SSP 525 The Jetta Hybrid

Service Training
Self-Study Programme 525
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The Jetta Hybrid is the 2nd hybrid vehicle to be introduced at Volkswagen and follows the Touareg Hybrid in series
production. This Self-Study Programme describes the changes.
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An electric hybrid drive is a combination of combustion engine and three-phase current drive.
This means that in the Jetta Hybrid, a TSI engine with 110 kW of power operates in parallel with a three-phase
current drive with 20 kW of power. The lithium-ion battery technology used in the Jetta Hybrid, as well as the 7-
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Separate aSelf-Study Programmes are available on eo
the following current topics:
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• Self-Study Programme 390 – “The 7-speed Double-clutch Gearbox 0AM”

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• Self-Study Programme 492 – “The Jetta 2011 EU”

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• Self-Study Programme 499 – “Basics of Electric Drives in Automobiles”

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• Self-Study Programme 511 – “The new EA211 Petrol Engine Family”

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The contents will not be updated.
2
Contents d byV
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In Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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High-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3
In Brief
The production of the Jetta Hybrid

The Jetta Hybrid is produced in Mexico at the Puebla
plant.
Volkswagen de Mexico
Number of employees: approx. 15,290
Models: Jetta (the version sold in the

North American market and
Europe), Jetta Hybrid, Golf Estate,
Beetle, Beetle Cabriolet
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Plant founded: 1964, 100% Volkswagen AG
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Technical data on the Jetta Hybrid
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Combustion engine 1.4 l 110 kW TSI turbocharged engine

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Combustion engine output 110 kW

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Gearbox 7-speed DSG® dual-clutch gearbox

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Three-phase current drive Permanently excited synchronous motor

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Three-phase current drive output 15 kW in normal operation and 20 kW in electric driving

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Maximum total output during boost 125 kW

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Maximum total torque during boost 250 Nm

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Battery technology Lithium-ion battery

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High-voltage battery voltage 222 volt

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High-voltage battery energy content t. C 1.1 kWh
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Top speed 210 km/h (130 mph), speed-limited
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Acceleration from 0 to 100 km/h 8.6 s
Additional weight due to the hybrid components Approx. 103 kg
4
Dimensions
889 mm 2651 mm 1104 mm
4644 mm
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1482 mm
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1535 mm 1538 mm
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1778 mm 2020 mm
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Weights, volumes and other data

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Kerb weight 1505 kg pyri Tank capacity
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Gross vehicle weight 2020 kg Drag coefficient 0.28
Roof load 75 kg Luggage compartment volume 374 l
The data refers to the basic model with a 90% tank volume.
5
In Brief
Distinguishing features
Dash panel with hybrid logo
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Hybrid logo in engine compartment
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Hybrid logo on the front area
Hybrid logo at the side
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Dash panel insert with power meter
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High-voltage battery in
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Button for extended electric drive

mode in the centre console
7
Body
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Body structure y V gu
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The structure of the body for the Jetta Hybrid is s
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reinforcements for NAR*.
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The body structure has been modified and optimised for the Jetta Hybrid.
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• Use of ultra high-strength and hot-formed steels
• Additional reinforcements for the high-voltage battery
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* NAR = North American Region
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Body components of the Jetta 2011

Reinforcements for NAR in the Jetta 2011
Additional modifications for the Jetta Hybrid
8
Aerodynamics
Measures to improve the aerodynamics were carried out in order to reduce olkfuel
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drag coefficient for the Jetta Hybrid to be improved even further.
Volks drag coefficient is 0.28.
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This was achieved by using the following measures: th
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Stall strip
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Rear diffuser
on the bumper
Sills fitted
Bumper cover
flow-optimised technology
Cooling air inlet Underbody
modified flow optimised with the aid of
additional trims and end plates
Front cover
flow-optimised technology
9
Power units
The 1.4 l 110 kW TSI engine

The 1.4 l 110 kW TSI engine for the Jetta Hybrid is based on the 1.4 l 103 kW TSI engine from the new EA211
engine family. For use in the Jetta Hybrid, modifications were made to facilitate integration of the three-phase
current drive VX54.
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• Cylinder
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drive motor V141 as well as hydraulic fluid for
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• Crankshaft with splines for linking the electric drive
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• Coolant pump for high-temperature circuit V467
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• Cylinder block with one duct for the secondary air
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• Due to emissions requirements, the materials used
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Technical data Torque and performance diagram
Engine code CRJA (EU6) 280 160
Design 4-cylinder inline engine 260 140

Displacement 1395 cm3
240 120
Bore 74.5 mm
Stroke 80 mm 220 100
Torque (Nm)
Power (kW)
Valves per cylinder 4

200 80
Compression ratio 10.0:1
Max. output 110 kW at 5000 - 6000 rpm 180 60
Max. torque 250 Nm at 1600 - 3500 rpm 160 40

Engine management Bosch MED 17.01.21
140 20
Fuel Super unleaded with RON 95
Exhaust gas aftertreat- Three-way catalytic converter 120 0
ment One broadband Lambda 1000 3000 5000
probe before the catalytic
converter and one step-type Speed (rpm)
Lambda probe after. S525_030
Emissions standard EU6
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Cylinder block with sealing flange (on gearbox side)
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Hydraulic fluid Coolant supply

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Crankshaft
The crankshaft is also very similar to the basic engine. Hollow-bored conrod
With a five-point bearing, it has four counterweights journals
and a main bearing and conrod bearing diameter of
Conrod bearing
48 mm. To reduce its weight even further, the conrod
journals have been hollow-bored.
They are distinguished by:

