Volkswagen Golf 2013 User manual

Golf, GTI
& Golf R
Quick Reference
Specification Book
2013

VW Golf & GTI Quick Reference Specication Book • September 2012 i
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 Identication..................................................... 9
Vehicle Identication Number (VIN) Location ..........................9
VIN Decoder ..........................................................................10
VIN on Longitudinal Member Extension ................................11
Vehicle Data Label.................................................................12
Sales Codes ................................................................. 13
Engine Codes ........................................................................13
Transmission Codes ..............................................................13
Vehicle Lifting .............................................................. 14
Hoist and Jack Mounting Points .........................................14
Front ......................................................................................14
Rear.......................................................................................15
ENGINES
Engine Mechanical – 2.0L CJAA (TDI) ....................... 16
General, Technical Data .....................................................16
Engine Number Location .......................................................16
Engine Data...........................................................................17
Engine Assembly - 2.0L CJAA (TDI)...................................18
Fastener Tightening Specications........................................18
Engine Mount Tightening Specications................................18
Transmission Mount Tightening Specications......................19
Pendulum Support Tightening Specications ........................20
Engine Mount Bracket Tightening Specications ..................21
Crankshaft, Cylinder Block – 2.0L CJAA (TDI) ...................22
Fastener Tightening Specications........................................22
Accessory Bracket Tightening Specications ........................24
Crankshaft Dimensions .........................................................25
Piston and Cylinder Dimensions............................................25
Piston Ring End Gaps ...........................................................25
Piston Ring Clearance...........................................................25

ii VW Golf & GTI Quick Reference Specication Book • September 2012
Cylinder Head, Valvetrain – 2.0L CJAA (TDI) .....................26
Fastener Tightening Specications........................................26
Valve Dimensions ..................................................................27
Compression Pressures ........................................................27
Cylinder Head Cover Tightening Specications ....................28
Cylinder Head Tightening Specications ...............................29
Bearing Frame Tightening Specications ..............................30
Lubrication – 2.0L CJAA (TDI)............................................31
Fastener Tightening Specications........................................31
Cooling System – 2.0L CJAA (TDI) ....................................32
Fastener Tightening Specications........................................32
Fuel Supply – 2.0L CJAA (TDI)...........................................32
Fastener Tightening Specications........................................32
Turbocharger – 2.0L CJAA (TDI) ........................................33
Fastener Tightening Specications........................................33
Exhaust System – 2.0L CJAA (TDI)....................................33
Fastener Tightening Specications........................................33
Ignition/Glow Plug System – 2.0L CJAA (TDI)....................35
Fastener Tightening Specications........................................35
Diesel Fuel Injection – 2.0L CJAA (TDI) .............................35
Fastener Tightening Specications........................................35
ENGINE MECHANICAL – 2.0L CBFA, CCTA ............. 36
General, Technical Data .....................................................36
Engine Number Location .......................................................36
Engine Data...........................................................................37
Engine Assembly – 2.0L CBFA, CCTA ...............................38
Fastener Tightening Specications........................................38
Crankshaft, Cylinder Block – 2.0L CBFA, CCTA.................39
Cylinder Block Bearing Shell Identication ............................39
Bearing Cap Bearing Shell Identication ...............................41
Fastener Tightening Specications........................................42
Crankshaft Dimensions .........................................................43
Piston Ring End Gaps ...........................................................43
Piston Ring Clearance...........................................................43
Piston and Cylinder Dimensions............................................43
Accessory Assembly Bracket Tightening Specications........44
Sealing Flange Tightening Specications..............................45
Crankshaft Assembly Tightening Specications ....................46
Cylinder Head, Valvetrain – 2.0L CBFA, CCTA ..................47
Fastener Tightening Specications........................................47
Valve Dimensions ..................................................................48

