases to the turbine. The ports ofcylinders 1 and 4 and cylinders 2 and 3 areseparated based on the firing order. Thedivider also prevents the exhaust gaspressure from expanding into the othercylinders.
This maintains turbine speed and optimizesturbocharger response.
Divider
Cylinder 1
Terminal Block
332_026
332_025
43
Engines
Charge Air Ducting and Boost PressureControl
The boost pressure and intake pressure areconverted to control pressure by the pulsewidth modulated Wastegate BypassRegulator Valve N75. Control pressure actson the pressure unit that actuates thewastegate flap. The wastegate flap opens abypass and allows some of the exhaustgases to flow past the turbine wheel intothe exhaust system. This control systemregulates the turbine speed and sets themaximum boost pressure.
If the control system fails, theboost pressure acts directly onthe pressure unit. The increasedspring pressure reducesmaximum boost down tominimum boost.
Pressure Unit
Charge Air Cooler
Wastegate
Water Connection
Brake Booster Servo
Vacuum Pump
Oil FilterModule
TurbochargerRecirculating ValveN249
Wastegate BypassRegulator Valve N75
Evaporative Emission(EVAP) Canister PurgeRegulator Valve N80
332_011
44
Engines
Overrun Air Divert Control
If the throttle valve closes when the engineis in overrun, back pressure develops in theturbo housing. Back pressure reduces thespeed of the turbine, which reduces boostpressure and increases turbo lag.
To avoid this, the Turbocharger RecirculatingValve N249 is opened by an electricalactuator. This allows the compressed air toflow back to the intake side of the circuitthrough the turbine. This maintains turbinespeed. The Turbocharger Recirculating ValveN249 closes when the throttle valve opensagain and boost pressure is immediatelyavailable.
Overrun Mode
Divert Air Valve Open
Divert AirValve Closed
Engine Running Under Load
Air IntakeFrom AirFilter
332_012
45
Engines
Cooling System
To prevent carbon build-up on the turbineshaft in the turbocharger, an auxiliary waterpump provides additional water circulationfor up to 15 minutes after the engine is shutoff hot. The pump forces the lowertemperature coolant against the normaldirection of flow. The coolant flows fromthe radiator through the turbocharger to theengine block and back to the cooler.
ConnectionExpansion Tank
RadiatorOutlet
Engine BlockConnection
Oil Cooler
ConnectionExhaust-DrivenTurbocharger
Water Port
Connection HeatExchanger
CoolantThermostat
RadiatorInlet
AuxiliaryWaterPump
332_028
46
Engines
Tumble Flaps
At different engine rpms, tumble flaps areactivated 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 withDouble Non-ReturnValve
Throttle ValveActuator
Intake AirTemperatureSensor
High-Pressure/Low-PressureFuel Port
Plastic Flapwith Steel Shaft
High-Pressure Rail
Activated CharcoalFilter Valve
PressureLimitingValve
TumbleFlapActuator
332_058
47
Engines
Fuel Supply
Fuel for the 2.0L direct-injection engine issupplied by a demand-controlled fuel pump.This demand control was developed toreduce the demands on the fuel pump andimprove fuel economy.
The fuel pump maintains system pressurebut only supplies as much fuel as theengine requires. The Engine Control Module(ECM) and an electronic power modulecontrol fuel pump speed through pulsewidth modulation.
