2014 Golf, GTI & Golf R - ?· VW Golf & GTI Quick Reference Specification Book • January 2014 i 2014…

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  • Golf, GTI & Golf RQuick Reference Specification Book

    2014

  • VW Golf & GTI Quick Reference Specification Book January 2014 i

    2014 Volkswagen Golf, GTI, & Golf RQuick Reference Specification Book

    TaBle of ConTenTS

    General Information ...................................................... 1Decimal and Metric Equivalents ...........................................1Tightening Torque .................................................................2Warnings and Cautions ........................................................4

    Vehicle Identification ..................................................... 9Vehicle Identification Number (VIN) Location ..........................9VIN Decoder ..........................................................................10VIN on Longitudinal Member Extension ................................11Vehicle Data Label .................................................................12

    Sales Codes ................................................................. 13Engine Codes ........................................................................13Transmission Codes ..............................................................13

    Vehicle Lifting .............................................................. 14Hoist and Jack Mounting Points .........................................14

    Front ......................................................................................14Rear .......................................................................................15

    ENGINESEngine Mechanical 2.0L CBFA and CCTA .............. 16

    General, Technical Data .....................................................16Engine Number Location .......................................................16Engine Data ...........................................................................17

    Engine Assembly 2.0L CBFA and CCTA ..........................18Engine/Transmission Mount Overview ..................................18Fastener Tightening Specifications ........................................19

    Crankshaft, Cylinder Block 2.0L CBFA and CCTA ...........20Ribbed Belt Drive Overview ...................................................20Accessory Bracket Bolt Tightening Sequence .......................21Sealing Flange and Dual Mass Flywheel/Drive Plate Overview .........................................................................22Sealing Flange Tightening Specifications ..............................23Crankshaft Overview .............................................................24Crankshaft Assembly Tightening Specifications ....................25Piston and Connecting Rod Overview ...................................26

  • ii VW Golf & GTI Quick Reference Specification Book January 2014

    Crankshaft Dimensions .........................................................27Piston Ring End Gaps ...........................................................27Piston Ring Clearance ...........................................................27Piston and Cylinder Dimensions ............................................27

    Cylinder Head, Valvetrain 2.0L CBFA and CCTA .............28Cylinder Head Overview ........................................................28Crankcase Ventilation Tightening Specification .....................30Loosening the Cylinder Head Bolts .......................................31Cylinder Head Tightening Specifications ...............................32Timing Chain Cover Overview ...............................................34Upper Timing Chain Cover Tightening Specifications ...........35Lower Timing Chain Cover with 8 Bolts Tightening

    Specifications ..................................................................36Lower Timing Chain Cover with 15 Bolts Tightening

    Specifications ..................................................................37Camshaft Timing Chain Overview .........................................38Balance Shaft Timing Chain Overview ..................................40Intermediate Sprocket Bolt Tightening Sequence .................41Valvetrain Overview ...............................................................42Cylinder Head Cover Tightening Specifications ....................43Valve Dimensions ..................................................................44Compression Pressures ........................................................44

    Lubrication 2.0L CBFA and CCTA ....................................46Oil Pan and Oil Pump Overview ............................................46Upper Oil Pan Tightening Specifications ...............................48Oil Pan Tightening Specifications ..........................................49Oil Separator Tightening Specification ..................................50Oil Filter, Oil Cooler and Oil Pressure Switch Overview ........52

    Cooling System 2.0L CBFA and CCTA ............................54Coolant Pump and Thermostat Overview ..............................54Coolant Pump Tightening Specification .................................55After-Run Coolant Pump -V51- Overview ..............................56Coolant Pipes Overview ........................................................57Radiator, Fan Shroud and Fan Overview ..............................58

    Fuel Supply 2.0L CBFA and CCTA ..................................60Accelerator Pedal Module Overview .....................................60Fuel Tank and Attachments Overview ...................................62EVAP System Overview ........................................................64

    Turbocharger 2.0L CBFA and CCTA ................................66Charge Air Cooler System Overview .....................................66Noise Generator Overview ....................................................68Structure-Borne Sound Actuator -R214- and Structure-Borne

    Sound Control Module -J869- Overview .........................70

  • VW Golf & GTI Quick Reference Specification Book January 2014 iii

    Wastegate Bypass Regulator Valve -N75- and Turbocharger Recirculation Valve -N249- .......................72Coolant Supply and Oil Return Pipes Overview ....................74Turbocharger and Coolant Return Pipe Overview .................76Turbocharger Nut Tightening Specifications ..........................77Vacuum Diaphragm Overview ...............................................78

    Multiport Fuel Injection 2.0L CBFA and CCTA .................80Air Filter Housing Overview ...................................................80Intake Manifold Overview ......................................................82Fuel Rail and Injector Overview .............................................84High Pressure Pump Overview .............................................86Technical Data .......................................................................87

    Exhaust System 2.0L CBFA and CCTA ...........................88Exhaust System Overview .....................................................88Tightening Torque and Installed Dimension of the Clamping Sleeve .............................................................90

    Ignition 2.0L CBFA and CCTA ..........................................91Ignition System Component Overview ..................................91Technical Data .......................................................................92