VW Golf & GTI Quick Reference Specication Book • September 2012 iii
Compression Pressures ........................................................48
Cylinder Head Tightening Specications ...............................49
Cylinder Head Cover Tightening Specications ....................50
Crankcase Ventilation Tightening Specication.....................51
Upper Timing Chain Cover Tightening Specications ...........51
Lower Timing Chain Cover Tightening Specications
with 15 Bolts....................................................................52
Lower Timing Chain Cover Tightening Specications
with 8 Bolts......................................................................53
Lubrication – 2.0L CBFA, CCTA .........................................54
Fastener Tightening Specications........................................54
Upper Oil Pan Tightening Specications ...............................54
Oil Pan Tightening Specications ..........................................55
Oil Separator Tightening Specication ..................................56
Cooling System – 2.0L CBFA, CCTA..................................56
Fastener Tightening Specications........................................56
Coolant Pump Tightening Specication.................................57
Fuel Supply – 2.0L CBFA, CCTA........................................57
Fastener Tightening Specications........................................57
Turbocharger, G-Charger – 2.0L CBFA, CCTA...................58
Fastener Tightening Specications........................................58
Turbocharger Tightening Specications ................................59
Exhaust System – 2.0L CBFA, CCTA.................................60
Fastener Tightening Specications........................................60
Multiport Fuel Injection – 2.0L CBFA, CCTA.......................60
Technical Data .......................................................................60
Fastener Tightening Specications........................................61
Ignition – 2.0L CBFA, CCTA ...............................................62
Technical Data .......................................................................62
Fastener Tightening Specications........................................62
ENGINE MECHANICAL – 2.0L CRZA.......................... 63
General, Technical Data .....................................................63
Engine Number Location .......................................................63
Engine Data...........................................................................64
Engine Assembly – 2.0L CRZA...........................................65
Fastener Tightening Specications........................................65
Engine Mount Tightening Specications................................65
Transmission Mount Tightening Specications......................66
Pendulum Support Tightening Specications ........................67
Crankshaft, Cylinder Block – 2.0L CRZA............................68
Upper Crankshaft Bearing Identication................................68

iv VW Golf & GTI Quick Reference Specication Book • September 2012
Fastener Tightening Specications........................................69
Crankshaft Dimensions .........................................................70
Piston Ring End Gaps ...........................................................70
Piston Ring Clearance...........................................................70
Piston and Cylinder Dimensions............................................70
Accessory Assembly Bracket Tightening Specication .........71
Sealing Flange Tightening Specications..............................72
Cylinder Head, Valvetrain – 2.0L CRZA..............................73
Fastener Tightening Specications........................................73
Valve Dimensions ..................................................................74
Compression Pressures ........................................................74
Cylinder Head Tightening Specications ...............................75
Cylinder Head Cover Tightening Specication ......................76
Lubrication – 2.0L CRZA.....................................................77
Fastener Tightening Specications........................................77
Oil Pan Tightening Specications ..........................................78
Cooling System – 2.0L CRZA.............................................79
Fastener Tightening Specications........................................79
Fuel Supply – 2.0L CRZA ...................................................79
Fastener Tightening Specications........................................79
Turbocharger, G-Charger – 2.0L CRZA..............................80
Fastener Tightening Specications........................................80
Exhaust System – 2.0L CRZA ............................................81
Fastener Tightening Specications........................................81
Multiport Fuel Injection – 2.0L CRZA..................................81
Technical Data .......................................................................81
Fastener Tightening Specications........................................82
Ignition – 2.0L CRZA...........................................................83
Technical Data .......................................................................83
Fastener Tightening Specications........................................83
Engine Mechanical – 2.5L CBTA, CBUA.................... 84
General, Technical Data .....................................................84
Engine Number......................................................................84
Engine Data...........................................................................85
Cylinder Numbering ..............................................................86
Engine Assembly – 2.5L CBTA, CBUA...............................87
Fastener Tightening Specications........................................87
Engine Mount Tightening Specications................................87
Transmission Mount Tightening Specications......................88
Pendulum Support Tightening Specications ........................89

