Page 1 2013 Golf, GTI & Golf R Quick Reference Specification Book...
Page 3: Table Of Contents
2013 Volkswagen Golf & GTI Quick Reference Specification Book TaBle of ConTenTS General Information ............1 Decimal and Metric Equivalents ...........1 Tightening Torque ..............2 Warnings and Cautions ............4 Vehicle Identification ............. 9 Vehicle Identification Number (VIN) Location ......9 VIN Decoder ................10 VIN on Longitudinal Member Extension ........
Page 4 Cylinder Head, Valvetrain – 2.0L CJAA (TDI) .....26 Fastener Tightening Specifications ........26 Valve Dimensions ..............27 Compression Pressures ............27 Cylinder Head Cover Tightening Specifications ....28 Cylinder Head Tightening Specifications .......29 Bearing Frame Tightening Specifications ......30 Lubrication – 2.0L CJAA (TDI) ..........31 Fastener Tightening Specifications ........31 Cooling System –...
Page 5 Compression Pressures ............48 Cylinder Head Tightening Specifications .......49 Cylinder Head Cover Tightening Specifications ....50 Crankcase Ventilation Tightening Specification .....51 Upper Timing Chain Cover Tightening Specifications ...51 Lower Timing Chain Cover Tightening Specifications with 15 Bolts ..............52 Lower Timing Chain Cover Tightening Specifications with 8 Bolts ..............53 Lubrication –...
Page 6 Fastener Tightening Specifications ........69 Crankshaft Dimensions ............70 Piston Ring End Gaps ............70 Piston Ring Clearance ............70 Piston and Cylinder Dimensions ..........70 Accessory Assembly Bracket Tightening Specification ..71 Sealing Flange Tightening Specifications ......72 Cylinder Head, Valvetrain – 2.0L CRZA ......73 Fastener Tightening Specifications ........73 Valve Dimensions ..............74 Compression Pressures ............74 Cylinder Head Tightening Specifications .......75...
Page 7 Crankshaft, Cylinder Block – 2.5L CBTA, CBUA ....90 Crankshaft Upper Bearing Shell (for Cylinder Block) Allocation .................90 Crankshaft Lower Bearing Shell (for Bearing Cap) Allocation .................91 Fastener Tightening Specifications ........92 Crankshaft Dimensions ............93 Piston and Cylinder Dimensions ..........93 Piston Ring End Gap .............94 Piston Ring Clearance ............94 Cylinder Head, Valvetrain –...
Page 8 Clutch – 0A4 ..............109 Fastener Tightening Specifications ........109 Controls, Housing – 0A4 ...........110 Fastener Tightening Specifications ........110 Transmission to Engine Tightening Specifications ....111 Transmission Mount Bracket to Transmission Bolt Tightening Specification ..........112 Transmission Mount to Transmission Mount Bracket Bolt Tightening Specification ..........
Page 9 Gears, Hydraulic Controls – 09G ........133 Fastener Tightening Specifications ........133 Transmission Fluid Pan Tightening Specification ....134 Direct Shift Gearbox (DSG) Transmission – 02E ..135 General, Technical Data ...........135 Identification on Transmission ..........135 Transmission Allocation Codes ..........137 Controls, Housing (DSG) – 02E ........138 Fastener Tightening Specifications ........138 Mechatronic Tightening Specifications ........139 Oil Pump Tightening Specifications...
Page 10 Anti-lock Brake System (ABS) ..........161 Fastener Tightening Specifications ........161 Mechanical Components ..........161 Fastener Tightening Specifications ........161 Hydraulic Components .............162 Fastener Tightening Specifications ........162 Body ................163 Air Gap Body Dimensions ..........163 Body, Front ................163 Body, Center ................164 Body, Rear ................165 Body Exterior ..............166 Bulkhead, Front Fender Tightening Specifications ....166 Lock Carrier Tightening Specifications ........166...
Page 11 Electrical System ............175 Electrical Equipment ............175 Battery, Starter, Generator, Cruise Control Fastener Tightening Specifications ..........175 Windshield Wiper/Washer Tightening Specifications ...176 Exterior Lights, Switches Tightening Specifications ....176 Interior Lights, Switches Tightening Specifications ....176 Wiring Tightening Specification ...........176 Left E-box in Engine Compartment Tightening Specifications ..............177 DTC Chart ..............
Page 12 DTC Chart ..............233 Engine Codes CRZA ............233 Fuel and Air Mixture, Additional Emission Regulations ..233 Ignition System ..............239 Additional Exhaust Regulation ..........241 Speed and Idle Control ............242 Control Module and Output Signals ........242 Fuel and Air Ratios Control Module ........244 Additional Emissions Regulations ........246 DTC Chart ..............
Page 13: General Information
GENERAL INFORMATION Decimal and Metric Equivalents Distance/Length To calculate: mm x 0.03937 = in. 0.002 0.00008 0.01 0.0004 0.004 0.04 0.004 0.00016 0.02 0.0008 0.008 0.08 0.006 0.00024 0.03 0.0012 0.012 0.12 0.008 0.00031 0.04 0.0016 0.016 0.16 0.010 0.00039 0.05 0.0020 0.020...
Page 14: Tightening Torque
Tightening Torque Nm-to-lb·ft (ft·lb) To calculate: Nm x 0.738 = lb·ft lb·ft lb·ft lb·ft (ft·lb) (ft·lb) (ft·lb) VW Golf & GTI Quick Reference Specification Book • Sepetember 2012...
Page 15 Nm-to-lb·in (in·lb), kg·cm To calculate: Nm x 8·85 = lb·in • Nm x 10.20 = kg·cm lb·in lb·in kg·cm kg·cm (in·lb) (in·lb) N·cm-to-lb·in (in·lb), kg·cm To calculate: N·cm x 0.089 = lb·in • N·cm x 0.102 = kg·cm lb·in lb·in N·cm kg·cm N·cm...
Page 16: Warnings And Cautions
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 lb·in lb·in kg·cm N·cm kg·cm N·cm (in·lb) (in·lb) 1079 1177 1275 1373 1471 1569 1667 1765 1863 1961 2059 2157 2256 2354 2452 Warnings and Cautions WARNINGS •...
Page 17 • 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 crushed by heavy parts. • Tie back long hair. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines.
Page 18 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 trapped in the cells and causes the battery to explode.
Page 19 • 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 installing jack stands. • Battery acid (electrolyte) can cause severe burns. Flush contact area with water, seek medical attention.
Page 20 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 disconnecting the battery cables. •...
Page 21: Vehicle Identification
VEHICLE IDENTIFICATION Vehicle Identification Number (VIN) Location Æ The VIN ( ) is on the left side of the vehicle in the area of the windshield wiper mount. It is visible from the outside. VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 22: Vin Decoder
VIN Decoder 2013 Volkswagen VIN Decoder (except Routan) Series: H= CC V6 Lux w/Auto Trans, A= CC Sport w/Man Trans, D = 2013 Beetle 2.5L TDI w/5 Spd Golf 2dr w/5 Spd Manual, Manual, GTI 4dr w/Auto Passat S, Tiguan w/Auto...
Page 23: Vin On Longitudinal Member Extension
VIN on Longitudinal Member Extension The Vehicle Identification Number (VIN) is located on the longitudinal member extension ( Æ VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 24: Vehicle Data Label
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. VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 25: Sales Codes
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 5-speed manual 6-speed manual 6-speed Direct Shift Gearbox (DSG) 6-speed automatic VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 26: Vehicle Lifting
VEHICLE LIFTING Hoist and Jack Mounting Points Front Position the support plate in the side member vertical reinforcement area ( Æ VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 27: Rear
Rear Position the support plate in the side member vertical reinforcement area ( Æ VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 28: Engine Mechanical - 2.0L Cjaa (Tdi)
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 are also located on a label found on the toothed belt guard. VW Golf &...
Page 29: Engine Data
Engine Data Identification code CJAA Manufactured From 09.09 Emission values in accordance with ULEV2 Standard Displacement liter Output kW at RPM 103 @ 4200 Torque Nm at RPM 320 @ 1750 to 2500 Bore diameter mm 81.0 Stroke 95.5 Valves per cylinder Compression ratio 16.5 Fuel...
Page 30: Engine Assembly - 2.0L Cjaa (Tdi)
Engine Assembly - 2.0L CJAA (TDI) Fastener Tightening Specifications Component Fastener size Bolts and nuts M12 collar bolt tightening specification: 75 Nm. Engine Mount Tightening Specifications Component Bolts A 40 plus an additional 90° (¼ turn) Bolts B 60 plus an additional 90°...
Page 31: Transmission Mount Tightening Specifications
Transmission Mount Tightening Specifications Component Bolts 1 40 plus an additional 90° (¼ turn) Bolts 2 60 plus an additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 32: Pendulum Support Tightening Specifications
Pendulum Support Tightening Specifications Component Bolt A 40 plus an additional 90° (¼ turn) Bolt B 60 plus an additional 90° (¼ turn) Bolt C 100 plus an additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 33: Engine Mount Bracket Tightening Specifications
Engine Mount Bracket Tightening Specifications Step Component Tighten bolts 1 through 3 in sequence Hand-tighten Tighten bolts 1 through 3 in sequence Tighten bolts 1 through 3 in sequence an additional 180° (½ turn) Replace fastener(s). WARNING Always use the correct tightening sequence and specifications for the engine mount bracket bolts.
Page 34: Crankshaft, Cylinder Block - 2.0L Cjaa (Tdi)
Crankshaft, Cylinder Block – 2.0L CJAA (TDI) Fastener Tightening Specifications Component Air conditioning compressor-to-accessory bracket bolt Bracket-to-oil filter bracket bolt Camshaft sprocket-to-camshaft bolt 20 plus an additional 45° (⅛ turn) Center toothed belt guard-to-lower toothed belt guard bolt Connecting piece-to-cylinder block bolt Connecting rod cap-to-connecting rod bolt 30 plus an 1) 4)
Page 35 Fastener Tightening Specifications (cont’d) Component Protective plate-to-rear toothed belt guard bolt Rear toothed belt guard-to-cylinder block bolt Ribbed belt tensioner-to-accessory bracket bolt 20 plus an additional 180° (½ turn) Sealing flange-to-cylinder block bolt Toothed belt idler pulley-to-cylinder block bolt 50 plus an additional 90°...
Page 36: Accessory Bracket Tightening Specifications
Accessory Bracket Tightening Specifications Step Component Tighten bolts 1 through 6 in sequence Hand-tighten Tighten bolts 1 through 6 in sequence Tighten bolts 3 and 4 an additional 45° (⅛ turn) Tighten bolts 1, 2, 5 and 6 an additional 90°...
Page 37: Crankshaft Dimensions
Crankshaft Dimensions Honing Crankshaft bearing Connecting rod bearing dimension in mm pin diameter in mm pin diameter in mm Basic dimension 54.000 -0.022 50.900 -0.022 -0.042 -0.042 Piston and Cylinder Dimensions Honing Piston diameter Cylinder bore dimension in mm diameter Basic dimension 80.960 81.010...
