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Volkswagen Golf 2013 Quick Reference Specification Book - Brake System

Summary of Golf 2013

  • Page 1

    Golf, gti & golf r quick reference specification book 2013.

  • Page 3: Engines

    Vw golf & gti quick reference specification book • september 2012 i 2013 volkswagen golf & gti quick reference specification book table of contents general information ...................................................... 1 decimal and metric equivalents ...........................................1...

  • Page 4

    Ii vw golf & gti quick reference specification book • september 2012 cylinder head, valvetrain – 2.0l cjaa (tdi) .....................26 fastener tightening specifications ........................................26 valve dimensions ..................................................................27...

  • Page 5

    Vw golf & gti quick reference specification book • september 2012 iii compression pressures ........................................................48 cylinder head tightening specifications ...............................49 cylinder head cover tightening specifications ....................50 crankc...

  • Page 6

    Iv vw golf & gti quick reference specification book • september 2012 fastener tightening specifications ........................................69 crankshaft dimensions .........................................................70 piston ring end gaps .....................................................

  • Page 7: Transmissions

    Vw golf & gti quick reference specification book • september 2012 v crankshaft, cylinder block – 2.5l cbta, cbua ................90 crankshaft upper bearing shell (for cylinder block) allocation .........................................................................90 crankshaft lower bearing shel...

  • Page 8

    Vi vw golf & gti quick reference specification book • september 2012 clutch – 0a4 .....................................................................109 fastener tightening specifications ......................................109 controls, housing – 0a4 ...............................................

  • Page 9: Chassis

    Vw golf & gti quick reference specification book • september 2012 vii gears, hydraulic controls – 09g ......................................133 fastener tightening specifications ......................................133 transmission fluid pan tightening specification ................134 direct shif...

  • Page 10

    Viii vw golf & gti quick reference specification book • september 2012 anti-lock brake system (abs) ..........................................161 fastener tightening specifications ......................................161 mechanical components ..................................................161 f...

  • Page 11

    Vw golf & gti quick reference specification book • september 2012 ix electrical system ....................................................... 175 electrical equipment .........................................................175 battery, starter, generator, cruise control fastener tightening specifi...

  • Page 12

    X vw golf & gti quick reference specification book • sepetember 2012 dtc chart ................................................................... 233 engine codes crza ........................................................233 fuel and air mixture, additional emission regulations .......233 igniti...

  • Page 13: General

    General information vw golf & gti quick reference specification book • september 2012 1 general information decimal and metric equivalents distance/length to calculate: mm x 0.03937 = in. Mm in. Mm in. Mm in. Mm in. 0.002 0.00008 0.01 0.0004 0.1 0.004 1 0.04 0.004 0.00016 0.02 0.0008 0.2 0.008 2 0.0...

  • Page 14: Tightening Torque

    2 vw golf & gti quick reference specification book • sepetember 2012 tightening torque nm-to-lb·ft (ft·lb) to calculate: nm x 0.738 = lb·ft nm lb·ft (ft·lb) nm lb·ft (ft·lb) nm lb·ft (ft·lb) 10 7 55 41 100 74 11 8 56 41 105 77 12 9 57 42 110 81 13 10 58 43 115 85 14 10 59 44 120 89 15 11 60 44 125 9...

  • Page 15: General

    General information vw golf & gti quick reference specification book • september 2012 3 nm-to-lb·in (in·lb), kg·cm to calculate: nm x 8·85 = lb·in • nm x 10.20 = kg·cm nm lb·in (in·lb) kg·cm nm lb·in (in·lb) kg·cm 1 9 10 26 230 265 2 18 20 27 239 275 3 27 31 28 248 286 4 35 41 29 257 296 5 44 51 30 ...

  • Page 16: Warnings and Cautions

    4 vw golf & gti quick reference specification book • sepetember 2012 kg·cm-to-lb·in (in·lb), n·cm to calculate: kg·cm x 0.868 = lb·in • kg·cm x 9.81 = n·cm kg·cm lb·in (in·lb) n·cm kg·cm lb·in (in·lb) n·cm 5 4 49 110 95 1079 6 5 59 120 104 1177 7 6 69 130 113 1275 8 7 78 140 122 1373 9 8 88 150 130 ...

  • Page 17: General

    General information vw golf & gti quick reference specification book • september 2012 5 • never run the engine unless the work area is well ventilated. Carbon monoxide kills. • remove rings, bracelets and other jewelry so they cannot cause electrical shorts, get caught in running machinery, or be cr...

  • Page 18: Warnings

    6 vw golf & gti quick reference specification book • sepetember 2012 warnings (cont’d) • batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it ignites the gas...

  • Page 19: General

    General information vw golf & gti quick reference specification book • september 2012 7 • place jack stands only at locations specified by manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only. Use a heavy duty floor jack to lift the vehicle before instal...

  • Page 20: Cautions

    8 vw golf & gti quick reference specification book • sepetember 2012 cautions (cont’d) • label battery cables before disconnecting. On some models, battery cables are not color coded. • disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes prior to ...

  • Page 21: Vehicle

    Vehicle identification vw golf & gti quick reference specification book • september 2012 9 vehicle identification vehicle identification number (vin) location the vin ( Æ ) is on the left side of the vehicle in the area of the windshield wiper mount. It is visible from the outside..

  • Page 22: Vin Decoder

    10 vw golf & gti quick reference specification book • september 2012 vin decoder 2013 volkswagen vin decoder (except routan) c ount ry of or igin m an uf act urer ve hic le ty pe seri es engine r es tr ai nt s ys te m ch eck di gi t m od el ye ar assemb ly pl an t 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

  • Page 23: Vehicle

    Vehicle identification vw golf & gti quick reference specification book • september 2012 11 vin on longitudinal member extension the vehicle identification number (vin) is located on the longitudinal member extension ( Æ )..

  • Page 24: Vehicle Data Label

    12 vw golf & gti quick reference specification book • september 2012 vehicle data label the vehicle data label ( Æ ) is located on the left side of the spare wheel well. The vehicle data label is also in the customer’s maintenance booklet..

  • Page 25: Sales Codes

    Sales codes vw golf & gti quick reference specification book • september 2012 13 sales codes engine codes cjaa 2.0l tdi 4-cylinder 4v turbo diesel cbfa/ccta 2.0l tfsi 4-cylinder 4v crza 2.0l tfsi 4-cylinder 4v cbta/cbua 2.5l 5-cylinder 4v transmission codes 0a4 5-speed manual 02q 6-speed manual 02e ...

  • Page 26: Vehicle Lifting

    14 vw golf & gti quick reference specification book • september 2012 vehicle lifting hoist and jack mounting points front position the support plate in the side member vertical reinforcement area ( Æ )..

  • Page 27: Vehicle Lifting

    Vehicle lifting vw golf & gti quick reference specification book • september 2012 15 rear position the support plate in the side member vertical reinforcement area ( Æ )..

  • Page 28: (Tdi)

    16 vw golf & gti quick reference specification book • september 2012 engine mechanical – 2.0l cjaa (tdi) general, technical data engine number location the engine number (engine code and serial number) ( Æ ) is located at the front of the engine/transmission joint. The engine code and serial number ...

  • Page 29: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 17 engine data identification code cjaa manufactured from 09.09 emission values in accordance with ulev2 2) standard displacement liter 2.0 output kw at rpm 103 @ 4200 torque nm at rpm 320 @ 1750 to 2500 bore ...

  • Page 30

    18 vw golf & gti quick reference specification book • september 2012 engine assembly - 2.0l cjaa (tdi) fastener tightening specifications component fastener size nm bolts and nuts m6 10 m7 15 m8 25 m10 40 m12 65 1) 1) m12 collar bolt tightening specification: 75 nm. Engine mount tightening specifica...

  • Page 31: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 19 transmission mount tightening specifications component nm bolts 1 1) 40 plus an additional 90° (¼ turn) bolts 2 1) 60 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 32

    20 vw golf & gti quick reference specification book • september 2012 pendulum support tightening specifications component nm bolt a 1) 40 plus an additional 90° (¼ turn) bolt b 1) 60 plus an additional 90° (¼ turn) bolt c 1) 100 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 33: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 21 engine mount bracket tightening specifications step component nm 1 tighten bolts 1 through 3 in sequence 1) hand-tighten 2 tighten bolts 1 through 3 in sequence 40 3 tighten bolts 1 through 3 in sequence an...

  • Page 34: (Tdi)

    22 vw golf & gti quick reference specification book • september 2012 crankshaft, cylinder block – 2.0l cjaa (tdi) fastener tightening specifications component nm air conditioning compressor-to-accessory bracket bolt 25 bracket-to-oil filter bracket bolt 10 camshaft sprocket-to-camshaft bolt 20 plus ...

  • Page 35: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 23 component nm protective plate-to-rear toothed belt guard bolt 5 rear toothed belt guard-to-cylinder block bolt 2) 10 1) 20 ribbed belt tensioner-to-accessory bracket bolt 1) 20 plus an additional 180° (½ tu...