Picture 041, Crankshaft
• a crankshaft with splines for linking the electric
drive motor V141 to the engine
• sealing screws for sealing the cylinder block from s525_041
engine oil, as a flywheel has not been bolted to
the crankshaft
Main bearing
Crankshaft splines
Sealing screw
11
Power units
Cooling system
The basic design of the cooling system is identical to the one used in the 1.4 l 103 kW TSI engine. It is a dual circuit
cooling system and consists of the engine cooling system and the charge air cooling system.
The hybrid drive made the following modifications necessary:
• The electric drive motor and the coolant pump for the high-temperature circuit are integrated into the engine
cooling system. The pump is activated by the engine map.
• The power and control electronics for electric drive are integrated into the charge air cooling system. It is
supplied by the coolant pump for the low-temperature circuit.
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Electric drive motor V141

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Water radiator for charge air Coolant pump for low-temperature

cooling circuit circuit V468
12
Power transmission
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The 7-speed dual-clutch gearbox
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The dual clutch gearbox 0AM forms the basis for the dual clutch gearbox 0CG.
To make designing a functioning hybrid module possible (see page 25), the following changes were made:
• Clutch housing extended by 83 mm

• Brackets for the drive shaft extended by 83 mm
• Additional valve block with integrated clutch master cylinder and pressure regulator for disengagement
clutch N511
• Additional hydraulic lines for the clutch master and clutch slave cylinders
• Additional clutch slave cylinder (on crankcase)
• Additional disengagement clutch K0
Conventional Jetta Jetta Hybrid
Description 0AM 0CG
Weight 70 kg 73 kg
13
Power transmission
The hydraulic system for the disengagement clutch K0

Screw joint
Diagram showing the principles of the for the hydraulic pipe on the engine block
hydraulic system
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No pressure – supply line

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Pressure from the mechatronic unit hydraulic pump

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The descriptions of the function of the Oil gallery

disengagement clutch K0 on the following The oil enters the clutch slave
pages are also based on the diagram cylinder via an oil passage
showing the principles.
Clutch slave cylinder
Pressure plate
from the disengagement clutch K0
Clutch plate
from the disengagement clutch K0
14
Hydraulic pipe
connects the clutch master cylinder to the cylinder block
Clutch slave cylinder
Run-on tank
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Mechatronic unit
Oil pump (gear pump)

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Power transmission
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Run-on tank Clutch slave cylinder
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Filling chamber
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Mechatronic unit Pressure regulator for
disengagement clutch N511
s525_033
Gear pump Clutch slave cylinder
Valve block
No pressure – supply line Pressure from the mechatronic No pressure – return line
unit hydraulic pump
Function
The spring force of the diaphragm spring keeps the cylinder and the disengagement clutch K0 remains
disengagement clutch K0 closed. The hydraulic closed.
system is not under pressure and the clutch master Furthermore, the run-on tank in the valve block
and clutch slave cylinder are both in the idle position. ensures the level in the hydraulic system between the
Oil flowing back from the filling chamber flows clutch master and clutch slave cylinders remains in
through the pressure regulator for disengagement equilibrium. Unwanted air in the hydraulic system,
clutch N511 into the run-on tank. The oil settles here e.g. due to repairs, is returned to the mechatronic unit
before it flows back to the mechatronic unit. via the run-on tank.
The gear pump in the mechatronic unit generates the
pressure for the gear and clutch hydraulics according The closed disengagement clutch K0 ensures a
to requirements. If the pressure regulator for force-fit connection between the combustion
disengagement clutch N511 is in the idle position, the engine and the electric drive motor V141.
oil pressure cannot be applied to the clutch master
16
Hydraulic plan when the disengagement clutch K0 is opened
Clutch plate
Pressure plate
Working chamber
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If the pressure regulator for disengagement clutch Please note:

N511 is activated by the engine control unit J623, the The stroke limiter allows a precisely defined volume of
oil enters the filling chamber of the clutch master oil to be pressed into the clutch slave cylinder. The
cylinder. The oil pressure acts against the force of the disengagement path of the clutch slave cylinder is
dished springs and presses the piston up to the stroke therefore specified.
limiter. The oil from the working chamber flows into
the clutch slave cylinder. The clutch release bearing The opened disengagement clutch K0 disconnects
and the dished springs disconnect the pressure plate the combustion engine from the electric drive motor
from the clutch plate. The transmission of energy from V141.
the combustion engine to the gearbox is stopped.
17
Power transmission
Disengagement clutch K0 operating modes

Combustion engine Combustion engine and electric boost
Coupling closed Coupling closed
Torque Torque
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Gearbox Gearbox
input torque input torque
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s525_025 s525_026
When the combustion engine is powering the vehicle, When the electric drive motor V141 supports the
the engine torque from the combustion engine is combustion engine, the engine torque from the
transferred to the dual-mass flywheel via the clutch electric drive motor V141 is transferred to the
plate. dual-mass flywheel via the rotor.
Combustion engine
Gearbox input
18
Electric driving Energy recovery
Clutch open Clutch open
Torque
Electric drive motor V141 Rotor
Air gap Air gap
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input torque from the gearbox
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During electric driving, the engine torque from the by copy During recuperation, the drive torque from the
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electric drive motor V141 is transferred to the Prote gearbox is transferred to the dual-mass flywheel.
AG.
dual-mass flywheel. When doing so, the clutch
pressure plate is not connected to the pressure plate.
19
Running gear
Running gear
The running gear in the Jetta Hybrid is the same design as the running gear of the the Jetta 2011 EU. The
suspension and the shock absorbers have been modified for the additional weight of the hybrid components. The
Jetta Hybrid is also equipped with a four-link rear axle suspension.
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• Electronic yV
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• Brake servo with dual-rate characteristic curve
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• Modern McPherson strut front

suspension
• Electronic brake servo vacuum pump with 8 vanes
20
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• Tyre Pressure Loss Indicator (optional)
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s525_032
• Brake assistant
• Floor-mounted accelerator pedal with contact-

free senders for the accelerator pedal position
21
High-voltage system
The high-voltage system