Page 38: Cylinder Head, Valvetrain - 2.0L Cjaa (Tdi)
Cylinder Head, Valvetrain – 2.0L CJAA (TDI) Fastener Tightening Specifications Component Adapter to cylinder head bolt Camshaft Position (CMP) sensor-to-cylinder head bolt Camshaft sprocket-to-camshaft bolt 20 plus an additional 90° (¼ turn) Center toothed belt guard to lower toothed belt guard bolt Coolant pump to cylinder block bolt Crankshaft toothed belt gear to crankshaft bolt 120 plus an...
Page 39: Valve Dimensions
Valve Dimensions Dimension Intake valve Exhaust valve Diameter a 26.60 26.00 Diameter b 5.940 5.940 ∠° 99.30 99.10 α NOTE: Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted. Compression Pressures Wear limit Difference between Bar positive pressure Bar positive pressure cylinders...
Page 40: Cylinder Head Cover Tightening Specifications
Cylinder Head Cover Tightening Specifications Step Component Tighten bolts 1 through 7 in sequence Hand-tighten Tighten bolts 1 through 7 in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 41: Cylinder Head Tightening Specifications
Cylinder Head Tightening Specifications Step Component Tighten bolts 1 through 10 in sequence Tighten bolts 1 through 10 in sequence Tighten bolts 1 through 10 in sequence an additional 90° (¼ turn) Tighten bolts 1 through 10 in sequence an additional 90°...
Page 42: Bearing Frame Tightening Specifications
Bearing Frame Tightening Specifications Step Component Tighten bolts and nuts 1 through 24 in sequence Hand-tighten Tighten bolts and nuts 1 through 24 in sequence The bearing frame must be in contact with the entire contact surface of the cylinder head.
Page 43: Lubrication - 2.0L Cjaa (Tdi)
Lubrication – 2.0L CJAA (TDI) Fastener Tightening Specifications Component Chain tensioner with tensioning rail-to-cylinder block bolt Oil filter bracket cap Oil filter bracket connection Oil filter bracket cover Oil filter bracket-to-cylinder block bolt 15 plus an 1) 2) additional 90° (¼...
Page 44: Cooling System - 2.0L Cjaa (Tdi)
Cooling System – 2.0L CJAA (TDI) Fastener Tightening Specifications Component 4/2 way valve with thermostat-to-cylinder block bolt Coolant expansion tank to body stud bolt Coolant fan shroud nut Coolant pump-to-cylinder block bolt Coolant reservoir-to-body stud bolt Cylinder block connecting piece bolt Engine pre-heater coolant pipe/engine pre-heater bracket to cylinder block bolt Radiator fan shroud bolt...
Page 45: Turbocharger - 2.0L Cjaa (Tdi)
Turbocharger – 2.0L CJAA (TDI) Fastener Tightening Specifications Component Adapter-to-connecting piece bolt Charge Air Cooler (CAC) mount bolt Charge air pipe-to-cylinder block bolt Charge air pipe-to-charge air hose clamp Charge air pressure sensor with intake air temperature sensor-to-charge air pipe bolt Connecting pipe-to-connecting piece bolt Connecting pipe-to-exhaust manifold nut Control line bracket-to-exhaust manifold stud nut...
Page 46 Fastener Tightening Specifications (cont’d) Component Control line bracket-to-particulate filter bolt Control line-to-Exhaust Gas Recirculation (EGR) housing Control line-to-particulate filter Exhaust Gas Recirculation (EGR) cooler-to-Exhaust Gas Recirculation (EGR) housing bolt Exhaust Gas Recirculation (EGR) filter-to-Exhaust Gas Recirculation (EGR) housing bolt Exhaust Gas Recirculation (EGR) filter-to-particulate filter securing clamp Exhaust Gas Recirculation (EGR) filter-to-turbocharger stud bolt nut...
Page 47: Ignition/Glow Plug System - 2.0L Cjaa (Tdi)
Ignition/Glow Plug System – 2.0L CJAA (TDI) Fastener Tightening Specifications Component Fuel line bracket-to-intake manifold bolt Glow plug Diesel Fuel Injection – 2.0L CJAA (TDI) Fastener Tightening Specifications Component Air duct-to-lock carrier bolt Connecting pipe-to-Exhaust Gas Recirculation (EGR) vacuum regulator solenoid valve with Exhaust Gas Recirculation (EGR) potentiometer bolt Exhaust Gas Recirculation (EGR) vacuum regulator solenoid valve with Exhaust Gas Recirculation (EGR)
Page 48: Engine Mechanical - 2.0L Cbfa, Ccta
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 behind the oil filter. VW Golf &...
Page 49: Engine Data
Engine Data Code letters CBFA CCTA Manufactured from 10.09 from 06.08 Emissions values SULEV ULEV 2 Displacement liter Output kW at RPM 147 @ 5100 147 @ 5100 Torque Nm at RPM 280 @ 1700 280 @ 1700 Bore diameter mm 82.5 82.5 Stroke...
Page 50: Engine Assembly - 2.0L Cbfa, Ccta
Engine Assembly – 2.0L CBFA, CCTA Fastener Tightening Specifications Component Fastener size Bolts and nuts Engine mount bracket-to-engine bolt 40 plus an additional 180° (½ turn) Engine mount-to-body bolt 40 plus an additional 90° (¼ turn) Engine mount-to-engine mount bracket 60 plus an bolt additional 90°...
Page 51: Crankshaft, Cylinder Block - 2.0L Cbfa, Ccta
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 (transmission side) of the cylinder block. VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 52 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 Black Yellow Blue White VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 53: Bearing Cap Bearing Shell Identification
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 Color of bearing Black Yellow Blue White VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 54: Fastener Tightening Specifications
Fastener Tightening Specifications Component Fastener size Air conditioning compressor-to-accessory bracket bolt Connecting rod bearing cap-to-connecting 30 plus an rod bolt additional 90° (¼ turn) 45 plus an additional 90° (¼ turn) Dual mass flywheel/drive plate-to- 60 plus an crankshaft bolt additional 90°...
Page 55: Crankshaft Dimensions
Crankshaft Dimensions Reconditioning Crankshaft bearing Connecting rod dimension in mm pin diameter bearing pin diameter Basic dimension 58.00 47.80 The preparation of worn crankshafts is not provided. Piston Ring End Gaps Piston ring Wear limit dimensions in mm Compression ring 0.20 to 0.40 Oil scraping ring 0.25 to 0.50...
Page 56: Accessory Assembly Bracket Tightening Specifications
Accessory Assembly Bracket Tightening Specifications Step Component Tighten bolts 1 through 5 in sequence Hand-tighten Tighten bolts 1 through 5 in sequence Tighten bolts 1 through 5 in sequence an additional 90° (¼ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 57: Sealing Flange Tightening Specifications
Sealing Flange Tightening Specifications Step Component Tighten bolts 1 through 8 in sequence Hand-tighten Tighten bolts 1 through 8 in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 58: Crankshaft Assembly Tightening Specifications
Crankshaft Assembly Tightening Specifications Step Component Tighten bolts 1 through 10 and A in sequence Hand-tighten Tighten bolts 1 through 10 in sequence Tighten bolts 1 through 10 in sequence an additional 90° (¼ turn) Tighten bolts A Tighten bolts A an additional 90°...
Page 59: Cylinder Head, Valvetrain - 2.0L Cbfa, Ccta
Cylinder Head, Valvetrain – 2.0L CBFA, CCTA Fastener Tightening Specifications Component Fastener size Balance shaft-to-cylinder block bolt Balance shaft timing chain guide rail-to- cylinder block guide pin Balance shaft timing chain tensioner-to- cylinder block Balance shaft timing chain tensioning rail- to-cylinder block guide pin Ball stud-to-cylinder head cover Bearing bracket-to-cylinder head bolt...
Page 60: Valve Dimensions
Fastener Tightening Specifications (cont’d) Component Fastener size Transport strap-to-cylinder head bolt Vacuum pump-to-cylinder head bolt Replace fastener(s). Engine code CBFA only. Left hand threads. Valve Dimensions Dimension Intake valve Exhaust valve Diameter a 33.85 ± 0.10 28.0 ± 0.1 Diameter b 5.98 ±...
Page 61: Cylinder Head Tightening Specifications
Cylinder Head Tightening Specifications Step Component Tighten bolts 1 through 5 in sequence Tighten bolts 1 through 5 in sequence an additional 90° (¼ turn) Tighten bolts 1 through 5 in sequence an additional 90° (¼ turn) Tighten bolts (Æ) an additional Tighten bolts (Æ) 90°...
Page 62: Cylinder Head Cover Tightening Specifications
Cylinder Head Cover Tightening Specifications Step Component Tighten bolts 1 through 6 in sequence in several Hand-tighten stages Tighten bolts 1 through 6 in sequence Tighten bolts 1 through 6 in sequence an additional 90° (¼ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 63: Crankcase Ventilation Tightening Specification
Crankcase Ventilation Tightening Specification Step Component Tighten bolts 1 through 10 in sequence Upper Timing Chain Cover Tightening Specifications Step Component Tighten bolts 1 through 5 in sequence, in Hand-tighten several stages Tighten bolts 1 through 5 in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 64: Lower Timing Chain Cover Tightening Specifications With 15 Bolts
Lower Timing Chain Cover Tightening Specifications with 15 Bolts Step Component Tighten bolts 1 through 15 in sequence Tighten bolts 1 through 15 in sequence an additional 45° (⅛ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 65: Lower Timing Chain Cover Tightening Specifications With 8 Bolts
Lower Timing Chain Cover Tightening Specifications with 8 Bolts Step Component Tighten bolts 1 through 8 in sequence Tighten bolts 1 through 8 in sequence an additional 45° (⅛ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 66: Lubrication - 2.0L Cbfa, Ccta
Lubrication – 2.0L CBFA, CCTA Fastener Tightening Specifications Component Fastener size Oil baffle-to-upper oil pan bolt Oil cooler-to-accessory bracket bolt Oil drain plug-to-lower oil pan Oil filter element-to-accessory bracket Oil intake pipe-to-oil pump bolt Oil pressure switch-to-accessory bracket Oil pump drive chain tensioner guide pin-to- cylinder block bolt Oil pump-to-upper oil pan bolt Upper Oil Pan Tightening Specifications...
Page 67: Oil Pan Tightening Specifications
Oil Pan Tightening Specifications Step Component Tighten bolts 1 through 20 in sequence Hand-tighten Tighten bolts 1 through 20 in sequence Tighten bolts 1 through 20 in sequence an additional 45° (⅛ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 68: Oil Separator Tightening Specification
Oil Separator Tightening Specification Step Component Tighten bolts 1 through 9 in sequence Cooling System – 2.0L CBFA, CCTA Fastener Tightening Specifications Component After run coolant pump bracket bolt After run coolant pump bracket-to-upper oil pan bolt Coolant expansion tank bolt Coolant fan shroud nut Coolant pump connecting piece bolt Coolant pump toothed belt guard bolt...
Page 69: Coolant Pump Tightening Specification
Coolant Pump Tightening Specification Step Component Tighten bolts 1 through 5 in sequence Fuel Supply – 2.0L CBFA, CCTA Fastener Tightening Specifications Component Fastener size Accelerator Pedal Position (APP) sensor with Accelerator Pedal Position 2 (APP2) sensor-to-body bolt Air filter housing-to-Leak Detection Pump (LDP) bracket bolt Evaporative Emission (EVAP) canister bolt...