Pressure Limiting Valve
Low-PressureFuel Circuit
High-PressureFuel Circuit
High-PressureInjector
Triple Pump Cam
High-PressurePump
Low FuelPressureSensorG410
Fuel Pressure Sensor G247
Fuel Pressure Regulator Valve N276
Fuel Delivery Module With Fuel Tank SensorElectrical Fuel Delivery
Fuel Demand Control System
ElectronicPowerModule
ECM
Fuel Filter With PressureLimiting Valve
Injector System
PressureSensor
Injectors
SuspensionStrut Turret
Pressure ControlValve For PressureExceeding 120 Bar
PressureSensor
0.5-5 BarRail Pressure 50-110 Bar
Short Return Line
332_078
332_073
48
Engines
Actuators and Sensor Diagram
Mass Air Flow (MAF) Sensor G70
Charge Air Pressure Sensor G31Manifold Absolute Pressure (MAP) Sensor G71
Engine Speed (RPM) Sensor G28
Camshaft Position (CMP) Sensor G40
Throttle Drive Angle Sensor 1 [for ElectronicPower Control (EPC)] G187Throttle Drive Angle Sensor 2 [for ElectronicPower Control (EPC)] G188Throttle Valve Control Module J338
Throttle Position (TP) Sensor G79Accelerator Pedal Position Sensor 2 G185
Brake Light Switch FBrake Light Switch F63
Fuel Pressure Sensor G247
Intake Manifold Runner Position Sensor G336
Knock Sensor (KS) 1 G61Knock Sensor (KS) 2 G66
Engine Coolant Temperature (ECT) Sensor G62
Engine Coolant Temperature (ECT) Sensor(on Radiator) G83
Low Fuel Pressure Sensor G410
Intake Air Temperature (IAT) Sensor G42
Heated Oxygen Sensor (HO2S) G39Oxygen Sensor (O2S) Behind Three WayCatalytic Converter (TWC) G130
Exhaust Gas Temperature (EGT) Sensor 1 G235
Clutch Position Sensor G476
Alternator DF
Barometric Pressure(BARO) Sensor F96Motronic EngineControl Module J220
Diagnosis Connection
S891403_88
49
Engines
Cruise control On/Off
Fuel Level Sensor GTransfer Fuel Pump (FP) G6
Cylinder 1 Fuel Injector N30Cylinder 2 Fuel Injector N31Cylinder 3 Fuel Injector N32Cylinder 4 Fuel Injector N33
Ignition Coil 1 with Power Output Stage N70Ignition Coil 2 with Power Output Stage N127Ignition Coil 3 with Power Output Stage N291Ignition Coil 4 with Power Output Stage N292
Throttle Valve Control Module J338Throttle Drive [for Electronic Power Control(EPC)] G186
Motronic Engine Control Module (ECM) PowerSupply Relay J271
Engine Component Power Supply Relay J757
Voltage Supply Terminal 15 (B+) Relay J329
Evaporative Emission (EVAP) Canister PurgeRegulator Valve N80
Fuel Pressure Regulator Valve N276
Intake Door Motor V157
Camshaft Adjustment Valve 1 N205
Wastegate Bypass Regulator Valve N75
Turbocharger Recirculating Valve N249
Oxygen Sensor (O2S) Heater Z19Oxygen Sensor (O2S) Heater 1 [behind ThreeWay Catalytic Converter (TWC)] Z29
Coolant Circulation Pump Relay J151
After-Run Coolant Pump V51
Coolant Fan Control (FC) Control Module J293
Fuel Pump ControlModule J538
S891403_89
50
Engines
1.9L/105 HP TDI Engine with2-Valve Technology
Special Features:• Switchable EGR cooler
• Crankshaft sealing flange withintegrated engine speed sender wheel
• Accelerator pedal module withcontactless accelerator pedal positionsenders
• Contactless clutch pedal switch
S318_033
Technical Data
Torq
ue (F
t. L
bs.)
Hor
sepo
wer
S318_197
295
236
177
118
59
1000 2000 3000 4000
Engine Speed [rpm]
Torque and Power
S891403_70
Engine code TypeDisplacementBore Stroke Valves per cylinderCompression ratio Max. output Max. torque Engine management Fuel Exhaust gas treatment
TBD4-cylinder in-line engine116 cu. in. (1896cc)3.1 in. (79.5mm)3.6 in. (95.5mm)219:1105 HP (77 kW) at 4,000 rpm184 ft. lb. (250 Nm) at 1,900 rpmBosch EDC 16Diesel, min. 49 CN Exhaust gas recirculation and oxidizing catalytic converter
136
109
82
54
27
51
Engines
Pedal Assembly
The pedal assembly includes accelerator,brake and clutch control modules.
The brake pedal module housing is made ofaluminium and sheet steel.
The accelerator pedal and the clutch pedalmodule housings are made of plastic. Pedalposition sensors recognize the pedalposition without making direct contact withpedal sensing components.
ClutchPedalModule
AcceleratorPedalModule
BrakePedalModule S318_038
Clutch Position Sensor G476
The Clutch Position Sensor G476 is a Halleffect device that signals the engine controlmodule that the clutch pedal has moved.This deactivates the cruise control systemand briefly reduces fuel to the fuel injectorsto prevent engine shudder during theresulting gear change.
For additional information on theaccelerator, brake and clutchpedal assembly please refer toSSP 861403 “The new JettaSteering and Suspension”.