VW Golf & GTI Quick Reference Specication Book • September 2012 v
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 Specications........................................92
Crankshaft Dimensions .........................................................93
Piston and Cylinder Dimensions............................................93
Piston Ring End Gap .............................................................94
Piston Ring Clearance...........................................................94
Cylinder Head, Valvetrain – 2.5L CBTA, CBUA..................95
Fastener Tightening Specications........................................95
Valve Dimensions ..................................................................96
Compression Pressures ........................................................96
Cylinder Head Cover Tightening Specication ......................97
Cylinder Head Tightening Specications ...............................98
Guide Frame Tightening Specications.................................99
Lubrication – 2.5L CBTA, CBUA.......................................100
Fastener Tightening Specications......................................100
Cooling System – 2.5L CBTA, CBUA ...............................101
Fastener Tightening Specications......................................101
Fuel Supply – 2.5L CBTA, CBUA......................................101
Fastener Tightening Specications......................................101
Exhaust System, Emission Controls –
2.5L CBTA, CBUA.............................................................102
Fastener Tightening Specications......................................102
Secondary Air Injection Pipe Tightening Specications.......103
Multiport Fuel Injection – 2.5L CBTA, CBUA ....................104
Fastener Tightening Specications......................................104
Lower Air Filter Housing
Bolt Tightening Specications ......................................104
Ignition – 2.5L CBTA, CBUA.............................................105
Fastener Tightening Specications......................................105
Technical Data .....................................................................105
TRANSMISSIONS
Manual Transmission – 0A4 ..................................... 106
General, Technical Data ...................................................106
Transmission Identication ..................................................106
Codes Letters, Transmission Allocation and Capacities......108

vi VW Golf & GTI Quick Reference Specication Book • September 2012
Clutch – 0A4 .....................................................................109
Fastener Tightening Specications......................................109
Controls, Housing – 0A4...................................................110
Fastener Tightening Specications......................................110
Transmission to Engine Tightening Specications .............. 111
Transmission Mount Bracket to Transmission Bolt
Tightening Specication ................................................112
Transmission Mount to Transmission Mount Bracket Bolt
Tightening Specication ................................................113
Transmission Support to Transmission Bracket and
Transmission Bolt Tightening Specication...................114
Reverse Shaft Support to Transmission Housing Bolt
Tightening Sequence and Specication........................ 115
Gears, Shafts – 0A4 .........................................................116
Fastener Tightening Specication .......................................116
Determining Shim Thickness...............................................116
Adjustment Shim Table........................................................ 116
Manual Transmission – 02Q ......................................118
General, Technical Data ...................................................118
Transmission Identication ..................................................118
Codes Letters, Transmission Allocation and Capacities......120
Clutch – 02Q.....................................................................121
Fastener Tightening Specications......................................121
Controls, Housing – 02Q ..................................................122
Transmission to Engine Tightening Specications ..............122
Front Wheel Drive Fastener Tightening Specications........122
Adjustment Shim Table........................................................123
Rear Final Drive, Differential – 02Q..................................124
Fastener Tightening Specications......................................124
All Wheel Drive Fastener Tightening Specications ............124
Transmission Mount ............................................................125
Brace under Diaphragm ......................................................126
Transmission Bracket to Transmission ................................127
Identication on Transmission .............................................128
Automatic Transmission – 09G ................................ 129
General, Technical Data ...................................................129
Identication on Transmission .............................................129
Code Letters, Assembly Allocation and Ratios ....................130
Controls, Housing .............................................................131
Fastener Tightening Specications......................................131
Transmission to Engine Tightening Specications ..............132

