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Volkswagen GTI 2013 User Manual
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94
VW Golf & GTI Quick Reference Speciîš¿cation Book
•
September 2012
Piston Ring End Gap
Piston ring
dimensions in mm
New
Wear limit
Compression rings
0.20 to 0.40
0.8
Oil scraping ring
0.25 to 0.50
0.8
Piston Ring Clearance
Piston ring
dimensions in mm
New
Wear limit
Compression rings
0.06 to 0.09
0.20
Oil scraping ring
0.03 to 0.06
0.15
Fastener T
ightening Speciîš¿cations
(cont’d)
105
107
Table of Contents
Default Chapter
3
Table of Contents
3
General Information
13
Decimal and Metric Equivalents
13
Tightening Torque
14
Warnings and Cautions
16
Vehicle Identification
21
Vehicle Identification Number (VIN) Location
21
VIN Decoder
22
VIN on Longitudinal Member Extension
23
Vehicle Data Label
24
Sales Codes
25
Engine Codes
25
Transmission Codes
25
Vehicle Lifting
26
Hoist and Jack Mounting Points
26
Front
26
Rear
27
Engine Mechanical - 2.0L CJAA (TDI)
28
General, Technical Data
28
Engine Number Location
28
Engine Data
29
Engine Assembly - 2.0L CJAA (TDI)
30
Fastener Tightening Specifications
30
Engine Mount Tightening Specifications
30
Transmission Mount Tightening Specifications
31
Pendulum Support Tightening Specifications
32
Engine Mount Bracket Tightening Specifications
33
Crankshaft, Cylinder Block - 2.0L CJAA (TDI)
34
Fastener Tightening Specifications
34
Accessory Bracket Tightening Specifications
36
Crankshaft Dimensions
37
Piston and Cylinder Dimensions
37
Piston Ring End Gaps
37
Piston Ring Clearance
37
Cylinder Head, Valvetrain - 2.0L CJAA (TDI)
38
Fastener Tightening Specifications
38
Valve Dimensions
39
Compression Pressures
39
Cylinder Head Cover Tightening Specifications
40
Cylinder Head Tightening Specifications
41
Bearing Frame Tightening Specifications
42
Lubrication - 2.0L CJAA (TDI)
43
Fastener Tightening Specifications
43
Cooling System - 2.0L CJAA (TDI)
44
Fastener Tightening Specifications
44
Fuel Supply - 2.0L CJAA (TDI)
44
Turbocharger - 2.0L CJAA (TDI)
45
Fastener Tightening Specifications
45
Exhaust System - 2.0L CJAA (TDI)
45
Ignition/Glow Plug System - 2.0L CJAA (TDI)
47
Fastener Tightening Specifications
47
Diesel Fuel Injection - 2.0L CJAA (TDI)
47
Engine Mechanical - 2.0L Cbfa, Ccta
48
General, Technical Data
48
Engine Number Location
48
Engine Data
49
Engine Assembly - 2.0L CBFA, CCTA
50
Fastener Tightening Specifications
50
Crankshaft, Cylinder Block - 2.0L CBFA, CCTA
51
Cylinder Block Bearing Shell Identification
51
Bearing Cap Bearing Shell Identification
53
Fastener Tightening Specifications
54
Crankshaft Dimensions
55
Piston Ring End Gaps
55
Piston Ring Clearance
55
Piston and Cylinder Dimensions
55
Accessory Assembly Bracket Tightening Specifications
56
Sealing Flange Tightening Specifications
57
Crankshaft Assembly Tightening Specifications
58
Cylinder Head, Valvetrain - 2.0L CBFA, CCTA
59
Fastener Tightening Specifications
59
Valve Dimensions
60
Compression Pressures
60
Cylinder Head Tightening Specifications
61
Cylinder Head Cover Tightening Specifications
62
Crankcase Ventilation Tightening Specification
63
Upper Timing Chain Cover Tightening Specifications
63
Lower Timing Chain Cover Tightening Specifications with 15 Bolts
64
Lower Timing Chain Cover Tightening Specifications with 8 Bolts
65
Lubrication - 2.0L CBFA, CCTA
66
Fastener Tightening Specifications
66
Upper Oil Pan Tightening Specifications
66
Oil Pan Tightening Specifications
67
Oil Separator Tightening Specification
68
Cooling System - 2.0L CBFA, CCTA
68
Fastener Tightening Specifications
68
Coolant Pump Tightening Specification
69
Fuel Supply - 2.0L CBFA, CCTA
69
Fastener Tightening Specifications
69
Turbocharger, G-Charger - 2.0L CBFA, CCTA
70
Fastener Tightening Specifications
70
Turbocharger Tightening Specifications
71
Exhaust System - 2.0L CBFA, CCTA
72
Fastener Tightening Specifications
72
Multiport Fuel Injection - 2.0L CBFA, CCTA
72
Technical Data
72
Fastener Tightening Specifications
73
Ignition - 2.0L CBFA, CCTA
74
Technical Data
74
Fastener Tightening Specifications
74
Engine Mechanical - 2.0L Crza
75
General, Technical Data
75
Engine Number Location
75
Engine Data
76
Engine Assembly - 2.0L CRZA
77
Fastener Tightening Specifications
77
Engine Mount Tightening Specifications
77
Transmission Mount Tightening Specifications
78
Pendulum Support Tightening Specifications
79