  • Page 36

    24 vw golf & gti quick reference specification book • september 2012 accessory bracket tightening specifications step component nm 1 tighten bolts 1 through 6 in sequence hand-tighten 2 tighten bolts 1 through 6 in sequence 40 3 tighten bolts 3 and 4 an additional 45° (⅛ turn) 4 tighten bolts 1, 2, ...

  • Page 37: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 25 crankshaft dimensions honing dimension in mm crankshaft bearing pin diameter in mm connecting rod bearing pin diameter in mm basic dimension 54.000 -0.022 50.900 -0.022 -0.042 -0.042 piston and cylinder dim...

  • Page 38: (Tdi)

    26 vw golf & gti quick reference specification book • september 2012 cylinder head, valvetrain – 2.0l cjaa (tdi) fastener tightening specifications component nm adapter to cylinder head bolt 10 camshaft position (cmp) sensor-to-cylinder head bolt 10 camshaft sprocket-to-camshaft bolt 20 plus an addi...

  • Page 39: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 27 valve dimensions dimension intake valve exhaust valve diameter a mm 26.60 26.00 diameter b mm 5.940 5.940 c mm 99.30 99.10 α ∠° 45 45 note: intake and exhaust valves must not be refaced by grinding. Only la...

  • Page 40

    28 vw golf & gti quick reference specification book • september 2012 cylinder head cover tightening specifications step component nm 1 tighten bolts 1 through 7 in sequence hand-tighten 2 tighten bolts 1 through 7 in sequence 10

  • Page 41: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 29 cylinder head tightening specifications step component nm 1 tighten bolts 1 through 10 in sequence 30 2 tighten bolts 1 through 10 in sequence 50 3 tighten bolts 1 through 10 in sequence an additional 90° (...

  • Page 42

    30 vw golf & gti quick reference specification book • september 2012 bearing frame tightening specifications step component nm 1 tighten bolts and nuts 1 through 24 in sequence hand-tighten 1) 2 tighten bolts and nuts 1 through 24 in sequence 10 1) the bearing frame must be in contact with the entir...

  • Page 43: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 31 lubrication – 2.0l cjaa (tdi) fastener tightening specifications component nm chain tensioner with tensioning rail-to-cylinder block bolt 15 oil filter bracket cap 25 oil filter bracket connection 30 oil fi...

  • Page 44

    32 vw golf & gti quick reference specification book • september 2012 cooling system – 2.0l cjaa (tdi) fastener tightening specifications component nm 4/2 way valve with thermostat-to-cylinder block bolt 15 coolant expansion tank to body stud bolt 5 coolant fan shroud nut 5 coolant pump-to-cylinder b...

  • Page 45: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 33 turbocharger – 2.0l cjaa (tdi) fastener tightening specifications component nm adapter-to-connecting piece bolt 8 charge air cooler (cac) mount bolt 5 charge air pipe-to-cylinder block bolt 8 charge air pip...

  • Page 46

    34 vw golf & gti quick reference specification book • september 2012 component nm control line bracket-to-particulate filter bolt 9 control line-to-exhaust gas recirculation (egr) housing 23 control line-to-particulate filter 45 exhaust gas recirculation (egr) cooler-to-exhaust gas recirculation (eg...

  • Page 47: Engine –

    Engine – 2.0l cjaa (tdi) vw golf & gti quick reference specification book • september 2012 35 ignition/glow plug system – 2.0l cjaa (tdi) fastener tightening specifications component nm fuel line bracket-to-intake manifold bolt 8 glow plug 12 diesel fuel injection – 2.0l cjaa (tdi) fastener tighteni...

  • Page 48: Engine Mechanical – 2.0L

    36 vw golf & gti quick reference specification book • september 2012 engine mechanical – 2.0l cbfa, ccta general, technical data engine number location the engine number (engine code and serial number) is located at the engine/transmission joint. The engine code is also printed on the cylinder block...

  • Page 49: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 37 engine data code letters cbfa ccta manufactured from 10.09 from 06.08 emissions values sulev 1) ulev 2 2) displacement liter 2.0 2.0 output kw at rpm 147 @ 5100 147 @ 5100 torque nm at rpm 280 @ 1700 280 ...

  • Page 50

    38 vw golf & gti quick reference specification book • september 2012 engine assembly – 2.0l cbfa, ccta fastener tightening specifications component fastener size nm bolts and nuts m6 10 m7 15 m8 25 m10 40 m12 60 engine mount bracket-to-engine bolt 1) - 40 plus an additional 180° (½ turn) engine moun...

  • Page 51: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 39 crankshaft, cylinder block – 2.0l cbfa, ccta cylinder block bearing shell identification the cylinder block bearing shell identification is located on either the oil pan sealing surface or on the top (tra...

  • Page 52

    40 vw golf & gti quick reference specification book • september 2012 the identification on the cylinder block is for the upper bearing shell. Note the letter and match it to the color identification in the table. Letter on cylinder block color of bearing s black r red g yellow b blue w white.

  • Page 53: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 41 bearing cap bearing shell identification the identification on the crankshaft is for the lower bearing shell. Note the letter and match it to the color identification in the table. Letter on crankshaft co...

  • Page 54

    42 vw golf & gti quick reference specification book • september 2012 fastener tightening specifications component fastener size nm air conditioning compressor-to-accessory bracket bolt - 25 connecting rod bearing cap-to-connecting rod bolt 1) m8 30 plus an additional 90° (¼ turn) m9 45 plus an addit...

  • Page 55: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 43 crankshaft dimensions reconditioning dimension in mm 1) crankshaft bearing pin diameter connecting rod bearing pin diameter basic dimension 58.00 47.80 1) the preparation of worn crankshafts is not provid...

  • Page 56: Accessory Assembly Bracket

    44 vw golf & gti quick reference specification book • september 2012 accessory assembly bracket tightening specifications step component nm 1 tighten bolts 1 through 5 in sequence hand-tighten 2 tighten bolts 1 through 5 in sequence 20 3 tighten bolts 1 through 5 in sequence an additional 90° (¼ tur...

  • Page 57: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 45 sealing flange tightening specifications step component nm 1 tighten bolts 1 through 8 in sequence hand-tighten 2 tighten bolts 1 through 8 in sequence 9.

  • Page 58

    46 vw golf & gti quick reference specification book • september 2012 crankshaft assembly tightening specifications step component nm 1 tighten bolts 1 through 10 and a in sequence hand-tighten 2 tighten bolts 1 through 10 in sequence 65 3 tighten bolts 1 through 10 in sequence an additional 90° (¼ t...

  • Page 59: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 47 cylinder head, valvetrain – 2.0l cbfa, ccta fastener tightening specifications component fastener size nm balance shaft-to-cylinder block bolt - 9 balance shaft timing chain guide rail-to- cylinder block ...

  • Page 60: Valve Dimensions

    48 vw golf & gti quick reference specification book • september 2012 component fastener size nm transport strap-to-cylinder head bolt - 25 vacuum pump-to-cylinder head bolt - 9 1) replace fastener(s). 2) engine code cbfa only. 3) left hand threads. Valve dimensions dimension intake valve exhaust val...

  • Page 61: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 49 cylinder head tightening specifications step component nm 1 tighten bolts 1 through 5 in sequence 40 2 tighten bolts 1 through 5 in sequence an additional 90° (¼ turn) 3 tighten bolts 1 through 5 in seque...

  • Page 62

    50 vw golf & gti quick reference specification book • september 2012 cylinder head cover tightening specifications step component nm 1 tighten bolts 1 through 6 in sequence in several stages hand-tighten 2 tighten bolts 1 through 6 in sequence 8 3 tighten bolts 1 through 6 in sequence an additional ...

  • Page 63: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 51 crankcase ventilation tightening specification step component nm 1 tighten bolts 1 through 10 in sequence 11 upper timing chain cover tightening specifications step component nm 1 tighten bolts 1 through ...

  • Page 64: Specifications With 15 Bolts

    52 vw golf & gti quick reference specification book • september 2012 lower timing chain cover tightening specifications with 15 bolts step component nm 1 tighten bolts 1 through 15 in sequence 8 2 tighten bolts 1 through 15 in sequence an additional 45° (⅛ turn).

  • Page 65: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 53 lower timing chain cover tightening specifications with 8 bolts step component nm 1 tighten bolts 1 through 8 in sequence 4 2 tighten bolts 1 through 8 in sequence an additional 45° (⅛ turn).

  • Page 66

    54 vw golf & gti quick reference specification book • september 2012 lubrication – 2.0l cbfa, ccta fastener tightening specifications component fastener size nm oil baffle-to-upper oil pan bolt - 9 oil cooler-to-accessory bracket bolt - 15 oil drain plug-to-lower oil pan - 30 oil filter element-to-a...

  • Page 67: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 55 oil pan tightening specifications step component nm 1 tighten bolts 1 through 20 in sequence hand-tighten 2 tighten bolts 1 through 20 in sequence 8 3 tighten bolts 1 through 20 in sequence an additional ...

  • Page 68

    56 vw golf & gti quick reference specification book • september 2012 oil separator tightening specification step component nm 1 tighten bolts 1 through 9 in sequence 9 cooling system – 2.0l cbfa, ccta fastener tightening specifications component nm after run coolant pump bracket bolt 8 after run coo...

