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VW Golf & GTI Quick Reference Specification Book • January 2014

SUSpEnSIon, WHEELS,

StEErInG

Front Suspension

Subframe, Stabilizer Bar and Control Arms overview

1 - nut

65 Nm

Always replace if removed

2 - Coupling rod

3 - Bracket

4 - mounting Bracket

5 - Bolt

50 Nm + 90° turn

Always replace if removed

6 - Bolt

Summary of Contents for 2014 Golf

Page 1: ... and Cautions 4 WARNINGS 4 CAUTIONS 7 Vehicle Identification 9 Vehicle Identification 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 CHASSIS Suspension Wheels Steering 16 Front Suspension 16 Subframe Stabilizer Bar and Contro...

Page 2: ... Coil Spring Overview 40 Stabilizer Bar Overview 41 All Wheel Drive AWD 42 Subframe Final Drive Overview 42 Transverse Link Tie Rod Overview 44 Left Rear Level Control System Sensor G76 Overview 46 Shock Absorber Coil Spring 47 Wheel Bearing Housing and Trailing Arm Assembly Overview 48 Stabilizer Bar AWD Overview 50 Drive Axle Overview 52 Self Leveling Suspension 54 Left and Right Front Level Con...

Page 3: ...5 Front Wheel Speed Sensor Overview 85 Rear Wheel Speed Sensor Overview 86 Hydraulic Unit and Brake Booster Master Cylinder Overview ABS Mark 70 ABS ASR 88 Hydraulic Unit and Brake Booster Master Cylinder Overview ABS Mark 60 EC ABS EDL ASR ESP 90 Mechanical Components 92 Front Brakes Overview FS III Overview 92 Front Brakes Overview FN 3 94 Front Brakes Overview FNR G 96 Tightening Specification ...

Page 4: ...y Trim Panel Center Overview 128 Underbody Trim Panel Rear Overview 129 Hood Lids 130 Hood Overview 130 Rear Lid Gas Filled Strut Overview 131 Rear Lid Hinge Overview 132 Fuel Filler Door Unit and Actuator Overview 133 Front Doors Central Locking System 134 Door Handle and Door Lock Overview 134 Door Hinge Overview 136 Front Door Overview 138 Rear Doors 140 Door Handle and Door Lock Overview 140 D...

Page 5: ...quipment 169 Roof Grab Handles 169 Tightening Specifications 169 Passenger Protection Airbags Seat Belts 170 Front Seat Belts 2 door Assembly Overview 170 Front Seat Belts 4 door Assembly Overview 172 Rear Outer Seat Belts Assembly Overview 173 Rear Center Three Point Seat Belt Assembly Overview 174 Airbag Control Module J234 175 Driver and Passenger Side Airbag 176 Driver and Passenger Side Curta...

Page 6: ...rator Overview 194 Starter Overview 196 Fastener Tightening Specifications 197 Windshield Wiper Washer System 198 Rear Window Wiper System Overview 198 Windshield Wiper System Overview 199 Exterior Lights Switches 200 Fog Lamp Golf Overview 200 Fog Lamp GTI Overview 201 Halogen Headlamps Overview 202 HID Headlamp and Cornering Lamp Overview 204 Rear Lid Tail Lamps Overview 206 Steering Column Swit...

Page 7: ...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...

Page 8: ...2 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 20...

Page 9: ...8 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 4 5 250 22 25 60 5 6 300 27 31...

Page 10: ...d dealer service department or other qualified 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 wo...

Page 11: ...h draining fuel oil or brake fluid Do not use food or beverage containers that might mislead someone into drinking from them Store flammable fluids away from fire 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 protectiv...

Page 12: ...t 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 flame Excessive heat increases system pressure and may cause the system to burst Some aerosol tire inflators are highly flammable Be extremely cautious...

Page 13: ...instructions thoroughly and do not attempt shortcuts Use tools appropriate to the work and use only replacement parts meeting original specifications 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 tigh...

Page 14: ...o 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...

Page 15: ...nce Specification Book January 2014 9 Vehicle Identification Vehicle Identification Number VIN Location The VIN Æ is on the left side of the vehicle in the area of the windshield wiper mount It is visible from the outside typical illustration shown ...

Page 16: ...gs Calculate per NHTSA Code Sequential Product Number Calculate per nHtSA Code E 2014 WVW Europe Pass Car 1VW USA Pass Car 3VW Mexico Pass Car WVG Europe S U V K Jetta SportWagen w 5 Spd Man Trans L Jetta SEL TDI w Auto Trans m Jetta SportWagen w 6 Spd Manual n Golf 4dr w 6 Spd Manual p Jetta SportWagen w 6 Spd Auto Trans r Beetle TDI w 6 Spd Man CC Exec w Auto Trans V Beetle R Line w 6 Spd Auto T...

Page 17: ...cle Identification VW Golf GTI Quick Reference Specification Book January 2014 11 VIN on Longitudinal Member Extension The Vehicle Identification Number VIN is located on the longitudinal member extension Æ ...

Page 18: ...I Quick Reference Specification Book January 2014 Vehicle Data Label The vehicle data label Æ is located on the left side of the spare wheel well The vehicle data label is also in the customer s Maintenance booklet ...

Page 19: ...3 Sales Codes Engine Codes CJAA 2 0L TDI 4 cylinder 4V turbo diesel CBFA CCTA 2 0L TFSI 4 cylinder 4V CZRA 2 0L TFSI 4 cylinder 4V CBTA CBUA 2 5L 5 cylinder 4V Transmission Codes 0A4 5 speed manual 02Q 6 speed manual 02E 6 speed Direct Shift Gearbox DSG 09G 6 speed automatic ...

Page 20: ...14 VW Golf GTI Quick Reference Specification Book January 2014 Vehicle Lifting Hoist and Jack Mounting Points Front Position the support plate in the side member vertical reinforcement area Æ ...

Page 21: ...Vehicle Lifting VW Golf GTI Quick Reference Specification Book January 2014 15 Rear Position the support plate in the side member vertical reinforcement area Æ ...

Page 22: ...Book January 2014 Suspension Wheels Steering Front Suspension Subframe Stabilizer Bar and Control Arms Overview 1 Nut 65 Nm Always replace if removed 2 Coupling Rod 3 Bracket 4 Mounting Bracket 5 Bolt 50 Nm 90 turn Always replace if removed 6 Bolt ...

Page 23: ...nt 14 Nut Cast steel control arm 60 Nm Steel and aluminum control arms 100 Nm Always replace if removed 15 Nut 9 Nm Always replace if removed 16 Bolt 70 Nm 90 turn M12 x 1 5 x 100 Always replace if removed 17 Bolt 20 Nm 90 turn Always replace if removed 18 Bolt 70 Nm 90 turn M12 x 1 5 x 75 Always replace if removed 19 Bolt 100 Nm 90 turn M14 x 1 5 x 70 Always replace if removed 20 Underbody Protec...

Page 24: ... Rubber Bushing for Pendulum Support 26 Shield For FWD vehicles only 27 Bolt 6 Nm 28 Subframe Various versions 29 Upper Bonded Rubber Bushing for Pendulum Support 30 Bolt 70 Nm 90 turn M12 x 1 5 x 110 Always replace if removed 31 Nut 65 Nm Always replace if removed 32 Stabilizer Bar Various versions ...

Page 25: ...fication Book January 2014 19 Left Front Level Control System Sensor Assembly Overview 1 Subframe 2 Bolt 9 Nm M6 x 16 3 Left Front Level Control System Sensor G78 and Right Front Level Control System Sensor G289 4 Control Arm 5 Nut 9 Nm Always replace if removed ...

Page 26: ...unt FS III Brake 2 Wheel Hub with Wheel Bearing 3 Point Mount FS III Brake 3 Suspension Strut 4 Bolt 5 Left Front ABS Wheel Speed Sensor G47 Right Front ABS Wheel Speed Sensor G45 6 Bolt 8 Nm 7 Tie Rod End 8 Cover Plate 9 Bolt 10 Nm 10 Nut 20 Nm 90 turn Always replace if removed 11 Wheel Bearing Housing 4 Point Mount FS III Brake ...