Accelerator Pedal Position Sensors G79and G185
The Accelerator Pedal Position Sensors G79and G185 are located in the acceleratorpedal module. Both are inductive sensorsthat provide the exact position of theaccelerator pedal to the engine controlmodule. The engine control module usesthis information to control the amount offuel available to the fuel injectors.
Master CylinderClutch Pedal
Clutch PositionSensor G476
S318_064
Position SensorsG79 and G185
S318_054
Metal Plate
AcceleratorPedal
52
Automatic Transmission
02E DSG features include:• Six forward gears and one reverse gear
• Normal shift control program “D” andSport shift control program “S”
• Tiptronic shift control and steeringwheel shift control
• Mechatronics: electronic and hydrauliccontrol modules in a single unit areintegral to the transmission
• Oil cooler and compressed air filter aremounted on the transmission
• Maximum torque 258 ft. lbs. (349 Nm)
For additional information on theDSG, please refer to SSP 841403“Volkswagen 02E Direct ShiftGearbox”.
Compressed Air Filter
Oil Cooler
MechatronicsControlModules
Multi-Plate Clutches
S318_002
6-Speed Direct Shift Gearbox(DSG) 02E
The 02E 6-speed gearbox combines theadvantages of a manual transmission withthose of an automatic transmission:
Manual:• High efficiency
• Rugged design
• Sporty performance
Automatic:
• Comfort and convenience whenchanging gears
The 02E meets the high standards ofcomfort expected by automatictransmission users by using two multi-plateclutches and several automatic shiftprograms.
The 02E also provides pure drivingenjoyment for manual transmission usersby allowing the driver to control the gearselection and shifts with its quick, smoothgearshifts. The 02E also provides better fueleconomy than typical manualtransmissions.
53
Automatic Transmission
For additional information on thistransmission, please refer to SSP851503 “The 6-Speed AutomaticTransmission 09G”.
S318_024
6-Speed Automatic Transmission09G
The 6-speed automatic transmission 09G istransverse mounted, compact, lightweightand electronically controlled.
Features of 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 simpleplanetary gear sets with a doubleRavigneaux planetary gear set.
Modulating valves are activated by thetransmission control module to controlpressure build-up in the multi-plate clutchesand plate brakes. By allowing a delayedpressure build-up the modulating valvesdeliver fast response times and smoothshifts.
54
Suspension
Suspension Features
The suspension of the new Jetta sets thestandard in its class. An optimized frontaxle strut suspension provides state of theart handling characteristics. The newbalanced four-link rear axle suspensioncomplements the front suspension with itsown superior performance characteristics.Electro-mechanical power steering providesexcellent handling assistance whilemaintaining road feel. This variable assistsystem also automatically adjusts the levelof assist depending on vehicle speed.
• Dual rate brake servo
• Teves MK 60 Electronic stabilizationsystem
• Electro-mechanicalpower steering
• Optimized McPherson strut suspension
• Floor mounted accelerator pedalassembly with redundant positionsensors
• Direct 1 to 1 anti-roll bar connection
55
Suspension
For additional information on thesuspension, please refer to SSP861403, “The new Jetta Steeringand Suspension”.
• Four-link rear suspension
• Tire pressure monitoringsystem (delayed introduction)
• Power brakes
• Toe and camberadjustments on rearsuspension
S891403_27
56
Electrical System
Fuse and Relay Locations
Mounting Locations
The electrical system on the new Jetta isentirely redesigned. Because the electricalsystem has been completely reconfigured,the mounting location of fuse and relaycenters have changed.
The adjacent diagram shows the variousfitting locations.
For additional information on theelectrical system, please refer toSSP 873403, “The new JettaElectrical System Design andFunction”.