    Engine Mechanical 2.0L CRZA ................................ 93General, Technical Data .....................................................93

    Engine Number Location .......................................................93Engine Data ...........................................................................94

    Engine Assembly 2.0L CRZA...........................................95Engine Mount Tightening Specifications ................................95Transmission Mount Tightening Specifications ......................96Pendulum Support Tightening Specifications ........................97Fastener Tightening Specifications ........................................97

    Crankshaft, Cylinder Block 2.0L CRZA ............................98Ribbed Belt Drive Overview ...................................................98Accessory Bracket Bolt Tightening Sequence .......................99Toothed Belt Overview .........................................................100Cylinder Block Overview ......................................................102Sealing Flange Overview .....................................................104Crankshaft Overview ...........................................................105Piston and Connecting Rod Overview .................................106Crankshaft Dimensions .......................................................107Piston Ring End Gaps .........................................................107Piston Ring Clearance .........................................................107Piston and Cylinder Dimensions ..........................................107

    Cylinder Head, Valvetrain 2.0L CRZA ............................108Cylinder Head Overview ......................................................108

  • iv VW Golf & GTI Quick Reference Specification Book January 2014

    Cylinder Head Cover Tightening Specifications ..................110Cylinder Head Tightening Specifications ............................. 111Valvetrain Overview .............................................................112Valve Dimensions ................................................................114Compression Pressures ......................................................114

    Lubrication 2.0L CRZA...................................................116Oil Pan and Oil Pump Overview ..........................................116Oil Pump and Balance Shaft Drive ......................................118Oil Filter Adapter Overview ..................................................120

    Cooling System 2.0L CRZA ...........................................122Coolant Pump/Thermostat Overview ...................................122Cooling System Components Overview, Body Side ............124Cooling System Components Overview, Engine Side .........126Coolant Recirculation Pump Overview ................................128

    Fuel Supply 2.0L CRZA .................................................129Accelerator Pedal Module Overview ...................................129Fuel Tank and Attachments Overview .................................130EVAP System Overview ......................................................132

    Turbocharger 2.0L CRZA ...............................................134Charge Air Cooler System Overview ...................................134Structure-Borne Sound Actuator -R214- and Structure-Borne

    Sound Control Module -J869- Overview .......................136Wastegate Bypass Regulator Valve and Intake Tube ..........138Coolant Supply and Oil Pipes Overview ..............................140Turbocharger and Coolant Return Pipe Overview ...............142

    Multiport Fuel Injection 2.0L CRZA ................................144Engine Cover with Air Filter Overview .................................144Intake Manifold Overview ....................................................146Fuel Rail and Injector Overview ...........................................148High Pressure Pump Overview ...........................................150Technical Data .....................................................................151

    Exhaust System 2.0L CRZA ..........................................152Exhaust System Overview ...................................................152

    Ignition 2.0L CRZA.........................................................154Ignition System Component Overview ................................154Technical Data .....................................................................155

    Engine Mechanical 2.0L CJAA .............................. 156General, Technical Data ...................................................156

    Engine Number Location .....................................................156Engine Data .........................................................................157

    Engine Assembly 2.0L CJAA .........................................158Engine Mount Tightening Specifications ..............................158

  • VW Golf & GTI Quick Reference Specification Book January 2014 v

    Transmission Mount Tightening Specifications ....................159Pendulum Support Tightening Specifications ......................160Fastener Tightening Specifications ......................................160

    Crankshaft, Cylinder Block 2.0L CJAA ..........................161Ribbed Belt Drive Overview .................................................161Cylinder Block Assembly Overview, Belt Pulley Side ..........162Ribbed Belt Pulley Side Sealing Flange - Tightening

    Specifications and Sequence ........................................163Cylinder Block Overview ......................................................164Crankshaft Overview ...........................................................165Piston and Connecting Rod Overview .................................166Accessory Bracket Bolt Tightening Sequence and

    Specification ..................................................................167Engine Mount Bracket Bolt Tightening Sequence and

    Specification ..................................................................168Crankshaft Dimensions .......................................................169Piston Ring End Gaps .........................................................169Piston Ring Clearance .........................................................169Piston and Cylinder Dimensions ..........................................169

    Cylinder Head, Valvetrain 2.0L CJJA .............................170Cylinder Head Cover Overview ...........................................170Cylinder Head Overview ......................................................172Toothed Belt Overview .........................................................174Valvetrain Overview .............................................................176Cylinder Head Cover Bolt Tightening Sequence and

    Specification ..................................................................177Cylinder Head Bolt Tightening Sequence and Specification ..................................................................178Bearing Frame Bolt Tightening Sequence and Specification ..................................................................179Valve Dimensions ................................................................180Compression Pressures ......................................................180

    Lubrication 2.0L CJAA ...................................................182Oil Filter Adapter and Engine Oil Cooler Overview ..............182Oil Pump/Oil Pan Overview .................................................184

    Cooling System 2.0L CJAA............................................186Engine Pre-Heater Overview ...............................................186Coolant Pipe Overview, Engin...