Page 70: Turbocharger, G-Charger - 2.0L Cbfa, Ccta
Turbocharger, G-Charger – 2.0L CBFA, CCTA Fastener Tightening Specifications Component Charge Air Cooler (CAC) mounting bolt Charge air pipe bolt Charge air pipe clamp Charge air pressure sensor-to-charge air pipe bolt Coolant return pipe-to-turbocharger banjo bolt Coolant return pipe-to-turbocharger bolt Coolant supply pipe-to-cylinder block banjo bolt Coolant supply pipe-to-cylinder block bolt Coolant supply pipe-to-turbocharger banjo bolt...
Page 71: Turbocharger Tightening Specifications
Turbocharger Tightening Specifications Step Component Tighten bolts 1 through 5 in sequence Tighten bolts 1 through 5 in sequence Tighten bolts 1 through 5 in sequence Tighten bolts 1 through 5 in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 72: Exhaust System - 2.0L Cbfa, Ccta
Exhaust System – 2.0L CBFA, CCTA Fastener Tightening Specifications Component Clamping sleeve nut - Individual clamp - Continuous clamp Front exhaust pipe with catalytic converter-to-exhaust manifold/turbocharger nut 1) 3) Oxygen Sensor (O2S) Secondary Air Injection (AIR) pump motor bracket-to- underbody nut Secondary Air Injection (AIR) pump motor-to-bracket Secondary Air Injection (AIR) solenoid valve bolt Suspended mount-to-subframe bolt...
Page 73: Fastener Tightening Specifications
Fastener Tightening Specifications Component Fastener size Fuel rail adapter (VAS 6394/2) Fuel pressure sensor-to-pressure sensor tester (VAS 6394/1) Fuel pressure sensor-to-fuel rail Fuel supply line union nut to high pressure pump Fuel supply line union nut-to-fuel rail Fuel supply line connection-to-fuel rail High pressure fuel line connection-to-high pressure pump - With inner threads - With outer threads...
Page 74: Ignition - 2.0L Cbfa, Ccta
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 Intervals Rep. Gr. 03 Fastener Tightening Specifications Component Camshaft Position (CMP) sensor bolt...
Page 75: Engine Mechanical - 2.0L Crza
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 also stamped on the right side of the cylinder head and on the cylinder block.
Page 76: Engine Data
Engine Data Engine code CRZA Manufactured from 10.11 Emission values in accordance with ULEV II Displacement 1984 Output KW at RPM 188 @ 6000 Torque Nm at RPM 330 @ 2500 Bore diameter mm 82.5 Stroke 92.8 Compression ratio Valves per cylinder Research Octane Number (RON) Fuel injection, ignition Motronic MED 9.1...
Page 77: Engine Assembly - 2.0L Crza
Engine Assembly – 2.0L CRZA Fastener Tightening Specifications Component Fastener size Bolts and nuts Engine Mount Tightening Specifications Component Bolts A 20 plus an additional 90° (¼ turn) Bolts B 40 plus an additional 90° (¼ turn) Bolts C 60 plus an additional 90°...
Page 78: Transmission Mount Tightening Specifications
Transmission Mount Tightening Specifications Component Bolts 1 40 plus an additional 90° (¼ turn) Bolts 2 60 plus an additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 79: Pendulum Support Tightening Specifications
Pendulum Support Tightening Specifications Component Bolts A with a strength category of 8.8 40 plus an additional 90° (¼ turn) Bolts A with a strength category of 10.9 50 plus an additional 90° (¼ turn) Bolt B 100 plus an additional 90°...
Page 80: Crankshaft, Cylinder Block - 2.0L Crza
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. The letters marked on the lower sealing surface of the cylinder block identify which bearing thickness must be installed in which location.
Page 81: Fastener Tightening Specifications
Fastener Tightening Specifications Component Air conditioning compressor-to-accessory bracket bolt Coolant pump-to-cylinder block bolt Coolant thermostat housing-to-cylinder block bolt Connecting rod bearing cap-to-connecting rod bolt 45 plus an additional 90° (¼ turn) Crankshaft bearing cap-to-cylinder block bolt 65 plus an additional 90° (¼...
Page 82: Crankshaft Dimensions
Crankshaft Dimensions Honing dimensions in Crankshaft bearing Connecting rod pin diameter bearing pin diameter Basic dimension 54.00 -0.017 47.80 -0.022 -0.037 -0.042 oversize 53.75 -0.017 47.55 -0.022 -0.037 -0.042 oversize 53.50 -0.017 47.30 -0.022 -0.037 -0.042 Stage III 53.25 -0.017 47.05 -0.022 -0.037...
Page 83: Accessory Assembly Bracket Tightening Specification
Accessory Assembly Bracket Tightening Specification Step Component Tighten bolts A through F in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 84: Sealing Flange Tightening Specifications
Sealing Flange Tightening Specifications Step Component Hand-tighten Tighten bolts (Æ) Tighten bolts (Æ) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 85: Cylinder Head, Valvetrain - 2.0L Crza
Cylinder Head, Valvetrain – 2.0L CRZA Fastener Tightening Specifications Component Camshaft adjuster-to-camshaft bolt 20 plus an additional 45° (⅛ turn) Camshaft adjustment valve 1-to-housing bolt Camshaft Position (CMP) sensor-to-cylinder head bolt Camshaft timing chain tensioner-to-cylinder block bolt Crankcase ventilation valve-to-cylinder head cover bolt Exhaust manifold stud bolt-to-cylinder head Guide frame-to-cylinder head bolt 8 plus an...
Page 86: Valve Dimensions
Valve Dimensions Dimension Intake valve Exhaust valve Diameter a 33.75 to 33.95 27.90 to 28.10 Diameter b 5.98 5.95 ∠° 103.97 101.87 α NOTE: Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted. Compression Pressures Wear limit Difference between Bar positive pressure...
Page 87: Cylinder Head Tightening Specifications
Cylinder Head Tightening Specifications Step Component Tighten bolts 1 through 10 in sequence Tighten bolts 1 through 10 in sequence an additional 90° (¼ turn) Tighten bolts 1 through 10 in sequence an additional 90° (¼ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 88: Cylinder Head Cover Tightening Specification
Cylinder Head Cover Tightening Specification Step Component Tighten bolts 1 through 14 in sequence in several stages VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 89: Lubrication - 2.0L Crza
Lubrication – 2.0L CRZA Fastener Tightening Specifications Component Chain tensioner with tensioning rail-to-cylinder block bolt Charge air pipe-to-oil pan bolt Engine oil cooler-to-oil filter adapter bolt Oil drain plug-to-lower oil pan Oil filter adapter-to-cylinder block bolt 15 plus an additional 90° (¼...
Page 90: Oil Pan Tightening Specifications
Oil Pan Tightening Specifications Step Component Tighten all the oil pan to cylinder block bolts in Hand-tighten sequence Hand-tighten Tighten oil pan to transmission bolts Æ Tighten all the oil pan to cylinder block bolts 1 Hand-tighten through 20 in sequence Tighten the oil pan to transmission bolts Æ...
Page 91: Cooling System - 2.0L Crza
Cooling System – 2.0L CRZA Fastener Tightening Specifications Component Coolant expansion tank-to-body stud bolt Coolant fan-to-fan shroud nut Coolant line bolt Coolant line-to-thermostat housing bolt Coolant pump-to-cylinder block bolt Coolant recirculation pump-to-bracket bolt Coolant recirculation pump line nut Radiator fan shroud bolt Radiator-to-lock carrier bolt Thermostat housing-to-cylinder block bolt Water connection-to-cylinder head bolt...
Page 92: Turbocharger, G-Charger - 2.0L Crza
Turbocharger, G-Charger – 2.0L CRZA Fastener Tightening Specifications Component Bracket-to-Charge Air Cooler (CAC) bolt Bracket-to-cylinder head nut 1) 3) Charge air pipe bolt Charge air pipe clamp Charge air pressure sensor-to-charge air pipe bolt Connection-to-turbocharger bolt Coolant return pipe bracket-to-cylinder head bolt Coolant return pipe-to-turbocharger banjo bolt Coolant return pipe-to-turbocharger bolt Coolant supply pipe-to-cylinder block banjo bolt...
Page 93: Exhaust System - 2.0L Crza
Exhaust System – 2.0L CRZA Fastener Tightening Specifications Component Clamping sleeve nut Cross member-to-underbody bolt Exhaust pipe with catalytic converter-to-exhaust manifold/turbocharger nut 1) 2) Oxygen Sensor (O2S) Suspended mount-to-subframe bolt Suspended mount-to-underbody bolt Replace fastener(s). Lubricate the stud bolts on the exhaust manifold/turbocharger with hot bolt paste (G 052 112 A3).
Page 94: Fastener Tightening Specifications
Fastener Tightening Specifications Component Adapter (VAS 6394/2)-to-fuel rail Fuel pressure sensor-to-pressure sensor tester (VAS 6394/1) Fuel pressure sensor-to-fuel rail Fuel rail-to-intake manifold bolt Heat shield-to-engine cover/upper air filter housing bolt High pressure pipe bracket bolt High pressure pipe union nut-to-high pressure pump High pressure pipe union nut-to-threaded connection High pressure pump-to-cylinder head bolt Intake air temperature sensor-to-intake manifold bolt...
Page 95: Ignition - 2.0L Crza
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 Maintenance Intervals, Rep. Gr. 03 Fastener Tightening Specifications Component Camshaft Position (CMP) sensor bolt Knock Sensor (KS) bolt...
Page 96: Engine Mechanical - 2.5L Cbta, Cbua
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 sticker with the engine code and serial number is applied to the cylinder head cover.
Page 97: Engine Data
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 SULEV Golf from MY 2010 Tier2/BIN5 (US SULEV coalition) Displacement...
Page 98: Cylinder Numbering
Cylinder Numbering Ignition sequence 1 - 2 - 4 - 5 - 3 VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 99: Engine Assembly - 2.5L Cbta, Cbua
Engine Assembly – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Fastener size Bolts and nuts Engine Mount Tightening Specifications Component Bolts 1 40 plus an additional 90° (¼ turn) Bolts 2 20 plus an additional 90° (¼ turn) Bolts 3 60 plus an additional 90°...
Page 100: Transmission Mount Tightening Specifications
Transmission Mount Tightening Specifications Component Bolts A 40 plus an additional 90° (¼ turn) Bolts B 60 plus an additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 101: Pendulum Support Tightening Specifications
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 Bolts A 40 plus an additional 90° (¼ turn) 10.9 50 plus an additional 90°...
Page 102: Crankshaft, Cylinder Block - 2.5L Cbta, Cbua
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 identify the bearing thicknesses. The letters marked on the lower sealing surface of the cylinder block identify which bearing thickness must be installed in which location.
Page 103: Crankshaft Lower Bearing Shell (For Bearing Cap) Allocation
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 identify bearing shell thickness. The allocation of the bearing shell for the bearing cap is identified by a series of letters on the crankshaft/ vibration damper pulley flange.
Page 104: Fastener Tightening Specifications