  • Page 69: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 57 coolant pump tightening specification step component nm 1 tighten bolts 1 through 5 in sequence 9 fuel supply – 2.0l cbfa, ccta fastener tightening specifications component fastener size nm accelerator pe...

  • Page 70: Ccta

    58 vw golf & gti quick reference specification book • september 2012 turbocharger, g-charger – 2.0l cbfa, ccta fastener tightening specifications component nm charge air cooler (cac) mounting bolt 5 charge air pipe bolt 8 charge air pipe clamp 5.5 charge air pressure sensor-to-charge air pipe bolt 5...

  • Page 71: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 59 turbocharger tightening specifications step component nm 1 tighten bolts 1 through 5 in sequence 5 2 tighten bolts 1 through 5 in sequence 12 3 tighten bolts 1 through 5 in sequence 16 4 tighten bolts 1 t...

  • Page 72: Technical Data

    60 vw golf & gti quick reference specification book • september 2012 exhaust system – 2.0l cbfa, ccta fastener tightening specifications component nm clamping sleeve nut - individual clamp 25 - continuous clamp 35 front exhaust pipe with catalytic converter-to-exhaust manifold/turbocharger nut 1) 3)...

  • Page 73: Engine –

    Engine – 2.0l cbf a, cct a vw golf & gti quick reference specification book • september 2012 61 fastener tightening specifications component fastener size nm fuel rail adapter (vas 6394/2) - 27 fuel pressure sensor-to-pressure sensor tester (vas 6394/1) - 27 fuel pressure sensor-to-fuel rail 2) - 27...

  • Page 74: Technical Data

    62 vw golf & gti quick reference specification book • september 2012 ignition – 2.0l cbfa, ccta technical data engine codes cbfa and ccta ignition sequence 1-3-4-2 spark plugs vw/audi 101 905 631 h electrode gap 1.0 to 1.1 mm tightening specifications 25 nm change intervals refer to maintenance inte...

  • Page 75: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 63 engine mechanical – 2.0l crza general, technical data engine number location the engine number (engine code and serial number) is located on the left side at the engine/transmission partition. The engine code is ...

  • Page 76: Engine Data

    64 vw golf & gti quick reference specification book • september 2012 engine data engine code crza manufactured from 10.11 emission values in accordance with ulev ii displacement cm 3 1984 output kw at rpm 188 @ 6000 torque nm at rpm 330 @ 2500 bore diameter mm 82.5 stroke mm 92.8 compression ratio 9...

  • Page 77: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 65 engine assembly – 2.0l crza fastener tightening specifications component fastener size nm bolts and nuts m6 10 m7 15 m8 25 m10 40 m12 60 engine mount tightening specifications component nm bolts a 1) 20 plus an a...

  • Page 78

    66 vw golf & gti quick reference specification book • september 2012 transmission mount tightening specifications component nm bolts 1 1) 40 plus an additional 90° (¼ turn) bolts 2 1) 60 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 79: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 67 pendulum support tightening specifications component nm bolts a with a strength category of 8.8 1) 40 plus an additional 90° (¼ turn) bolts a with a strength category of 10.9 1) 50 plus an additional 90° (¼ turn)...

  • Page 80

    68 vw golf & gti quick reference specification book • september 2012 crankshaft, cylinder block – 2.0l crza upper crankshaft bearing identification the upper bearing shells are allocated to the cylinder block with the correct thickness by the factory. Colored dots identify the bearing thicknesses. T...

  • Page 81: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 69 fastener tightening specifications component nm air conditioning compressor-to-accessory bracket bolt 25 coolant pump-to-cylinder block bolt 15 coolant thermostat housing-to-cylinder block bolt 15 connecting rod ...

  • Page 82: Crankshaft Dimensions

    70 vw golf & gti quick reference specification book • september 2012 crankshaft dimensions honing dimensions in mm crankshaft bearing pin diameter connecting rod bearing pin diameter basic dimension 54.00 -0.017 47.80 -0.022 -0.037 -0.042 1 st oversize 53.75 -0.017 47.55 -0.022 -0.037 -0.042 2 nd ov...

  • Page 83: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 71 accessory assembly bracket tightening specification step component nm 1 tighten bolts a through f in sequence 40

  • Page 84

    72 vw golf & gti quick reference specification book • september 2012 sealing flange tightening specifications step component nm 1 tighten bolts (Æ) hand-tighten 2 tighten bolts (Æ) 15.

  • Page 85: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 73 cylinder head, valvetrain – 2.0l crza fastener tightening specifications component nm camshaft adjuster-to-camshaft bolt 20 plus an additional 45° (⅛ turn) camshaft adjustment valve 1-to-housing bolt 4 camshaft p...

  • Page 86: Valve Dimensions

    74 vw golf & gti quick reference specification book • september 2012 valve dimensions dimension intake valve exhaust valve diameter a mm 33.75 to 33.95 27.90 to 28.10 diameter b mm 5.98 5.95 c mm 103.97 101.87 α ∠° 45 45 note: intake and exhaust valves must not be refaced by grinding. Only lapping i...

  • Page 87: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 75 cylinder head tightening specifications step component nm 1 tighten bolts 1 through 10 in sequence 40 2 tighten bolts 1 through 10 in sequence an additional 90° (¼ turn) 3 tighten bolts 1 through 10 in sequence a...

  • Page 88

    76 vw golf & gti quick reference specification book • september 2012 cylinder head cover tightening specification step component nm 1 tighten bolts 1 through 14 in sequence in several stages 10

  • Page 89: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 77 lubrication – 2.0l crza fastener tightening specifications component nm chain tensioner with tensioning rail-to-cylinder block bolt 15 charge air pipe-to-oil pan bolt 8 engine oil cooler-to-oil filter adapter bol...

  • Page 90

    78 vw golf & gti quick reference specification book • september 2012 oil pan tightening specifications step component nm 1 tighten all the oil pan to cylinder block bolts in sequence hand-tighten 2 tighten oil pan to transmission bolts Æ hand-tighten 3 tighten all the oil pan to cylinder block bolts...

  • Page 91: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 79 cooling system – 2.0l crza fastener tightening specifications component nm coolant expansion tank-to-body stud bolt 5 coolant fan-to-fan shroud nut 5 coolant line bolt 1) 5 23 40 coolant line-to-thermostat housin...

  • Page 92

    80 vw golf & gti quick reference specification book • september 2012 turbocharger, g-charger – 2.0l crza fastener tightening specifications component nm bracket-to-charge air cooler (cac) bolt 5 bracket-to-cylinder head nut 1) 3) 30 charge air pipe bolt 10 charge air pipe clamp 5.5 charge air pressu...

  • Page 93: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 81 exhaust system – 2.0l crza fastener tightening specifications component nm clamping sleeve nut 23 cross member-to-underbody bolt 25 exhaust pipe with catalytic converter-to-exhaust manifold/turbocharger nut 1) 2)...

  • Page 94

    82 vw golf & gti quick reference specification book • september 2012 fastener tightening specifications component nm adapter (vas 6394/2)-to-fuel rail 22 fuel pressure sensor-to-pressure sensor tester (vas 6394/1) 22 fuel pressure sensor-to-fuel rail 2) 22 fuel rail-to-intake manifold bolt 8 heat sh...

  • Page 95: Engine –

    Engine – 2.0l crza vw golf & gti quick reference specification book • september 2012 83 ignition – 2.0l crza technical data engine code crza ignition sequence 1-3-4-2 spark plugs vw/audi 101 905 631 h electrode gap 0.7 to 0.8 mm tightening specification 25 nm change intervals refer to the maintenanc...

  • Page 96: Engine Mechanical –

    84 vw golf & gti quick reference specification book • september 2012 engine mechanical – 2.5l cbta, cbua general, technical data engine number the engine code (a) and serial number (b) are located on the rear side of the engine, above the cylinder block/upper oil pan partition. In addition, a sticke...

  • Page 97: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 85 engine data engine code cbta cbua manufactured rabbit from my 2004 from 05.07 from 05.07 golf from my 2010 from 05.09 from 05.09 emission values in accordance with rabbit from my 2004 ulev 2 1) sulev 2) go...

  • Page 98: Cylinder Numbering

    86 vw golf & gti quick reference specification book • september 2012 cylinder numbering ignition sequence 1 - 2 - 4 - 5 - 3.

  • Page 99: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 87 engine assembly – 2.5l cbta, cbua fastener tightening specifications component fastener size nm bolts and nuts m6 10 m7 15 m8 25 m10 40 m12 60 engine mount tightening specifications component nm bolts 1 40...

  • Page 100

    88 vw golf & gti quick reference specification book • september 2012 transmission mount tightening specifications component nm bolts a 1) 40 plus an additional 90° (¼ turn) bolts b 1) 60 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 101: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 89 pendulum support tightening specifications secure the pendulum support to the transmission first and then to the subframe. To remove, first remove bolt b, then bolts a. Component fastener size nm bolts a 1...

  • Page 102: Cbua

    90 vw golf & gti quick reference specification book • september 2012 crankshaft, cylinder block – 2.5l cbta, cbua crankshaft upper bearing shell (for cylinder block) allocation the upper bearing shells are allocated to the cylinder block with the correct thickness from the factory. Colored dots iden...