Overview
The hybrid concept developed at Volkswagen for the Jetta is based on the parallel hybrid drive. For the
mechanical drive system, the three-phase current drive and combustion engine combine to form a joint drive train.
Both drive types are mounted onto a shaft.
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By using the three-phase current drive as a source of power, as an alternator and as a starter, the 12-volt starter
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and the alternator, as well as the poly V-belt, have been dispensed with. Furthermore:
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• the electromechanical power steering motor V187 (12 volts) cted agen
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• the brake servo vacuum pump V469 (12 volts)
are all driven electrically. To guarantee that climate control can run independently of the combustion engine, the
electric air conditioner compressor V470 has been added.
22
Warning signs
Please note that work on the hybrid vehicle performed near high-voltage components or on the components
themselves may only be carried out by qualified and therefore authorised Volkswagen high-voltage technicians.
Improper handling of high-voltage systems involves a risk of fatal injury due to electric shock.
Also observe the instructions in the workshop manual and in the diagnostic tester.
Warning on the front lock carrier
Warning of a danger area as per

DIN 4844-2 (BGV A8) Warning against touching live parts
S525_080
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Warning of dangerousor electrical voltage Information tnotice:
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as per DIN 4844-2
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Warning of dangerous electrical Instruction markers:

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23
High-voltage system
Warning at the front left in engine compartment
Warning of a danger area
S525_081
Notice about separation Information notice:

point for rescue services Observe rescue card
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Sticker on the high-voltage
a battery ac
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1 High voltages can result in severe injury or even

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tools, jewellery or other objects made of metal. wit

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2 The high-voltage battery contains hazardous fluid 1
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and sold substances. In the event of outgassing,

t to the co
severe chemical burns and blindness could result.

When working on the high-voltage battery, suitable
2
eye protection and protective clothing must be worn
rrectness of i
to prevent skin and eye contact with battery acid. If

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skin or eye contact with battery acid occurs, the areas

affected must be rinsed for at least 15 minutes using 3
clean fresh water, and a doctor should be consulted
nform
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immediately.
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3 The high-voltage battery is flammable. The high-

in t
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voltage battery must never be exposed to fire, sparks 5

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4 Always keep the high-voltage battery away from cop Vo
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5 More detailed information and warnings can be

found in the owner's manual and in the workshop
manual.
24
AG. Volkswagen AG d
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The three-phase current drive VX54 (hybrid module) s a c
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The three-phase current drive VX54 consists of the electric drive motor V141, the disengagement clutch K0 and the
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dual-mass flywheel; it is referred to as the hybrid module in the following text. The water-cooled hybrid module
ot
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produces high torque while maintaining optimal use of the available installation space. The hybrid module is
h re
hole
located between the combustion engine and the gearbox. The interface between the dual-mass flywheel and the
spec
es, in part or in w
dual clutch gearbox is identical to that of the standard gearbox.
t to the co
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Combustion engine 1.4 l 110 kW TSI
nform
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Hybrid module
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Dual clutch gearbox
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Disengagement clutch K0
Dual-mass flywheel S525_012
The hybrid module is used as:
• Starter for the combustion engine

• Generator for charging the high-voltage battery and the 12-volt battery
• Electric drive motor
The Jetta Hybrid can be driven in electric mode at speeds up to approx. 125 km/h over flat terrain. The maximum
speed and fuel range depend on a variety of factors:
• Driving resistances (drag, rolling resistance, friction coefficient and incline angle)
• Charge status of the high-voltage battery
• Load requirements
• Climate control requirements
25
High-voltage system
Electric drive motor

swa
gV141
en AG. V (electric
olkswagen AG
doesmotor)
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The electric drive motor
rise V141 is integrated into the hybrid module.
nte The electric drive motor is referred to as the
tho eo
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electric motor sina the following. The electric motor converts the three-phase voltage into drive power. It can be
s c
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operated alone as an electric drive motor or together with the combustion engine. It also starts the combustion
un
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engine. If the electric motor is not being used as the drive motor or the starter, then it functions as a generator for
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the high-voltage battery and the 12-volt onboard supply.
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Technical data
High-voltage
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connection
Output 20 kW
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Torque 150 Nm
nform
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Generator output 18 kW
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Efficiency up to 93%
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Rotor
Stator
High-voltage connection
The three-phase connections are routed to the solenoids in such a way that three respective adjacent coils with
differing phases are connected.
Stator
The stator is comprised of of 24 coils which are supplied with voltage via the three-phase lines. The stator is bolted
to the sealing flange on the engine side. The drive motor temperature sender G712 is also found in the stator. The
inside cooling jacket is connected in parallel to the cylinder head of the combustion engine.
Rotor
The rotor contains the 32 permanent magnets and the clutch slave cylinder for controlling the disengagement
clutch. The rotor and the flywheel are bolted to each other.
26
The power and control electronics for electric drive JX1
The water-cooled power and control electronics for electric drive JX1 is installed in the front left of the engine
compartment. It is integrated into the low-temperature cooling circuit and has a control unit of its own. It is
responsible for charging the high-voltage and 12-volt batteries, as well as for controlling the electric drive motor. It
converts DC current into AC current for electric driving. The conversion is reversed for charging the battery.
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Power and control electronics for s525_016

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To make it easier to understand, the power and control electronics for electric drive JX1 is shortened to “power
rrectne
electronics” in the following.