Crankshaft, Cylinder Block - 2.0L CRZA
80
Upper Crankshaft Bearing Identification
80
Fastener Tightening Specifications
81
Crankshaft Dimensions
82
Piston Ring End Gaps
82
Piston Ring Clearance
82
Piston and Cylinder Dimensions
82
Accessory Assembly Bracket Tightening Specification
83
Sealing Flange Tightening Specifications
84
Cylinder Head, Valvetrain - 2.0L CRZA
85
Fastener Tightening Specifications
85
Valve Dimensions
86
Compression Pressures
86
Cylinder Head Tightening Specifications
87
Cylinder Head Cover Tightening Specification
88
Lubrication - 2.0L CRZA
89
Fastener Tightening Specifications
89
Oil Pan Tightening Specifications
90
Cooling System - 2.0L CRZA
91
Fastener Tightening Specifications
91
Fuel Supply - 2.0L CRZA
91
Turbocharger, G-Charger - 2.0L CRZA
92
Fastener Tightening Specifications
92
Exhaust System - 2.0L CRZA
93
Fastener Tightening Specifications
93
Multiport Fuel Injection - 2.0L CRZA
93
Technical Data
93
Fastener Tightening Specifications
94
Ignition - 2.0L CRZA
95
Technical Data
95
Fastener Tightening Specifications
95
Engine Mechanical - 2.5L CBTA, CBUA
96
General, Technical Data
96
Engine Number
96
Engine Data
97
Cylinder Numbering
98
Engine Assembly - 2.5L CBTA, CBUA
99
Fastener Tightening Specifications
99
Engine Mount Tightening Specifications
99
Transmission Mount Tightening Specifications
100
Pendulum Support Tightening Specifications
101
Crankshaft, Cylinder Block - 2.5L CBTA, CBUA
102
Crankshaft Upper Bearing Shell (for Cylinder Block) Allocation
102
Crankshaft Lower Bearing Shell (for Bearing Cap) Allocation
103
Fastener Tightening Specifications
104
Crankshaft Dimensions
105
Piston and Cylinder Dimensions
105
Piston Ring End Gap
106
Piston Ring Clearance
106
Cylinder Head, Valvetrain - 2.5L CBTA, CBUA
107
Fastener Tightening Specifications
107
Valve Dimensions
108
Compression Pressures
108
Cylinder Head Cover Tightening Specification
109
Cylinder Head Tightening Specifications
110
Guide Frame Tightening Specifications
111
Lubrication - 2.5L CBTA, CBUA
112
Fastener Tightening Specifications
112
Cooling System - 2.5L CBTA, CBUA
113
Fastener Tightening Specifications
113
Fuel Supply - 2.5L CBTA, CBUA
113
Exhaust System, Emission Controls - 2.5L CBTA, CBUA
114
Fastener Tightening Specifications
114
Secondary Air Injection Pipe Tightening Specifications
115
Multiport Fuel Injection - 2.5L CBTA, CBUA
116
Fastener Tightening Specifications
116
Lower Air Filter Housing Bolt Tightening Specifications
116
Ignition - 2.5L CBTA, CBUA
117
Fastener Tightening Specifications
117
Technical Data
117
Manual Transmission - 0A4
118
General, Technical Data
118
Transmission Identification
118
Codes Letters, Transmission Allocation and Capacities
120
Manual Transmission - 0A4
118
Clutch - 0A4
121
Fastener Tightening Specifications
121
Controls, Housing - 0A4
122
Fastener Tightening Specifications
122
Transmission to Engine Tightening Specifications
123
Transmission Mount Bracket to Transmission Bolt Tightening Specification
124
Transmission Mount to Transmission Mount Bracket Bolt Tightening Specification
125
Transmission Support to Transmission Bracket and Transmission Bolt Tightening Specification
126
Reverse Shaft Support to Transmission Housing Bolt Tightening Sequence and Specification
127
Gears, Shafts - 0A4
128
Fastener Tightening Specification
128
Determining Shim Thickness
128
Adjustment Shim Table
128
Manual Transmission - 02Q
130
General, Technical Data
130
Transmission Identification
130
Codes Letters, Transmission Allocation and Capacities
132
Clutch - 02Q
133
Fastener Tightening Specifications
133
Controls, Housing - 02Q
134
Transmission to Engine Tightening Specifications
134
Front Wheel Drive Fastener Tightening Specifications
134
Adjustment Shim Table
135
Rear Final Drive, Differential - 02Q
136
Fastener Tightening Specifications
136
All Wheel Drive Fastener Tightening Specifications
136
Transmission Mount
137
Brace under Diaphragm
138
Transmission Bracket to Transmission
139
Identification on Transmission
140
Automatic Transmission - 09G
141
General, Technical Data
141
Identification on Transmission
141
Code Letters, Assembly Allocation and Ratios
142
Controls, Housing
143
Fastener Tightening Specifications
143
Transmission to Engine Tightening Specifications
144
Gears, Hydraulic Controls - 09G
145
Fastener Tightening Specifications
145
Transmission Fluid Pan Tightening Specification
146
Direct Shift Gearbox (DSG) Transmission - 02E