VW Golf & GTI Quick Reference Specication Book • September 2012 vii
Gears, Hydraulic Controls – 09G......................................133
Fastener Tightening Specications......................................133
Transmission Fluid Pan Tightening Specication ................134
Direct Shift Gearbox (DSG) Transmission – 02E .... 135
General, Technical Data ...................................................135
Identication on Transmission .............................................135
Transmission Allocation Codes............................................137
Controls, Housing (DSG) – 02E .......................................138
Fastener Tightening Specications......................................138
Mechatronic Tightening Specications ................................139
Oil Pump Tightening Specications
Without Countersunk Bolt .............................................140
With Countersunk Bolt.........................................................140
Oil Pump Cover Tightening Specications ..........................141
Transmission Mount Tightening Specications....................142
Transmission to Engine Tightening Specications ..............143
CHASSIS
Suspension, Wheels, Steering ................................. 144
Front Suspension .............................................................144
Fastener Tightening Specications......................................144
Rear Suspension ..............................................................146
Fastener Tightening Specications......................................146
Self-Leveling Suspension .................................................148
Fastener Tightening Specications......................................148
Wheels, Tires, Wheel Alignment.......................................148
Fastener Tightening Specications......................................148
Wheel Alignment Data ......................................................149
Wheel Alignment Specied Values ......................................149
Steering ............................................................................154
Fastener Tightening Specications......................................154
Brake System............................................................. 156
General, Technical Data ...................................................156
Vehicle Data Sticker PR Number Allocation ........................156
Front Brakes ........................................................................157
Rear Brakes.........................................................................157
Brake Master Cylinder and Brake Booster ..........................157
Front Brakes ........................................................................158
Rear Brakes C38 .................................................................160

viii VW Golf & GTI Quick Reference Specication Book • September 2012
Anti-lock Brake System (ABS)..........................................161
Fastener Tightening Specications......................................161
Mechanical Components ..................................................161
Fastener Tightening Specications......................................161
Hydraulic Components .....................................................162
Fastener Tightening Specications......................................162
Body............................................................................ 163
Air Gap Body Dimensions ................................................163
Body, Front ..........................................................................163
Body, Center........................................................................164
Body, Rear...........................................................................165
Body Exterior ....................................................................166
Bulkhead, Front Fender Tightening Specications ..............166
Lock Carrier Tightening Specications ................................166
Underbody Trim, Noise Insulation Tightening
Specications ................................................................166
Tunnel Bridge, Plenum Chamber Tightening
Specications ................................................................167
Front Hood Tightening Specications..................................167
Rear Lid, Fuel Filler Door Tightening Specications............167
Front and Rear Door Tightening Specications...................167
Sunroof Tightening Specications .......................................168
Front Bumper Tightening Specications..............................168
Rear Bumper, Trailer Hitch Tightening Specications .........168
Mirror Tightening Specications ..........................................168
Exterior Equipment Tightening Specications .....................168
Body Interior .....................................................................169
Storage Compartments, Covers and Trim Tightening
Specications ................................................................169
Passenger Protection Fastener Tightening Specications ..169
Interior Trim Fastener Tightening Specications .................170
Seat Frames Fastener Tightening Specications ................170
Heating, Ventilation and Air Conditioning............... 171
General, Technical Data ...................................................171
Refrigerant Oil Distribution ..................................................171
Refrigerant R134a Vapor Pressure Table ............................172
Heating, Ventilation...........................................................173
Fastener Tightening Specications......................................173
Air Conditioning ................................................................174
Fastener Tightening Specications......................................174