Fastener Tightening Specifications Component Accessory bracket-to-cylinder block bolt Air conditioning compressor-to-accessory bracket bolt Air conditioning compressor ribbed belt tensioner-to- accessory bracket bolt Axial bearing disc-to-cylinder block bolt Belt tensioner to accessory bracket Bracket-to-cylinder block bolt Brake booster vacuum pump-to-control housing cover bolt Connecting rod bearing cap-to-connecting rod bolt 30 plus an...
Page 105: Crankshaft Dimensions
Component Knock Sensor (KS)-to-cylinder block bolt Lower idler pulley with bracket-to-accessory bracket bolt Oil filter bracket-to-cylinder block bolt Oil pump drive chain tensioner-to-cylinder block bolt Oil pump sprocket-to-oil pump bolt 20 plus an additional 90° (¼ turn) Pressure relief valve Sealing flange-to-cylinder block bolt Shield-to-cylinder block bolt Tensioning rail pin-to-cylinder block...
Page 106: Piston Ring End Gap
Fastener Tightening Specifications (cont’d) Piston Ring End Gap Piston ring Wear limit dimensions in mm Compression rings 0.20 to 0.40 Oil scraping ring 0.25 to 0.50 Piston Ring Clearance Piston ring Wear limit dimensions in mm Compression rings 0.06 to 0.09 0.20 Oil scraping ring 0.03 to 0.06...
Page 107: Cylinder Head, Valvetrain - 2.5L Cbta, Cbua
Cylinder Head, Valvetrain – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Axial bearing disc-to-cylinder block bolt Camshaft adjustment valve 1-to-cylinder head bolt Camshaft clamp (T40070)-to-camshaft bolt Camshaft Position (CMP) sensor-to-cylinder head bolt Camshaft timing chain tensioner-to-cylinder head bolt Cap-to-cylinder head bolt Chain compartment cover-to-cylinder head bolt Coolant distribution housing-to-chain compartment cover bolt...
Page 108: Valve Dimensions
Valve Dimensions Dimension Intake valve Exhaust valve Diameter a 26.80 to 27.00 29.80 to 30.00 Diameter b 5.95 to 5.97 5.94 to 5.95 ∠° 104.84 to 105.34 103.64 to 104.14 α Compression Pressures Wear limit Difference between Bar positive pressure Bar positive pressure cylinders Bar positive pressure...
Page 109: Cylinder Head Cover Tightening Specification
Cylinder Head Cover Tightening Specification Step Component Tighten bolts 1 through 16 in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 110: Cylinder Head Tightening Specifications
Cylinder Head Tightening Specifications Step Component Tighten bolts 1 through 12 in sequence Tighten bolts 1 through 12 in sequence an additional 90° (¼ turn) Tighten bolts 1 through 12 in sequence an additional 90° (¼ turn) Tighten bolts 13 VW Golf &...
Page 111: Guide Frame Tightening Specifications
Guide Frame Tightening Specifications Step Component Tighten bolts 1 through 7 in sequence Tighten bolts 1 through 7 in sequence an additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 112: Lubrication - 2.5L Cbta, Cbua
Lubrication – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Cylinder block locking bolt Intake manifold support/oil dipstick guide tube-to-cylinder block bolt Lower oil pan-to-upper oil pan bolt Oil cooler-to-oil filter bracket bolt Oil filter bracket-to-cylinder block bolt Oil filter housing-to-oil filter bracket Oil intake pipe decoupling element-to-upper oil pan bolt Oil intake pipe-to-oil pump bolt Oil pan drain plug...
Page 113: Cooling System - 2.5L Cbta, Cbua
Cooling System – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Connecting piece-to-coolant thermostat housing bolt Coolant distribution housing-to-chain compartment cover Coolant fan shroud nut Coolant pipe bolt/nut Coolant pipe-to-coolant distribution housing nut Coolant pump-to-cylinder block bolt Coolant thermostat housing-to-cylinder block bolt Expansion tank-to-body bolt Front coolant pipe-to-accessory bracket bolt Oil filter bracket-to-cylinder block bolt...
Page 114: Exhaust System, Emission Controls - 2.5L Cbta, Cbua
Exhaust System, Emission Controls – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Clamp nut Exhaust manifold-to-cylinder head nut Front cross member-to-underbody nut Front exhaust pipe with catalytic converter-to-exhaust manifold nut Heat shield-to-exhaust manifold bolt Heat shield-to-front exhaust pipe with catalytic converter - Front bolts - Rear bolts Intake manifold support-to-cylinder block bolt...
Page 115: Secondary Air Injection Pipe Tightening Specifications
Secondary Air Injection Pipe Tightening Specifications Step Component Tighten bolts 1 through 3 in sequence Hand-tighten Tighten bolts 1 through 3 in sequence VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 116: Multiport Fuel Injection - 2.5L Cbta, Cbua
Multiport Fuel Injection – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Fuel rail-to-intake manifold bolt Intake manifold-to-cylinder head bolt Intake manifold support-to-cylinder block bolt Intake manifold support-to-intake manifold bolt Intake tube-to-lock carrier bolt Manifold Absolute Pressure (MAP) sensor-to-intake manifold bolt Mass Air Flow (MAF) sensor with Intake Air Temperature (IAT) sensor-to-intake tube bolt Oil dipstick guide tube-to-cylinder block bolt...
Page 117: Ignition - 2.5L Cbta, Cbua
Ignition – 2.5L CBTA, CBUA Fastener Tightening Specifications Component Camshaft Position (CMP) sensor bolt Knock Sensor (KS) bolt Spark plug Tightening specifications affect the function of the Knock Sensor (KS). Technical Data Engine codes BGP, BGQ CBTA and CBUA Ignition sequence 1-2-4-5-3 Spark plugs Refer to the Parts Catalog...
Page 118: Manual Transmission - 0A4
MANUAL TRANSMISSION – 0A4 General, Technical Data Transmission Identification Code letters and build date (1) manual transmission 0A4 (2). Manual transmission 0A4 (2). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 119 Transmission code letters and build date. Example: Identification code Month Year (2003) of manufacture NOTE: The transmission code letters are also included on the vehicle data label. VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 120: Codes Letters, Transmission Allocation And Capacities
Codes Letters, Transmission Allocation and Capacities Manual transmission 5 Speed (0A4) Identification codes Manufactured from 08.09 08.09 05.10 through 09.09 05.10 Allocation Engine 2.5L - 2.5L - 2.5L - 125 kW 125 kW 125 kW Ratio Final drive 62:17 61:18 61:18 = 3.647 = 3.778...
Page 121: Clutch - 0A4
Clutch – 0A4 Fastener Tightening Specifications Component Fastener size Ball stud-to-transmission Clutch pedal bolt nut Clutch pedal bracket-to-bulkhead nut Clutch slave cylinder-to-transmission bolt Guide sleeve-to-transmission bolt Hose/line assembly bracket-to-transmission bolt Impact bolster support-to-steering column bracket - Secured with two bolts - Secured with one bolt Pressure plate-to-flywheel bolt Transmission support-to-transmission...
Page 122: Controls, Housing - 0A4
Controls, Housing – 0A4 Fastener Tightening Specifications Component Fastener size gear drive gear-to-output shaft bolt 80 plus an additional 90° (¼ turn) gear selector fork base-to-transmission housing bolt gear shift jaw-to-selector fork with rail bolt Backup lamp switch-to-shift unit Cable bracket-to-transmission bolt Flange shaft bolt Gear shift unit with selector cover-to- transmission housing bolt...
Page 123: Transmission To Engine Tightening Specifications
Transmission to Engine Tightening Specifications Item Bolt Quantity M12 x 65 M12 x 170 M12 x 170 M10 x 65 M12 x 95 M6 x 8 Also for the starter to transmission. Small flywheel cover plate (not present here). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 124: Transmission Mount Bracket To Transmission Bolt Tightening Specification
Transmission Mount Bracket to Transmission Bolt Tightening Specification Step Component Hand-tighten Tighten bolts Æ 40 plus an Tighten bolts Æ additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 125: Transmission Mount To Transmission Mount Bracket Bolt Tightening Specification
Transmission Mount to Transmission Mount Bracket Bolt Tightening Specification Step Component Hand-tighten Tighten bolts Æ 60 plus an Tighten bolts Æ additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 126: Transmission Support To Transmission Bracket And Transmission Bolt Tightening Specification
Transmission Support to Transmission Bracket and Transmission Bolt Tightening Specification Step Component Hand-tighten Tighten bolts Æ 20 plus an Tighten bolts Æ additional 90° (¼ turn) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 127: Reverse Shaft Support To Transmission Housing Bolt Tightening Sequence And Specification
Reverse Shaft Support to Transmission Housing Bolt Tightening Sequence and Specification Step Component Tighten bolt a Æ Tighten bolt b (lower illustration Tighten bolt c VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 128: Gears, Shafts - 0A4
Gears, Shafts – 0A4 Fastener Tightening Specification Component Output shaft bearing support-to-clutch housing nut 25 plus an additional 90° (¼ turn) Replace fastener(s). Determining Shim Thickness Example: Bearing clearance measured Adjustment shim thickness value according to the table 1.21 mm 1.175 mm Adjustment Shim Table Bearing play...
Page 129 Bearing play Adjusting shim Measured value (mm) Thickness (mm) 1.275 to 1.229 1.250 1.300 to 1.324 1.275 1.325 to 1.349 1.300 1.350 to 1.374 1.325 1.375 to 1.399 1.350 1.400 to 1.424 1.375 1.425 to 1.449 1.400 1.450 to 1.474 1.425 1.475 to 1.499 1.450...
Page 130: Manual Transmission - 02Q
MANUAL TRANSMISSION – 02Q General, Technical Data Transmission Identification Code letters and build date (1) for the manual transmission 02Q (2). Manual transmission 02Q (2). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 131 Transmission code letters and build date ( Æ Example: Identification codes Month Year (2003) of manufacture VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 132: Codes Letters, Transmission Allocation And Capacities
Codes Letters, Transmission Allocation and Capacities Manual transmission 6 Speed Transmission (02Q) Identification codes Manufactured from 05.09 05.11 through 05.11 Allocation Engine 2.0L - 103 kW 2.0L - 103 kW turbo diesel turbo diesel Ratio: Z Final drive 69:20 = 3.450 69:20 = 3.450 Final drive 69:25 = 2.760...
Page 133: Clutch - 02Q
Clutch – 02Q Fastener Tightening Specifications Component Fastener size Clutch pedal mounting bracket-to-cross panel nut Clutch pedal-to-mounting bracket through bolt nut Impact bolster support to steering column bracket bolt - Secured with one bolt - Secured with two bolts Pressure plate-to-dual mass flywheel bolt Slave cylinder with release bearing-to-transmission bolt - Slave cylinder with metal housing (without locking fluid)
Page 134: Controls, Housing - 02Q
Controls, Housing – 02Q Transmission to Engine Tightening Specifications Item Bolt Quantity M12 x 55 With a long M8 threaded pin M12 x 55 With a short M8 threaded pin or M12 x 50 Without threaded pin M12 x 165 With an M8 threaded pin Also starter to transmission M10 x 105 M10 x 50...