Page 27: ...olt Various versions Always replace if removed 14 Bolt Tightening specification refer to Brake System Mechanical Components 15 Wheel Hub with Wheel Bearing 4 Point Mount 16 Wheel Bearing Housing 4 Point Mount FN3 Brake 17 Bolt 70 Nm 90 turn Always replace if removed 18 Drive Axle 19 Nut 70 Nm 90 turn Always replace if removed ...

Page 28: ...rut Assembly Overview 1 Shock Absorber 2 Buffer Stop 3 Protective Sleeve 4 Coil Spring 5 Axial Groove Ball Bearing 6 Suspension Strut Bearing 7 Nut 60 Nm M14 x 1 5 Always replace if removed 8 Suspension Strut Dome 9 Bolt 15 Nm 90 turn Always replace if removed 10 Protective Cap ...

Page 29: ...Steering VW Golf GTI Quick Reference Specification Book January 2014 23 Drive Axle Heat Shields Front Wheel Drive FWD Component Nm Bolts 1 25 Nm All Wheel Drive AWD Component Nm Nuts 1 20 Nm Pre tighten all nuts to 10 Nm ...

Page 30: ...24 VW Golf GTI Quick Reference Specification Book January 2014 All Wheel Drive AWD Component Nm Nuts 1 20 Nm Pre tighten all nuts to 10 Nm ...

Page 31: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 25 ...

Page 32: ...t VL90 and VL100 1 Outer CV Joint 2 Bolt Various versions Twelve point bolt with ribs is 70 Nm 90 Twelve point bolt without ribs is 200 Nm 180 Always replace if removed 3 Right Drive Axle 4 Clamp 5 Protective Boot 6 Clamp Always replace if removed 7 Dished Washer 8 Thrust Washer 9 Securing Ring 10 CV Boot ...

Page 33: ...mp Always replace if removed 12 Left Drive Axle 13 Backing Plate 14 Bolt First tighten to 10 Nm in a diagonal sequence then tighten to tightening specification in a diagonal sequence 40 Nm M8 x 48 Always replace bolts after disassembly 15 Securing Ring 16 Gasket 17 Inner CV Joint 18 Dished Washer ...

Page 34: ...L107 1 Outer CV Joint 2 Bolt Various versions Twelve point bolt with ribs is 70 Nm 90 Twelve point bolt without ribs is 200 Nm 180 Always replace if removed 3 Securing Ring Always replace if removed 4 Thrust Washer 5 Dished Washer 6 Clamp Always replace if removed 7 Protective Boot 8 Clamp Always replace if removed ...

Page 35: ...s replace if removed 11 CV Boot 12 Clamp Always replace if removed 13 Backing Plate 14 Cover 15 Inner CV Joint 16 Gasket 17 Securing Ring 18 Cover 19 Bolt First tighten to 10 Nm in a diagonal sequence then tighten to tightening specification in a diagonal sequence 70 Nm M10 x 52 Always replace bolts after disassembly ...

Page 36: ...L107 1 Outer CV Joint 2 Bolt Various versions Twelve point bolt with ribs is 70 Nm 90 Twelve point bolt without ribs is 200 Nm 180 Always replace if removed 3 Securing Ring Always replace if removed 4 Thrust Washer 5 Dished Washer 6 Clamp Always replace if removed 7 Protective Boot 8 Clamp Always replace if removed ...

Page 37: ...W Golf GTI Quick Reference Specification Book January 2014 31 9 Drive Axle 10 Clamp Allways replace if removed 11 CV Joint Protective Boot 12 Securing Ring Allways replace if removed 13 Clamp Allways replace if removed 14 CV Joint ...

Page 38: ...nt AAR3300i 1 Outer CV Joint 2 Bolt Various versions Twelve point bolt with ribs is 70 Nm 90 Twelve point bolt without ribs is 200 Nm 180 Always replace if removed 3 Securing Ring Always replace if removed 4 Thrust Washer 5 Dished Washer 6 Clamp Always replace if removed 7 CV Boot 8 Clamp Always replace if removed ...

Page 39: ...ace if removed 11 Protective Joint Boot for Triple Roller Joint 12 Clamp Allways replace if removed 13 Triple Roller Star with Rollers 14 Securing Ring Allways replace if removed 15 Bolt First tighten to 10 Nm in a diagonal sequence then tighten to tightening specification in a diagonal sequence 70 Nm M10 x 23 16 Joint Piece ...

Page 40: ...nsion Front Wheel Drive FWD Subframe Transverse Link and Tie Rod Overview 1 Eccentric Bolt 2 Nut 95 Nm Always replace if removed 3 Eccentric Washer 4 Eccentric Bolt After loosening perform vehicle alignment 5 Eccentric Washer 6 Nut 95 Nm Always replace if removed 7 Subframe ...

Page 41: ... if removed 12 Threaded Rivet M6 13 Expanding Rivet 14 Stone Chip Protection 15 Bolt 8 Nm 16 Nut 130 Nm 90 turn Always replace if removed 17 Bolt Always replace if removed 18 Upper Transverse Link 19 Washer 20 Nut 130 Nm 90 turn Always replace if removed 21 Wheel Bearing Housing 22 Washer 23 Bolt Always replace if removed 24 Tie Rod Various versions 25 Bolt Always replace if removed 26 Nut 90 Nm 9...

Page 42: ... Golf GTI Quick Reference Specification Book January 2014 Left Rear Level Control System Sensor G76 Overview 1 Subframe 2 Lower Transverse Link 3 Bolt 5 Nm M5 x 20 4 Left Rear Level Control System Sensor G76 ...

Page 43: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 37 ...

Page 44: ...verview 1 Bolt 50 Nm 90 turn Always replace if removed 2 Mounting Bracket 3 Bolt 90 Nm 90 turn Always replace if removed 4 Coupling Rod 5 Bolt 90 Nm 90 turn M12 x 1 5 x 40 Always replace if removed 6 Trailing Arm 7 Bolt 8 Nm 8 Right Rear ABS Wheel Speed Sensor G44 Left Rear ABS Wheel Speed Sensor G46 ...

Page 45: ...anuary 2014 39 9 Wheel Bearing Housing 10 Bonded Rubber Bushing 11 Nut 45 Nm Always replace if removed 12 Bolt 4 Nm 13 Brake Disc 14 Dust Cap Always replace if removed 15 Bolt 180 Nm 90 turn Always replace if removed 16 Wheel Hub with Wheel Bearing 17 Bolt 12 Nm 18 Cover Plate ...

Page 46: ...on Book January 2014 Shock Absorber Coil Spring Overview 1 Upper Spring Support 2 Coil Spring 3 Lower Spring Support 4 Bolt 180 Nm 5 Bolt 50 Nm 90 turn Always replace if removed 6 Shock Absorbers 7 Lower Transverse Link 8 Wheel Bearing Housing ...

Page 47: ...Book January 2014 41 Stabilizer Bar Overview 1 Stabilizer Bar 2 Rubber Mount 3 Clamp 4 Bolt 25 Nm 90 turn Tighten uniformly Always replace if removed 5 Wheel Bearing Housing 6 Nut 45 Nm Always replace if removed 7 Bolt Always replace if removed 8 Coupling Rod 9 Subframe ...

Page 48: ...uary 2014 All Wheel Drive AWD Subframe Final Drive Overview 1 Subframe 2 Rear Bonded Rubber Bushing 3 Front Bonded Rubber Bushing 4 Final Drive 5 Bolt 60 Nm 90 turn Always replace if removed 6 Washer 7 Washer 8 Bolt 60 Nm 90 turn Always replace if removed ...

Page 49: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 43 ...