Fuse and relay center underthe hood on the driverside
Back-up fuse box under thehood on the driverside
Fuse box behind the instrumentcluster on the driverside
57
Electrical System
Relay carrier belowthe instrumentcluster on thedriverside, abovethe power supplycontrol module Relay carrier inside the power supply
control module, below the instrumentcluster on the driverside
S891403_61
58
Electrical System
KeyD Ignition/Starter SwitchE221 Control Module in Steering WheelG85 Steering Angle SensorG397 Rain/Light Recognition SensorH8 Alarm HornJ104 ABS Control ModuleJ136 Memory Seat/Steering Column
Adjustment Control ModuleJ217 Transmission Control Module (TCM)J220 Motronic Engine Control ModuleJ234 Airbag Control ModuleJ255 Climatronic Control ModuleJ285 Instrument Cluster Control ModuleJ334 Anti-Theft Engine Disable Control ModuleJ364 Auxiliary Heater Control ModuleJ386 Driver's Door Control ModuleJ387 Front Passenger's Door Control ModuleJ388 Left Rear Door Control ModuleJ389 Right Rear Door Control ModuleJ393 Comfort System Central Control ModuleJ400 Wiper Motor Control ModuleJ431 Headlamp Range Control ModuleJ446 Parking Aid Control ModuleJ500 Power Steering Control ModuleJ503 Radio/Navigation Display Control ModuleJ519 Vehicle Electrical System Control ModuleJ525 Digital Sound System Control ModuleJ527 Steering Column Electronic Systems
Control ModuleJ533 Data Bus On Board Diagnostic InterfaceJ587 Selector Lever Sensor System Control
Module*J604 Auxiliary Air Heater Control ModuleJ743* Direct Shift Gearbox (DSG) MechatronicR RadioT16 16-Pin Connector*On direct shift gearboxes only
CAN Networking Concept
Networked Control Modules
To allow the new Jetta’s control modules tocommunicate, they are connected byvarious data bus systems.
The Data Bus On Board DiagnosticInterface J533 provides access to thefollowing data bus systems:• Drivetrain CAN-bus
• Convenience CAN-bus
• Infotainment CAN-bus
• Instrument cluster CAN-bus
• Diagnosis CAN-bus
In addition to the CAN-bus, anumber of electric componentsare networked via the LIN databus.
Refer to SSP 873403, “The newJetta Electrical System Designand Function” for detailedinformation on CAN-buscommunications.
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 H8
Wiper Motor CM J400
Auxiliary Air Heater
CM J604*
Right Rear Door CM J389
Front Passenger
Door CM J387
Driver's Door CM J386
Left Rear 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
CM E221
Parking Aid CM J446
Steering Angle Sensor G85
Steering Column Electronic Systems
CM J527
Ignition/Starter Switch D
Rain/Light Recognition Sensor G397
Comfort System Central
CM J393
Transmission CM J217
* May not be available on North American market vehicles
16-PinConnector
T16
Drivetrain CAN-bus
ConvenienceCAN-bus
Infotainment CAN-bus
LIN Bus
Instrument ClusterCAN-bus
Diagnosis CAN-bus
CAN-busWire
CommunicationsLine
60
Electrical System
Air Conditioning Systems
Dual Zone Climatronic
The new Jetta is equipped with adual zone air conditioning system. Thetemperature on the driver's and frontpassenger's sides can be controlledseparately to between 60°F (16°C) and 85°F(29.5°C). Pressing the “Auto” button forlonger than two seconds allows thetemperatures on both sides to besynchronized to the driver's side.
Two air-conditioning zones are achieved byusing two temperature doors within the airconditioner. All air conditioner doors on theDual Zone Climatronic are actuated by sixcontrol motors with integratedpotentiometers. The Dual Zone Climatroniccan be operated either automatically ormanually.
To prevent fogging of the windshield, theDual Zone Climatronic automaticallyincreases air flow to the windshield if thecompressor is off and the windshieldwipers are on. The defrost door is alsoopened wider.
The Dual Zone Climatronic also reduces thefresh air blower speed depending onvehicle speed. This minimizes the airflownoise of the air conditioner. The fresh airblower is automatically adjusted as afunction of road speed. This adjustment inblower speed is not noticeable by thevehicle occupants.
S891403_56
61
Electrical System
Climatic System
The Climatic system manages the interiorof the vehicle as one climate zone. TheClimatic air conditioner has a combinedfresh air/recirculating door that, like thetemperature control door, is driven by acontrol motor. The Climatic system uses aflexible shaft to control the position of theair distribution doors. Temperature requestsare relayed to the control module by apotentiometer in the rotary switch. Therequested temperature setting is achievedby adjusting the position of the temperaturedoor.
Interface with the Air Conditioner
The various components of the Climaticsystem and the heating system are dividedinto two units: an electronic front unit and amechanical rear unit that is controlled by aflexible shaft. The heater is controlled by abowden cable. The air conditioner isserviced similarly to other vehicles.