  • Page 103: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 91 crankshaft lower bearing shell (for bearing cap) allocation bearing shells with the correct thickness are allocated to the bearing cap at the factory. Colored dots on the sides of the bearing shells identi...

  • Page 104

    92 vw golf & gti quick reference specification book • september 2012 fastener tightening specifications component nm accessory bracket-to-cylinder block bolt 25 air conditioning compressor-to-accessory bracket bolt 25 air conditioning compressor ribbed belt tensioner-to- accessory bracket bolt 35 ax...

  • Page 105: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 93 component nm knock sensor (ks)-to-cylinder block bolt 3) 20 lower idler pulley with bracket-to-accessory bracket bolt 25 oil filter bracket-to-cylinder block bolt 25 oil pump drive chain tensioner-to-cylin...

  • Page 106: Piston Ring End Gap

    94 vw golf & gti quick reference specification book • september 2012 piston ring end gap piston ring dimensions in mm new wear limit compression rings 0.20 to 0.40 0.8 oil scraping ring 0.25 to 0.50 0.8 piston ring clearance piston ring dimensions in mm new wear limit compression rings 0.06 to 0.09 ...

  • Page 107: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 95 cylinder head, valvetrain – 2.5l cbta, cbua fastener tightening specifications component nm axial bearing disc-to-cylinder block bolt 10 camshaft adjustment valve 1-to-cylinder head bolt 2 camshaft clamp (...

  • Page 108: Valve Dimensions

    96 vw golf & gti quick reference specification book • september 2012 valve dimensions dimension intake valve exhaust valve diameter a mm 26.80 to 27.00 29.80 to 30.00 diameter b mm 5.95 to 5.97 5.94 to 5.95 c mm 104.84 to 105.34 103.64 to 104.14 α ∠° 45 45 compression pressures new bar positive pres...

  • Page 109: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 97 cylinder head cover tightening specification step component nm 1 tighten bolts 1 through 16 in sequence 10

  • Page 110

    98 vw golf & gti quick reference specification book • september 2012 cylinder head tightening specifications step component nm 1 tighten bolts 1 through 12 in sequence 40 2 tighten bolts 1 through 12 in sequence an additional 90° (¼ turn) 3 tighten bolts 1 through 12 in sequence an additional 90° (¼...

  • Page 111: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 99 guide frame tightening specifications step component nm 1 tighten bolts 1 through 7 in sequence 1) 8 2 tighten bolts 1 through 7 in sequence an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 112

    100 vw golf & gti quick reference specification book • september 2012 lubrication – 2.5l cbta, cbua fastener tightening specifications component nm cylinder block locking bolt 45 intake manifold support/oil dipstick guide tube-to-cylinder block bolt 25 lower oil pan-to-upper oil pan bolt 10 oil cool...

  • Page 113: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 101 cooling system – 2.5l cbta, cbua fastener tightening specifications component nm connecting piece-to-coolant thermostat housing bolt 5 coolant distribution housing-to-chain compartment cover nut 10 coolan...

  • Page 114: 2.5L Cbta, Cbua

    102 vw golf & gti quick reference specification book • september 2012 exhaust system, emission controls – 2.5l cbta, cbua fastener tightening specifications component nm clamp nut 25 exhaust manifold-to-cylinder head nut 1) 25 front cross member-to-underbody nut 23 front exhaust pipe with catalytic ...

  • Page 115: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 103 secondary air injection pipe tightening specifications step component nm 1 tighten bolts 1 through 3 in sequence hand-tighten 2 tighten bolts 1 through 3 in sequence 10

  • Page 116: Lower Air Filter Housing

    104 vw golf & gti quick reference specification book • september 2012 multiport fuel injection – 2.5l cbta, cbua fastener tightening specifications component nm fuel rail-to-intake manifold bolt 3.5 intake manifold-to-cylinder head bolt 9 intake manifold support-to-cylinder block bolt 25 intake mani...

  • Page 117: Engine –

    Engine – 2.5l cbt a, cbua vw golf & gti quick reference specification book • september 2012 105 ignition – 2.5l cbta, cbua fastener tightening specifications component nm camshaft position (cmp) sensor bolt 10 knock sensor (ks) bolt 1) 20 spark plug 25 1) tightening specifications affect the functio...

  • Page 118: General, Technical Data

    106 vw golf & gti quick reference specification book • september 2012 manual transmission – 0a4 general, technical data transmission identification code letters and build date (1) manual transmission 0a4 (2). Manual transmission 0a4 (2)..

  • Page 119: Manual T

    Manual t rans. – 0a4 vw golf & gti quick reference specification book • september 2012 107 transmission code letters and build date. Example: fne 10 11 3 identification code day month year (2003) of manufacture note: the transmission code letters are also included on the vehicle data label..

  • Page 120: Codes Letters, Transmission

    108 vw golf & gti quick reference specification book • september 2012 codes letters, transmission allocation and capacities manual transmission 5 speed (0a4) identification codes kcd kpf lea manufactured from through 08.09 09.09 08.09 05.10 05.10 allocation engine 2.5l - 125 kw 2.5l - 125 kw 2.5l - ...

  • Page 121: Manual T

    Manual t rans. – 0a4 vw golf & gti quick reference specification book • september 2012 109 clutch – 0a4 fastener tightening specifications component fastener size nm ball stud-to-transmission - 25 clutch pedal bolt nut 1) - 25 clutch pedal bracket-to-bulkhead nut 1) - 25 clutch slave cylinder-to-tra...

  • Page 122: Controls, Housing – 0A4

    110 vw golf & gti quick reference specification book • september 2012 controls, housing – 0a4 fastener tightening specifications component fastener size nm 5 th gear drive gear-to-output shaft bolt - 80 plus an additional 90° (¼ turn) 5 th gear selector fork base-to-transmission housing bolt - 25 5 ...

  • Page 123: Manual T

    Manual t rans. – 0a4 vw golf & gti quick reference specification book • september 2012 111 transmission to engine tightening specifications item bolt quantity nm 1 m12 x 65 2 80 2 m12 x 170 1) 1 80 3 m12 x 170 1) 1 80 4 m10 x 65 3 40 5 m12 x 95 1 80 6 m6 x 8 2) 1 10 1) also for the starter to transm...

  • Page 124

    112 vw golf & gti quick reference specification book • september 2012 transmission mount bracket to transmission bolt tightening specification step component nm 1 tighten bolts 1) Æ hand-tighten 2 tighten bolts Æ 40 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 125: Manual T

    Manual t rans. – 0a4 vw golf & gti quick reference specification book • september 2012 113 transmission mount to transmission mount bracket bolt tightening specification step component nm 1 tighten bolts 1) Æ hand-tighten 2 tighten bolts Æ 60 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 126

    114 vw golf & gti quick reference specification book • september 2012 transmission support to transmission bracket and transmission bolt tightening specification step component nm 1 tighten bolts 1) Æ hand-tighten 2 tighten bolts Æ 20 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 127: Manual T

    Manual t rans. – 0a4 vw golf & gti quick reference specification book • september 2012 115 reverse shaft support to transmission housing bolt tightening sequence and specification step component nm 1 tighten bolt a Æ 30 2 tighten bolt b (lower illustration 20 3 tighten bolt c 25.

  • Page 128: Gears, Shafts – 0A4

    116 vw golf & gti quick reference specification book • september 2012 gears, shafts – 0a4 fastener tightening specification component nm output shaft bearing support-to-clutch housing nut 1) 25 plus an additional 90° (¼ turn) 1) replace fastener(s). Determining shim thickness example: bearing cleara...

  • Page 129: Manual T

    Manual t rans. – 0a4 vw golf & gti quick reference specification book • september 2012 117 bearing play adjusting shim measured value (mm) thickness (mm) 1.275 to 1.229 1.300 to 1.324 1.325 to 1.349 1.250 1.275 1.300 1.350 to 1.374 1.375 to 1.399 1.400 to 1.424 1.325 1.350 1.375 1.425 to 1.449 1.450...

  • Page 130: General, Technical Data

    118 vw golf & gti quick reference specification book • september 2012 manual transmission – 02q general, technical data transmission identification code letters and build date (1) for the manual transmission 02q (2). Manual transmission 02q (2)..

  • Page 131: Manual T

    Manual t rans. – 02q vw golf & gti quick reference specification book • september 2012 119 transmission code letters and build date ( Æ ). Example: grf 25 11 3 identification codes day month year (2003) of manufacture.

  • Page 132: Codes Letters, Transmission

    120 vw golf & gti quick reference specification book • september 2012 codes letters, transmission allocation and capacities manual transmission 6 speed transmission (02q) identification codes lhd nfp manufactured from through 05.09 05.11 05.11 allocation engine 2.0l - 103 kw turbo diesel 2.0l - 103 ...

  • Page 133: Manual T

    Manual t rans. – 02q vw golf & gti quick reference specification book • september 2012 121 clutch – 02q fastener tightening specifications component fastener size nm clutch pedal mounting bracket-to-cross panel nut 1) - 25 clutch pedal-to-mounting bracket through bolt nut 1) - 25 impact bolster supp...