Page 50: ...olt 2 Nut 95 Nm When adjusting can be loosened and tightened up to 5 times Always replace if removed 3 Eccentric Washer 4 Eccentric Bolt 5 Eccentric Washer 6 Nut 95 Nm When adjusting can be loosened and tightened up to 5 times Always replace if removed 7 Subframe 8 Bolt 90 Nm 90 turn Always replace if removed ...

Page 51: ...et 14 Stone Chip Protection 15 Bolt 8 Nm 16 Nut Always replace if removed 17 Washer 18 Bolt 130 Nm 90 turn Always replace if removed 19 Washer 20 Upper Transverse Link 21 Washer 22 Nut Always replace if removed 23 Wheel Bearing Housing 24 Washer 25 Bolt 130 Nm 90 turn Always replace if removed 26 Tie Rod 27 Bolt 90 Nm 90 turn Always replace if removed 28 Bolt Always replace if removed 29 Nut 90 Nm...

Page 52: ... Golf GTI Quick Reference Specification Book January 2014 Left Rear Level Control System Sensor G76 Overview 1 Subframe 2 Lower Transverse Link 3 Bolt 5 Nm M5 x 20 4 Left Rear Level Control System Sensor G76 ...

Page 53: ...cation Book January 2014 47 Shock Absorber Coil Spring 1 Low Spring Support 2 Assembly Aid 3 Coil Spring 4 Upper Spring Support 5 Bolt 180 Nm 6 Bolt 50 Nm 90 turn Always replace if removed 7 Shock Absorbers 8 Washer 9 Lower Transverse Link 10 Wheel Bearing Housing ...

Page 54: ... Housing and Trailing Arm Assembly Overview 1 Mounting Bracket 2 Cover 3 Bolt 90 Nm 90 turn Always replace if removed 4 Coupling Rod 5 Bolt 90 Nm 90 turn Always replace if removed 6 Trailing Arm 7 Drive Axle 8 Bolt 70 Nm 90 turn Always replace if removed 9 Wheel Bearing Housing ...

Page 55: ...r G46 11 Bolt 8 Nm 12 Bonded Rubber Bushing 13 Nut 45 Nm Always replace if removed 14 Bolt 50 Nm 90 turn Always replace if removed 15 Bolt 4 Nm 16 Brake Disc 17 Bolt Various versions Twelve point bolt with ribs is 70 Nm 90 turn Twelve point bolt without ribs is 200 Nm 180 turn Always replace if removed 18 Wheel Hub with Wheel Bearing 19 Bolt 12 Nm 20 Cover Plate ...

Page 56: ...014 Stabilizer Bar AWD Overview 1 Stabilizer Bar 2 Rubber Mount 3 Clamp 4 Internal Multi Point Bolt 25 Nm 90 turn Always replace if removed 5 Wheel Bearing Housing 6 Nut 45 Nm Always replace if removed 7 Bolt Always replace if removed 8 Coupling Rod 9 Subframe ...

Page 57: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 51 ...

Page 58: ...t Various versions Twelve point bolt with ribs is 70 Nm 90 turn Twelve point bolt without ribs is 200 Nm 180 turn Always replace if removed 3 Drive Axle 4 Clamp Always replace if removed 5 Protective Boot 6 Clamp Always replace if removed 7 Dished Washer 8 Securing Ring Always replace if removed 9 CV Boot ...

Page 59: ...replace if removed 11 Backing Plate 12 Bolt First tighten to 10 Nm in a diagonal sequence then tighten to tightening specification in a diagonal sequence 40 Nm M8 x 48 Always replace if removed 13 Securing Ring Always replace if removed 14 Gasket Always replace if removed 15 Inner CV Joint 16 Dished Washer ...

Page 60: ...y 2014 Self Leveling Suspension Left and Right Front Level Control System Sensor Overview 1 Subframe 2 Bolt 9 Nm M6 x 16 3 Left Front Level Control System Sensor G78 and Right Front Level Control Sensor G289 4 Control Arm 5 Nut 9 Nm Always replace if removed ...

Page 61: ...teering VW Golf GTI Quick Reference Specification Book January 2014 55 Left Rear Level Control System Sensor Overview FWD 1 Subframe 2 Bolt 5 Nm M5 x 20 3 Left Rear Level Control System Sensor G76 4 Lower Transverse Link ...

Page 62: ... GTI Quick Reference Specification Book January 2014 Left Rear Level Control System Sensor Assembly Overview AWD 1 Subframe 2 Bolt 5 Nm M5 x 20 3 Left Rear Level Control System Sensor G76 4 Lower Transverse Link ...

Page 63: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 57 ...

Page 64: ... Left Front Dampening Adjustment Valve N336 2 Buffer Stop 3 Protective Sleeve 4 Coil Spring 5 Axial Groove Ball Bearing 6 Suspension Strut Bearing 7 Nut 60 Nm M14 x 1 5 Always replace if removed 8 Suspension Strut Dome 9 Bracket 10 Left Front Body Acceleration Sensor G341 11 Bolt 5 Nm Always replace if removed ...

Page 65: ...ls Steering VW Golf GTI Quick Reference Specification Book January 2014 59 12 Bolt 15 Nm 90 turn Always replace if removed 13 Bracket 14 Right Front Body Acceleration Sensor G342 15 Nut 5 Nm Always replace if removed ...

Page 66: ...orber Overview FWD 1 Lower Spring Support 2 Coil Spring 3 Upper Spring Support 4 Bracket 5 Rear Body Acceleration Sensor G343 6 Bolt 5 Nm Always replace if removed 7 Bolt 180 Nm M14 x 1 5 x 85 Always replace if removed 8 Bolt 50 Nm 90 turn M10 x 35 Always replace if removed ...

Page 67: ...eels Steering VW Golf GTI Quick Reference Specification Book January 2014 61 9 Shock Absorber with Left and Right Rear Dampening Adjustment Valve N338 N339 10 Washer 11 Lower Transverse Link 12 Wheel Bearing Housing ...

Page 68: ...14 Shock Absorber Overview AWD 1 Lower Spring Support 2 Coil Spring 3 Upper Spring Support 4 Bracket 5 Rear Body Acceleration Sensor G343 6 Bolt 5 Nm Always replace if removed 7 Bolt 180 Nm M14 x 1 5 x 70 8 Bolt 50 Nm 90 turn M10 x 35 9 Shock Absorber 10 Washer ...

Page 69: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 63 11 Lower Transverse Link 12 Wheel Bearing Housing ...

Page 70: ...GTI Quick Reference Specification Book January 2014 Wheels Tires Wheel Alignment Tire Pressure Sensor Overview 1 Tire Pressure Sensor 2 Valve Core 3 Sealing Washer 4 Seal 5 Disk Wheel 6 Union Nut 8 Nm 7 Valve Cap ...

Page 71: ...20 1 Replace fastener s 2 Always tighten in curb weight position 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 PR No 2UA G58 2UC Total toe wheels not pressed 10 10 10 10 Camber wheels in straight ahead position 30 30 41 30 Maximum...

Page 72: ...7 17 30 Maximum permissible difference between both sides 30 30 Standing height mm 367 10 402 10 1 The toe angle difference can also be indicated negatively in alignment computer depending on manufacturer Front suspension Basic Suspension with Adaptive Chassis DCC Basic Suspension with 18 Wheels and Adaptive Chassis DCC Production Relevant No PR No G01 G03 G01 G03 Total toe wheels not pressed 10 1...

Page 73: ...d right 1 22 20 1 22 20 Caster 7 47 30 7 51 30 Maximum permissible difference between both sides 30 30 Standing height mm 360 10 358 10 1 The toe angle difference can also be indicated negatively in alignment computer depending on manufacturer 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 2...

Page 74: ... 10 400 10 Rear Suspension Basic Suspension with Adaptive Chassis DCC Basic Suspension with 18 Wheels and Adaptive Chassis DCC Camber 1 20 30 1 20 30 Maximum permissible difference between both sides 30 30 Total toe at prescribed camber 10 12 5 10 12 5 Maximum permissible deviation from direction of rotation 20 20 Standing height mm 370 10 370 10 Rear Suspension GTI without and with Adaptive Chass...