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The power electronics regulate the electric drive motor by generating AC current, setting the frequency and the
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current rating. This allows speed and torque to be generated according to the load requirements.
form
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The power electronics consist of the following components:

n
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• Electric drive control unit J841

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• Intermediate circuit capacitor 1 C25 yi

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• Voltage converter A19 t. C py
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Cooling system integrated into the housing with connection pieces for the low-temperature cooling circuit
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• Fuse for the air conditioner compressor
• Pilot line connector
27
High-voltage system
Connections agen
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The power electronics have the followingho connections: eo
aut high-voltage battery ra
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1 connection for air
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• For the lines to the high-voltage battery
du
conditioner compressor
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• For the lines to the electric drive motor
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12-volt onboard
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• For the charging cable to the 12-volt battery
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• For the 12-volt onboard supply connector
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• For the connection to the vehicle coolant circuit
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Charging cable
for 12-volt
battery
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The power electronics feature protection
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rating IP 6K9K
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or c
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(IP = Internal Protection,

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s525_017
iv
3 connections for
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6K = dust-tight, complete protection

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electric drive motor
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9K = Protection from water under high t. Co py
Connecting pieces for coolant
rig
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pressure/steam spray cleaning, specific to py by
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road vehicles). cted agen
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Before the power electronics are opened, they must Pilot line
be certified as having had the voltage disconnected. connector
The pilot line is disconnected every time the power

electronics are opened. A pilot line connector is
installed in the cover of the power electronics for this
purpose.
Cover Housing
More detailed information on the pilot line Power Power
s525_018
can be found in Self-Study Programme electronics electronics
no. 499 “Basics of Electric Drives in
Automobiles”.
28
The high-voltage battery A38 (hybrid battery)
The Jetta Hybrid features Volkswagen's first use of a battery using lithium-ion technology as the electrochemical
energy storage medium. Compared to a nickel-metal hydride battery, this technology allows a greater energy
density. The high-voltage battery stores electrical energy and supplies it when electric driving requires it.
lkswage es n
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Technical data th or
au ac
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Nominal voltage 222 volts
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Energy content 1.1 kW/h
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60 cells á 3.7 volts and 5 Ah
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4 modules with 15 cells each
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Max. output 180 A
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ercia
High-voltage battery installation position

m
at
om
ion
c
in t
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The high-voltage battery is installed in the luggage compartment behind the rear seat bench on the luggage
o
his
ate
compartment floor. The protective frame is used to ensure the high-voltage battery has a stable position in the
do
priv
cum
or
vehicle.
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High-voltage battery A38
Protective frame s525_019
29
High-voltage system
Main components – overview

The overview shows you the main components of the high-voltage battery
A38 and their physical layout within the battery.
Lithium-ion cells
Battery regulation control unit J840
Four battery modules in total with
Monitoring of charge and discharge function
15 cells each connected in parallel
Needs-based cooling of the high-voltage battery
Monitoring of the insulation resistance monitoring
Monitoring of the pilot line
Monitoring of the cells
High-voltage contactor control
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Battery
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Potential equalisation line

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Connection for the bleeder for corrosive gas

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Direction of travel
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Maintenance connector for high-voltage system TW

ss o
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With an integrated 125 A fuse

f inform
The high-voltage battery A38 features the protection

mer
atio
rating IP 5K3
om
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(IP = Internal Protection,

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5K = protected against a damaging quantity of dust,

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complete protection against contact

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3 = protection against water falling as a spray at any py
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angle up to 60° from the vertical). rig
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30
Battery module with
lithium-ion cells
Bleeder for corrosive gas

For a controlled discharge of gases
in an emergency
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Low-voltage connections
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Air ducts for battery cooling

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Stabilising protective frame
Switching unit for high-voltage battery SX6

Comprised of the high-voltage fuses and the holder for the maintenance connector
High-voltage connections
31
High-voltage system
Switching unit for high-voltage battery SX6

The high-voltage contactors and the pre-charging contactor for the high-voltage battery are found in the switching
unit for high-voltage battery SX6. The high-voltage contactors are used to create a controlled connection between
the high-voltage battery and the high-voltage components. A pre-charging contactor, a contactor for “positive”
and a contactor for “negative” are installed for this purpose. The pre-charging contactor has an integrated
resistance of 10 ohm and is connected before the “positive” high-voltage contactor. It is used to charge the
intermediate circuit capacitor 1 C25 in the power electronics. The “positive” high-voltage contactor is then
connected.
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J840 ss Switching unit SX6
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Maintenance connector for
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high-voltage system TW
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Circuit diagram
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Battery Battery
module 1 module 2
rrectness of i
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Battery Battery
nform
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module 3 module 4
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High-voltage contactor
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J840 TW
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Pre-charging contactor
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High-voltage contactor
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agen Switching unit for high-
s525_010 Prote AG.
voltage battery SX6
The battery regulation control unit J840 closes the high-voltage contactor as soon as terminal 15 is switched on.
The high-voltage contacts are opened by the battery regulation control unit J840 when:
• terminal 15 switches off
• the pilot line is disconnected
• a crash signal is sent from airbag control unit J234
• or the 12-volt voltage supply for the battery regulation control unit J840 is disconnected.
32
The battery cooling system d byV
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To keep the heat emissions under control when the high-voltage battery is charging and discharging, the high-
itte
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voltage battery features an air cooling system of its own.
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If the heat cannot be sufficiently discharged into the surroundings, then the output of the high-voltage battery is
wit
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restricted at temperatures of 55 °C or above.
hole
spec
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Design
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This core element of the cooling system is an electric fan controlled by the battery regulation control unit J840. The
l purpos
fan is part of the high-voltage battery module and utilises air from the vehicle interior to cool the high-voltage
battery. It is powered by the 12-volt onboard supply voltage. In the service literature, the fan is referred to as
nform
ercia
battery fan 1 V457.

