Volkswagen Jetta 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Volkswagen Model: Jetta Year: 2004 Codes Chassis Code: A4 (Mk4) 👋 Introduction Market Position Positioning: The Volkswagen Jetta (A4/Mk4) was positioned as a compact sedan...

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Description

🏷️ Basic Information

Identification

Make:

Volkswagen

Model:

Jetta

Year:

Codes

Chassis Code:

A4 (Mk4)

👋 Introduction

Market Position

Positioning:

The Volkswagen Jetta (A4/Mk4) was positioned as a compact sedan offering European driving dynamics, build quality, and a more premium feel than many competitors in its segment.

Competitive Analysis

Competitors:

Key competitors included the Honda Civic, Toyota Corolla, Ford Focus, Mazda3, and Chevrolet Cavalier/Cobalt.

Key Features

Features:

Known for its solid chassis, refined ride, accessible powertrain options, and German engineering heritage.

Manual Purpose

Target Audience:

Mechanics and DIY enthusiasts seeking accurate, factory-level repair and maintenance information.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF, though not explicitly stated, common for this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair of all engine components, including cylinder head, pistons, crankshaft, camshafts, timing systems, and lubrication.

Engine Management:

Diagnosis and repair of fuel injection systems (MPI), ignition systems, emissions control systems, and engine control module (ECM) functions.

Transmission Manual:

Repair and overhaul procedures for manual transmissions, including clutch, gearbox internals, and shifting mechanisms.

Transmission Automatic:

Diagnostic and repair procedures for automatic transmissions (likely 4-speed or 5-speed depending on engine), including valve body, torque converter, and electronic controls.

Suspension Steering:

Repair and adjustment of front and rear suspension components (MacPherson struts, torsion beams/multi-link), power steering system, and steering rack.

Brakes:

Detailed service and repair for hydraulic brake systems, including ABS, brake calipers, rotors, pads, master cylinder, and brake fluid specifications.

Electrical System:

Comprehensive wiring diagrams, troubleshooting guides for all electrical components, including lighting, starting/charging system, power windows, locks, and interior electronics.

HVAC:

Diagnosis and repair of heating, ventilation, and air conditioning systems, including refrigerant handling and component replacement.

Body And Trim:

Procedures for exterior and interior trim removal/installation, body panel repair, door mechanisms, and glass replacement.

Procedures Included

Maintenance:

Routine scheduled maintenance, fluid changes, filter replacements, spark plug service, and belt inspections.

Troubleshooting:

Systematic diagnostic procedures and fault finding for common and uncommon issues, often with flowcharts.

Repair:

Step-by-step instructions for the removal, disassembly, reassembly, and installation of all vehicle components.

Adjustment:

Procedures for calibrating and adjusting various systems, such as throttle position sensor, idle speed, and suspension alignment.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including torque specifications and specialized tool requirements.

📊 Manual Specifications

File Format

File Type:

Likely PDF (Portable Document Format)

Searchability:

Typically searchable text within PDF for quick information retrieval.

Print Quality

Printability:

Designed for printing, with clear diagrams and text layouts.

Binding Type

Binding:

If printed, would typically be a spiral-bound or comb-bound format for lay-flat use in a workshop.

Paper Type

Paper Quality:

If printed, likely on durable, coated paper to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Options 2004:

2.0L (8-valve SOHC) ABA, 2.0L (20-valve DOHC) AEG/APK/AQY, 1.8L (20-valve DOHC) Turbocharged AGU/AWP/AUQ (GLI models).

Performance

2.0L Sohc (Aba):

Approx. 115 hp @ 5200 rpm, 122 lb-ft @ 2600 rpm

2.0L DOHc (Aeg/Apk/Aqy):

Approx. 115 hp @ 5000 rpm, 122 lb-ft @ 3200 rpm

1.8L Turbo (Awp/Auq):

Approx. 180 hp @ 5500 rpm, 173 lb-ft @ 1950-4700 rpm (with overboost)

Fuel System

Injection Type:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Requirement:

87 octane regular unleaded (non-turbo), 91 octane premium unleaded (turbocharged 1.8T)

Engine Codes Manual References

Common Engine Codes:

ABA, AEG, APK, AQY, AGU, AWP, AUQ

🔧 Transmission

Standard

Standard Transmission Options:

5-speed Manual Transmission

Optional

Optional Transmission Options:

4-speed Automatic Transmission (01M) for 2.0L engines, 5-speed Automatic Transmission (01N) for 1.8T engines.