VW Golf & GTI Quick Reference Specication Book • September 2012 ix
Electrical System....................................................... 175
Electrical Equipment.........................................................175
Battery, Starter, Generator, Cruise Control Fastener
Tightening Specications ..............................................175
Windshield Wiper/Washer Tightening Specications...........176
Exterior Lights, Switches Tightening Specications ............176
Interior Lights, Switches Tightening Specications..............176
Wiring Tightening Specication ...........................................176
Left E-box in Engine Compartment Tightening
Specications ................................................................177
DTC Chart................................................................... 178
Engine Codes CBFA.........................................................178
Fuel and Air Mixture,
Additional Emission Regulations...................................178
Ignition System ....................................................................185
Additional Exhaust Regulation.............................................187
Speed and Idle Control........................................................189
Control Module and Output Signals.....................................189
Fuel and Air Ratios Control Module.....................................191
Additional Emissions Regulations .......................................194
DTC Chart................................................................... 196
Engine Codes CCTA.........................................................196
Fuel and Air Mixture,
Additional Emission Regulations...................................196
Ignition System ....................................................................202
Additional Exhaust Regulation.............................................204
Speed and Idle Control........................................................205
Control Module and Output Signals.....................................205
Fuel and Air Ratios Control Module.....................................207
Additional Emissions Regulations .......................................210
DTC Chart....................................................................211
Engine Codes CJAA ........................................................211
Fuel and Air Mixture,
Additional Emission Regulations...................................211
Fuel and Air Ratios Control Module ....................................222
Ignition System ....................................................................223
Additional Exhaust Regulation.............................................224
Speed and Idle Control........................................................228
Control Module and Output Signals.....................................229

x VW Golf & GTI Quick Reference Specication Book • Sepetember 2012
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................................................................... 248
Engine Codes CBTA, CBUA.............................................248
Fuel and Air Mixture,
Additional Emission Regulations...................................248
Ignition System ....................................................................256
Additional Exhaust Regulation.............................................258
Speed and Idle Control........................................................260
Control Module and Output Signals.....................................260
Fuel and Ratio Control Module............................................262

General
Information
VW Golf & GTI Quick Reference Specication Book • September 2012 1
GENERAL INFORMATION
Decimal and Metric Equivalents
Distance/Length
To calculate: mm x 0.03937 = in.
mm in. mm in. mm in. mm in.
0.002 0.00008 0.01 0.0004 0.1 0.004 1 0.04
0.004 0.00016 0.02 0.0008 0.2 0.008 2 0.08
0.006 0.00024 0.03 0.0012 0.3 0.012 3 0.12
0.008 0.00031 0.04 0.0016 0.4 0.016 40.16
0.010 0.00039 0.05 0.0020 0.5 0.020 5 0.20
0.020 0.00079 0.06 0.0024 0.6 0.024 6 0.24
0.030 0.00118 0.07 0.0028 0.7 0.028 7 0.28
0.040 0.00157 0.08 0.0031 0.8 0.031 8 0.31
0.050 0.00197 0.09 0.0035 0.9 0.035 90.35
0.060 0.00236 0.10 0.0039 1.0 0.039 10 0.39
0.070 0.00276 0.20 0.0079 2.0 0.079 20 0.79
0.080 0.00315 0.30 0.0118 3.0 0.118 30 1.18
0.090 0.00354 0.40 0.0157 4.0 0.157 40 1.57
0.100 0.00394 0.50 0.0197 5.0 0.197 50 1.97
0.200 0.00787 0.60 0.0236 6.0 0.236 60 2.36
0.300 0.01181 0.70 0.0276 7.0 0.276 70 2.76
0.400 0.01575 0.80 0.0315 8.0 0.315 80 3.15
0.500 0.01969 0.90 0.0354 9.0 0.354 90 3.54
0.600 0.02362 1.00 0.0394 10.0 0.394 100 3.94
0.700 0.02756 2.00 0.0787 20.0 0.787
0.800 0.03150 3.00 0.1181 30.0 1.181
0.900 0.03543 4.00 0.1575 40.0 1.575
1.000 0.03937 5.00 0.1969 50.0 1.969
2.000 0.07874 6.00 0.2362 60.0 2.362
3.000 0.11811 7.00 0.2756 70.0 2.756
4.000 0.15748 8.00 0.3150 80.0 3.150
5.000 0.19685 9.00 0.3543 90.0 3.543
6.000 0.23622 10.00 0.3937 100.0 3.937
7.000 0.27559 20.00 0.7874
8.000 0.31496 30.00 1.1811
9.000 0.35433 40.00 1.5748
10.000 0.39370 50.00 1.9685
20.000 0.78740 60.00 2.3622
30.000 1.18110 70.00 2.7559
40.000 1.57480 80.00 3.1496
50.000 1.96850 90.00 3.5433
60.000 2.36220 100.00 3.9370
70.000 2.75591
80.000 3.14961
90.000 3.54331
100.000 3.93701