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Intake from the vehicle interior
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Battery fan 1 V457
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Forced ventilation
Battery regulation control unit J840 s525_037
How it works
If the battery regulation control unit J840 registers an excessive battery temperature, it activates battery fan 1
V457. The air is sucked in via the intake duct located beneath the centre rear seat, and is routed to the high-
voltage battery. The fan then routes the heated air behind the right-hand side trim of the luggage compartment.
The air can escape from here by means of the forced ventilation in the side panel. The air in the vehicle interior is
adjusted to the right temperature, dried and filtered, making it optimally suited for cooling the high-voltage
battery.
33
High-voltage system
The high-voltage connections

The Jetta Hybrid features high-voltage connections which are screwed onto the high-voltage battery, the power
electronics and the electric drive motor.
Gasket
High-voltage screw contact
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S525_046
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Pre-tensioning spring
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Mechanically coded
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screw connection
es, in part or in w
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The high-voltage connection for the air conditioner compressor is a connector with a pilot line, high-voltage
“positive” and high-voltage “negative”.
nform
ercia
The connector has a dual disconnection system:

m
at
om
ion
c
in t
or
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1. Pilot line disconnection

at
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2. High-voltage contact disconnection

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Pilot line contacts
s525_047
Release
34
The high-voltage cable for the battery, power electronics and the electric drive motor features double insulation
and a single-pole design.
1. Insulation 2. Insulation
Cable
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Electromagnetic compatibility shield
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The high-voltage cable for the air conditioner compressor features single insulation and a two-phase design. For
rrectne
safety reasons, the pilot line has been integrated into the cable.
ss o
cial p
Reason:
f inform
If the cable is broken in the event of minor front damage without triggering the airbag, the pilot line is also
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atio
disconnected and the high-voltage system is shut off.

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High-voltage “negative”
Electromagnetic compatibility shield

s525_049
35
High-voltage system
High voltage system control

The operating strategy for the electric drive motor and combustion engine functions is integrated into the engine
control unit J623. The operating strategy automatically selects the optimal operating state for the drive train and
thereby avoids operating ranges of the combustion engine with a low level of efficiency. Where only a low torque
or power output is required, the engine is switched off.
Engine control unit J623
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The engine control unit is connected to the high-voltage battery and the power electronics by the hybrid CAN bus.
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The state of the high-voltage components is sent to the engine control unit, which controls the electrical ready-to-
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drive mode. All other information which is required for electric driving or charging the high-voltage battery, such
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as the load requirements, air conditioning requirements, temperature, etc. are exchanged via the hybrid CAN bus
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36
Electric driving function
For operating and displaying electric driving mode, the Jetta Hybrid features:
A G. Volkswagen AG d
• A display in the radio and navigation agenunit oes
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• A display in dash panel insert
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• The button for electric o eo
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Button for electric drive E656
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When the button is activated, the operating strategy
for hybrid drive is no longer set for achieving
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optimum overall efficiency, but is instead set to
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system. This allows – while slightly increasing fuel
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consumption – a substantially enhanced electric

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Button for electric drive E656
Electric driving can be activated at speeds of up to 70 km/h. The framework conditions, such as the charge state of
the high-voltage battery, the air conditioning requirements or the temperature of the high-voltage components,
must be satisfied. In the event of excessive acceleration or if the charge level of the battery falls below the minimum
threshold, electric driving is stopped. Once the parameters are correct again, electric driving is automatically
reactivated without the driver needing to press the button again.
If the high-voltage battery or the electric drive motor gets too hot, e.g. due to constant use of electric driving, the
electric driving is deactivated.
37
High-voltage system
Sensors
Drive motor temperature sender G712
The drive motor temperature sender G712 is installed

between two solenoids to provide better signal Drive motor temperature sender G712
detection. It is an NTC sensor and sends the
temperature to the power electronics. The signal is
required in order to prevent the electric drive motor
from overheating. If the cooling output using the high-
temperature circuit is not sufficient, then the electric
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drive motor is first restricted oes
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Effect upon failure an

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Drive motor rotor position sender 1 G713

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The drive motor rotor position sender 1 G713 is

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Drive motor rotor position sender 1 G713

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installed in the clutch housing of the gearbox.

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the rotor in relation to the stator. This information is

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fies the engine speed, direction of rotation and the AG.
phase shift. The information is transmitted as sine/

cosine signals to the power electronics in order to
activate the electric drive motor coils at the correct
point in time.
s525_015
38
Design
AG. Volkswagen A
The sender is an inductive sender with enhanced agen G do
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and two supply lines (“positive” and searth).
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converted internally into high-frequency DC voltage. This high-frequency DC voltage or supplies the four integrated
aut ac
ss two coils for cosine. The coils are influenced by the copper
coils, with two coils for sine and trace on the rotor.
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Drive motor rotor
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1. Sine coil 2. Cosine coil
1. Cosine coil 2. Sine coil
Function
The copper trace on the rotor is equivalent to an electrical consumer. A wide copper trace is equivalent to a large
consumer and a narrow copper trace in equivalent to a small consumer. When the rotor turns, the width of the
copper trace which is guided past the sender for the rotor position changes, and therefore the timing ratio of
voltage and current in the coils. This change is measured in the evaluation electronics of the sensor, processed and
transmitted to the power electronics. From the ratios of the individual coil signals to each other, the sender and the
power electronics identify the component tolerances and the direction in which the electric drive motor is rotating.
The functional principle of all 4 coils is identical.
Effect upon failure
If the sender fails, the hybrid system indicator lamp lights up in the dash panel insert. The vehicle remains ready for
driving, however the electric drive motor is no longer activated.
39
Electrical system
Networking
New components have been integrated into the electrical network of the Jetta Hybrid for networking the control
units, and some of the existing ones have been modified. This is necessary in order to integrate the new Hybrid
components into the network. The new components are:
• The three-phase current drive VX54 • The power and control electronics for electric drive
• The disengagement clutch K0 JX1
• A hybrid-specific mechatronic unit for dual clutch • The electrical air conditioner compressor V470
gearbox J743 • The battery regulation control unit J840
These new components in the control unit network are participants in the new hybrid CAN bus, which makes direct
communication between the mechatronic unit for dual clutch gearbox J743, the power and control electronics for
electric drive JX1, and the battery regulation control unit J840 possible.
Furthermore, a number of control units belonging to the basic equipment of the vehicle have been modified to
meet hybrid-specific requirements.
Modified control units in the drive area: Modified control units in the running gear area:
• The engine control unit J623, which is the master • The ABS control unit J104 and
for the hybrid electrical system and • the power steering control unit J500
• control unit in the dash panel insert J285 with the
power meter and the electric power . Volkswagen AG
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• Climatronic control unit J255