Page 75: ...tion Book January 2014 69 Steering Steering Column Assembly Overview Vehicles without Knee Airbags 1 Assembly Carrier with Bracket 2 Steering Column 3 Brake Pedal Crash Brace 4 Bolt 20 Nm 5 Bolt 20 Nm 6 Clutch Pedal Crash Brace 7 Bolt 30 Nm Always replace if removed ...

Page 76: ...tion Book January 2014 Steering Column Assembly Overview Vehicles with Knee Airbags 1 Assembly Carrier with Bracket 2 Steering Column 3 Bolt 20 Nm 4 Bolt 9 Nm 5 Knee Airbag Mount 6 Bolt 9 Nm 7 Bolt 20 Nm 8 Bolt 30 Nm Always replace if removed ...

Page 77: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 71 ...

Page 78: ... 2014 Electro Mechanical Steering Gear Overview 1 Electrical Wiring 2 Universal Joint 3 Bolt 30 Nm M8 x 35 Always replace if removed 4 Torx Bolt 6 Nm 5 Shield 6 Steering Gear 7 Left Wheel Bearing Housing 8 Nut 20 Nm 90 turn M12 x 1 5 Always replace if removed ...

Page 79: ...Suspension Wheels Steering VW Golf GTI Quick Reference Specification Book January 2014 73 9 Bolt 50 Nm 90 turn Always replace if removed 10 Subframe 11 Right Wheel Bearing Housing ...

Page 80: ...mber Allocation The Product Relevant PR number on the vehicle data label describes which brake system is installed in the vehicle Example Arrow 1 rear brakes 1KD Arrow 2 front brakes 1ZF There is a vehicle data label in the spare wheel well and also one in the customer Maintenance booklet Allocation refer to the Parts Catalog ...

Page 81: ...t Brakes Engine Version PR Number Front Wheel Brake 2 0L 103 kW TDI 1ZE 1ZP FN 3 15 2 5L 125 kW 1LJ 1ZA 1LL 1ZB FN3 16 2 0L 147 kW T FSI 1LJ 1ZA 1LL 1ZB FN3 16 Rear Brakes Engine Version PR Number Rear Wheel Brake 2 0L 103 kW TDI 1KD C 38 15 2 5L 125 kW 1KS Bosch ZOH 38 16 2 0L 147 kW T FSI 1KS Bosch ZOH 38 16 Brake Master Cylinder and Brake Booster Component Diamter in mm Brake master cylinder 23...

Page 82: ...FS III Front Brakes Item PR Number 1ZF 1 Brake caliper FS III 15 2 Brake pad thickness mm 14 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 280 Brake disc thickness mm 22 Brake disc wear limit mm 19 4 Brake caliper piston Diameter in mm 54 ...

Page 83: ...14 77 FN 3 Front Brakes Item PR Number 1ZE 1ZP 1 Brake caliper FN 3 15 2 Brake pad thickness mm 14 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 288 Brake disc thickness mm 25 Brake disc wear limit mm 22 4 Brake caliper piston Diameter in mm 54 ...

Page 84: ...er 1LJ 1ZD 1LL 1LV 1ZA 1ZB 1 Brake caliper FN 3 16 2 Brake pad thickness mm 14 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 312 Brake disc thickness mm 25 Brake disc wear limit mm 22 4 Brake caliper piston Diameter in mm 54 FN 3 Front Brakes cont d ...

Page 85: ...014 79 FNR G Front Brakes Item PR Number 1ZK 1 Brake caliper FNR G 17 2 Brake pad thickness mm 14 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 345 Brake disc thickness mm 30 Brake disc wear limit mm 27 4 Brake caliper piston Diameter in mm 57 ...

Page 86: ...14 C 38 Rear Brakes Item PR Number 1KD 1 Brake caliper C 38 15 2 Brake pad thickness mm 11 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 253 Brake disc thickness mm 10 Brake disc wear limit mm 8 4 Brake caliper piston Diameter in mm 38 ...

Page 87: ...4 81 CII 38 Rear Brakes Item PR Number 1KY 1KV 1 Brake caliper CII 38 16 2 Brake pad thickness mm 11 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 282 Brake disc thickness mm 12 Brake disc wear limit mm 10 4 Brake caliper piston Diameter in mm 38 ...

Page 88: ... 41 15 Rear Brakes Item PR Number 1KF 1KE 1 Brake caliper CII 41 15 2 Brake pad thickness mm 11 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 256 Brake disc thickness mm 12 Brake disc wear limit mm 10 4 Brake caliper piston Diameter in mm 41 ...

Page 89: ...4 83 CII 41 17 Rear Brakes Item PR Number 1KW 1 Brake caliper CII 41 17 2 Brake pad thickness mm 11 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 310 Brake disc thickness mm 22 Brake disc wear limit mm 20 4 Brake caliper piston Diameter in mm 41 ...

Page 90: ... 38 16 Rear Brakes Item PR Number 1KS 1KT 1 Brake caliper Bosch ZOH 38 16 2 Brake pad thickness mm 12 Brake pad wear limit without back plate mm 2 3 Brake disc Diameter in mm 272 Brake disc thickness mm 10 Brake disc wear limit mm 8 4 Brake caliper piston Diameter in mm 38 ...

Page 91: ...uary 2014 85 Anti lock Brake System ABS Front Wheel Speed Sensor Overview 1 ABS Speed Sensor Before inserting the speed sensor clean the inner surface of the hole and coat it with hot bolt paste G 052 112 A3 2 Hex Socket Bolt 8 Nm 3 Wheel Bearing Unit 4 Drive Axle ...

Page 92: ...ion Book January 2014 Rear Wheel Speed Sensor Overview 1 ABS Speed Sensor Before inserting the speed sensor clean the inner surface of the hole and coat it with hot bolt paste G 052 112 A3 2 Hex Socket Bolt 8 Nm 3 Wheel Hub with Wheel Bearing ...

Page 93: ...Brake System VW Golf GTI Quick Reference Specification Book January 2014 87 ...

Page 94: ...draulic Unit and Brake Booster Master Cylinder Overview ABS Mark 70 ABS ASR 1 ABS Control Module J104 2 ABS Hydraulic Unit N55 3 Brake Line 4 Brake Line 5 Brake Line 6 Brake Line 7 Brake Line 8 Brake Line 9 Inner Torx Bolt 5 5 Nm Use new bolts 10 Bracket 11 Bolt 8 Nm ...

Page 95: ...nce Specification Book January 2014 89 12 Gasket 13 Brake Booster 14 Seal 15 Brake Master Cylinder 16 Nut 25 Nm Always replace if removed 17 Sealing Plug 18 Brake Fluid Reservoir 19 Cap 20 Sealing Plug 21 Vacuum Hose 22 Vacuum Sensor G608 ...

Page 96: ...ake Booster Master Cylinder Overview ABS Mark 60 EC ABS EDL ASR ESP 1 ABS Control Module J104 2 Inner Torx Bolt 2 Nm 0 8 Nm Use new bolts 3 ABS Hydraulic Unit N55 4 Brake Line 5 Brake Line 6 Brake Line 7 Brake Line 8 Brake Line 9 Brake Line 10 Brake Booster 11 Bracket 12 Torx Bolt 8 Nm ...

Page 97: ...Brake System VW Golf GTI Quick Reference Specification Book January 2014 91 13 Rubber Insulation 14 Hex Bolt 8 Nm 15 Bracket 16 Rubber Insulation 17 Nut 20 Nm 18 Heat Shield 19 Nut 8 Nm ...

Page 98: ... January 2014 Mechanical Components Front Brakes Overview FS III Overview 1 Torx Bolt 12 Nm 2 Brake Rotor 3 Torx Bolt 4 Nm 4 Brake Pads 5 Harner Connector 6 Brake Caliper 7 Guide Pins 30 Nm 8 Cap 9 Brake Hose with Ring Connection and Banjo Bolt 35 Nm ...