  • Page 134: Controls, Housing – 02Q

    122 vw golf & gti quick reference specification book • september 2012 controls, housing – 02q transmission to engine tightening specifications item bolt quantity nm 1 m12 x 55 with a long m8 threaded pin 1 80 2 m12 x 55 with a short m8 threaded pin or m12 x 50 without threaded pin 1 80 3 m12 x 165 w...

  • Page 135: Manual T

    Manual t rans. – 02q vw golf & gti quick reference specification book • september 2012 123 component fastener size nm cable mounting bracket-to-transmission bolt/nut - 20 gear shift unit-to-transmission housing bolt 1) 20 oil fill or drain plug - multipoint socket head - 45 - hex socket head - 30 sh...

  • Page 136

    124 vw golf & gti quick reference specification book • september 2012 rear final drive, differential – 02q fastener tightening specifications component fastener size nm flange shaft to threaded piece bolt - 33 all wheel drive fastener tightening specifications component fastener size nm backup lamp ...

  • Page 137: Manual T

    Manual t rans. – 02q vw golf & gti quick reference specification book • september 2012 125 transmission mount item bolt quantity 1 m10 x 21 3 2 m10 x 45 2 3 m10 x 62 1.

  • Page 138: Brace Under Diaphragm

    126 vw golf & gti quick reference specification book • september 2012 brace under diaphragm item bolt quantity a m10 x 21 2 b m10 x 45 1 step component nm 1 tighten all bolts hand-tighten 2 tighten bolts a 40 3 tighten bolts b 40

  • Page 139: Manual T

    Manual t rans. – 02q vw golf & gti quick reference specification book • september 2012 127 transmission bracket to transmission tighten bolts Æ 60 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 140

    128 vw golf & gti quick reference specification book • september 2012 identification on transmission tighten bolts Æ 60 plus an additional 90° (¼ turn) 1) replace fastener(s)..

  • Page 141: Automatic T

    Automatic t rans. – 09g vw golf & gti quick reference specification book • september 2012 129 automatic transmission – 09g general, technical data identification on transmission code letters ( Æ )..

  • Page 142

    130 vw golf & gti quick reference specification book • september 2012 code letter (1) indicates 6-speed automatic transmission 09g (2). Example: ggz 08 05 02 identification codes day month year (2002) of manufacture the transmission code letters are also included on the vehicle data labels. Code let...

  • Page 143: Automatic T

    Automatic t rans. – 09g vw golf & gti quick reference specification book • september 2012 131 controls, housing fastener tightening specifications component nm inspection plug-to-transmission oil pan 27 multifunction transmission range switch-to-shift rod nut 7 multifunction transmission range switc...

  • Page 144

    132 vw golf & gti quick reference specification book • september 2012 transmission to engine tightening specifications component fastener size nm drive plate-to-converter - 60 bolts m12 80 or 65, if using t10179 bolts located in the lower flange m10 40 Æ alignment pins for centering.

  • Page 145: Automatic T

    Automatic t rans. – 09g vw golf & gti quick reference specification book • september 2012 133 gears, hydraulic controls – 09g fastener tightening specifications.

  • Page 146

    134 vw golf & gti quick reference specification book • september 2012 transmission fluid pan tightening specification component nm tighten the transmission pan bolts (Æ) diagonally in several steps 7.

  • Page 147: Direct Shift (Dsg)

    Direct shift (dsg) trans. – 02e vw golf & gti quick reference specification book • september 2012 135 direct shift gearbox (dsg) transmission – 02e general, technical data identification on transmission the transmission code letters can be found on the transmission near the selector lever cable ( Æ ...

  • Page 148

    136 vw golf & gti quick reference specification book • september 2012 example: gkf 10 05 02 identification codes day month year (2002) of manufacture the transmission code letters are also included on the vehicle data labels..

  • Page 149: Direct Shift (Dsg)

    Direct shift (dsg) trans. – 02e vw golf & gti quick reference specification book • september 2012 137 to read the transmission code letters under the transmission mount bracket, support the engine and transmission and remove the transmission mount bracket (a). Refer to elsaweb for the transmission m...

  • Page 150

    138 vw golf & gti quick reference specification book • september 2012 controls, housing (dsg) – 02e fastener tightening specifications component nm bevel box-to-transmission bolt 2) 40 drive axle heat shield-to-bevel box bolt 2) 25 mechatronic cover bolt 1) 16 oil filter housing 20 oil pump cover bo...

  • Page 151: Direct Shift (Dsg)

    Direct shift (dsg) trans. – 02e vw golf & gti quick reference specification book • september 2012 139 mechatronic tightening specifications step component nm 1 tighten bolts 1 through 10 in sequence 1) hand-tighten 2 tighten bolts 1 through 10 in sequence 5 3 tighten bolts 1 through 10 in sequence a...

  • Page 152: Without Countersunk Bolt

    140 vw golf & gti quick reference specification book • september 2012 oil pump tightening specifications without countersunk bolt component nm oil pump bolts (Æ) with flat heads 5 plus an additional 90° (¼ turn) with countersunk bolt component nm oil pump countersunk bolt 8 3 remaining oil pump bolt...

  • Page 153: Direct Shift (Dsg)

    Direct shift (dsg) trans. – 02e vw golf & gti quick reference specification book • september 2012 141 oil pump cover tightening specifications component nm tighten bolts (Æ) in several steps in a diagonal sequence 1) 8 1) replace fastener(s)..

  • Page 154

    142 vw golf & gti quick reference specification book • september 2012 transmission mount tightening specifications fastener component nm 1 and 2 install all new bolts and tighten hand-tighten 1 transmission mount-to-body 40 plus an additional 90° (¼ turn) 2 transmission mount-to-transmission support...

  • Page 155: Direct Shift (Dsg)

    Direct shift (dsg) trans. – 02e vw golf & gti quick reference specification book • september 2012 143 transmission to engine tightening specifications component fastener size nm bolts m12 80 or 65 if using t10179 bolts m10 40 Æ alignment pins for centering.

  • Page 156: Suspension, Wheels,

    144 vw golf & gti quick reference specification book • september 2012 suspension, wheels, steering front suspension fastener tightening specifications component fastener size nm abs wheel speed sensor-to-wheel bearing housing bolt - 8 ball joint-to-control arm nut 1) - with cast steel control arm - ...

  • Page 157: Suspension,

    Suspension, wheels, steering vw golf & gti quick reference specification book • september 2012 145 component fastener size nm mounting bracket-to-body bolt 1) m12 x 1.5 x 90 70 plus an additional 90° (¼ turn) mounting bracket-to-console bolt 1) - 50 plus an additional 90° (¼ turn) pendulum support-t...

  • Page 158: Rear Suspension

    146 vw golf & gti quick reference specification book • september 2012 rear suspension fastener tightening specifications component fastener size nm abs wheel speed sensor-to-wheel bearing housing bolt - 8 brake disc bolt - 4 coupling rod-to-stabilizer bar nut 1) - 45 coupling rod-to-trailing arm nut...

  • Page 159: Suspension,

    Suspension, wheels, steering vw golf & gti quick reference specification book • september 2012 147 component fastener size nm tie rod-to-subframe nut 1) 2) - 90 plus an additional 90° (¼ turn) tie rod-to-wheel bearing housing 1) 2) - nut (fwd) - 130 plus an additional 90° (¼ turn) - bolt (awd) - 130...

  • Page 160: Self-Leveling Suspension

    148 vw golf & gti quick reference specification book • september 2012 self-leveling suspension fastener tightening specifications component fastener size nm front body acceleration sensor-to-bracket bolt - 5 front level control system sensor bolt m6 x 16 9 front level control system sensor nut 1) - ...

  • Page 161: Suspension,

    Suspension, wheels, steering vw golf & gti quick reference specification book • september 2012 149 wheel alignment data wheel alignment specified values front suspension basic suspension sport suspension without 18” wheels/ gtd without 18” wheels/ gtd with adaptive chassis dcc without 18” wheels pro...

  • Page 162

    150 vw golf & gti quick reference specification book • september 2012 front suspension sport suspension with 18”/ gti north america with 18” wheels/ gtd with 18” wheels/ gtd with 18” wheels and adaptive chassis dcc heavy duty suspension production relevant no. (pr. No.) g02, g05, g07,g33,g58, 2uc, 2...

  • Page 163: Suspension,

    Suspension, wheels, steering vw golf & gti quick reference specification book • september 2012 151 front suspension basic suspension with adaptive chassis dcc basic suspension with 18” wheels and adaptive chassis dcc production relevant no. (pr. No.) g01, g03 g01, g03 total toe (wheels not pressed) ...

  • Page 164

    152 vw golf & gti quick reference specification book • september 2012 front suspension gti without and with adaptive chassis dcc golf r production relevant no. (pr. No.) g03, g08 g09, 1jr, g45, ub9 total toe (wheels not pressed) 10’ ± 10′ 10’ ± 10′ camber (wheels in straight ahead position) -44′ ± 3...