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• Airbag control unit J234

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• Entry and start authorisation control unit J518 • Battery monitor control unit J367
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A37 DC/AC converter for drive motor J503 Control unit with display for radio and navigation
G273 Interior monitoring sensor J518 Entry and start authorisation control unit
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G384 Vehicle inclination sender J519 Onboard supply control unit

G397 Rain and light sensor J533 Data bus diagnostic interface
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H12 Alarm horn J623 Engine control unit

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J104 ABS control unit J743 Mechatronic unit for dual clutch gearbox
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J234 Airbag control unit J840 Battery regulation control unit

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J255 Climatronic control unit J842 Control unit for air conditioning compressor
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J285 Control unit in dash panel insert

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J362 Immobiliser control unit R Radio

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J367 Battery monitor control unit py

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Hybrid CAN bus
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s525_062
Powertrain CAN bus CAN instrument cluster data bus

Hybrid CAN bus LIN data bus
CAN diagnostic data bus CAN data bus line
Convenience CAN data bus LIN data bus line
Infotainment CAN bus
41
Electrical system
The installation locations

J104 - ABS control unit
R - radio J500 - power steering control unit
V470 - electrical air conditioner compressor J234 - airbag control unit
VX54 - three-phase current drive
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Disengagement clutch K0
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J623 - engine control unit J518 - entry and start

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authorisation control unit

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J743 - mechatronic unit for JX1 - power and control
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J533 - data bus diagnostics interface J285 - control unit in dash panel insert
42
J840 - battery regulation control unit
AG. Volkswagen AG d J367 - battery monitor

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Key
Basic vehicle components
Components modified for the hybrid
Hybrid components
43
Infotainment
Dash panel insert

A n AG d G. Volkswage
The Jetta Hybrid is being offered with two dash panel inserts. The agen equipment version
basic oesfeatures a two-tone
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centre display and there is also an optional multi-colour centreby V display. Both variants are equipped
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multifunction display. ho eo
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NO 14:02 D5
Electric motor
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Warning lamps in the dash panel insert
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The warning lamp warns about hybrid system malfunctions. In addition, a text display is shown.
NO 14:02 D5 NO 14:02 D5
Error: Error:
Hybrid system. Hybrid system.
Workshop! Park vehicle!
s525_069 s525_070
If the yellow warning lamp lights up, the driver should If the red warning lamp lights up, the driver must stop
take the vehicle to the nearest specialist workshop the vehicle as soon as possible in a safe spot and
immediately. contact a specialist workshop.
44
AG. Volkswagen AG d
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Power meter s aut
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The power meter shows the power requested by the driver. If the indicator remains in the Eco range, then the
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vehicle is being moved efficiently and it is possible to drive electrically.
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Economic driving Range in which the combustion
engine kicks in
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Ready-to-drive/ready
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Combustion engine 100%
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Recuperation range
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(sleep mode)
s525_064
Coolant temperature display
Electric power meter

The electric power meter shows the power available
NO 14:02 D5
from the electric drive motor. The electric power meter
allows the driver to depress the accelerator pedal Electric motor
only so far that the output of 20 kW is not exceeded.
This allows the driver to prevent an unwanted start of
the combustion engine.
S525_083
Electric power meter
45
Infotainment n AG. Volkswagen AG do
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The radio and radio navigation systems
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The Jetta Hybrid is being offered with two different audio systems.
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• Radio system RCD 510 with colour display – standard equipment
spec
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• Radio navigation system RNS 315 – optional
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RCD 510 radio system
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s525_065
The RCD 510 features a new key assignment.

The TP button has been replaced by the CAR menu button for the hybrid-specific displays.
The sound system of the RCD 510 features 8 loudspeakers, digital radio reception DAB+, and also the multi-media
socket “AUX-IN”. The innovative diversity aerial rounds off the aerial concept. Furthermore, the RDC 510 features
a TFT touchscreen with the hybrid-specific energy flow display, an mp3 playback function and an internal 6-disc
CD changer.
Radio navigation system RNS 315
s525_066
The radio navigation system RNS 315 has been modified to meet hybrid-specific requirements.
Instead of a traffic button, it has the CAR button. The traffic information is now shown in the navigation menu.
46
Hybrid-specific displays
The Car menu features two soft keys in the display, with the Hybrid soft key with the Zero Emission display and the
energy flow display on the left side, and the soft key for driving data with the data from the multi-function display
from start and long-term on the right side.
Hybrid soft key
The Zero Emission display shows the user the

percentage of time driven electrically. The display is
updated once a minute. The blue area shows the
percentage of time spent driving just in electric mode.
The remaining black area, up to the 100% mark,
shows the percentage of time spent driving
conventionally with the combustion engine.
Hybrid Zero Emission Driv. data
s525_067
The energy flow display can be shown as a diagram in the dash panel insert using the electric power meter (see
page 45) and in the radio display. This allows the customer to see the drive unit being used to currently power the
vehicle.
Fully electric driving Recuperation lkswage Driving with thees not
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Hybrid Power flow Driv. data Hybrid Power flow Driv. data Hybrid Power flow Driv. data
t to the co
s525_068 S525_113 S525_114

rrectness of i
Driving with the combustion “Boost” driving with the combustion

engine and charging the high- engine and electric drive motor
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voltage battery
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Engine Boost
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47
Heating and air conditioning
The electric air conditioner compressor V470

The Jetta Hybrid features an electric air conditioner compressor. It is bolted onto the combustion engine and
connected to the power electronics via a high-voltage line. The air conditioner compressor is supplied with
222 volts DC voltage.
Technical data
Type Scroll compressor
Nominal voltage 222 volts
Rotational speed 800 - 8600 rpm
Power consumption Max. 6.2 kW
Operating temperature –10 to +125 °C
Weight Approx. 6.0 kg
Refrigerant R134a
Refrigerant oil ND8, 100 cm³
Communication LIN bus
Electrical air conditioner S525_054

n AG. Volkswagen AG do compressor V470
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The air au
conditioning system in the Jetta Hybrid is a 2-zone Climatronic
which guarantees that the ac as standard,
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battery ventilation can be controlled. Data measured for the interior temperature and the sunlight penetration are
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These functions can only be carried out by the fully-automatic Climatronic.