2 VW Golf & GTI Quick Reference Specication Book • Sepetember 2012
Tightening Torque
Nm-to-lb·ft (ft·lb)
To calculate: Nm x 0.738 = lb·ft
Nm lb·ft
(ft·lb) Nm lb·ft (ft·lb) Nm lb·ft (ft·lb)
10 7 55 41 100 74
11 8 56 41 105 77
12 957 42 110 81
13 10 58 43 115 85
14 10 59 44 120 89
15 11 60 44 125 92
16 12 61 45 130 96
17 13 62 46 135 100
18 13 63 46 140 103
19 14 64 47 145 107
20 15 65 48 150 111
21 15 66 49 155 114
22 16 67 49 160 118
23 17 68 50 165 122
24 18 69 51 170 125
25 18 70 52 175 129
26 19 71 52 180 133
27 20 72 53 185 136
28 21 73 54 190 140
29 21 74 55 195 144
30 22 75 55 200 148
31 23 76 56 205 151
32 24 77 57 210 155
33 24 78 58 215 159
34 25 79 58 220 162
35 26 80 59 225 166
36 27 81 60 230 170
37 27 82 60 235 173
38 28 83 61 240 177
39 29 84 62 245 181
40 30 85 63 250 184
41 30 86 63 260 192
42 31 87 64 270 199
43 32 88 65 280 207
44 32 89 66 290 214
45 33 90 66 300 221
46 34 91 67 310 229
47 35 92 68 320 236
48 35 93 69 330 243
49 36 94 69 340 251
50 37 95 70 350 258
51 38 96 71 360 266
52 38 97 72 370 273
53 39 98 72 380 280
54 40 99 73 390 288
55 41 100 74 400 295

General
Information
VW Golf & GTI Quick Reference Specication Book • September 2012 3
Nm-to-lb·in (in·lb), kg·cm
To calculate: Nm x 8·85 = lb·in • Nm x 10.20 = kg·cm
Nm lb·in
(in·lb) kg·cm Nm lb·in (in·lb) kg·cm
1910 26 230 265
2 18 20 27 239 275
3 27 31 28 248 286
435 41 29 257 296
544 51 30 266 306
6 53 61 31 274 316
7 62 71 32 283 326
8 71 82 33 292 337
980 92 34 301 347
10 89 102 35 310 357
11 97 112 36 319 367
12 106 122 37 327 377
13 115 133 38 336 387
14 124 143 39 345 398
15 133 153 40 354 408
16 142 163 41 363 418
17 150 173 42 372 428
18 159 184 43 381 438
19 168 194 44 389 449
20 177 204 45 398 459
21 186 214 46 407 469
22 195 224 47 416 479
23 204 235 48 425 489
24 212 245 49 434 500
25 221 255 50 443 510
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
N·cm lb·in
(in·lb) kg·cm N·cm lb·in (in·lb) kg·cm
50 45 250 22 25
60 5 6 300 27 31
70 6 7 350 31 36
80 7 8 400 35 41
90 8 9450 40 46
100 910 500 44 51
110 10 11 550 49 56
120 11 12 600 53 61
130 12 13 650 58 66
140 12 14 700 62 71
150 13 15 750 66 76
160 14 16 800 71 82
170 15 17 850 75 87
180 16 18 900 80 92
190 17 19 950 84 97
200 18 20 1000 89 102