  • Page 165: Suspension,

    Suspension, wheels, steering vw golf & gti quick reference specification book • september 2012 153 rear suspension basic suspension sport suspension without 18” wheels/ gtd without 18” wheels/ gtd with adaptive chassis dcc without 18” wheels camber -1°20′ ± 30′ -1°20′ ± 30′ maximum permissible diffe...

  • Page 166: Steering

    154 vw golf & gti quick reference specification book • september 2012 rear suspension basic suspension with adaptive chassis dcc basic suspension with 18” wheels and adaptive chassis dcc camber -1°20’ ± 30’ -1°20’ ± 30’ maximum permissible difference between both sides 30’ 30’ total toe (at prescrib...

  • Page 167: Suspension,

    Suspension, wheels, steering vw golf & gti quick reference specification book • september 2012 155 component fastener size nm steering column-to-steering gear bolt 1) m8 x 35 30 steering gear-to-subframe bolt 1) - 50 plus an additional 90° (¼ turn) steering wheel-to-steering column bolt 1) - 30 plus...

  • Page 168: Brake System

    156 vw golf & gti quick reference specification book • september 2012 brake system general, technical data vehicle data sticker pr number allocation the production relevant no. (pr. No.) on the vehicle data label describes which brake system is installed in the vehicle. Example: 1. Rear brakes - 1kd...

  • Page 169: Brake System

    Brake system vw golf & gti quick reference specification book • september 2012 157 front brakes engine version pr number front wheel brake 2.0l - 103 kw tdi 1zp fn 3 (15”) 2.5l - 125 kw 2.0l - 147 kw t- fsi 1ll/1zb fn 3 (16”) rear brakes engine version pr number rear wheel brake 2.0l - 103 kw tdi 1k...

  • Page 170: Front Brakes

    158 vw golf & gti quick reference specification book • september 2012 front brakes item pr number 1ze/1zp 1 brake caliper fn 3 (15”) 2 brake pad thickness mm 14 brake pad wear limit without back plate mm 2 3 brake disc diameter in mm 288 brake disc thickness mm 25 brake disc wear limit mm 22 4 brake...

  • Page 171: Brake System

    Brake system vw golf & gti quick reference specification book • september 2012 159 item pr number 1lj/1zd/1ll/ 1lv/1za/1zb 1 brake caliper fn 3 (16”) 2 brake pad thickness mm 14 brake pad wear limit without back plate mm 2 3 brake disc diameter in mm 312 brake disc thickness mm 25 brake disc wear li...

  • Page 172: Rear Brakes C38

    160 vw golf & gti quick reference specification book • september 2012 rear brakes c38 item pr number 1kd 1 brake caliper c 38 (15”) 2 brake pad thickness mm 11 brake pad wear limit without back plate mm 2 3 brake disc diameter in mm 253 brake disc thickness mm 10 brake disc wear limit 8 4 brake cali...

  • Page 173: Brake System

    Brake system vw golf & gti quick reference specification book • september 2012 161 anti-lock brake system (abs) fastener tightening specifications component nm abs control module-to-hydraulic unit bolt 1) - abs mark 70 (abs/asr) 5.5 - abs mark 60 ec (abs/edl/asr/esp) 2 + 0.8 abs hydraulic unit-to-br...

  • Page 174: Hydraulic Components

    162 vw golf & gti quick reference specification book • september 2012 hydraulic components fastener tightening specifications component nm brake booster-to-pedal assembly nut 1) 25 brake caliper bleeder valve 10 brake line 14 brake lamp switch-to-master cylinder bolt 5 brake system vacuum pump-to-br...

  • Page 175: Body

    Body vw golf & gti quick reference specification book • september 2012 163 body air gap body dimensions body, front component mm a 4.5 ± 0.5 b 3.5 ± 0.5 c 0.5 ± 0.5 d 3.5 ± 0.5 e 5.0 ± 0.5.

  • Page 176: Body, Center

    164 vw golf & gti quick reference specification book • september 2012 body, center component mm a 4.5 ± 0.5 b 0.0 - 1.0 c 3.5 ± 0.5 d 4.5 ± 0.5 e 0.0 - 1.0 f 3.5 ± 0.5.

  • Page 177: Body

    Body vw golf & gti quick reference specification book • september 2012 165 body, rear component mm a 4.0 ± 1.0 b 5.0 ± 0.5 c 2.0 ± 1.0 d 5.0 ± 0.5 e 1.0 ± 0.5 f 4.5 ± 0.5.

  • Page 178: Body Exterior

    166 vw golf & gti quick reference specification book • september 2012 body exterior bulkhead, front fender tightening specifications component nm bulkhead bolts 25 front fender bolts 6 front fender brace bolts 6 lock carrier tightening specifications component nm air guide channel bolts 2 angle brac...

  • Page 179: Body

    Body vw golf & gti quick reference specification book • september 2012 167 tunnel bridge, plenum chamber tightening specifications component nm plenum chamber bulkhead bolts/nuts 8 tunnel bridge bolts 20 front hood tightening specifications component nm front hood hinge bolt/nut 22 hood latch bolts ...

  • Page 180

    168 vw golf & gti quick reference specification book • september 2012 sunroof tightening specifications component nm slotted guide rail bolts 5 sunroof insulation unit bolts 8 sunroof motor screws 3.5 sunroof spring glider bolts 1.8 sunshade motor screws 3.5 front bumper tightening specifications co...

  • Page 181: Body

    Body vw golf & gti quick reference specification book • september 2012 169 body interior storage compartments, covers and trim tightening specifications component nm center console nuts 1) 1.5 2.5 8 footwell trim bolts 1.5 glove compartment bolts 1.5 headliner frame bolts 2 instrument panel crossmem...

  • Page 182

    170 vw golf & gti quick reference specification book • september 2012 interior trim fastener tightening specifications component nm airbag emblem screw - screw 4 - nut 1.5 ashtray control module 9 ashtray screw 1.5 backrest adjuster screw 2.5 bracket for front seat support and operating lever 3.5 br...

  • Page 183: Heating &

    Heating & air conditioning vw golf & gti quick reference specification book • september 2012 171 heating, ventilation and air conditioning general, technical data refrigerant oil distribution component approximate % of total amount of oil in component a/c compressor 50 condenser 10 suction hose 10 e...

  • Page 184

    172 vw golf & gti quick reference specification book • september 2012 refrigerant r134a vapor pressure table temperature in °c (°f) pressure in bar (positive pressure) (psi) of r134a -45 (-49) -0.61 (-8.84) -40 (-40) -0.49 (-7.10) -35 (-31) -0.34 (-4.93) -30 (-22) -0.16 (-2.32) -25 (-13) 0.06 (0.87)...

  • Page 185: Heating &

    Heating & air conditioning vw golf & gti quick reference specification book • september 2012 173 heating, ventilation fastener tightening specifications component nm air intake grille flange nuts 2.5 ± 0.4 auxiliary heater heating element nut 9 ± 1 auxiliary heater heating element bolt 1.4 bracket 1...

  • Page 186: Air Conditioning

    174 vw golf & gti quick reference specification book • september 2012 air conditioning fastener tightening specifications component nm a/c compressor 25 ± 2 a/c line bracket-to-frame nut 1) 6 a/c line retainer screw 2) 3.5 a/c line-to-dash panel bracket nut 3) 20 a/c line-to-dash panel bracket retai...

  • Page 187: Electrical System

    Electrical system vw golf & gti quick reference specification book • september 2012 175 electrical system electrical equipment battery, starter, generator, cruise control fastener tightening specifications component fastener size nm a/c compressor mounting bolts 3) m8 23 accessory bracket-to-engine ...

  • Page 188

    176 vw golf & gti quick reference specification book • september 2012 windshield wiper/washer tightening specifications component nm front wiper arm mounting nuts 20 rear wiper arm mounting nut 12 telescopic cylinder for spray jets-to-front bumper cover 4.5 windshield and headlamp washer fluid reser...

  • Page 189: Electrical System

    Electrical system vw golf & gti quick reference specification book • september 2012 177 left e-box in engine compartment tightening specifications component fastener size nm central bolt e-box (2) - 9 nuts (1) m5 4 nuts (1) m6 6.

  • Page 190: Dtc Chart

    178 vw golf & gti quick reference specification book • september 2012 dtc chart engine codes cbfa fuel and air mixture, additional emission regulations dtc error message malfunction criteria and threshold value p000a intake camshaft position slow response bank 1 signal change > 8 crk ° for > 2.9 sec...

  • Page 191: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 179 dtc error message malfunction criteria and threshold value p0070 ambient air temperature sensor circuit ambient air temperature °c p0071 ambient air temperature sensor range/performance • difference in value between ect ...

  • Page 192

    180 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0112 intake air temperature sensor 1 circuit low input iat > 141.0 °c p0113 intake air temperature sensor 1 circuit high input iat p0116 engine coolant temperature sensor...

  • Page 193: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 181 dtc error message malfunction criteria and threshold value p0132 o2 sensor circuit (bank 1, sensor 1) high voltage vm > 3.25 v un > 4.40 v ia or ip > 7 v p0133 o2 circuit slow response (bank 1, sensor 1) signal dynamic s...