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In the event of installation work on the air conditioner compressor, the high-voltage system
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must be de-energised by a Volkswagen high-voltage technician beforehand.

nform
ercia
For work on the refrigerant circuit for the air conditioning system, a certificate of expertise is
required.
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48
Design and function
The DC voltage is converted into three-phase AC
voltage in the control unit for the air conditioning High-voltage connection
compressor J842. This three-phase AC voltage
supplies the electric motor which drives the
Low-voltage connection
compressor. The compressor operation is the same as
a spiral or scroll compressor. AG. Volkswagen AG d
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The compressor speed regulates olksw the amount of not
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coolant pumped. Theoricoolant also cools the nte
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Compressor
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Control unit for air conditioning

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compressor J842
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spirals to form several, increasingly small chambers in Prote AG.
which the coolant is compressed.
When the process begins, the gaseous coolant is

drawn in on the outside of the spiral, and is trapped
by the continuing rotation of the spirals. The eccentric
movement of the rotating spirals compresses the
coolant further and force it into the centre. It is
discharged here under high pressure. Discharge Compression
S525_078
49
Heating and air conditioning system
The electric air conditioner compressor V470 is activated by the Climatronic control unit J255 and is sent to the
control unit for air conditioning compressor J842 via the LIN bus.
System circuit diagram
AG. Volkswagen AG d
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JX1 Power and control electronics for electric drive

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High-voltage line
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J842 Control unit for air conditioning compressor

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P3 High-voltage wire for electrical air conditioner

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Convenience CAN bus line

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LIN data bus line Cop V470 Electrical air conditioner compressor
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Air conditioner
compressor fuse S355
(40 A)
The voltage supply is protected by the air conditioner
compressor fuse S355. This fuse is fitted in the power
electronics unit and can be replaced.
s525_060
Power and control

electronics for electric
drive JX1
50
Auxiliary air heater element Z35
The auxiliary air heater element Z35 is installed in the rear air conditioning unit behind the heat exchanger for the
water heating. It assists the water heating AG. Volkasw
nduring agenstart.
cold AG doIn electric driving mode, it is responsible for keeping
lkswage es n
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the interior temperature at a constant
by V level and switches on and off uautomatically.
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The request to switch the PTC or heating and fresh air system on and off isntgenerated
is ee by the Climatronic control unit
th or
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J255 and is sent to thessdata bus diagnostic interface via the convenience CAN bus. From here, the request is
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forwarded to the engine control unit. The engine control unit then activates the PTC heating and fresh air system via
pt
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a relay.
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Onboard supply
connection
Activation conditions
• The vehicle is ready to drive (terminal 50 active).
• Coolant temperature < 80 °C
• Outside temperature < 10 °C
• Heating required > 90%
The load management can affect the power used by the auxiliary air heating. Depending on the load on the 12-
volt onboard supply, the heater element operates with different heating outputs:
• Low heating output of 333 watts

• Medium heating output of 666 watts
• High heating output of 999 watts
51
Heating and air conditioning system n AG. Volkswagen AG do
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CAN data bus interface/ G17 Ambient temperature sensor

LIN data bus G62 Coolant temperature sensor
Powertrain CAN bus J255 Climatronic control unit
Hybrid CAN bus J285 Control unit in dash panel insert
Convenience CAN bus J359 Low heat output relay
CAN instrument cluster data bus J360 High heat output relay
CAN data bus line J533 Data bus diagnostic interface
Actuator line J623 Engine control unit
Sensor line Z35 Auxiliary air heater element
Heating level 1
Heating level 2
Heating level 3
Activation of the heating levels of the auxiliary air heating

Low heating output activated via relay J359 heating level 1
Medium heating output activated via relay J360 heating level 2/3
High heating output activated via relay J359/J360 heating level 1/2/3
52
Service
Information symbols
1. Maintenance
There is no additional maintenance work for a high-voltage vehicle. The
high-voltage system is low-maintenance. A visual inspection of the cables
and components is adequate.
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3. Welding work
The high-voltage system does not have to be de-energised during welding
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work if there is enough space to access the high-voltage components.
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4. Drying chamber
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The high-voltage components do not have to be removed up to 60 °C and

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5. Air-conditioning servicing
No de-energisation is required to extract and fill the coolant.
S525_088
6. Towing away
The vehicle may only be towed for a maximum of 50 km and at a
maximum speed of 50 km/h.
S525_089
Please observe the updates in ELSA

(Electronic Service Information System).
53
Service AG. Volkswagen AG d
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Special tools
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Description Tool Usage
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VAS 6649 Live voltage warning sign
Warning sign
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VAS 6650A This must be affixed to vehicle,
c
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“Switching prohibited” warning visible location.