Page 135: Adjustment Shim Table
Fastener Tightening Specifications (cont’d) Component Fastener size Cable mounting bracket-to-transmission bolt/nut Gear shift unit-to-transmission housing bolt Oil fill or drain plug - Multipoint socket head - Hex socket head Shift Housing to Body Nut Transmission housing-to-clutch housing bolt - Round head socket bolt = “to transmission 8 plus an build date 6 December 2006“...
Page 136: Rear Final Drive, Differential - 02Q
Rear Final Drive, Differential – 02Q Fastener Tightening Specifications Component Fastener Size Flange shaft to threaded piece bolt All Wheel Drive Fastener Tightening Specifications Component Fastener size Backup lamp switch-to-transmission housing Bevel box-to-clutch housing 40 plus an additional 90° (¼ turn) Bevel box-to-transmission 40 plus an additional 45°...
Page 137: Transmission Mount
Transmission Mount Item Bolt Quantity M10 x 21 M10 x 45 M10 x 62 VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 138: Brace Under Diaphragm
Brace under Diaphragm Item Bolt Quantity M10 x 21 M10 x 45 Step Component Tighten all bolts Hand-tighten Tighten bolts A Tighten bolts B VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 139: Transmission Bracket To Transmission
Transmission Bracket to Transmission 60 plus an additional Æ Tighten bolts 90° (¼ turn) 1) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 140: Identification On Transmission
Identification on Transmission 60 plus an additional Æ Tighten bolts 90° (¼ turn) 1) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 141: Automatic Transmission - 09G
AUTOMATIC TRANSMISSION – 09G General, Technical Data Identification on Transmission Æ Code letters ( VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 142: Code Letters, Assembly Allocation And Ratios
Code letter (1) indicates 6-speed automatic transmission 09G (2). Example: Identification codes Month Year (2002) of manufacture The transmission code letters are also included on the vehicle data labels. Code Letters, Assembly Allocation and Ratios If original replacement parts are needed for a repair, always pay attention to the transmission codes.
Page 143: Controls, Housing
Controls, Housing Fastener Tightening Specifications Component Inspection plug-to-transmission oil pan Multifunction transmission range switch-to-shift rod nut Multifunction transmission range switch-to-transmission bolt Selector lever-to-selector shaft nut Selector housing-to-body nut Selector lever cable adjustment bolt Selector lever and selector mechanism with selector lever cable-to-body bolt Transmission mount bracket-to-transmission bolt 40 plus an...
Page 144: Transmission To Engine Tightening Specifications
Transmission to Engine Tightening Specifications Component Fastener size Drive plate-to-converter Bolts 80 or 65, if using T10179 Bolts located in the lower flange Æ Alignment pins for centering VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 145: Gears, Hydraulic Controls - 09G
Gears, Hydraulic Controls – 09G Fastener Tightening Specifications VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 146: Transmission Fluid Pan Tightening Specification
Transmission Fluid Pan Tightening Specification Component Tighten the transmission pan bolts (Æ) diagonally in several steps VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 147: Direct Shift Gearbox (Dsg) Transmission - 02E
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 ( ) or under the transmission mount bracket. Æ VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 148 Example: Identification codes Month Year (2002) of manufacture The transmission code letters are also included on the vehicle data labels. VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 149: Transmission Allocation Codes
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 mount bracket (A) removal procedure. Transmission Allocation Codes If original replacement parts are needed for a repair, always pay attention to the transmission codes.
Page 150: Controls, Housing (Dsg) - 02E
Controls, Housing (DSG) – 02E Fastener Tightening Specifications Component Bevel box-to-transmission bolt Drive axle heat shield-to-bevel box bolt Mechatronic cover bolt Oil filter housing Oil pump cover bolt Overflow tube-to-transmission Selector housing-to-body nut Selector lever cable adjustment bolt Selector mechanism with selector lever and selector lever cable-to-body bolt Selector shaft lever nut Transmission drain plug...
Page 151: Mechatronic Tightening Specifications
Mechatronic Tightening Specifications Step Component Tighten bolts 1 through 10 in sequence Hand-tighten Tighten bolts 1 through 10 in sequence Tighten bolts 1 through 10 in sequence an additional 90° (¼ turn) 1) Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 152: Oil Pump Tightening Specifications Without Countersunk Bolt
Oil Pump Tightening Specifications Without Countersunk Bolt Component 5 plus an Oil pump bolts (Æ) with flat heads additional 90° (¼ turn) With Countersunk Bolt Component Oil pump countersunk bolt 3 remaining oil pump bolts 8 plus an additional 90° (¼...
Page 153: Oil Pump Cover Tightening Specifications
Oil Pump Cover Tightening Specifications Component Tighten bolts (Æ) in several steps in a diagonal sequence Replace fastener(s). VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 154: Transmission Mount Tightening Specifications
Transmission Mount Tightening Specifications Fastener Component 1 and 2 Install all new bolts and tighten Hand-tighten Transmission mount-to-body 40 plus an additional 90° (¼ turn) Transmission mount-to-transmission support 60 plus an additional 90° (¼ turn) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 155: Transmission To Engine Tightening Specifications
Transmission to Engine Tightening Specifications Component Fastener size Bolts 80 or 65 if using T10179 Bolts Æ Alignment pins for centering VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 156: Suspension, Wheels, Steering
SUSPENSION, WHEELS, STEERING Front Suspension Fastener Tightening Specifications Component Fastener size ABS wheel speed sensor-to-wheel bearing housing bolt Ball joint-to-control arm nut - With cast steel control arm - With sheet steel or aluminum control arm Ball joint-to-wheel bearing housing nut M12 x 1.5 Console-to-body bolt M12 x 1.5...
Page 157 Fastener Tightening Specifications (cont’d) Component Fastener size Mounting bracket-to-body bolt M12 x 1.5 70 plus an x 90 additional 90° (¼ turn) Mounting bracket-to-console bolt 50 plus an additional 90° (¼ turn) Pendulum support-to-subframe bonded M14 x 1.5 100 plus an rubber bushing bolt x 70 additional 90°...
Page 158: Rear Suspension
Rear Suspension Fastener Tightening Specifications Component Fastener size ABS wheel speed sensor-to-wheel bearing housing bolt Brake disc bolt Coupling rod-to-stabilizer bar nut Coupling rod-to-trailing arm nut Cover plate-to-wheel bearing housing bolt Constant Velocity (CV) joint boot clamp Drive axle-to-rear final drive flange shaft M8 x 48 bolt 1) 4)
Page 159 Fastener Tightening Specifications (cont’d) Component Fastener size Tie rod-to-subframe nut 90 plus an 1) 2) additional 90° (¼ turn) Tie rod-to-wheel bearing housing 1) 2) - Nut (FWD) 130 plus an additional 90° (¼ turn) - Bolt (AWD) 130 plus an additional 90°...
Page 160: Self-Leveling Suspension
Self-Leveling Suspension Fastener Tightening Specifications Component Fastener size Front body acceleration sensor-to-bracket bolt Front level control system sensor bolt M6 x 16 Front level control system sensor nut Left rear level control system sensor bolt M5 x 20 Rear body acceleration sensor-to-bracket mounting bolt Shock-to-body bolt M10 x 35...
Page 161: Wheel Alignment Data
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 Production Relevant No. G58, 2UC (PR. No.) Total toe 10’ ± 10′ 10’...
Page 162 Wheel Alignment Specified Values (cont’d) Front suspension Sport suspension Heavy duty with 18”/ suspension GTI North America with 18” wheels/ GTD with 18” wheels/ GTD with 18” wheels and adaptive chassis Production Relevant No. G02, G05, (PR. No.) G07,G33,G58, 2UC, Total toe 10’...
Page 163 Front Suspension Basic Suspension Basic Suspension with Adaptive with 18” Wheels and Chassis DCC Adaptive Chassis Production Relevant No. G01, G03 G01, G03 (PR. No.) Total toe (wheels not 10’ ± 10′ 10’ ± 10′ pressed) Camber (wheels in -37′ ± 30′ -37′...
Page 164 Front Suspension GTI without and with Golf R Adaptive Chassis Production Relevant No. G03, G08 G09, 1JR, G45, UB9 (PR. No.) Total toe (wheels not 10’ ± 10′ 10’ ± 10′ pressed) Camber (wheels in -44′ ± 30′ -45′ ± 30′ straight ahead position) Maximum permissible maximum 30’...
Page 165 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 30’ 30’ difference between both sides Total toe +10′ ± 12,5′ +10′...
Page 166: Steering
Rear suspension Basic suspension Basic suspension with adaptive chassis with 18” wheels and adaptive chassis Camber -1°20’ ± 30’ -1°20’ ± 30’ Maximum permissible 30’ 30’ difference between both sides Total toe +10′ ± 12.5′ +10′ ± 12.5′ (at prescribed camber) Maximum permissible 20’...
Page 167 Fastener Tightening Specifications (cont’d) Component Fastener size Steering column-to-steering gear bolt M8 x 35 Steering gear-to-subframe bolt 50 plus an additional 90° (¼ turn) Steering wheel-to-steering column bolt 30 plus an additional 90° (¼ turn) Subframe-to-body bolt 70 plus an additional 90°...
Page 168: Brake System
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 2. Front brakes - 1ZF There is a vehicle data label in the spare wheel well and also one in the customer Maintenance booklet.
Page 169: Front Brakes
Front Brakes Engine version PR number Front Wheel Brake 2.0L - 103 kW TDI 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 C 38 (15”) 2.0L - 147 kW T- FSI...
Page 170: Front Brakes
Front Brakes Item PR Number 1ZE/1ZP Brake caliper FN 3 (15”) Brake pad thickness Brake pad wear limit without back plate Brake disc Diameter in Brake disc thickness Brake disc wear limit Brake caliper, piston Diameter in VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 171 Item PR Number 1LJ/1ZD/1LL/ 1LV/1ZA/1ZB Brake caliper FN 3 (16”) Brake pad thickness Brake pad wear limit without back plate Brake disc Diameter in Brake disc thickness Brake disc wear limit Brake caliper, piston Diameter in VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 172: Rear Brakes C38
Rear Brakes C38 Item PR Number Brake caliper C 38 (15”) Brake pad thickness Brake pad wear limit without back plate Brake disc Diameter in Brake disc thickness Brake disc wear limit Brake caliper, piston Diameter in VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 173: Anti-Lock Brake System (Abs)