Page 99: ... Quick Reference Specification Book January 2014 93 10 Guide Pins 30 Nm 11 Universal Joint 12 Cap Remove 13 Bracket 14 Wheel Bearing Housing 15 ABS Speed Sensor 16 Hex Socket Head Bolt 8 Nm 17 Wheel Bearing Unit 18 Cover Plate ...

Page 100: ...January 2014 Front Brakes Overview FN 3 1 Torx Bolt 4 Nm 2 Brake Rotor 3 Brake Pads 4 Spring 5 Brake Carrier 6 Brake Caliper 7 Guide Pins 30 Nm 8 Cap Remvoe 9 Brake Hose with Ring Connection and Banjo Bolt 35 Nm 10 Ribbed Bolt 190 Nm 11 Bolt 12 Bracket ...

Page 101: ...ake System VW Golf GTI Quick Reference Specification Book January 2014 95 13 Wheel Bearing Housing 14 ABS Speed Sensor 15 Hex Socket Head Bolt 8 Nm 16 Cover Plate 17 Torx Bolt 12 Nm 18 Wheel Bearing Unit ...

Page 102: ...cation Book January 2014 Front Brakes Overview FNR G 1 Cover Plate 2 Torx Bolt 12 Nm 3 Brake Rotor 4 Nm 4 Torx Bolt 4 Nm 5 Ribbed Bolt 6 Brake Carrier 7 Brake Pads 8 Spring 9 Brake Caliper 10 Guide Bushings 11 Guide Pins 30 Nm 12 Cap Remove ...

Page 103: ...5 Bolt 10 Nm 16 Dust Cap 17 Brake Line 14 Nm 18 Bolt 15 Nm 19 Bracket 20 Brake Hose 21 Hex Socket Head Bolt 8 Nm 22 Bracket 23 Spring Clamp Tightening Specification for the Ribbed Bolts Step Component Nm 1 Tighten both ribbed bolts on the brake carrier 15 2 Tighten both ribbed bolts on the brake carrier 200 ...

Page 104: ...1 ABS Speed Sensor 2 Hex Socket Head Bolt 8 Nm 3 Internal Multi Point Bolt 90 Nm 90 turn Always replace if removed 4 Wheel Bearing Housing 5 Cover Plate 6 Torx Bolt 12 Nm 7 Wheel Hub with Wheel Bearing 8 Brake Rotor 9 Bolt 4 Nm 10 Bolt 11 Brake Pads 12 Brake Carrier with Guide Pins and Cap ...

Page 105: ...Brake System VW Golf GTI Quick Reference Specification Book January 2014 99 13 Brake Caliper 14 Hose Retainer 15 Brake Line 14 Nm 16 Self Locking Bolt 35 Nm Replace 17 Parking Brake Cable 18 Brake Hose ...

Page 106: ...verview CII 41 1 ABS Speed Sensor 2 Hex Socket Head Bolt 8 Nm 3 Internal Multi Point Bolt 90 Nm 90 turn Always replace if removed 4 Wheel Bearing Housing 5 Cover Plate 6 Torx Bolt 12 Nm Torx bolt M6 x 12 7 Wheel Hub with Wheel Bearing 8 Brake Rotor 9 Torx Bolt 4 Nm 10 llar Bolt ...

Page 107: ...ary 2014 101 11 Brake Pads 12 Brake Carrier with Different Guide Pins and Protective Cap 13 Brake Pad Retaining Plate 14 Brake Caliper 15 Hose Retainer 16 Brake Line 14 Nm 17 Self Locking Bolt 35 Nm Always replace after removing 18 Parking Brake Cable 19 Brake Hose ...

Page 108: ...w Bosch 1 ABS Speed Sensor 2 Bolt 8 Nm 3 Bolt 90 Nm 90 turn Always replace if removed 4 Wheel Bearing Housing 5 Cover Plate 6 Bolt 12 Nm M6 x12 7 Wheel Hub with Wheel Bearing 8 Bolt Refer to Suspension Wheels Steering Rear Suspension 9 Dust Cap Only on front wheel drive 10 Brake Rotor ...

Page 109: ...03 11 Bolt 4 Nm 12 Brake Pads 13 Brake Carrier with Different Guide Pins and Protective Cap 14 Brake Pad Retaining Plate 15 Brake Pad Retaining Plate 16 Brake Caliper 17 Bolt 35 Nm Always replace if removed 18 Parking Brake Cable 19 Brake Hose 35 Nm With banjo bolt and seals ...

Page 110: ...Reference Specification Book January 2014 Parking Brake Lever Overview 1 Parking Brake Lever 2 Nut 15 Nm 3 Trim for Parking Brake Lever 4 Relay Rod 5 Compensator 6 Adjustment Nut 7 Parking Brake Cables 8 Parking Brake Switch ...

Page 111: ...uary 2014 105 Brake Pedal Overview 1 Bracket 2 Self Locking Nut 25 Nm Always replace if removed 3 Noise Insulation on the Brake Pedal 4 Clamping Washer 5 Brake Pedal 6 Self Locking Nut 25 Nm 7 Cover 8 Bearing Shell 9 Mount 10 Bolt 11 Bearing Bushing 12 Bearing Pin ...

Page 112: ...ary 2014 Hydraulic Components Front Brake Caliper Overview FS III 1 Dust Cap 2 Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 3 Caps 4 Guide Pins 30 Nm 5 Bushing 6 Brake Caliper 7 Cap 8 Pistons 9 Seal ...

Page 113: ... 2014 107 Front Brake Caliper Overview FN 3 1 Dust Cap 2 Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 3 Caps 4 Guide Pins 30 Nm 5 Bearing Bushing 6 Brake Caliper 7 Brake Carrier 8 Spring 9 Seal 10 Pistons 11 Cap ...

Page 114: ...14 Front Brake Caliper Overview FNR G 1 Dust Cap 2 Bleeder Valve 12 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 3 Caps 4 Guide Pins 30 Nm 5 Bearing Bushing 6 Brake Caliper 7 Brake Carrier 8 Seal 9 Pistons 10 Cap 11 Spring ...

Page 115: ...rake Caliper with Parking Brake Cable Lever 2 Dust Cap 3 Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 4 Self Locking Bolt 35 Nm Replace 5 Guide Pins 6 Cap 7 Brake Carrier with Guide Pins and Protective Caps 8 Cap 9 Piston with Automatic Adjustment 10 Seal ...

Page 116: ...CII 41 1 Brake Caliper with Parking Brake Cable Lever 2 Dust Cap 3 Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 4 Self Locking Bolt 35 Nm Replace 5 Guide Pin with Stepping 6 Guide Pins 7 Cap 8 Brake Pad with Damper 9 Cap 10 Piston with Automatic Adjustment 11 Seal ...

Page 117: ...17 inch Brake Caliper CII 41 1 Brake Caliper with Parking Brake Cable Lever 2 Dust Cap 3 Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 4 Self Locking Bolt 35 Nm Replace 5 Guide Pins 6 Cap 7 Rear Brake Carrier 8 Cap 9 Piston with Automatic Adjustment 10 Seal ...

Page 118: ...r Overview Bosch 1 Brake Caliper with Parking Brake Cable Lever 2 Bleeder Valve 10 Nm Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in 3 Dust Cap 4 Bolt 35 Nm Replace 5 Upper Guide Pins 6 Cap 7 Lower Guide Pins 8 Guide Grommet 9 Brake Carrier 10 Cap ...

Page 119: ...Brake System VW Golf GTI Quick Reference Specification Book January 2014 113 11 Piston with Automatic Adjustment 12 Seal ...

