Service Training

Self Study Program 890323

The Jetta Hybrid
Design and Function

Volkswagen Group of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 08/2012
Course Number 890323

©2012 Volkswagen Group 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 Group of America, Inc., its
affiliated companies and its licensors. All rights are reserved
to make changes at any time without notice. No part of this
document may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means, electronic,
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without the prior expressed written permission of the
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All requests for permission to copy and redistribute
information should be referred to Volkswagen Group 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.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
High Voltage Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mechanical Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Note

This Self-Study Program provides information
regarding the design and function of new
models.
This Self-Study Program is not a Repair Manual.

Important!

This information will not be updated.
For maintenance and repair procedures,
always refer to the latest electronic
service information.

iii

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Introduction
The Jetta Hybrid from Volkswagen combines innovative full-hybrid technology and low fuel consumption in a
compact sedan. German engineering, European design, and Volkswagen’s high-quality is setting new quality
standards for hybrid vehicles in the US.
The highly modern hybrid drivetrain includes ground breaking technical elements: an economical 150 hp (110 kW)
TSI engine with a 20hp (15 kW) electric engine, a lithium ion battery with the latest technology, and the efficient
7-speed dual clutch transmission (DSG®).
The exterior and interior unmistakably display the design and quality of Volkswagen. At the same time, the use of
eco-friendly materials emphasizes VW’s strong environmental commitment.
As a sporty high-tech hybrid, the Jetta Hybrid offers uncompromising power and plenty of driving fun with low
fuel consumption and the highest environmental compatibility.

S525_031

1

Introduction
Hybrid lettering on the dashboard

Hybrid powerflow representations in
the radio navigation system

Hybrid lettering in the engine
compartment

High voltage A/C compressor

Hybrid lettering on the grille

2

Introduction
Hybrid information in the instrument cluster
Hybrid lettering on the rear of the vehicle

High-voltage battery in the
luggage compartment

Electric mode button

E-machine
S525-001

3

Introduction
The Jetta Hybrid Concept

S525_002

The Jetta Hybrid concept is based on a parallel hybrid
drive. The electric motor and the internal combustion
engine are both used for mechanically driving the
drivetrain. Both components are mounted on a
single symbolic shaft.

Using electrical systems, the following components
are electrically-driven instead of mechanically-driven
using a belt:
• Coolant pumps (12 volt)
• Power steering (12 volt)
• Vacuum pump for brake boost (12 volt)
• Air compressor (high voltage)

4

Introduction
Drive
Volkswagen is extending its range of hybrid vehicles
using the Jetta Hybrid. The following reliable
concepts from the Touareg Hybrid are used in the
Jetta Hybrid:

The Jetta Hybrid was designed with the following
additional requirements:
• Reduced fuel consumption
• Smaller internal combustion engine

• Electric driving (using the electric motor only)

• Improved boost mode performance

• Boost (combined power of the internal combustion
engine and the electric motor)

• 7-speed dual-clutch transmission

• Recuperation (using deceleration to recharge the
high voltage battery)

• Use of existing components and systems
• Extensive use of space and weight saving
components

Even with these capabilities, the following needed to
be retained:
• Comfort
• Quick acceleration
• Ease of use
• Durability

S525_031

5

Introduction
Performance and Consumption
The overall goal of the Jetta Hybrid was to combine impressive driving performance with low fuel consumption.
Thanks to the following technologies and features, a Jetta Hybrid of the same size and power (as compared to
conventional vehicles) will have a fuel consumption advantage of more than 30% in city driving and up to 20% in
combined operation. The following help to achieve this fuel reduction:
• The latest engine and transmission technology with the 1.4 L TSI, twin clutch transmission and the latest
integrated hybrid module
• Aerodynamic optimization of the vehicle in the modified bumpers, side skirts and flat rear spoiler
• Coasting mode
• Hybrid functions: Electric driving, start/stop system, and brake recuperation
The TSI engine is not only turned off during pure electric driving (up to 37 mph or 60 km/h on level surfaces) but is
decoupled using a separating clutch to prevent engine drag. This separation also occurs when the driver releases
the gas pedal (coasting). The Jetta rolls significantly longer due to the elimination of engine drag. This occurs at
speeds of up to 77 mph (125 km/h).
Significant fuel savings are achieved in city driving from regenerated brake energy as well as the start/stop
system.
When the internal combustion engine and the E-machine are working simultaneously (boosting), the output is
briefly 170 hp (125 kW) and the torque is 184 lb/ft (250 Nm).