S891403_57
62
Heating and Air Conditioning
Interior TemperatureSensor
S891403_63
LED Indicators
Front Passenger Seat Heating ControlDriver SeatHeating Control
Dual Zone Climatronic System
Introduction
The new Jetta’s heating, ventilation and airconditioning systems (HVAC) is available intwo versions, depending on the optionselected.• The Dual Zone Climatronic heating and
air conditioning system
• The Climatic heating and air conditioningsystem
All operating controls for the system arelocated on the control panel. FeedbackLEDs on all buttons provide an indication ofactive functions. The Dual Zone Climatronicand Climatic systems include an interiortemperature sensor.
63
Heating and Air Conditioning
Climatic System
The “AC” button on the Climatic system islabelled “ECON.”
Air conditioning is deactivated bypressing the “ECON” button.
Floating Mount Installation
To ensure a uniform fit, the system controlunits are installed using floating mounts.This installation method allows perfectalignment with the trim panel when thepanel is installed.
“AC” is renamed “ECON”.
InteriorTemperature Sensor Feedback LED
S891403_64
S318_079
Floating Mounts
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 G150Right Vent Temperature Sensor G151
Left Footwell Vent Temperature Sensor G261Right Footwell Vent Temperature Sensor G262
Fresh Air 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
With series resistor
Left
Left
By pressing the air recirculation button
When driving in reverse
In wipe-wash mode
Two doors actuated by control motors
Actuated by control motor
Actuated by control motor
One door actuated by a control motor
With electronic control
Left and right
Left and right
Actuated by flexible shaft
Actuated by flexible shaft
No
No
No
Yes
Yes
Yes
Yes
YesYes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
S891403_28
65
Heating and Air Conditioning
• The rear passenger area is vented by asingle air duct leading to the left andright footwells.
The Dual Zone Climatronic airducts in the instrument panelprovide indirect ventilationthrough vents in the top of theinstrument panel.
Air Distribution System
The air distribution system on the new Jettais similar to the systems on previous Jettas.However, significant improvements to thesystem have been made, including:• The cross sectional area of all air ducts
has been increased.
• The air duct to the defrost andinstrument panel vents runs through theinstrument panel.
• The front side windows are nowventilated through new vents in theA-pillar.
S318_191
S318_020
S318_181
Rear RightFootwell Vent
Rear LeftFootwell Vent
Door ControlledCenter RearFootWell Vent
Ventsin theA-Pillar
Air ConditioningSystem
Dummy Cover
Rear FootWell Vent Duct
Indirect Ventilation inthe Instrument Panel
A center console vent is available thatdirects airflow to the center rear ventsthrough a common air duct.
66
Heating and Air Conditioning
The main difference between theClimatronic and Climatic systems is themethod used to control air distribution. TheDual Zone Climatronic system has anadditional fresh air door, which closes atspeeds above 60 mph (97 kph). Thisprovides constant fresh air flow at differentvehicle speeds.
The figure below shows the air conditionerof the Dual Zone Climatronic system.
The heating/ventilation systemand Climatic system use afresh recirculation door. TheDual Zone Climatronic uses afresh flow door and a separate airrecirculation door.
Defrost Door
Left FootWell VentTemperature Sensor G261
Central Door (Instrument Panel),Footwell Doors Not Visible
Defroster DoorMotor V107
Left TemperatureDoor Motor V158
Central Air DoorMotor V70(Instrument Panel/Footwell)
Left Rear Footwell VentRight Rear Footwell Vent
Rear Center Vent (center console only)
Evaporator Vent TemperatureSensor G263
Right Temperature Door MotorV159
Right FootWell, VentTemperature Sensor, G262
Fresh/RecirculatingAir Door MotorV154
Air Flow DoorMotor V71
Fresh Air/Air Flow Door
Fresh Air IntakeDuct TemperatureSensor G89
RecirculatedAir Door
Temperature Doors,Left and Right
S318_131
67
Heating and Air Conditioning
Storage Box Cooling
All vehicles are equipped with a cooledglovebox storage compartment located inthe front passenger side area. The storagecompartment is cooled directly by air fromthe evaporator. The cooling level is adjustedmanually by turning an adjustable nozzle.
Adjustable Vent
S318_006Adjustable Vent
S318_004
The center console also has an adjustablevent for temperature control. Cooled air isdirected from the center console air duct tothe storage compartment. This cooled airsupply can also be adjusted manually byturning an adjustable nozzle.