147
General, Technical Data
147
Identification on Transmission
147
Transmission Allocation Codes
149
Controls, Housing (DSG) - 02E
150
Fastener Tightening Specifications
150
Mechatronic Tightening Specifications
151
Oil Pump Tightening Specifications Without Countersunk Bolt
152
With Countersunk Bolt
152
Oil Pump Cover Tightening Specifications
153
Transmission Mount Tightening Specifications
154
Transmission to Engine Tightening Specifications
155
Suspension, Wheels, Steering
156
Front Suspension
156
Fastener Tightening Specifications
156
Rear Suspension
158
Fastener Tightening Specifications
158
Self-Leveling Suspension
160
Fastener Tightening Specifications
160
Wheels, Tires, Wheel Alignment
160
Wheel Alignment Data
161
Wheel Alignment Specified Values
161
Steering
166
Fastener Tightening Specifications
166
Brake System
168
General, Technical Data
168
Vehicle Data Sticker PR Number Allocation
168
Front Brakes
169
Rear Brakes
169
Brake Master Cylinder and Brake Booster
169
Front Brakes
170
Rear Brakes C38
172
Anti-Lock Brake System (ABS)
173
Fastener Tightening Specifications
173
Mechanical Components
173
Hydraulic Components
174
Fastener Tightening Specifications
174
Body
175
Air Gap Body Dimensions
175
Body, Front
175
Body, Center
176
Body, Rear
177
Body Exterior
178
Bulkhead, Front Fender Tightening Specifications
178
Lock Carrier Tightening Specifications
178
Underbody Trim, Noise Insulation Tightening Specifications
178
Tunnel Bridge, Plenum Chamber Tightening Specifications
179
Front Hood Tightening Specifications
179
Rear Lid, Fuel Filler Door Tightening Specifications
179
Front and Rear Door Tightening Specifications
179
Sunroof Tightening Specifications
180
Front Bumper Tightening Specifications
180
Rear Bumper, Trailer Hitch Tightening Specifications
180
Mirror Tightening Specifications
180
Exterior Equipment Tightening Specifications
180
Body Interior
181
Storage Compartments, Covers and Trim Tightening Specifications
181
Passenger Protection Fastener Tightening Specifications
181
Interior Trim Fastener Tightening Specifications
182
Seat Frames Fastener Tightening Specifications
182
Heating, Ventilation and Air Conditioning
183
General, Technical Data
183
Refrigerant Oil Distribution
183
Refrigerant R134A Vapor Pressure Table
184
Heating, Ventilation
185
Fastener Tightening Specifications
185
Air Conditioning
186
Fastener Tightening Specifications
186
Electrical System
187
Electrical Equipment
187
Battery, Starter, Generator, Cruise Control Fastener Tightening Specifications
187
Windshield Wiper/Washer Tightening Specifications
188
Exterior Lights, Switches Tightening Specifications
188
Interior Lights, Switches Tightening Specifications
188
Wiring Tightening Specification
188
Left E-Box in Engine Compartment Tightening Specifications
189
DTC Chart
190
Engine Codes CBFA
190
Fuel and Air Mixture, Additional Emission Regulations
190
Ignition System
197
Additional Exhaust Regulation
199
Speed and Idle Control
201
Control Module and Output Signals
201
Fuel and Air Ratios Control Module
203
Additional Emissions Regulations
206
DTC Chart
208
Engine Codes CCTA
208
Fuel and Air Mixture, Additional Emission Regulations
208
Ignition System
214
Additional Exhaust Regulation
216
Speed and Idle Control
217
Control Module and Output Signals
217
Fuel and Air Ratios Control Module
219
Additional Emissions Regulations
222
DTC Chart
223
Engine Codes CJAA
223
Fuel and Air Mixture, Additional Emission Regulations
223
Fuel and Air Ratios Control Module
234
Ignition System
235
Additional Exhaust Regulation
236
Speed and Idle Control
240
Control Module and Output Signals
241
DTC Chart
245
Engine Codes CRZA
245
Fuel and Air Mixture, Additional Emission Regulations
245
Ignition System
251
Additional Exhaust Regulation
253
Speed and Idle Control
254
Control Module and Output Signals
254
Fuel and Air Ratios Control Module
256
Additional Emissions Regulations
258
DTC Chart
260
Engine Codes CBTA, CBUA
260
Fuel and Air Mixture
260
Additional Emission Regulations
260
Ignition System
268
Additional Exhaust Regulation
270
Speed and Idle Control
272
Control Module and Output Signals
272
Fuel and Ratio Control Module
274
5
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Volkswagen GTI 2013 Specifications
General
Brand
Volkswagen
Model
GTI 2013
Category
Automobile
Language
English
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