  • Page 194

    182 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p013a o2 sensor slow response rich to lean bank 1 sensor 2 • ewma filtered max differential transient time at fuel cutoff >= 0.5 sec. • number of checks, >= 3 p0140 o2 cir...

  • Page 195: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 183 dtc error message malfunction criteria and threshold value p0191 fuel rail pressure sensor circuit range/performance actual pressure > 20.6 mpa p0192 fuel rail pressure sensor circuit low input signal voltage p0201 injec...

  • Page 196

    184 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0245 turbocharger wastegate solenoid low signal voltage p0246 turbocharger wastegate solenoid high signal current > 2.2 to 4 a p025a fuel pump module control circuit open...

  • Page 197: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 185 dtc error message malfunction criteria and threshold value p2089 a camshaft position actuator control circuit high signal current > 2.2 a p2096 post catalyst fuel trim system too lean deviation lambda control p2097 post-...

  • Page 198

    186 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0327 knock sensor 1 circuit low • lower threshold or for signal range check • lower threshold p0328 knock sensor 1 circuit high • upper threshold > 1.00 v or for signal r...

  • Page 199: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 187 dtc error message malfunction criteria and threshold value p2309 ignition coil d primary control circuit low signal current > 24.0 ma p2310 ignition coil d primary control circuit high signal voltage > 5.1 - 7.0 v additi...

  • Page 200

    188 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p043f evaporative emission system leak detection reference orifice high flow engine off • evap pump current during reference measurement 15.0 ma engine on • evap pump curr...

  • Page 201: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 189 speed and idle control dtc error message malfunction criteria and threshold value p050a cold start idle air control system performance out of range low: • engine speed deviation rpm out of range high: • engine speed devi...

  • Page 202

    190 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0638 throttle actuator control range/performance • time to close to reference point > 6 sec. And • reference point 2.88% • tps 1 signal 0.40 - 0.60 v • tps 2 signal 4.20 ...

  • Page 203: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 191 dtc error message malfunction criteria and threshold value u0415 can communication with abs error • speed sensor initialization failed • speed sensor low voltage error failed • implausible message received u0422 invalid ...

  • Page 204

    192 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p13ea cold start ignition timing performance off idle difference between commanded spark timing vs. Actual value > 40% p150a engine off time performance difference between...

  • Page 205: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 193 dtc error message malfunction criteria and threshold value p2195 sensor signal biased/stuck lean bank 1 sensor 1 delta lambda of 2nd lambda control loop > 0.07 p2196 o2 sensor signal biased/ stuck rich bank 1 sensor 1 de...

  • Page 206

    194 vw golf & gti quick reference specification book • september 2012 additional emissions regulations dtc error message malfunction criteria and threshold value p2400 evaporative emission system leak detection pump control circuit/open signal voltage > 4.4 - 5.6 v p2401 evaporative emission system ...

  • Page 207: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 195 dtc error message malfunction criteria and threshold value p2414 o2 sensor exhaust sample error bank 1, sensor 1 threshold 1 • signal voltage 3.1 - 4.81 v threshold 2 • o2s signal 2.5 - 3.2 v p2431 secondary air injectio...

  • Page 208: Dtc Chart

    196 vw golf & gti quick reference specification book • september 2012 dtc chart engine codes ccta fuel and air mixture, additional emission regulations dtc error message malfunction criteria and threshold value p000a intake (a) camshaft position slow response bank 1 signal change p0010 intake (a) ca...

  • Page 209: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 197 dtc error message malfunction criteria and threshold value p0068 map/maf – throttle position correlation • plausibility with fuel system load calculation • plausibility with fuel system load calculation > 50% p0070 ambie...

  • Page 210

    198 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0111 intake air temperature sensor 1 circuit range/performance • difference in value iat - ect @ engine start (depending on engine off time) > 25 - 40 °k • difference in ...

  • Page 211: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 199 dtc error message malfunction criteria and threshold value p0131 o2 sensor circuit (bank 1, sensor 1) low voltage vm un ia or ip > 0.30 v p0132 o2 sensor circuit (bank 1, sensor 1) high voltage vm > 3 v un > 4 v ia or ip...

  • Page 212

    200 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0202 injector circuit/open - cylinder 2 • low side signal current • internal logic failure p0203 injector circuit/open - cylinder 3 • low side signal current • internal l...

  • Page 213: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 201 dtc error message malfunction criteria and threshold value p0261 cylinder 1 injector circuit low signal current p0262 cylinder 1 injector circuit high signal current > 14.70 a p0264 cylinder 2 injector circuit low signal...

  • Page 214: Ignition System

    202 vw golf & gti quick reference specification book • september 2012 ignition system dtc error message malfunction criteria and threshold value p0300 random misfire detected • emission threshold 1st interval misfire rate (mr), > 2.1% • catalyst damage misfire rate (mr), > 2.9% - 20% p0301 cylinder ...

  • Page 215: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 203 dtc error message malfunction criteria and threshold value p0340 camshaft position sensor a circuit (bank 1 or single sensor) cam adaption values out of range • > 20° kw • • difference of adapted and actual values > 9° k...

  • Page 216

    204 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2310 ignition coil d primary control circuit high signal voltage > 5.1 - 7.0 ma additional exhaust regulation dtc error message malfunction criteria and threshold value p...

  • Page 217: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 205 speed and idle control dtc error message malfunction criteria and threshold value p050a cold start idle air control system performance out of range low: • engine speed deviation rpm out of range high: • engine speed devi...

  • Page 218

    206 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0638 throttle actuator control range/performance - bank 1 • time to close to reference point > 0.56 sec. And • reference point 2.88% • time to close below reference point...

  • Page 219: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 207 dtc error message malfunction criteria and threshold value u0302 software incompatibility with transmission control module at vehicle ecm coded as mt vehicle u0402 invalid data received from gear shift control module a t...

  • Page 220

    208 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2101 throttle actuator control motor circuit range/ performance • duty cycle >80% • deviation throttle value angles vs. Calculated value 4 - 50% • ecm power stage no fail...

  • Page 221: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 209 dtc error message malfunction criteria and threshold value p2195 o2 sensor signal biased/ stuck lean (bank 1, sensor 1) delta lambda of 2nd lambda control loop > 0.07 p2196 o2 sensor signal biased/ stuck rich (bank 1, se...

  • Page 222

    210 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2294 fuel pressure regulator 2 control circuit • signal voltage 2.3 - 2.7 v or • signal pattern incorrect p2295 fuel pressure regulator 2 control circuit low signal volta...

  • Page 223: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 211 dtc chart engine codes cjaa fuel and air mixture, additional emission regulations dtc error message malfunction criteria and threshold value p000e fuel volume regulator control exceeded learning limit • number of learnin...

  • Page 224

    212 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0087 fuel rail/system pressure - too low • control deviation > 150 - 200 bar • exceeding absolute rail pressure limits bar or > 1950 bar • control deviation -300 bar p008...

  • Page 225: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 213 dtc error message malfunction criteria and threshold value p0112 intake air temperature sensor 1 circuit low input boost temperature sensor voltage p0113 intake air temperature sensor circuit high input boost temperature...

  • Page 226

    214 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0135 o2 sensor heater circuit bank 1 sensor 1 malfunction diagnostic signal from output driver sent or sensor element temperature 840 °c p0136 o2 sensor circuit bank 1 se...

  • Page 227: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 215 dtc error message malfunction criteria and threshold value p0191 fuel rail pressure sensor circuit range/performance • sensor voltage 613 mv • adaptation value out of limit 83% or > 130% p0192 fuel rail pressure sensor c...

  • Page 228

    216 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0204 cylinder 4 injector circuit open circuit diagnostic signal from output driver p0234 turbo charger overboost condition limit exceeded control deviation > -300 - -800 ...

  • Page 229: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 217 dtc error message malfunction criteria and threshold value p1005 torque difference cylinder 2 limiting value exceeded control error f (engine speed and desired torque) -50 to -30 nm or +50 to +30 nm p1006 torque differen...

  • Page 230

    218 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p13d6 sensor for internal pressure of cylinder 3 implausible signal • cylinder pressure sensor voltage 3.09 v or • deviation between min and max cylinder pressure # 3 20 b...

  • Page 231: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 219 dtc error message malfunction criteria and threshold value p13e1 sensor for internal pressure of cylinder 2 malfunction pressure based measured tdc vs. Crank position sensor for cyl. 2 out of range > 1.8 ca p13e2 sensor ...

  • Page 232

    220 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2008 intake manifold runner bank 1 control circuit low open load diagnostic signal from output driver p2009 intake manifold runner bank 1 control circuit low short to gro...

  • Page 233: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 221 dtc error message malfunction criteria and threshold value p2127 throttle/pedal position sensor e circuit low input sensor 2 voltage p2128 throttle/pedal position sensor d/e circuit voltage correlation sensor 2 voltage >...

  • Page 234

    222 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2294 fuel pressure regulator 2 control circuit open circuit diagnostic signal from output driver p2295 fuel pressure regulator 2 control circuit low grounded circuit diag...

  • Page 235: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 223 ignition system dtc error message malfunction criteria and threshold value p0300 random/multiple cylinder. Misfire detected • no rise in engine speed after fuel injection calculated based on values from last two engine r...