Anti-lock Brake System (ABS) Fastener Tightening Specifications Component ABS control module-to-hydraulic unit bolt - ABS Mark 70 (ABS/ASR) - ABS Mark 60 EC (ABS/EDL/ASR/ESP) 2 + 0.8 ABS hydraulic unit-to-bracket bolt ABS hydraulic unit bracket-to-body nut ABS speed sensor-to-wheel bearing housing bolt Brake lines-to-ABS unit Heat shield-to-ABS hydraulic unit bracket nut, ABS Mark 60 EC (ABS/EDL/ASR/ESP)
Page 174: Hydraulic Components
Hydraulic Components Fastener Tightening Specifications Component Brake booster-to-pedal assembly nut Brake caliper bleeder valve Brake line Brake lamp switch-to-master cylinder bolt Brake system vacuum pump-to-bracket bolt Brake system vacuum pump bracket-to-engine bolt Front brake caliper guide pins Heat shield/master cylinder to brake booster nut Master cylinder-to-brake booster nut Rear brake caliper-to-guide pin bolt Replace fastener(s).
Page 175: Body
BODy Air Gap Body Dimensions Body, Front Component 4.5 ± 0.5 3.5 ± 0.5 0.5 ± 0.5 3.5 ± 0.5 5.0 ± 0.5 VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 176: Body, Center
Body, Center Component 4.5 ± 0.5 0.0 - 1.0 3.5 ± 0.5 4.5 ± 0.5 0.0 - 1.0 3.5 ± 0.5 VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 177: Body, Rear
Body, Rear Component 4.0 ± 1.0 5.0 ± 0.5 2.0 ± 1.0 5.0 ± 0.5 1.0 ± 0.5 4.5 ± 0.5 VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 178: Body Exterior
Body Exterior Bulkhead, Front Fender Tightening Specifications Component Bulkhead bolts Front fender bolts Front fender brace bolts Lock Carrier Tightening Specifications Component Air guide channel bolts Angle bracket bolts Cross member bolts Guide piece bolts Lock carrier support bolts For bolt tightening clarification, refer to ElsaWeb, Lock Carrier Overview, items 13 and 14.
Page 179: Tunnel Bridge, Plenum Chamber Tightening Specifications
Tunnel Bridge, Plenum Chamber Tightening Specifications Component Plenum chamber bulkhead bolts/nuts Tunnel bridge bolts Front Hood Tightening Specifications Component Front hood hinge bolt/nut Hood latch bolts Striker pin bolts Rear Lid, Fuel Filler Door Tightening Specifications Component Angle bracket Fuel filler door unit screws Rear lid gas strut ball head pin 20 plus an additional 90°...
Page 180: Sunroof Tightening Specifications
Sunroof Tightening Specifications Component Slotted guide rail bolts Sunroof insulation unit bolts Sunroof motor screws Sunroof spring glider bolts Sunshade motor screws Front Bumper Tightening Specifications Component Bumper carrier bolts Bumper cover bolts 1.5-2 Side guide assembly bolts For bolt tightening clarification, refer to ElsaWeb, Front Bumper Carrier Overview, items 2, 3, and 4.
Page 181: Body Interior
Body Interior Storage Compartments, Covers and Trim Tightening Specifications Component Center console nuts Footwell trim bolts Glove compartment bolts Headliner frame bolts Instrument panel crossmember nuts Instrument panel trim bolts Roof grab handle bracket bolts Roof grab handle bracket bolts Storage compartment /ashtray bolts Steering column trim bolts Sun visor bolts...
Page 182: Interior Trim Fastener Tightening Specifications
Interior Trim Fastener Tightening Specifications Component Airbag emblem screw - Screw - Nut Ashtray control module Ashtray screw Backrest adjuster screw Bracket for front seat support and operating lever Bracket seat pan Drive side footwell cover screw Drive side left trim screw Drive side right trim screw Front door trim panel screw Front seat support...
Page 183: Heating, Ventilation And Air Conditioning
HEATING, VENTILATION AND AIR CONDITIONING General, Technical Data Refrigerant Oil Distribution Component Approximate % of total amount of oil in component A/C compressor Condenser Suction hose Evaporator Fluid reservoir VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 184: Refrigerant R134A Vapor Pressure Table
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) -20 (-4) 0.32 (4.64) -15 (5) 0.63 (9.13) -10 (14)
Page 185: Heating, Ventilation
Heating, Ventilation Fastener Tightening Specifications Component Air intake grille flange nuts 2.5 ± 0.4 Auxiliary heater heating element nut 9 ± 1 Auxiliary heater heating element bolt Bracket 8 ± 1 Bracket 9 ± 1.3 Cable bracket 4.5 ± 0.7 Center vent screw Footwell vent screw 1.5 ±...
Page 186: Air Conditioning
Air Conditioning Fastener Tightening Specifications Component A/C compressor 25 ± 2 A/C line bracket-to-frame nut A/C line retainer screw A/C line-to-dash panel bracket nut A/C line-to-dash panel bracket retainer screw A/C control head (Climatronic) bolt 9 ± 1.3 A/C control module J301 screws Air distribution door motor Air distribution housing bolts Aluminum support to cross member bolt...
Page 187: Electrical System
ELECTRICAL SySTEM Electrical Equipment Battery, Starter, Generator, Cruise Control Fastener Tightening Specifications Component Fastener size A/C compressor mounting bolts Accessory bracket-to-engine bolts Air filter housing-to-body bolt B+ terminal of generator B+ wire-to-starter mounting nut Battery terminal mounting nuts Battery clamping plate mounting bolt M8 x 35 Generator-to-accessory bracket collar bolts M8 x 90...
Page 188: Windshield Wiper/Washer Tightening Specifications
Windshield Wiper/Washer Tightening Specifications Component Front wiper arm mounting nuts Rear wiper arm mounting nut Telescopic cylinder for spray jets-to-front bumper cover Windshield and headlamp washer fluid reservoir-to-body Windshield wiper motor-to-wiper frame and linkage screws Windshield wiper motor crank-to-windshield wiper motor shaft Wiper frame with linkage-to-body bolts Exterior Lights, Switches Tightening Specifications...
Page 189: Left E-Box In Engine Compartment Tightening Specifications
Left E-box in Engine Compartment Tightening Specifications Component Fastener size Central bolt E-box (2) Nuts (1) Nuts (1) VW Golf & GTI Quick Reference Specification Book • September 2012...
Page 190: Dtc Chart
DTC CHART Engine Codes CBFA Fuel and Air Mixture, Additional Emission Regulations Error Message Malfunction Criteria and Threshold Value P000A Intake Camshaft Position Slow Signal change > 8 CRK ° for > Response Bank 1 2.9 Sec. and adjustment angle >= 2.50 CRK rev.
Page 191 Error Message Malfunction Criteria and Threshold Value P0070 Ambient Air Temperature Ambient air temperature < -50 Sensor Circuit °C P0071 Ambient Air Temperature • Difference in value between Sensor Range/Performance ECT and AAT at engine start (depending on engine off time) >...
Page 192 Error Message Malfunction Criteria and Threshold Value P0112 Intake Air Temperature Sensor IAT > 141.0 °C 1 Circuit Low Input P0113 Intake Air Temperature Sensor IAT < -46 °C 1 Circuit High Input P0116 Engine Coolant Temperature • No change on signal < 2 K Sensor 1 Circuit Range/ Performance •...
Page 193 Error Message Malfunction Criteria and Threshold Value P0132 O2 Sensor Circuit (Bank 1, VM > 3.25 V Sensor 1) High Voltage UN > 4.40 V IA or IP > 7 V P0133 O2 Circuit Slow Response Signal dynamic slope check (Bank 1, Sensor 1) •...
Page 194 Error Message Malfunction Criteria and Threshold Value P013A O2 Sensor Slow Response • EWMA filtered max differential Rich to Lean Bank 1 Sensor 2 transient time at fuel cutoff >= 0.5 Sec. • Number of checks, >= 3 P0140 O2 Circuit No Activity Signal voltage Detected (Bank 1, Sensor 2) •...
Page 195 Error Message Malfunction Criteria and Threshold Value P0191 Fuel Rail Pressure Sensor Actual pressure > 20.6 MPa Circuit Range/Performance P0192 Fuel Rail Pressure Sensor Signal voltage < 0.2 V Circuit Low Input P0201 Injector Circuit/Open - • Low side signal current < 2.1 A Cylinder 1 •...
Page 196 Error Message Malfunction Criteria and Threshold Value P0245 Turbocharger Wastegate Signal voltage < 3.25 - 2.15 V Solenoid Low P0246 Turbocharger Wastegate Signal current > 2.2 to 4 A Solenoid High P025A Fuel Pump Module Control Signal voltage 4.40 - 5.60 V Circuit Open P025C Fuel Pump Module Control Signal voltage 2.15 - 3.25 V...
Page 197: Ignition System
Error Message Malfunction Criteria and Threshold Value P2089 A Camshaft Position Actuator Signal current > 2.2 A Control Circuit High P2096 Post Catalyst Fuel Trim Deviation lambda control < -0.03 System Too Lean P2097 Post-Catalyst Fuel Trim Integral part of lambda control System Too Rich >...
Page 198 Error Message Malfunction Criteria and Threshold Value P0327 Knock Sensor 1 Circuit Low • Lower threshold < -70 V or for signal range check • Lower threshold < 0 - 1.60 V P0328 Knock Sensor 1 Circuit High • Upper threshold > 1.00 V or for signal range check •...
Page 199: Additional Exhaust Regulation
Error Message Malfunction Criteria and Threshold Value P2309 Ignition Coil D Primary Control Signal current > 24.0 mA Circuit Low P2310 Ignition Coil D Primary Control Signal voltage > 5.1 - 7.0 V Circuit High Additional Exhaust Regulation Error Message Malfunction Criteria and Threshold Value P0410...
Page 200 Error Message Malfunction Criteria and Threshold Value P043F Evaporative Emission System Engine off Leak Detection Reference • EVAP pump current during Orifice High Flow reference measurement < 15.0 mA Engine on • EVAP pump current during reference measurement > 15.0 P0441 Evaporative Emission System Deviation <...
Page 201: Speed And Idle Control
Speed and Idle Control Error Message Malfunction Criteria and Threshold Value P050A Cold Start Idle Air Control Out of range low: System Performance • Engine speed deviation < -80 Out of range high: • Engine speed deviation > 80 P050B Cold Start Ignition Timing Difference between commanded Performance...
Page 202 Error Message Malfunction Criteria and Threshold Value P0638 Throttle Actuator Control • Time to close to reference Range/Performance point > 6 Sec. • Reference point 2.88% • TPS 1 signal 0.40 - 0.60 V • TPS 2 signal 4.20 - 4.60 V •...
Page 203: Fuel And Air Ratios Control Module
Error Message Malfunction Criteria and Threshold Value U0415 CAN Communication With • Speed sensor initialization ABS Error failed • Speed sensor low voltage error failed • Implausible message received U0422 Invalid Data Received From Ambient temperature value Body Control Module (IPC) initialization failure.
Page 204 Error Message Malfunction Criteria and Threshold Value P13EA Cold Start Ignition Timing Difference between commanded Performance Off Idle spark timing vs. actual value > P150A Engine Off Time Performance Difference between engine off time and ECM after run time < -12 Sec.
Page 205 Error Message Malfunction Criteria and Threshold Value P2195 Sensor Signal Biased/Stuck Delta lambda of 2nd lambda Lean Bank 1 Sensor 1 control loop > 0.07 P2196 O2 Sensor Signal Biased/ Delta lambda of 2nd lambda Stuck Rich Bank 1 Sensor 1 control loop <...
Page 206: Additional Emissions Regulations