S525_038

6

Introduction
Technical Data

Internal Combustion Engine

1.4 L 4V TSI Engine with Turbocharger

Internal Combustion Engine Output

150 hp (110 kW)

Transmission

7-speed Dual Clutch Transmission (DSG®)

E-machine

Permanently Excited Synchronous Motor

E-machine Output

20 hp (15 kW)

Maximum Output in Boost

170 hp (125 kW)

Maximum Torque in Boost

184 lb/ft (250 Nm)

Battery Technology

Lithium Ion Battery with 60 Cells

Voltage of High-voltage Battery

220 V (3.7 V per cell)

Capacity of the High-voltage Battery

1.1 kWh

Acceleration from 0 to 62 mph (100 km/h)

8.9 s

Additional Weight from the Hybrid Components

Approximately. 227 lb (103 kg)

Torque/Performance
Because the E-machine has 100% of its power from 0 RPM, it can be used to assist with low-RPM acceleration.
This allows the Jetta Hybrid to have extraordinarily fast acceleration from a standstill for its weight class. In the
power curve, the drive output from the internal combustion engine and the E-machine add up to a maximum total
output of 170 hp (125 kW).
The increase in drive performance occurs over almost the entire speed range. Operation is mixed while the
internal combustion engine is running.
This integration enables the internal combustion engine to work within its optimum effective range. This load
point shift increases efficiency.

7

Introduction
Dimensions
The vehicle dimensions are identical to those of the Jetta without the hybrid drive, except for the trunk volume.
Because of the high-voltage battery, the trunk volume has been reduced from 18 ft3 to 11.3 ft3 (510 L to 320 L).

889 mm (35 inches)

2651 mm (104.4 inches)

1104 mm (43.4 inches)

4644 mm (182.8 inches)
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1535 mm (60 inches)

1538 mm (60.5 inches)

1778 mm (70 inches)

1985 mm (78 inches)

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8

Introduction
Wheels and Tires
195/65 R15 and 205/50 R17 tires with low rolling resistance are used with the Jetta Hybrid. The tires offered also include the
16 inch 205/55 R16 tire.

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15” Cast aluminum
6Jx15 H2 ET 47 195/65
R15 91H RoWi, all-season

16” Cast aluminum
6½Jx16 H2 ET 50 205/55
R16 91H, all-season

17” Cast aluminum
6Jx17 H2 ET 48.5 205/50 R17
93H RoWi, all-season

9

Introduction
Distinguishing Features
Xenon Headlamps
The bi-xenon headlamps with LED daytime running
lights have typical Volkswagen design features.

S525_032

A mercury-free “D3S” lamp is used for the xenon
bulb. In addition to the xenon projection module,
Light Emitting Diode (LED) lamps are used. These
15 individual LEDs are positioned around the module
in a unique light pattern. The pattern can be seen
during the day (daytime running lights) and at night
when the LEDs dim.

S525
S525_033
5_033
3

10

Introduction

Static Cornering Light
In addition to its basic functions and the turn signal,
the Adaptive Front-Lighting System (AFS) headlamps
also contain a static cornering light. This light
illuminates the road to the side of the vehicle at
speeds of less than 25 mph (40 km/h). This light is
controlled by activating the turn signal or the position
of the steering wheel angle.
The cornering light installation position, which
is higher than the combined cornering light/fog
lamp offered with halogen headlamps, improves
illumination because it works in addition to the wide
illumination range of the xenon lamp. This increases
driving safety for both day and night driving.

S525_034

LED Lights
s525_035

LEDs are used for the taillights and brake lights. The
taillights and brake lights are integrated into the twopart lamps in the body (turn signal lights and taillights
in one unit).
On average, approximately 45 W is saved compared
to the regular bulb version, reducing power
consumption by about half. In addition, weight has
been reduced by 0.55 lbs (250 g).

s525_036

11

High Voltage Safety
High Voltage Warnings
There are several warnings and stickers in the Jetta Hybrid to prevent high-voltage system hazard to users,
service and workshop personnel, as well as those working in technical and medical rescue services. These
stickers comply with all applicable Deutsche Industrie for Standardization (DIN) standards.
There are basically two types of warning labels:
• Yellow warning stickers with the symbol for “electric voltage” on the covers of high-voltage components.
• Warning stickers with the word “Danger” against a red background indicate components that conduct highvoltage.