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VAS 6786 The warning sign is used to

safeguard the working and sto-
High-voltage battery warning sign rage area for the high-voltage
battery.
s525_074
VAS 6558/A It is used for the following tasks:

• Measurement of de-energised
High-voltage measuring module state
• Insulation resistance
measurement
• Potential equalisation
measurement
• Ohmic continuity test
S525_092
VAS 6558/9 The test adapter is required for

the following measurements on
High-voltage test adapter the de-energised high-voltage
system:
• Insulation resistance
measurement
• Pilot line test
• Electrical test of the air
conditioner compressor
S525_098
54
Description Tool Usage
VAS 6565A For charging the high-voltage

battery
High-voltage diagnostic voltage
support device There are additional adapter
cables:
• VAS 6565/1 charging cable
Touareg Hybrid
• VAS 6565/2 charging cable
Jetta Hybrid
• VAS 6565/3 adapter for
VAS 6565
S525_099
T10506 For connecting the high-voltage

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T10513 Support for the removed high-

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es, in part or in w
Support
t to the co
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S525_096
nf
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T40155 For removal of the high-voltage

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battery
m
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Retaining straps
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VAS 6762/10 cted
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cables when de-energising
End caps
S525_100
55
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Test your knowledge

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Which answers are correct?
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1. What is the correct order of the rules when de-energising?
rrectness of i
❒ a) Create de-energised state, check de-energised state, secure against re-activation
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b) Create de-energised state, check de-energised state, secure against re-activation,
orm
cover adjacent energised parts
m
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c) Create de-energised state, check de-energised state, secure against re-activation,
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2. Which high-voltage safety functions are checked by the battery regulation control unit?
❒ a) Function of the potential equalisation lines, pilot line, insulation resistance monitoring system
❒ b) High-voltage protection shut-off, monitoring compliance with IP 67 on the components,

battery cooling
❒ c) Pilot line, insulation resistance monitoring system, high-voltage protection shut-off
❒ d) Battery cooling, high-voltage protection shut-off, electrolyte level in the cells
3. Which battery technology is installed in the Jetta Hybrid?
❒ a) Nickel metal hydride
❒ b) Nickel cadmium
❒ c) Hydrocarbon
❒ d) Lithium ion
56
4. How is the high-voltage battery cooled?
❒ a) By an evaporator of its own
❒ b) By coolant G13
❒ c) By dry ice.
❒ d) By air from the vehicle interior
5. How high is the rated voltage of the Jetta Hybrid high-voltage battery?
❒ a) 288 volt
❒ b) 324 volt
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❒ c) 180 volt
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❒ d) 222 volts ss c
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6. What role does the DC/DC converter have?

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❒ a) Charging the high-voltage battery

spec
es, in part or in w
t to the co
❒ b) Charging the 12-volt battery

rrectness of i
❒ c) Converting DC voltage into AC voltage

l purpos
❒ d) Converting AC voltage into DC voltage

nform
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57
Test your knowledge
7. What does the power meter in the dash panel insert measure?
❒ a) The increase in voltage in the electric drive motor
❒ b) The increase in the rated current in the high-voltage battery
❒ c) The output of the positive electrodes
❒ d) The power required by the user
8. Up to which vehicle speed can the electric driving mode be activated?
❒ a) 50 km/h
❒ b) 70 km/h
❒ c) 90 km/h
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❒ d) 125 km/h
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9. How many Hybrid logos are on the vehicle exterior?

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❒ a) none
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❒ b) 2
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❒ c) 4
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❒ d) 5
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1. d); 2. c); 3. d); 4. d); 5. d); 6. b); 7. d); 8. b);9. c)

Solution:
58
59
Notes
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spec
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© VOLKSWAGEN AG, Wolfsburg
All rights and rights to make technical alterations reserved.
000.2812.82.20 Technical status 07/2013
Volkswagen AG
After Sales Qualification
Service Training VSQ-2
Brieffach 1995
D-38436 Wolfsburg
❀ This paper was manufactured from pulp that was bleached without the use of chlorine.

SSP 525 The Jetta Hybrid

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SSP 525 The Jetta Hybrid

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Service Training

Self-Study Programme 525

The Jetta Hybrid AG. Volkswagen AG d

• Self-Study Programme 390 – “The 7-speed Double-clutch Gearbox 0AM”

• Self-Study Programme 492 – “The Jetta 2011 EU”

• Self-Study Programme 499 – “Basics of Electric Drives in Automobiles”

• Self-Study Programme 511 – “The new EA211 Petrol Engine Family”

Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

The production of the Jetta Hybrid

Number of employees: approx. 15,290

Models: Jetta (the version sold in the

Combustion engine 1.4 l 110 kW TSI turbocharged engine

Combustion engine output 110 kW

Gearbox 7-speed DSG® dual-clutch gearbox

Three-phase current drive Permanently excited synchronous motor

Three-phase current drive output 15 kW in normal operation and 20 kW in electric driving

Maximum total output during boost 125 kW

Maximum total torque during boost 250 Nm

Battery technology Lithium-ion battery

High-voltage battery voltage 222 volt

Acceleration from 0 to 100 km/h 8.6 s

Additional weight due to the hybrid components Approx. 103 kg

889 mm 2651 mm 1104 mm

Weights, volumes and other data

Roof load 75 kg Luggage compartment volume 374 l

Dash panel with hybrid logo

Hybrid logo on the front area

Hybrid logo at the side

Button for extended electric drive

* NAR = North American Region

Body components of the Jetta 2011

The 1.4 l 110 kW TSI engine

side) with coolant ducts for cooling the electric

• Crankshaft with splines for linking the electric drive

motor V141 to the engine

• Coolant pump for high-temperature circuit V467

injection (required in the NAR version)

for the pipes in the crankcase breather and the

fuel and activated charcoal filter system (required

You can find further information on this

for the NAR versions) have been changed.

engine in Self-Study Programme no. 511

“The New EA211 Petrol Engine Family”.

Technical data Torque and performance diagram

Engine code CRJA (EU6) 280 160

Design 4-cylinder inline engine 260 140

Valves per cylinder 4

Max. torque 250 Nm at 1600 - 3500 rpm 160 40

• one cast duct for secondary air injection (in the

Hydraulic fluid Coolant supply

They are distinguished by:

The hybrid drive made the following modifications necessary:

temperature circuit V467

Electric drive motor V141

Power and control

electronics for electric

Water radiator for charge air Coolant pump for low-temperature

• Clutch housing extended by 83 mm

Conventional Jetta Jetta Hybrid

Description 0AM 0CG

The hydraulic system for the disengagement clutch K0

No pressure – supply line

Pressure from the mechatronic unit hydraulic pump