Additional Emissions Regulations Error Message Malfunction Criteria and Threshold Value P2400 Evaporative Emission System Signal voltage > 4.4 - 5.6 V Leak Detection Pump Control Circuit/Open P2401 Evaporative Emission System Signal voltage < 2.15 to 3.25 V Leak Detection Pump Control Circuit Low P2402 Evaporative Emission System...
Page 207 Error Message Malfunction Criteria and Threshold Value P2414 O2 Sensor Exhaust Sample Threshold 1 Error Bank 1, Sensor 1 • Signal voltage 3.1 - 4.81 V Threshold 2 • O2S signal 2.5 - 3.2 V P2431 Secondary Air Injection • Difference between SAI Sensor Performance pressure sensor and ambient pressure NOT -60.0 to 60.0...
Page 208: Dtc Chart
DTC CHART Engine Codes CCTA Fuel and Air Mixture, Additional Emission Regulations Error Message Malfunction Criteria and Threshold Value P000A Intake (A) Camshaft Position Signal change < 1.9 - 4.2°CRK/s Slow Response Bank 1 P0010 Intake (A) Camshaft Position Signal voltage > 4.4 - 5.6 V Actuator Circuit/Open (Bank 1) P0011...
Page 209 Error Message Malfunction Criteria and Threshold Value P0068 MAP/MAF – Throttle Position • Plausibility with fuel system Correlation load calculation < -50% • Plausibility with fuel system load calculation > 50% P0070 Ambient Air Temperature Ambient air temperature < -45 Sensor Circuit °C P0071...
Page 210 Error Message Malfunction Criteria and Threshold Value P0111 Intake Air Temperature Sensor • Difference in value IAT - ECT 1 Circuit Range/Performance @ engine start (depending on engine off time) > 25 - 40 °K • Difference in value IAT - AAT @ engine start <...
Page 211 Error Message Malfunction Criteria and Threshold Value P0131 O2 Sensor Circuit (Bank 1, VM < 2.0 V Sensor 1) Low Voltage UN < 1.75 V IA or IP > 0.30 V P0132 O2 Sensor Circuit (Bank 1, VM > 3 V Sensor 1) High Voltage UN >...
Page 212 Error Message Malfunction Criteria and Threshold Value P0202 Injector Circuit/Open - • Low side signal current < 2.1 A Cylinder 2 • Internal logic failure P0203 Injector Circuit/Open - • Low side signal current < 2.1 A Cylinder 3 • Internal logic failure P0204 Injector Circuit/Open - •...
Page 213 Error Message Malfunction Criteria and Threshold Value P0261 Cylinder 1 Injector Circuit Low Signal current < 2.1 A P0262 Cylinder 1 Injector Circuit High Signal current > 14.70 A P0264 Cylinder 2 Injector Circuit Low Signal current < 2.1 A P0265 Cylinder 2 Injector Circuit High Signal current >...
Page 214: Ignition System
Ignition System 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 1 Misfire Detected • Emission threshold 1st interval Misfire Rate (MR), >...
Page 215 Error Message Malfunction Criteria and Threshold Value P0340 Camshaft Position Sensor Cam adaption values out of A Circuit (Bank 1 or Single range Sensor) • > 20° KW • < -20° KW • Difference of adapted and actual values > 9° KW P0341 Camshaft Position Sensor A Signal pattern incorrect...
Page 216: Additional Exhaust Regulation
Error Message Malfunction Criteria and Threshold Value P2310 Ignition Coil D Primary Control Signal voltage > 5.1 - 7.0 mA Circuit High Additional Exhaust Regulation Error Message Malfunction Criteria and Threshold Value P0420 Catalyst System Efficiency Front: Below Threshold (Bank 1) •...
Page 217: Speed And Idle Control
Speed and Idle Control Error Message Malfunction Criteria and Threshold Value P050A Cold Start Idle Air Control Out of range low: System Performance • Engine speed deviation < -80 Out of range high: • Engine speed deviation > 80 P050B Cold Start Ignition Timing •...
Page 218 Error Message Malfunction Criteria and Threshold Value P0638 Throttle Actuator Control • Time to close to reference Range/Performance - Bank 1 point > 0.56 Sec. • reference point 2.88% • Time to close below reference point, + 2.49%, > 0.56 Sec. •...
Page 219: Fuel And Air Ratios Control Module
Error Message Malfunction Criteria and Threshold Value U0302 Software Incompatibility with AT vehicle ECM coded as MT Transmission Control Module vehicle U0402 Invalid Data Received From Transmission Data Length Code Gear Shift Control Module A incorrect U0415 CAN Communication With •...
Page 220 Error Message Malfunction Criteria and Threshold Value P2101 Throttle Actuator Control • Duty cycle >80% Motor Circuit Range/ • Deviation throttle value angles Performance vs. calculated value 4 - 50% • ECM power stage no failure P2106 Throttle Actuator Control Internal check failed System - Forced Limited Power...
Page 221 Error Message Malfunction Criteria and Threshold Value P2195 O2 Sensor Signal Biased/ Delta lambda of 2nd lambda Stuck Lean (Bank 1, control loop > 0.07 Sensor 1) P2196 O2 Sensor Signal Biased/ Delta lambda of 2nd lambda Stuck Rich (Bank 1, Sensor 1) control loop <...
Page 222: Additional Emissions Regulations
Error Message Malfunction Criteria and Threshold Value P2294 Fuel Pressure Regulator 2 • Signal voltage 2.3 - 2.7 V Control Circuit • Signal pattern incorrect P2295 Fuel Pressure Regulator 2 Signal voltage 1.8 - 2.2 V Control Circuit Low P2296 Fuel Pressure Regulator 2 Signal voltage >...
Page 223: Dtc Chart
DTC CHART Engine Codes CJAA Fuel and Air Mixture, Additional Emission Regulations Error Message Malfunction Criteria and Threshold Value P000E Fuel Volume Regulator • Number of learning points at Control Exceeded Learning adaptation limits >= 8 of 64 Limit • Upper limit > 1.2 P00AF Turbocharger Boost Control Boost pressure actuator stuck...
Page 224 Error Message Malfunction Criteria and Threshold Value P0087 Fuel Rail/System Pressure - • Control deviation > 150 - 200 Too Low • Exceeding absolute rail pressure limits < 120 - 125 Bar or > 1950 Bar • Control deviation < -200 to -300 Bar P0088 Fuel Rail/System Pressure -...
Page 225 Error Message Malfunction Criteria and Threshold Value P0112 Intake Air Temperature Sensor Boost temperature sensor 1 Circuit Low Input voltage < 0.04 V P0113 Intake Air Temperature Sensor Boost temperature sensor Circuit High Input voltage > 2.88 V P0116 Engine Coolant Temperature •...
Page 226 Error Message Malfunction Criteria and Threshold Value P0135 O2 Sensor Heater Circuit Diagnostic signal from output Bank 1 Sensor 1 Malfunction driver sent OR Sensor element temperature < 720 or > 840 °C P0136 O2 Sensor Circuit Bank 1 • LSU internal resistance > Sensor 2 Malfunction 1104 ohms •...
Page 227 Error Message Malfunction Criteria and Threshold Value P0191 Fuel Rail Pressure Sensor • Sensor voltage < 428 mV or > Circuit Range/Performance 613 mV • Adaptation value out of limit < 83% or > 130% P0192 Fuel Rail Pressure Sensor Sensor voltage <...
Page 228 Error Message Malfunction Criteria and Threshold Value P0204 Cylinder 4 Injector Circuit Open circuit diagnostic signal from output driver P0234 Turbo Charger Overboost Control deviation > -300 - -800 Condition limit exceeded hPa @ delta engine speed/ injection quantity P0236 Turbocharger Boost Sensor Difference between barometric (A) Circuit Performance...
Page 229 Error Message Malfunction Criteria and Threshold Value P1005 Torque difference cylinder 2 Control error < limit from MAP Limiting value exceeded f (engine speed and desired torque) -50 to -30 Nm OR +50 to +30 Nm P1006 Torque difference cylinder 3 Control error <...
Page 230 Error Message Malfunction Criteria and Threshold Value P13D6 Sensor for internal pressure of • Cylinder pressure sensor cylinder 3 Implausible signal voltage < 0.33 V or > 3.09 V • Deviation between min and max cylinder pressure # 3 < 20 bar •...
Page 231 Error Message Malfunction Criteria and Threshold Value P13E1 Sensor for internal pressure of Pressure based measured TDC cylinder 2 Malfunction vs. crank position sensor for cyl. 2 out of range < 1.8 CA or > 1.8 CA P13E2 Sensor for internal pressure of Pressure based measured TDC cylinder 3 Malfunction vs.
Page 232 Error Message Malfunction Criteria and Threshold Value P2008 Intake Manifold Runner Bank Open load diagnostic signal 1 Control Circuit Low from output driver P2009 Intake Manifold Runner Bank Short to ground on output 1 or 1 Control Circuit Low 2 signal from output driver P2010 Intake Manifold Runner Short to voltage on output 1 or...
Page 233 Error Message Malfunction Criteria and Threshold Value P2127 Throttle/Pedal Position Sensor Sensor 2 voltage < 0.27 V E Circuit Low Input P2128 Throttle/Pedal Position Sensor Sensor 2 voltage > 2.43 V D/E Circuit Voltage Correlation P2138 Throttle/Pedal Position Sensor Voltage drift monitoring: D/E Circuit Voltage Correlation •...
Page 234: Fuel And Air Ratios Control Module
Error Message Malfunction Criteria and Threshold Value P2294 Fuel Pressure Regulator 2 Open circuit diagnostic signal Control Circuit from output driver P2295 Fuel Pressure Regulator 2 Grounded circuit diagnostic Control Circuit Low signal from output driver P2296 Fuel Pressure Regulator 2 Over current circuit diagnostic Control Circuit High signal from output driver...
Page 235: Ignition System
Ignition System Error Message Malfunction Criteria and Threshold Value P0300 Random/Multiple Cylinder. • No rise in engine speed after Misfire Detected fuel injection Calculated based on values from last two engine revolutions • Error threshold 82% misfire over 440 crankshaft revolutions P0301 Cylinder 1 Misfire Detected...
Page 236: Additional Exhaust Regulation
Error Message Malfunction Criteria and Threshold Value P0322 Engine Speed Input Circuit No No incremental signal. Internal Signal self test failed. P0381 Glow Plug/Heater Indicator Receipt bit for lamp request not Circuit equal with lamp request bit. P0383 Glow Plug Control Module Diagnostic error signal sent Control Circuit Low from output driver = 0 V.
Page 237 Error Message Malfunction Criteria and Threshold Value P0402 Exhaust Gas Recirculation Control deviation > limit from Excessive Flow Detected map (engine speed, desired airflow) P0403 Exhaust Gas Recirculation Valve stuck open > 17% or Circuit stuck closed < 17% P0405 Exhaust Gas Recirculation Position sensor signal range Sensor Circuit Low...
Page 238 Error Message Malfunction Criteria and Threshold Value P0473 Exhaust Pressure Sensor A Sensor voltage >4.9 V High P0474 Exhaust Pressure Sensor “A” Difference between modeled Circuit Intermittent/Erratic and measured differential pressure across low pressure EGR > 40hPa P0475 Exhaust Pressure Control Diagnostic signal from output Valve “A”...
Page 239 Error Message Malfunction Criteria and Threshold Value P242B Exhaust Gas Temperature • Comparison of upstream Sensor Circuit Bank 1 Sensor turbine exhaust gas temp vs 3 Range/Performance modeled temperature < 250 °C • Temperature difference to other temp sensors during cold start <...
Page 240: Speed And Idle Control
Error Message Malfunction Criteria and Threshold Value P2463 Diesel Particulate Filter - Soot Calculated particulate matter Accumulation trap loading > 40 g P247A Exhaust Gas Temperature Out Control deviation > limit from of Range Bank 1 Sensor 3 Map f or < limit from Map f (engine speed, torque) P2470 Exhaust Gas Temperature...