S525_074

Warning of dangerous electric voltage

Note usage instructions
Warning of dangerous electric
voltage
Warning of dangerous
electric voltage
Warning against touching
voltage-conducting parts
(Mortal Danger Warning)

Warning of hazardous site

S525_042

Note usage instructions

12

Warning against
touching voltageconducting parts

S525_041

Mechanical Construction
1.4 L Turbocharged Engine
The Jetta Hybrid is equipped with a 1.4 L 4V TSI
engine with a single turbocharger. It has the
following characteristics:
• Engine block with integrated secondary air
channel, hybrid oil passages and hybrid coolant
passages
• Crankshaft with splines for connection to the
E-machine
• Cylinder head with 4 valves per cylinder and
integrated exhaust manifold
S525_003

• Intake and exhaust camshaft adjustment
• Belt-driven camshafts
• Electrical and mechanical coolant pumps
190

190

160

175

• Water-cooled intercooler

135

160

• Electric vacuum pump

110

150

80

120

45

105

25

90

• Positive Crankcase Ventilation (PCV) unit on the
front of the engine block

• No accessory drive belt
• Integrated turbocharger module with electric
charge pressure controller, cast steel turbine
housings with integrated lambda sensor

0

0
1000

2000

3000

Engine Code

CNLA

Engine Configuration

1.4 L TSI with Turbocharger

Displacement

1,395 cm3 (85 in3)

Bore

74.5mm (2.9 inches)

Stroke

80mm (3.1 inches)

Valves per Cylinder

4

Internal Combustion Engine Output

150 hp (110 kW)

Maximum Torque (limited)

162 lb/ft (220 Nm)

Engine Management

Bosch MED 17.1.6

Emissions Rating

PZEV

4000

5000

6000

13

Mechanical Construction
The 7-Speed Dual Clutch Transmission 0CG

Clutch Housing Extension

K0 Clutch Control Valve
Clutch Housing

S252_005

Valve Body

The Jetta Hybrid has a 7-speed DSG transmission. This transmission has been used extensively in other markets,
and this is its first application in the North American market.
Due to the E-machine, the clutch housing was extended by 83 mm (3.3 inches). There is also a separate valve in
the valve body, external control valve and master cylinder to control the K0 clutch.
The K0 separating clutch is controlled by the ECM and not by the Mechatronics. The ECM controls the operation
of the valve in the valve body. The same fluid used by the Mechatronics is used in the clutch activation circuit.
The actuators of the K0 clutch and the Mechatronics
The transmission has a maximum torque rating of 184 lb/ft (250 Nm).

Note
Even though the 1.4L engine can produce up to 184 lb/ft (250 Nm) of torque, it is limited
to 162 lb/ft (220 Nm). This assures that when the E-Machine is providing torque (22 lb/ft),
the maximum transmission torque rating is not exceeded (184 lb/ft). This torque rating is
constantly adjusted by the ECM, even when the E-machine is working, to make sure that the
input torque does not exceed the transmission capabilities.

14

Mechanical Construction
The K0 Clutch
The single-disc dry clutch is located inside of the
E-machine between the engine and the E-machine.
The clutch actuator (N511 Decoupler Pressure
Actuator) is located on the top of the transmission
and is controlled by the hybrid system. The driver
does not have any direct influence on this clutch.
The hydraulic fluid is provided from the transmission
itself.
The clutch is engaged when:
• Starting the internal combustion engine
• The internal combustion engine is running

K0 Clutch

• The charge of the hybrid battery is low
The clutch is disengaged when:
• The vehicle is at a standstill
• The internal combustion engine is deactivated
• The vehicle is being driven electrically
• The vehicle is in recuperation mode
The E-machine
The foundation of the hybrid drive is the E-machine.
It takes on three essential tasks within the hybrid
system:
1. Starter for the internal combustion engine
2. Generator for charging the high-voltage battery

S252_004a

3. Electric engine for moving the vehicle.
The rotor runs inside of the stator without contact.

Purely electric driving on flat land is possible at
varying speeds. The maximum speed depends on
driving resistance and the charge of the high-voltage
battery.

15

Mechanical Construction

Pressure Sensor