Page 120: ... and Brake Master Cylinder Overview 1 Pedal Assembly 2 Self Locking Nut 25 Nm Always replace if removed 3 Gasket 4 Brake Booster 5 Seal 6 Brake Master Cylinder 7 Brake Lamp Switch F 8 Inner Torx Bolt 5 Nm 9 Clip 10 Heat Shield 11 Self Locking Nut 25 Nm Always replace if removed ...

Page 121: ...stem VW Golf GTI Quick Reference Specification Book January 2014 115 12 Brake Line 14 Nm 13 Brake Line 14 Nm 14 Sealing Plug 15 Brake Fluid Reservoir 16 Cap 17 Vacuum Hose 18 Vacuum Sensor G608 19 Sealing Plugs ...

Page 122: ...116 VW Golf GTI Quick Reference Specification Book January 2014 Body Body Exterior Body Front Component mm a 4 5 0 5 b 3 5 0 5 c 0 5 0 5 d 3 5 0 5 e 5 0 0 5 ...

Page 123: ...Body VW Golf GTI Quick Reference Specification Book January 2014 117 Body Center Component mm a 4 5 0 5 b 0 0 1 0 c 3 5 0 5 d 4 5 0 5 e 0 0 1 0 f 3 5 0 5 ...

Page 124: ...118 VW Golf GTI Quick Reference Specification Book January 2014 Body Rear Component mm a 4 0 1 0 b 5 0 0 5 c 2 0 1 0 d 5 0 0 5 e 1 0 0 5 f 4 5 0 5 ...

Page 125: ...Body VW Golf GTI Quick Reference Specification Book January 2014 119 Body Front Bulkhead Overview 1 Bulkhead 2 Body Flange 3 PUR Adhesive Sealant 4 Bolt 25 Nm ...

Page 126: ... VW Golf GTI Quick Reference Specification Book January 2014 Front Fender Overview 1 Fender 2 Bolt 6 Nm 3 Foam Piece 4 Fillet Plate Insulation 5 Spacer 6 Filler Piece 7 Fender Brace 8 Bolt 6 Nm 9 Nut 6 Nm ...

Page 127: ...Body VW Golf GTI Quick Reference Specification Book January 2014 121 ...

Page 128: ...ok January 2014 Lock Carrier Assembly Overview 1 Lock Carrier with Attachments 2 Cover 3 Assembly Piece 4 Bolt 2 Nm 5 Air Guide Channel 6 Bolt 8 Nm 7 Angle Bracket 8 Retaining Plate 9 Guide Piece 10 Bolt 5 Nm 11 Air Duct 12 Cross Member 13 Bolt 60 Nm ...

Page 129: ...Body VW Golf GTI Quick Reference Specification Book January 2014 123 14 Bolt 8 Nm 15 Support Lock Carrier 16 Bolt 12 Nm 17 Air Duct 18 Guide Piece 19 Retaining Plate ...

Page 130: ...124 VW Golf GTI Quick Reference Specification Book January 2014 Noise Insulation Overview 1 Noise Insulation 2 Bolt 2 Nm 3 Bolt 6 Nm 4 Bolt 2 Nm ...

Page 131: ...Body VW Golf GTI Quick Reference Specification Book January 2014 125 Plenum Chamber Bulkhead Overview 1 Plenum Chamber Bulkhead 2 Nut 8 Nm 3 Seal 4 Plenum Chamber 5 Bolt 8 Nm ...

Page 132: ...126 VW Golf GTI Quick Reference Specification Book January 2014 Tunnel Bridge Overview 1 Front Tunnel Bridge 2 Nut 20 Nm 3 Rear Tunnel Bridge ...

Page 133: ...fication Book January 2014 127 Underbody Impact Guard 1 Underbody Impact Guard 2 Right Side Angle Bracket 3 Hex Nut 20 Nm 4 Threaded Rivet 5 Bolt 35 Nm 6 Left Side Angle Bracket 7 Rear Retaining Strip 8 Bolt 70 Nm 9 Bolt 2 Nm 10 Bolt 20 Nm ...

Page 134: ...128 VW Golf GTI Quick Reference Specification Book January 2014 Underbody Trim Panel Center Overview 1 Underbody Cover 2 Hex Nut 2 Nm 3 Bolt 2 Nm 4 Cover 5 Cover ...

Page 135: ... Golf GTI Quick Reference Specification Book January 2014 129 Underbody Trim Panel Rear Overview 1 Hex Nut 20 Nm 2 Bolt 20 Nm 3 Angle Bracket 4 Expanding Nut 5 Lock Washer 1 5 Nm 6 Underbody Cover 7 Bolt 2 Nm ...

Page 136: ...ck Reference Specification Book January 2014 Hood Lids Hood Overview 1 Hood 2 Stiker Pin 3 Center Seal 4 Side Seal 5 Adjusting Buffer 6 Hinge 7 Hood Lock 8 Nut 22 Nm 9 Spray Nozzles 10 Gas Strut 11 Insulation 12 Side Seal ...

Page 137: ...Body VW Golf GTI Quick Reference Specification Book January 2014 131 Rear Lid Gas Filled Strut Overview 1 Gas Strut 2 Clips 3 Bolt 10 Nm 4 Angle Bracket 5 Ball Head Pin 20 Nm 90 turn ...

Page 138: ...132 VW Golf GTI Quick Reference Specification Book January 2014 Rear Lid Hinge Overview 1 Hinge 2 Bolt 10 Nm 3 Washer 4 Rear Lid ...

Page 139: ...I Quick Reference Specification Book January 2014 133 Fuel Filler Door Unit and Actuator Overview 1 Fuel Filler Door Unit 2 Opening Aid 3 Bolt 1 5 Nm 4 Water Drain Hose 5 Guide Piece 6 Actuator 7 Electrical Connection ...

Page 140: ...rence Specification Book January 2014 Front Doors Central Locking System Door Handle and Door Lock Overview 1 Door Lock 2 Bolt 4 Nm 3 Mounting Bracket 4 Lock Cylinder 5 Backing 6 Cover 7 Door Handle 8 Bolt 1 Nm 9 Cable 10 Cable ...

Page 141: ...Body VW Golf GTI Quick Reference Specification Book January 2014 135 11 Bolt 20 Nm 12 Cover ...

Page 142: ...rview 1 Door 2 Guide Bolt 10 Nm 3 Door Hinge with Door Arrester 4 Socket Head Bolt 38 Nm Always replace bolts after loosening them 5 Cover 6 Socket Head Bolt 50 Nm Always replace bolts after loosening them 7 Socket Head Bolt 38 Nm Always replace bolts after loosening them 8 Cover ...

Page 143: ... Lower Spacer Plate 11 Adjustment Ring 12 Bolt 28 Nm 13 Door Hinge 14 Socket Head Bolt 50 Nm Always replace bolts after loosening them 15 Socket Head Bolt 50 Nm Always replace bolts after loosening them 16 Cover 17 Socket Head Bolt 50 Nm Always replace bolts after loosening them 18 Eccentric Bolts 19 Upper Spacer Plate 20 Guide Bolt 10 Nm ...

Page 144: ... January 2014 Front Door Overview 1 Door 2 Window Guide 3 Door Window 4 Trim 5 Outer Window Recess Seal 6 Inner Window Recess Seal 7 Cover 8 Door Lock 9 Bolt 20 Nm 10 Outer Door Seal 11 Buffer 12 Cover 13 Subframe 14 Clips 15 Bolt 16 Bottom Door Hinge ...

Page 145: ...Body VW Golf GTI Quick Reference Specification Book January 2014 139 17 Bolt 8 Nm 18 Upper Door Hinge ...

Page 146: ... Golf GTI Quick Reference Specification Book January 2014 Rear Doors Door Handle and Door Lock Overview 1 Door Lock 2 Cable 3 Cable 4 Mounting Bracket 5 Bolt 4 5 Nm 6 Door Handle 7 Cover 8 Cover 9 Bolt 20 Nm ...

Page 147: ...Body VW Golf GTI Quick Reference Specification Book January 2014 141 ...