S318_143
68
Heating and Air Conditioning
Overview of the Dual ZoneClimatronic/Climatic System
Fresh Air Intake Duct Temperature SensorG89*
Left Footwell Vent Temperature SensorG261
Right Footwell Vent Temperature SensorG262*
Left Vent Temperature Sensor G150
Right Vent Temperature Sensor G151*
High Pressure Sensor G65
Evaporator Vent Temperature Sensor G263
Sunlight Photosensor 2 G134*
Defroster Door Control Motor PositionSensor G135*
Recirculation Door Motor Position SensorG143
Central Door Motor Position Sensor G112*
Back Pressure Door Motor Position SensorG113*
Left Temperature Door Potentiometer/Actuator G220
Right Temperature Door Potentiometer/Actuator G221*
S891403_58
ClimatronicControlModuleJ255
InstrumentCluster CAN-bus
Drivetrain CAN-bus
InstrumentClusterControlModule285
Motronic EngineControl Module J220
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 freshair blower controller. (In the Climaticsystem, air flow is not controlledelectronically, but through series resistors.)
S318_083
Steering ColumnElectronic SystemsControl Module J527
Auxiliary Air HeaterControl Module J604
ConvenienceCAN-bus
Vehicle ElectricalSystem ControlModule J519
Infotainment CAN-bus
Data Bus On BoardDiagnosticsInterface J533
* Only in combination with Dual ZoneClimatronic
70
Heating and Air Conditioning
Function Diagram - Air Conditioning Systems
Input SignalOutput SignalPositiveGroundCAN-bus
G89 Fresh Air Intake Duct Temperature SensorG261 Left Footwell Vent Temperature SensorG262 Right Footwell Vent Temperature SensorG263 Evaporator Vent Temperature SensorG150 Left Vent Temperature SensorG151 Right Vent Temperature SensorG134 Sunlight Photosensor 2
J255 Climatronic Control ModuleV70 Central Air Door MotorG112 Central Door Motor Position SensorV71 Air Flow Door MotorG113 Back Pressure Door Motor Position SensorV107 Defroster Door MotorG135 Defroster Door Motor Position Sensor
Heated Front Passenger Seat Control Module J132
S318_115
Heated Driver Seat Control Module J131
G89* G261 G262* G263 G150 G151* G134*
J255
V70* G112* V71* G113* V107* G135*
71
Heating and Air Conditioning
N280 A/C Compressor Regulator ValveG65 High Pressure SensorV2 Fresh Air BlowerJ533 Data Bus On Board Diagnostic InterfaceV154 Fresh/Recirculating Air Door MotorG143 Recirculation Door Control Motor Position Sensor
V158 Left Temperature Door MotorG220 Left Temperature Door Potentiometer/
ActuatorV159 Right Temperature Door MotorG221 Right Temperature Door Potentiometer/
Actuator
Term. 75Term. 30Term. 15Term. 31
J533
Convenience CAN-bus
N280 V2**
G65
UnventilatedInterior Temperature Sensor
V154 G143 V158 G220 V159* G221*
The Climatic sensors andactuators use differentdesignations. For additionalinformation, please refer tocurrent service repairinformation.
* Used with Dual Zone Climatronic system only** The V2 Fresh Air Blower motor used withDual Zone Climatronic only. Climatic and the heaterare controlled by series resistors.
S318_117
72
Heating and Air Conditioning
Signal Line to theControl Unit
Sensors
Interior Temperature Sensor
Function
The interior temperature sensor replacesthe Instrument Panel Interior TemperatureSensor G56 with ventilation motor. It is anintegral part of the control unit.
The new sensor measures:• Surface temperature
• Unit temperature
• Sunlight penetration
S318_141
S318_237
Its advantages over the previous sensorinclude:• The sensor housing is protected,
making it less susceptible toobstructions that could interfere withtemperature regulation
• No moving parts to wear and fail
• No openings in the trim provide a designadvantage
NTC Element and Photodiode
73
Heating and Air Conditioning
For additional information pleaserefer to the following:
SSP 881203 “HVAC Theory andOperation”
SSP 894303 “The PhaetonHeating and Air ConditioningSystem”
SSP 899303 “The TouaregHeating/Air Conditioning System”
Construction
The interior temperature sensor is notvented and consists of an integratedthermo-optical sensor, an NTC element incombination with a photodiode.