Features

Clutch Type:

Dry single-plate clutch (manual transmission)

Automatic Features:

Selectable modes (e.g., Sport/Comfort) may be present on some automatic transmissions.

📐 Dimensions

Exterior

Length:

Approx. 171.4 inches (4353 mm)

Width:

Approx. 68.3 inches (1735 mm)

Height:

Approx. 56.1 inches (1425 mm)

Wheelbase:

Approx. 101.5 inches (2578 mm)

Cargo

Trunk Volume:

Approx. 15.1 cubic feet (428 liters)

Weights

Curb Weight:

Ranges from approx. 2950 - 3250 lbs (1340 - 1475 kg) depending on engine and trim.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (Driver and Passenger)

NHTSA Side Impact:

4-Star (Front), 5-Star (Rear)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models.

Passive Features

Airbags:

Standard dual front airbags, optional side-impact airbags.

Seatbelts:

Three-point front and rear seatbelts, pretensioners, and load limiters for front occupants.

💡 Technology Features

Infotainment

Head Unit Options:

Factory installed radio/cassette player, optional CD player, and premium sound systems (e.g., Monsoon).

Display Technology:

Basic LCD displays for radio information, clock, and climate control. No integrated navigation or color screens.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Sensors:

Not typically available from the factory for this model year.

Connectivity

Auxiliary Input:

Not standard. May be available as an aftermarket option or dealer accessory.

Climate Control

HVAC Features:

Manual climate control, optional Climatronic automatic climate control.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 12 months, depending on driving conditions and oil type used.

Timing Belt Interval:

For 2.0L 8v (ABA) and 2.0L 20v (AEG, etc.), typically 60,000 - 105,000 miles (96,000 - 168,000 km) or 5-7 years. 1.8T uses a timing chain (low maintenance, but inspect tensioners).

Spark Plug Replacement:

Varies by plug type; typically 30,000 - 60,000 miles (48,000 - 96,000 km).

Fluid Specifications

Engine Oil Type:

VW 502 00 specification, SAE 5W-40 or 5W-30 (check owner's manual for specific viscosity and approval).

Coolant Type:

G12 or G12+ (red coolant). Never mix with older G11 (blue coolant).

Automatic Transmission Fluid:

ATF specification for the specific transmission (e.g., G 052 162 A2 for 01M, G 055 025 A2 for 01N). Requires specific VW fluid.

Brake Fluid Type:

DOT 4

Known Issues

Coil Packs:

Ignition coil packs are a common failure point, leading to misfires.

Window Regulators:

Plastic components in power window regulators can break.

Evaporative Emissions System:

EVAP system leaks (e.g., charcoal canister, vent valve) can trigger check engine lights.

Oil Leaks:

Valve cover gasket and oil pan gasket leaks can occur.

Automatic Transmission 01M:

The 01M automatic transmission can be prone to solenoid issues and torque converter problems.

Glowing Red Exhaust Manifold:

On 1.8T models, a glowing red exhaust manifold can indicate boost leaks or exhaust restrictions.

Maintenance Schedules Manual Coverage

Full Schedule Availability:

Manual provides detailed mileage and time-based maintenance schedules for all major systems.

📚 Vehicle History

Brand Heritage

Volkswagen Legacy:

Volkswagen has a long-standing reputation for engineering, build quality, and offering practical yet engaging vehicles.

Model Evolution

Jetta Mk4 Era:

The Mk4 Jetta (A4 platform) was produced from 1999 to 2005, representing a significant step up in refinement and features compared to its predecessors.

Production

Production Locations:

Primarily produced at Volkswagen's Puebla, Mexico plant.

Model Variants

Trim Levels 2004:

GL, GLS, GLX, and the sporty GLI (with the 1.8T engine).

🏆 Awards & Recognition

Recognitions

Consumer Reports Ratings:

Consumer Reports often rated the Jetta from this era as average to above average for reliability, with specific notes on engine and transmission performance.

Ratings

Ieda Reliability:

J.D. Power and Associates reliability ratings varied, but generally placed it in the middle of its class.

Certifications

Emission Standards:

Meets EPA and CARB emission standards for its model year.