Page 241: Control Module And Output Signals
Error Message Malfunction Criteria and Threshold Value P2563 Turbocharger Boost Control • Position sensor signal voltage Position Sensor Circuit < 0.3 or > 4.5 V Range/Performance • Position sensor signal > 1.72 or < 0.3 V P2564 Turbocharger Boost Control Position sensor signal voltage Position Sensor Circuit Low <...
Page 242 Error Message Malfunction Criteria and Threshold Value P0604 Internal Control Module • Write EEPROM not possible Random Access Memory • Checksum error in 3 or more (RAM) Error locations P0605 Internal Control Module Read • ECM internal ROM self test Only Memory (ROM) Error failed P0606...
Page 243 Error Message Malfunction Criteria and Threshold Value P0670 Glow Plug Module 1 Control Message from glow control unit Circuit electrical malfunction = 3.44 V electrical circuit P0671 Cylinder 1 Glow Plug Circuit Message from Glow Control Q10 Electrical Fault Unit, (glow current < 2.2 A) P0672 Cylinder 2 Glow Plug Circuit Message from Glow Control...
Page 244 Error Message Malfunction Criteria and Threshold Value U0121 Lost Communication With No messages received from Anti-Lock Brake System ABS module (ABS) Control Module U0146 Lost Communication With Fault message from gateway Gateway “A” = true U0155 Lost Communication With No messages received from Instrument Panel Cluster Instrument cluster (IPC) Control Module...
Page 245: Dtc Chart
DTC CHART Engine Codes CRZA Fuel and Air Mixture, Additional Emission Regulations Error Message Malfunction Criteria and Threshold Value P000A Camshaft Position Slow Difference between target and Response actual position > 8 °CRK for > 1.3 to 2.9 Sec. and adjustment angle >= 2.50 °CRK P0010 Camshaft Position Actuator...
Page 246 Error Message Malfunction Criteria and Threshold Value P0100 Mass Air Flow Circuit Fault MAF sensor signal 0 µs P0101 Mass Air Flow Circuit Mass air flow vs. Performance • Upper threshold model < 12% • Lower threshold model < 0.400 kg/h •...
Page 247 Error Message Malfunction Criteria and Threshold Value P0122 Pedal Position Sensor A Signal voltage < 0.20 V Circuit Low Input P0123 Pedal Position Sensor A Signal voltage > 4.81 V Circuit High Input P013A O2 Sensor Slow Response - EWMA filtered max differential Rich to Lean Bank 1 Sensor 2 transient time at fuel cutoff >= 0.5 Sec.
Page 248 Error Message Malfunction Criteria and Threshold Value P0137 O2 Circuit Low Voltage (Bank • Signal voltage < 0.06 V for > 1, Sensor 2) 3 Sec. • Difference with/without load pulse < 0.01 V P0138 O2 Circuit High Voltage (Bank Signal voltage 1.08 V for >...
Page 249 Error Message Malfunction Criteria and Threshold Value P0221 Pedal Position Sensor Circuit • TPS 1 - TPS 2 > 6.30% Performance • Actual TPS 2 calculated value > TPS 1 calculated value • TPS 2 – calc. value > 9.00% P0222 Pedal Position Sensor Circuit Signal voltage <...
Page 250 Error Message Malfunction Criteria and Threshold Value P12A1 Fuel Rail Pressure Sensor • Pressure control activity > 0.20 Inappropriately Low • Fuel trim activity < 0.80 • Difference between actual pressure vs target pressure -16.38 to 16.38 MPa P12A2 Fuel Rail Pressure Sensor •...
Page 251: Ignition System
Ignition System 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 Cylinder 1 Misfire Detected • Emission threshold 1st interval Misfire Rate (MR), >...
Page 252 Error Message Malfunction Criteria and Threshold Value P0333 Knock Sensor 2 Circuit High Signal range check upper Input threshold 4.5 to 30 P0341 Camshaft Position Sensor • Signal pattern incorrect Circuit Performance • Defect counter 12 P0342 Camshaft Position Sensor •...
Page 253: Additional Exhaust Regulation
Additional Exhaust Regulation Error Message Malfunction Criteria and Threshold Value P0420 Catalyst System Efficiency Front: Below Threshold • Oxygen storage capacity (OSC) vs OSC of borderline catalyst < 0.40 • Front catalyst < 1.30 • Main catalyst < 1.20 Main: •...
Page 254: Speed And Idle Control
Speed and Idle Control Error Message Malfunction Criteria and Threshold Value P050A Cold Start Idle Air Control Out of range low: System Performance • Engine speed deviation < -80 Out of range high: • Engine speed deviation > 80 P0501 Vehicle Speed Sensor Range/ VSS signal <...
Page 255 Error Message Malfunction Criteria and Threshold Value P0643 Sensor Reference Voltage A Signal voltage > 5 to 5.4 V Circuit High P0651 Sensor Reference Voltage B Signal voltage deviation > +/- Circuit 0.3 V P0652 Sensor Reference Voltage B Signal voltage < 4.6 - 5.0 V Circuit Low P0653 Sensor Reference Voltage B...
Page 256: Fuel And Air Ratios Control Module
Error Message Malfunction Criteria and Threshold Value U0155 CAN Instrument Cluster CAN messages not received U0415 CAN Communication With • Speed sensor initialization ABS Error failed • Speed sensor low voltage error failed • Speed > 326 km/h U0422 Invalid Data Received From Ambient temperature value Body Control Module (Cluster) initialization failure.
Page 257 Error Message Malfunction Criteria and Threshold Value P2089 A Camshaft Position Actuator Signal current > 2.2 A Control Circuit High P2096 Post Catalyst Fuel Trim Deviation lambda control < -0.04 System Too Lean P2097 Post Catalyst Fuel Trim Integral part of lambda control System Too Rich >...
Page 258: Additional Emissions Regulations
Error Message Malfunction Criteria and Threshold Value P2243 O2 Sensor Reference Voltage • O2S signal front < 0.30 V and Circuit Open (Bank 1, Internal resistance Sensor 1) > 1000 Ohms • O2S signal front > 3.25 V and Internal resistance >...
Page 259 Error Message Malfunction Criteria and Threshold Value P2403 Evaporative Emission System Low signal voltage > 0.5 Sec. Leak Detection Pump Sense Circuit/Open P2404 Evaporative Emission System • High signal voltage > 30.4 Sec. Leak Detection Pump Sense Circuit Range/Performance P2414 O2 Sensor Exhaust Sample Threshold 1 Error (Bank 1, Sensor 1)
Page 260: Dtc Chart
DTC CHART Engine Codes CBTA, CBUA Fuel and Air Mixture, Additional Emission Regulations Error Message Malfunction Criteria and Threshold Value P000A Intake Camshaft Position Slow • Difference between target and Response Bank 1 actual > 8° CRK for > 1.8 to 2.5 Sec.
Page 261 Error Message Malfunction Criteria and Threshold Value P0042 O2 Sensor Heater Control Heater voltage 2.34 to 3.59 V Circuit Bank 1 Sensor 3 (CBUA ONLY) P0043 O2 Sensor Heater Control Heater voltage < 2.34 V Circuit Bank 1 Sensor 3 Low (CBUA ONLY) P0044 O2 Sensor Heater Control...
Page 262 Error Message Malfunction Criteria and Threshold Value P0117 Engine Coolant Temperature • ECT >140 °C Sensor 1 Circuit Low Input P0118 Engine Coolant Temperature ECT < -40 °C Sensor 1 Circuit High Input P0121 Accelerator Pedal Position • TPS 1 - TPS 2 > 5.10 to 6.30% Sensor A Circuit Range/ •...
Page 263 Error Message Malfunction Criteria and Threshold Value P0137 O2 Circuit Low Voltage (Bank • Cold condition: Signal voltage 1, Sensor 2) < 0.06 V for > 3 Sec. • Difference of sensor voltage with and without load pulse < 0.01 V P0138 O2 Circuit High Voltage (Bank Signal voltage >...
Page 264 Error Message Malfunction Criteria and Threshold Value P0146 O2 Sensor Circuit No Activity • Signal voltage .40 to .60 V for Detected Bank 1 Sensor 3 > 3 Sec. • Voltage difference between load pulse and no load pulse >= 2.80 V •...
Page 265 Error Message Malfunction Criteria and Threshold Value P2088 “A” Camshaft Position Short to ground, signal voltage Actuator Control Circuit Low - 0.0 to 3.25 V Bank 1 P2089 “A” Camshaft Position Short to battery plus, signal Actuator Control Circuit High current >...
Page 266 Error Message Malfunction Criteria and Threshold Value P2243 O2 Sensor Reference Voltage • O2S signal front > 4.70 V and Circuit Open Bank 1, Sensor 1 Internal resistance > 950 Ω • O2S signal front < 0.20 V And Internal resistance > 950 Ω P2251 O2 Sensor Negative Current •...
Page 267 Error Message Malfunction Criteria and Threshold Value P2307 Ignition Coil C Primary Control • Signal voltage > 5.1 - 7.0 mA Circuit High P2309 Ignition Coil D Primary Control • Signal current > 24 mA Circuit Low P2310 Ignition Coil D Primary Control •...
Page 268: Ignition System
Error Message Malfunction Criteria and Threshold Value P2414 O2 Sensor Exhaust Sample • Threshold 1 Error Bank 1, Sensor 1 • Signal voltage 3.1 to 4.77 V • Threshold 2 • Signal Voltage 2.5 to 3.06 V P2431 Secondary Air Injection •...
Page 269 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 Misfire Rate), > 2.5 to 24% P0303 Cylinder 3 Misfire Detected •...
Page 270: Additional Exhaust Regulation
Error Message Malfunction Criteria and Threshold Value P0332 Knock Sensor 2 Circuit Low • Lower threshold < - 0.70 V Input • Signal range check < 0.55 to 5.60 V P0333 Knock Sensor 2 Circuit High • Upper threshold > 1 V Input •...
Page 271 Error Message Malfunction Criteria and Threshold Value P0420 Catalyst System Efficiency • Oxygen storage capacity Below Threshold (OSC) vs OSC value of borderline catalyst < 1.00 P043E Evaporative Emission System • EVAP pump current during Leak Detection Reference reference measurement > 40 Orifice Low Flow P043F Evaporative Emission System...
Page 272: Speed And Idle Control
Speed and Idle Control Error Message Malfunction Criteria and Threshold Value P0501 Vehicle Speed Sensor Range/ • Vehicle speed < 4 km/h Performance P0503 Vehicle Speed Sensor • Vehicle speed > 325 km/h Intermittent High Signal P0506 Idle Air Control System RPM •...
Page 273 Error Message Malfunction Criteria and Threshold Value P0638 Throttle Actuator Control • Time to close to reference Range/Performance - Bank 1 point > 0.6 Sec. and reference point = 2.88% • TPS 1 signal voltage, not 0.40 - 0.80 V •...
Page 274: Fuel And Ratio Control Module
Error Message Malfunction Criteria and Threshold Value U0121 Lost Communication With • No CAN messages received Anti-Lock Brake System (ABS) Control Module U0146 Lost Communication With •No CAN messages received Gateway “A” U0155 Lost Communication With • No CAN messages received Instrument Panel Cluster (IPC) Control Module U0302...
Page 275 Volkswagen Group of America. All rights under the copyright laws are expressly reserved by Volkswagen Group of America. Subject to alteration and amendment. Printed in the United States of America...
Page 276 GFGTIQUSPEC13...

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Vehicle Lifting

Engine Mechanical - 2.0L CJAA (TDI)

Engine Mechanical - 2.0L Cbfa, Ccta

Engine Mechanical - 2.0L Crza

Engine Mechanical - 2.5L CBTA, CBUA

Manual Transmission - 0A4

Manual Transmission - 02Q

Automatic Transmission - 09G

Direct Shift Gearbox (DSG) Transmission - 02E

Suspension, Wheels, Steering

Brake System

Body

Heating, Ventilation and Air Conditioning

Electrical System

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Summary of Contents for Volkswagen Golf 2013