Page 148: ...uide Bolt 10 Nm 3 Door Hinge with Door Arrester 4 Socket Head Bolt 38 Nm 5 Cover 6 Socket Head Bolt 50 Nm Always replace bolts after loosening them 7 Socket Head Bolt 38 Nm Always replace bolts after loosening them 8 Socket Head Bolt 50 Nm Always replace bolts after loosening them 9 Lower Spacer Plate ...

Page 149: ...11 Adjustment Ring 12 Bolt 28 Nm 13 Door Hinge 14 Socket Head Bolt 50 Nm Always replace bolts after loosening them 15 Socket Head Bolt 50 Nm Always replace bolts after loosening them 16 Socket Head Bolt 38 Nm Always replace bolts after loosening them 17 Eccentric Bolts 18 Lower Spacer Plate ...

Page 150: ... January 2014 Rear Door Overview 1 Door 2 Trim 3 Window Guide 4 Door Window 5 Outer Window Recess Seal 6 Inner Window Recess Seal 7 Door Lock 8 Bolt 20 Nm 9 Outer Door Seal 10 Buffer 11 Clips 12 Subframe 13 Bolt 14 Bottom Door Hinge 15 Upper Door Hinge ...

Page 151: ...dy VW Golf GTI Quick Reference Specification Book January 2014 145 Sunroof Installation Unit Overview 1 Installation Unit 2 Bolt 8 Nm 3 Connector 4 Connections for Water Drain Hoses 5 Sunroof Drive Motor ...

Page 152: ...nel Overview 1 Sunroof Glass Panel 2 Panel Seal 3 Sun Shade 4 Screw 1 8 Nm 5 Spring Glider 6 Bellows 7 Water Channel 8 Guide Locking Hook 9 End Piece Upper Part 10 End Piece Lower Part 11 Installation Unit 12 Bolt 3 5 Nm 13 Emergency Operation Hex Key 14 Electrical Drive Motor 15 Spring ...

Page 153: ...y VW Golf GTI Quick Reference Specification Book January 2014 147 16 Wind Deflector 17 Wind Deflector Bearing 18 Front Guide 19 Rear Guide Lower Part 20 Screw 5 Nm Torx T25 21 Slotted Guide Rail 22 Spacer ...

Page 154: ...148 VW Golf GTI Quick Reference Specification Book January 2014 Bumpers Front Bumper Cover Overview 1 Front Bumper Cover 2 Bolt 2 Nm 3 Bolt 2 Nm 4 Bolt 2 Nm 5 Side Marker Lamps 6 Bolt 2 Nm 7 Bolt 1 5 Nm ...

Page 155: ...Body VW Golf GTI Quick Reference Specification Book January 2014 149 Bumper Cover Overview GTI 1 Front Bumper Cover 2 Bolt 2 Nm 3 Bolt 2 Nm 4 Bolt 2 Nm 5 Side Marker Lamps 6 Bolt 2 Nm 7 Bolt 1 5 Nm ...

Page 156: ...150 VW Golf GTI Quick Reference Specification Book January 2014 Bumper Cover Overview Golf R 1 Front Bumper Cover 2 Bolt 2 Nm 3 Bolt 2 Nm 4 Bolt 2 Nm 5 Bolt 2 Nm 6 Bolt 2 Nm ...

Page 157: ...Body VW Golf GTI Quick Reference Specification Book January 2014 151 Front Bumper Carrier Overview 1 Front Bumper Cover 2 Bolt 60 Nm 3 Bolt 8 Nm 4 Bolt 8 Nm 5 Foam Piece ...

Page 158: ...152 VW Golf GTI Quick Reference Specification Book January 2014 Side Guide Overview 1 Side Guide 2 Bolt 2 Nm 3 Bolt 5 Nm 4 Expanding Nut ...

Page 159: ...Body VW Golf GTI Quick Reference Specification Book January 2014 153 Rear Bumper Cover Overview 1 Rear Bumper Cover 2 Bolt 2 Nm 3 Bolt 2 Nm 4 Bolt 2 Nm 5 Bolt 2 Nm ...

Page 160: ...154 VW Golf GTI Quick Reference Specification Book January 2014 Rear Bumper Cover Overview GTI 1 Rear Bumper Cover 2 Bolt 2 Nm 3 Bolt 2 Nm 4 Bolt 2 Nm 5 Bolt 2 Nm ...

Page 161: ...ar Bumper Cover Attachments GTI 1 Rear Bumper Cover 2 Bracket 3 Bolt 2 Nm 4 Right Rear Reflector 5 License Plate Lighting 6 Towing Eyelet Cap 7 Trailer Hitch Cover Cap 8 Spoiler 9 Clips 10 Pop Rivet Nut 11 Left Rear Reflector 12 License Plate Holder 13 Bracket 14 Bolt 2 Nm ...

Page 162: ...156 VW Golf GTI Quick Reference Specification Book January 2014 Rear Bumper Cover Overview Golf R 1 Rear Bumper Cover 2 Bolt 2 Nm 3 Bolt 2 Nm 4 Bolt 2 Nm 5 Bolt ...

Page 163: ...VW Golf GTI Quick Reference Specification Book January 2014 157 Rear Bumper Cover Substructure Overview 1 Center Guide 2 Guide Trim 3 Expanding Nut 4 Guide Trim 5 Nut 2 Nm 6 Nut 2 Nm 7 Screw 2 Nm 8 Nut 2 Nm ...

Page 164: ...158 VW Golf GTI Quick Reference Specification Book January 2014 Rear Bumper Carrier Overview 1 Rear Bumper Carrier 2 Bolt 20 Nm 3 Foam Piece 4 Bracket 5 Bolt 8 Nm ...

Page 165: ...Body VW Golf GTI Quick Reference Specification Book January 2014 159 Trailer Hitch Overview 1 Trailer Hitch 2 Ball Head 3 Bolt 20 Nm 4 Bolt 50 Nm 90 turn Always replace bolts after loosening them ...

Page 166: ... Reference Specification Book January 2014 Glass Window Regulators Tightening Specification Component Nm Front door window regulator motor bolts 3 5 Rear door window regulator motor bolts 3 5 Rear door fixed window bolts 8 ...

Page 167: ...erence Specification Book January 2014 161 Exterior Equipment Anti Rodent System Overview 1 Anti Rodent System Protection 2 Bolt 2 Nm 5 x 20 3 Upper Protection 4 Front Protection Anti Rodent System 5 Bolt 2 Nm 6 Noise Insulation ...

Page 168: ...Book January 2014 Exterior Mirror Overview 1 Mirror Base Plate 2 Insulation 3 Bolt 10 Nm 4 Connector 5 Assembly Piece 6 Entry Lamp Inside Exterior Mirror 7 Adjusting Unit with Motor 8 Bolt 1 Nm 9 Mirror Glass 10 Bolt 1 Nm 11 Frame 12 Mirror Housing ...

Page 169: ...ody VW Golf GTI Quick Reference Specification Book January 2014 163 Front Wheel Housing Liner Overview 1 Rear Part of Wheel Housing Liner 2 Bolt 2 Nm 3 Front Part of Wheel Housing Liner 4 Bolt 2 Nm 5 Nut ...

Page 170: ...164 VW Golf GTI Quick Reference Specification Book January 2014 Rear Wheel Housing Liner Overview 1 Rear Wheel Housing Liner 2 Bolt 2 Nm 3 Nut 4 Nut ...

Page 171: ...Body VW Golf GTI Quick Reference Specification Book January 2014 165 Sill Panel Cover Overview 1 Sill Panel Cover 2 Bolt 2 Nm 3 Nuts 4 Nuts ...

Page 172: ...166 VW Golf GTI Quick Reference Specification Book January 2014 Sill Panel Extension Overview GTI 1 Extended Sill Panel 2 Bracket 3 Bolt 1 2 Nm 4 Bolt 2 Nm ...