4 VW Golf & GTI Quick Reference Specication Book • Sepetember 2012
kg·cm-to-lb·in (in·lb), N·cm
To calculate: kg·cm x 0.868 = lb·in • kg·cm x 9.81 = N·cm
kg·cm lb·in
(in·lb) N·cm kg·cm lb·in (in·lb) N·cm
54 49 110 95 1079
6 5 59 120 104 1177
7 6 69 130 113 1275
8 7 78 140 122 1373
98 88 150 130 1471
10 998 160 139 1569
20 17 196 170 148 1667
30 26 294 180 156 1765
40 35 392 190 165 1863
50 43 490 200 174 1961
60 52 588 210 182 2059
70 61 686 220 191 2157
80 69 785 230 200 2256
90 78 883 240 208 2354
100 87 981 250 217 2452
Warnings and Cautions
WARNINGS
• Some repairs may be beyond your capability. If you lack the skills,
tools and equipment, or a suitable workplace for any procedure
described in this manual, we suggest you leave such repairs to an
authorized dealer service department or other qualied shop.
• Do not reuse any fasteners that have become worn or deformed
during normal use. Many fasteners are designed to be used only
once and become unreliable and may fail when used a second
time. This includes, but is not limited to, nuts, bolts, washers, self-
locking nuts or bolts, circlips and cotter pins. Always replace these
fasteners with new parts.
• Never work under a lifted car unless it is solidly supported on
stands designed for the purpose. Do not support a car on cinder
blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a car that is supported solely
by a jack. Never work under the car while the engine is running.
• If you are going to work under a car on the ground, make sure
the ground is level. Block the wheels to keep the car from rolling.
Disconnect the battery negative (-) terminal (ground strap) to
prevent others from starting the car while you are under it.

General
Information
VW Golf & GTI Quick Reference Specication Book • September 2012 5
• Never run the engine unless the work area is well ventilated.
Carbon monoxide kills.
• Remove rings, bracelets and other jewelry so they cannot cause
electrical shorts, get caught in running machinery, or be 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. If your hair, clothing, or jewelry were to get caught in the
machinery, severe injury could result.
• Do not attempt to work on your car if you do not feel well. You
increase the danger of injury to yourself and others if you are tired,
upset, or have taken medication or any other substance that may
keep you from being fully alert.
• Illuminate your work area adequately but safely. Use a portable
safety light for working inside or under the car. Make sure the bulb
is enclosed by a wire cage. The hot lament of an accidentally
broken bulb can ignite spilled fuel, vapors or oil.
• Use a suitable container to catch draining fuel, oil, or brake
uid. Do not use food or beverage containers that might mislead
someone into drinking from them. Store ammable uids away
from re hazards. Wipe up spills at once, but do not store oily rags
which can ignite and burn spontaneously.
• Always observe good workshop practices. Wear goggles when you
operate machine tools or work with battery acid. Wear gloves or
other protective clothing whenever the job requires working with
harmful substances.
• Greases, lubricants and other automotive chemicals contain toxic
substances, many of which are absorbed directly through the skin.
Read the manufacturer’s instructions and warnings carefully. Use
hand and eye protection. Avoid direct skin contact
• Disconnect the battery negative (-) terminal (ground strap)
whenever you work on the fuel or electrical system. Do not smoke
or work near heaters or other re hazards. Keep an approved re
extinguisher handy.
• Friction materials (such as brake pads or shoes or clutch discs)
contain asbestos bers or other friction materials. Do not create
dust by grinding, sanding, or cleaning with compressed air. Avoid
breathing dust. Breathing any friction material dust can lead to
serious diseases and may result in death.
(WARNINGS cont’d on next page)