  • Page 236

    224 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0322 engine speed input circuit no signal no incremental signal. Internal self test failed. P0381 glow plug/heater indicator circuit receipt bit for lamp request not equa...

  • Page 237: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 225 dtc error message malfunction criteria and threshold value p0402 exhaust gas recirculation excessive flow detected control deviation > limit from map (engine speed, desired airflow) p0403 exhaust gas recirculation circui...

  • Page 238

    226 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0473 exhaust pressure sensor a high sensor voltage >4.9 v p0474 exhaust pressure sensor “a” circuit intermittent/erratic difference between modeled and measured different...

  • Page 239: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 227 dtc error message malfunction criteria and threshold value p242b exhaust gas temperature sensor circuit bank 1 sensor 3 range/performance • comparison of upstream turbine exhaust gas temp vs modeled temperature °c or • t...

  • Page 240: Speed and Idle Control

    228 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2463 diesel particulate filter - soot accumulation calculated particulate matter trap loading > 40 g p247a exhaust gas temperature out of range bank 1 sensor 3 control de...

  • Page 241: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 229 dtc error message malfunction criteria and threshold value p2563 turbocharger boost control position sensor circuit range/performance • position sensor signal voltage 4.5 v or • position sensor signal > 1.72 or p2564 tur...

  • Page 242

    230 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0604 internal control module random access memory (ram) error • write eeprom not possible • checksum error in 3 or more locations p0605 internal control module read only ...

  • Page 243: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 231 dtc error message malfunction criteria and threshold value p0670 glow plug module 1 control circuit electrical malfunction electrical circuit message from glow control unit = 3.44 v p0671 cylinder 1 glow plug circuit q10...

  • Page 244

    232 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value u0121 lost communication with anti-lock brake system (abs) control module no messages received from abs module u0146 lost communication with gateway “a” fault message from...

  • Page 245: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 233 dtc chart engine codes crza fuel and air mixture, additional emission regulations dtc error message malfunction criteria and threshold value p000a camshaft position slow response difference between target and actual posi...

  • Page 246

    234 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0100 mass air flow circuit fault maf sensor signal 0 µs p0101 mass air flow circuit performance mass air flow vs. • upper threshold model • lower threshold model kg/h • l...

  • Page 247: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 235 dtc error message malfunction criteria and threshold value p0122 pedal position sensor a circuit low input signal voltage p0123 pedal position sensor a circuit high input signal voltage > 4.81 v p013a o2 sensor slow resp...

  • Page 248

    236 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0137 o2 circuit low voltage (bank 1, sensor 2) • signal voltage 3 sec. • difference with/without load pulse p0138 o2 circuit high voltage (bank 1, sensor 2) signal voltag...

  • Page 249: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 237 dtc error message malfunction criteria and threshold value p0221 pedal position sensor circuit performance • tps 1 - tps 2 > 6.30% • actual tps 2 calculated value > tps 1 calculated value • tps 2 – calc. Value > 9.00% p0...

  • Page 250

    238 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p12a1 fuel rail pressure sensor inappropriately low • pressure control activity > 0.20 mpa • fuel trim activity • difference between actual pressure vs target pressure -16...

  • Page 251: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 239 ignition system dtc error message malfunction criteria and threshold value p0300 random misfire detected • emission threshold 1st interval misfire rate (mr), > 3% • catalyst damage misfire rate (mr), > 2% - 15% p0301 cyl...

  • Page 252

    240 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0333 knock sensor 2 circuit high input signal range check upper threshold 4.5 to 30 p0341 camshaft position sensor circuit performance • signal pattern incorrect • defect...

  • Page 253: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 241 additional exhaust regulation dtc error message malfunction criteria and threshold value p0420 catalyst system efficiency below threshold front: • oxygen storage capacity (osc) vs osc of borderline catalyst • front catal...

  • Page 254: Speed and Idle Control

    242 vw golf & gti quick reference specification book • september 2012 speed and idle control dtc error message malfunction criteria and threshold value p050a cold start idle air control system performance out of range low: • engine speed deviation rpm out of range high: • engine speed deviation > 80...

  • Page 255: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 243 dtc error message malfunction criteria and threshold value p0643 sensor reference voltage a circuit high signal voltage > 5 to 5.4 v p0651 sensor reference voltage b circuit signal voltage deviation > +/- 0.3 v p0652 sen...

  • Page 256

    244 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value u0155 can instrument cluster can messages not received u0415 can communication with abs error • speed sensor initialization failed • speed sensor low voltage error failed ...

  • Page 257: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 245 dtc error message malfunction criteria and threshold value p2089 a camshaft position actuator control circuit high signal current > 2.2 a p2096 post catalyst fuel trim system too lean deviation lambda control p2097 post ...

  • Page 258

    246 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2243 o2 sensor reference voltage circuit open (bank 1, sensor 1) • o2s signal front internal resistance > 1000 ohms • o2s signal front > 3.25 v and internal resistance > ...

  • Page 259: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 247 dtc error message malfunction criteria and threshold value p2403 evaporative emission system leak detection pump sense circuit/open low signal voltage > 0.5 sec. P2404 evaporative emission system leak detection pump sens...

  • Page 260: Dtc Chart

    248 vw golf & gti quick reference specification book • september 2012 dtc chart engine codes cbta, cbua fuel and air mixture, additional emission regulations dtc error message malfunction criteria and threshold value p000a intake camshaft position slow response bank 1 • difference between target and...

  • Page 261: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 249 dtc error message malfunction criteria and threshold value p0042 o2 sensor heater control circuit bank 1 sensor 3 (cbua only) heater voltage 2.34 to 3.59 v p0043 o2 sensor heater control circuit bank 1 sensor 3 low (cbua...

  • Page 262

    250 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0117 engine coolant temperature sensor 1 circuit low input • ect >140 °c p0118 engine coolant temperature sensor 1 circuit high input ect p0121 accelerator pedal position...

  • Page 263: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 251 dtc error message malfunction criteria and threshold value p0137 o2 circuit low voltage (bank 1, sensor 2) • cold condition: signal voltage 3 sec. • difference of sensor voltage with and without load pulse 0.01 v p0138 o...

  • Page 264

    252 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0146 o2 sensor circuit no activity detected bank 1 sensor 3 • signal voltage .40 to .60 v for > 3 sec. • voltage difference between load pulse and no load pulse >= 2.80 v...

  • Page 265: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 253 dtc error message malfunction criteria and threshold value p2088 “a” camshaft position actuator control circuit low - bank 1 short to ground, signal voltage 0.0 to 3.25 v p2089 “a” camshaft position actuator control circ...

  • Page 266

    254 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2243 o2 sensor reference voltage circuit open bank 1, sensor 1 • o2s signal front > 4.70 v and internal resistance > 950 Ω • o2s signal front internal resistance > 950 Ω ...

  • Page 267: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 255 dtc error message malfunction criteria and threshold value p2307 ignition coil c primary control circuit high • signal voltage > 5.1 - 7.0 ma p2309 ignition coil d primary control circuit low • signal current > 24 ma p23...

  • Page 268: Ignition System

    256 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p2414 o2 sensor exhaust sample error bank 1, sensor 1 • threshold 1 • signal voltage 3.1 to 4.77 v • threshold 2 • signal voltage 2.5 to 3.06 v p2431 secondary air injecti...

  • Page 269: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 257 dtc error message malfunction criteria and threshold value p0302 cylinder 2 misfire detected • emission threshold 1st interval misfire rate (200 rev misfire rate) > 2.5% • emission threshold misfire rate (1000 rev misfir...

  • Page 270

    258 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value p0332 knock sensor 2 circuit low input • lower threshold • signal range check 5.60 v p0333 knock sensor 2 circuit high input • upper threshold > 1 v • signal range check >...

  • Page 271: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 259 dtc error message malfunction criteria and threshold value p0420 catalyst system efficiency below threshold • oxygen storage capacity (osc) vs osc value of borderline catalyst p043e evaporative emission system leak detec...

  • Page 272: Speed and Idle Control

    260 vw golf & gti quick reference specification book • september 2012 speed and idle control dtc error message malfunction criteria and threshold value p0501 vehicle speed sensor range/ performance • vehicle speed p0503 vehicle speed sensor intermittent high signal • vehicle speed > 325 km/h p0506 i...

  • Page 273: Dtc Chart

    Dtc chart vw golf & gti quick reference specification book • september 2012 261 dtc error message malfunction criteria and threshold value p0638 throttle actuator control range/performance - bank 1 • time to close to reference point > 0.6 sec. And reference point = 2.88% or • tps 1 signal voltage, n...

  • Page 274

    262 vw golf & gti quick reference specification book • september 2012 dtc error message malfunction criteria and threshold value u0121 lost communication with anti-lock brake system (abs) control module • no can messages received u0146 lost communication with gateway “a” •no can messages received u0...

  • Page 275

    Volkswagen group of america works constantly to develop and improve its products. We must therefore reserve the right to change or update any part of this technical manual at any time. No legal commitment can therefore be derived from the information, illustrations or descriptions in this manual. Th...

  • Page 276

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