The NTC element measures thetemperature and intensity of solar radiationon its surface. This allows the sensor tomeasure the air temperature in thevehicle’s interior even if the sensor'ssurface is heated. The sensor signals aretransmitted to the Climatic or Dual ZoneClimatronic. Software then evaluates thesensor signals and regulates thetemperature of the vehicle’s interior.
74
Heating and Air Conditioning
Actuators
Fresh Air Blower and Integrated FreshAir Blower Controller V2
The Dual Zone Climatronic system has afresh air blower with an integratedcontroller. The fresh air blower is accessiblefrom the front passenger footwell.
Fresh Air Blower Controller Activation
The Fresh Air Blower V2 with integratedelectronic fresh air blower controller iscontrolled by the air conditioner controlmodule via a pulse-width modulated signal(PWM) and can also send back a diagnosticfeedback signal.
A single pulse transmitted in the diagnosticfeedback signal indicates “no fault” to theair conditioner control module.
However, two pulses indicate that thecurrent is limited; three pulses indicate thatthe temperature is too high and may causethe fresh air blower to slow or shutdown.
One Pulse
Two Pulses
Three Pulses
Fresh Air Blower V2
Fresh AirBlower Rotor
Housing Cover
Electronics
S318_123
S318_195
Climatronic Control Module J255
Diagnosis
PWM
S318_165
Term. 30
Term. 31
ti = time segment of one pulsetp = time segment of one period
ti tp
75
Radio and Navigation
RCD 500 Radio System (Premium 7)
The premium radio in the new Jetta is theRCD 500 with the following features:• Four loudspeaker channels (each 20 W)
• RDS FM/AM
• Display of stored stations and RDSnames
• MP3 compatible
• FM-2 tuner
• Control by multi-function steering wheel(MFS) and multi-function display (MFD)
• Integrated 6 disc CD changer
• Controls for additional 6 disc CDchanger
• Telephone control (hands-free operation)
• SAT Optional Satellite Radio
• Sound adaptation capabilities
• Self-diagnosis including speakerdiagnosis
• Transport Mode
• Add-on amplifier capability
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Radio and Navigation Systems
RCD 300 Radio System (Base Radio)
The RCD 300 radio is a standard radiosystem. It has the following features:• Two or four loudspeaker channels (each
20 W)
• RDS FM/AM
• Display of stored stations and RDSnames
• MP3 compatible
• FM-2 tuner
• Control by multi-function steering wheel(MFS) and multi-function display (MFD)
• Integrated single CD drive
• Controls for external 6 disc CD changer
• Telephone control (hands-free operation)
• Self-diagnosis including speakerdiagnosis
• Transport Mode
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76
Radio and Navigation
MFD 2 Radio DVD Navigation System(Delayed Introduction)
The MFD 2 radio DVD navigation systemoperates similarly to the radio navigationsystem in the Touareg. Features include:• Multi-color display (MCD)
• Dynamic traffic guidance
• Four loudspeaker channels (each 20 W)
• RDS FM/AM
• Display of stored stations together withRDS names
• Control by multi-function steering wheel(MFS) and multi-function display (MFD)
• Controls for additional 6 disc CDchanger
• Self-diagnosis including speakerdiagnosis
To remove and install a radio,remove the cover to access themounting screws.
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77
Service
S318_052
S318_267
Straightening Bracket Set VAS 6240
Special Tools
Alignment bracket set VAS 6240 andsupplementary set VAS 6240/2 are requiredservice tools for new Jetta frame andchassis alignment and straightening.
New required equipment:• Alignment bracket set VAS 6240
• Supplementary set VAS 6240/2
• Portal gauge supplement VAS 5007/18
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 systems troubleshooting tools(1) Test box(2) Test adapters
(1) (2)
(2)
(1)
S318_269
S318_265
S318_291
S318_293
S318_295
S891403_29
New Special Tools
79
Notes
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 Certification tab
– Type the course number in the Search box
– Click “Go!” and wait until the screen refreshes
– Click “Start” to begin the Assessment
For Assistance, please call:
Certification Program Headquarters
1 – 877 – CU4 – CERT
(1 – 877 – 284 – 2378)
(8:00 a.m. to 8:00 p.m. EST)
Or, E-Mail:
Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.December, 2004