6 VW Golf & GTI Quick Reference Specication Book • Sepetember 2012
WARNINGS (cont’d)
• Batteries give off explosive hydrogen gas during charging. Keep
sparks, lighted matches and open ame 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.
• Connect and disconnect battery cables, jumper cables or a battery
charger only with the ignition off. Do not disconnect the battery
while the engine is running.
• Do not quick-charge the battery (for boost starting) for longer than
one minute. Wait at least one minute before boosting the battery a
second time.
• Do not allow battery charging voltage to exceed 16.5 volts. If
the battery begins producing gas or boiling violently, reduce the
charging rate. Boosting a sulfated battery at a high charging rate
can cause an explosion.
• The A/C system is lled with chemical refrigerant, which is
hazardous. The A/C system should be serviced only by trained
technicians using approved refrigerant recovery/recycling
equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
• Do not expose any part of the A/C system to high temperatures
such as open ame. Excessive heat increases system pressure
and may cause the system to burst.
• Some aerosol tire inators are highly ammable. Be extremely
cautious when repairing a tire that may have been inated using an
aerosol tire inator. Keep sparks, open ame or other sources of
ignition away from the tire repair area. Inate and deate the tire at
least four times before breaking the bead from the rim. Completely
remove the tire from the rim before attempting
any repair.
• Some cars are equipped with a Supplemental Restraint System
(SRS) that automatically deploys airbags and pyrotechnic seat
belt tensioners in the event of a frontal or side impact. These
are explosive devices. Handled improperly or without adequate
safeguards, they can be accidentally activated and cause serious
injury.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals and use extreme care when
working on a car with the engine running or the ignition on.

General
Information
VW Golf & GTI Quick Reference Specication Book • September 2012 7
• Place jack stands only at locations specied by manufacturer.
The vehicle lifting jack supplied with the vehicle is intended for tire
changes only. Use a heavy duty oor jack to lift the vehicle before
installing jack stands.
• Battery acid (electrolyte) can cause severe burns. Flush contact
area with water, seek medical attention.
• Aerosol cleaners and solvents may contain hazardous or deadly
vapors and are highly ammable. Use only in a well ventilated
area. Do not use on hot surfaces (such as engines or brakes).
• Do not remove coolant reservoir or radiator cap with the engine
hot. Burns and engine damage may occur.
CAUTIONS
• If you lack the skills, tools and equipment, or a suitable workshop
for any procedure described in this manual, we suggest you leave
such repairs to an authorized dealer or other
qualied shop.
• Before starting a job, make certain that you have all the necessary
tools and parts on hand. Read all the instructions thoroughly
and do not attempt shortcuts. Use tools appropriate to the work
and use only replacement parts meeting original specications.
Makeshift tools, parts and procedures will not make good repairs.
• Use pneumatic and electric tools only to loosen threaded parts and
fasteners. Never use these tools to tighten fasteners, especially on
light alloy parts. Always use a torque wrench to tighten fasteners to
the tightening torque specication listed.
• Be mindful of the environment and ecology. Before you drain the
crankcase, nd out the proper way to dispose of the oil. Do not
pour oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of in accordance with Federal, State and
Local laws.
• The control module for the Anti-lock Brake System (ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp in excess of 95 °C (203 °F) and should not be subjected to
temperatures exceeding 85 °C (185 °F) for more than two hours.
• Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative (-) terminal (ground strap) and the
ABS control module connector.
• Always make sure the ignition is off before disconnecting battery.
(CAUTIONS cont’d on next page)

8 VW Golf & GTI Quick Reference Specication Book • Sepetember 2012
CAUTIONS (cont’d)
• Label battery cables before disconnecting. On some models,
battery cables are not color coded.
• Disconnecting the battery may erase fault code(s) stored in control
module memory. Check for fault codes prior to disconnecting the
battery cables.
• If a normal or rapid charger is used to charge the battery,
disconnect the battery and remove it from the vehicle to avoid
damaging paint and upholstery.
• Do not quick-charge the battery (for boost starting) for longer than
one minute. Wait at least one minute before boosting the battery a
second time.
• Connect and disconnect a battery charger only with the battery
charger switched off.
• Sealed or “maintenance free” batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the
battery’s ampere-hour (Ah) rating.
• Do not allow battery charging voltage to exceed 16.5 volts. If
the battery begins producing gas or boiling violently, reduce the
charging rate. Boosting a sulfated battery at a high charging rate
can cause an explosion.