Page 173: ...W Golf GTI Quick Reference Specification Book January 2014 167 Sill Panel Extension Overview Golf R 1 Sill Panel Extension 2 Bolt 2 Nm 3 Adhesive Tape 4 Retaining Strip 5 Bolt 1 2 Nm 6 Bracket 7 Expanding Nut ...

Page 174: ...168 VW Golf GTI Quick Reference Specification Book January 2014 Wheel Cover Trim Overview 1 Rear Wheel Cover Trim 2 Bolt 2 Nm 3 Front Wheel Cover Trim 4 Protective Film ...

Page 175: ...nuary 2014 169 Body Interior Interior Equipment Roof Grab Handles 1 Caps 2 Screws 2 Nm Tightening Specifications Component Nm Inner wheel housing trim bolts 4 door without Side Airbag 1 5 Inner wheel housing trim nut 3 5 Inner wheel housing trim bolts 2 5 ...

Page 176: ...fication Book January 2014 Passenger Protection Airbags Seat Belts Front Seat Belts 2 door Assembly Overview 1 Bolt 20 Nm 2 Bolt 40 Nm 3 Window 4 Anchor Rail 5 Bolt 40 Nm 6 B Pillar Automatic Belt Retractor 7 Wiring Harness 8 Screws 4 5 Nm ...

Page 177: ...Body VW Golf GTI Quick Reference Specification Book January 2014 171 9 Belt Guide 10 Bolt 40 Nm 11 Belt Latch ...

Page 178: ...cification Book January 2014 Front Seat Belts 4 door Assembly Overview 1 Bolt 40 Nm 2 Belt Anchor 3 Bolt 40 Nm 4 B Pillar Automatic Belt Retractor 5 Wiring harness 6 Screws 4 5 Nm 7 Belt Guide 8 Bolt 40 Nm 9 Belt Guide Ring 10 Belt Latch ...

Page 179: ...ification Book January 2014 173 Rear Outer Seat Belts Assembly Overview 1 Bolt 40 Nm 2 Belt Anchor 3 Wiring Harness 4 Bolt 40 Nm 5 Automatic Belt Retractor With Belt Tensioner 6 Bolt 40 Nm 7 Automatic Belt Retractor Without Belt Tensioner ...

Page 180: ...174 VW Golf GTI Quick Reference Specification Book January 2014 Rear Center Three Point Seat Belt Assembly Overview 1 Bolt 40 Nm 2 Belt Latch 3 Hex Nut 40 Nm 4 Automatic Belt Retractor 5 Console ...

Page 181: ...Body VW Golf GTI Quick Reference Specification Book January 2014 175 Airbag Control Module J234 1 Connector 2 Control Module 3 Nuts 9 Nm ...

Page 182: ...176 VW Golf GTI Quick Reference Specification Book January 2014 Driver and Passenger Side Airbag 1 Harness 2 Bolt 9 Nm 3 Side Airbag ...

Page 183: ...Body VW Golf GTI Quick Reference Specification Book January 2014 177 Driver and Passenger Side Curtain Airbags 1 Screws 4 5 Nm 2 Cap Nuts 3 Igniter 4 Threaded Pins ...

Page 184: ...178 VW Golf GTI Quick Reference Specification Book January 2014 Driver and Front Passenger Side Curtain Airbag 4 Door 1 Bolt 4 5 Nm 2 Bolt 3 Nm 3 Bolt 3 Nm ...

Page 185: ...Body VW Golf GTI Quick Reference Specification Book January 2014 179 Knee Airbag 1 Nuts 9 Nm 2 Knee Airbag 3 Nuts 9 Nm 4 Bracket ...

Page 186: ...180 VW Golf GTI Quick Reference Specification Book January 2014 Passenger Airbag Unit 1 Bolt 9 Nm 2 Bolt 9 Nm 3 Bolt 9 Nm 4 Brackets 5 Brackets ...

Page 187: ...Body VW Golf GTI Quick Reference Specification Book January 2014 181 Rear Side Airbag 4 Door 1 Side Upholstery 2 Bolt 9 Nm 3 Rear Side Airbag ...

Page 188: ...182 VW Golf GTI Quick Reference Specification Book January 2014 Driver Side Rear Side Airbag Crash Sensor G256 1 Connector Lock 2 Connector 3 Driver Side Rear Side Airbag Crash Sensor G256 4 Bolt 9 Nm ...

Page 189: ...Body VW Golf GTI Quick Reference Specification Book January 2014 183 Front Door Crash Sensors 1 Wiring Harness 2 Bolt 2 5 Nm 3 Crash Sensor ...

Page 190: ...olf GTI Quick Reference Specification Book January 2014 Front Passenger Side Rear Side Airbag Crash Sensor G257 1 Connector Lock 2 Connector 3 Front Passenger Side Rear Side Airbag Crash Sensor G257 4 Bolt 9 Nm ...

Page 191: ...em 4 C pillar trim bolt under airbag emblem 4 C pillar trim nut 1 5 Front door trim bolts 4 5 Headliner storage compartment bolts 2 Lower B pillar trim bolts 4 Luggage compartment side trim anchor point bolts 8 Rear door trim bolts 4 5 Rear lid trim panel handle recess bolt 1 5 Rear lid handle recess bolt 2 Side trim cover bolt 2 door 2 Storage compartment luggage compartment cover bolts 1 5 ...

Page 192: ...port and operating lever bolts 3 5 Front bucket seat bracket and operating lever bolts 3 5 Seat trim bolts 2 5 Left front seat backrest bolt 34 5 Power seat bracket and support bolt 3 5 Right seat trim bolt 2 Seat drawer mount bolt 2 Rear Seats Center backrest bearing clamp bolt 9 Side upholstery nut 8 Seat Upholstery Covers Instrument Panel Tightening Specifications Component Nm Center armrest st...

Page 193: ...e Specification Book January 2014 187 HEATING VENTILATION AIR CONDITIONING General Technical Data Refrigerant Oil Distribution Component Approximate of total amount of oil in component A C compressor 50 Condenser 10 Suction hose 10 Evaporator 20 Fluid reservoir 10 ...

Page 194: ... Table Temperature in C Pressure in bar positive pressure of R134a 45 0 61 40 0 49 35 0 34 30 0 16 25 0 06 20 0 32 15 0 63 10 1 00 5 1 43 0 1 92 5 2 49 10 3 13 15 3 90 20 4 70 25 5 63 30 6 70 35 7 83 40 9 10 45 10 54 50 12 11 55 13 83 60 15 72 65 17 79 70 20 05 75 22 52 80 25 21 85 28 14 90 31 34 ...

Page 195: ...Heating Ventilation Air Conditioning VW Golf GTI Quick Reference Specification Book January 2014 189 ...

Page 196: ... Air Conditioning Refrigerant Circuit System Overview 1 Reservoir With Dryer Or Dryer Bag 2 A C Compressor 3 Condenser 4 High Pressure Sensor G65 5 Nuts 6 Nm 6 Bracket 7 Evacuating and Charging Valve 8 Screws 3 5 Nm 9 Bracket 10 Evacuating and Charging Valve 11 Expansion Valve 12 Bracket ...

Page 197: ...t 4 5 0 7 Condenser mounting bolts 5 0 5 Crossmember support bolt 20 3 Evacuating and charging valve 2 0 2 Expansion valve bolt 5 Fluid reservoir with dryer bolt 4 2 0 7 Fresh air blower 1 Fresh air recirculating air back pressure door adjuster 1 4 Fresh air intake 2 5 0 4 Heater core connection flange screw 2 Heater core coolant pipe clamps 2 Heating and A C unit bolt 8 1 Heat shield in front of ...

Page 198: ...quipment Battery Starter Generator Cruise Control Battery Overview 1 Battery Terminal Clamp Ground Wire 2 Mounting Nut For Battery Terminal Clamp Ground Wire 6 Nm M6 3 Battery Terminal Clamp Positive Wire 4 Mounting Nut For Battery Terminal Clamp Positive Wire 6 Nm M6 5 Battery 6 Clamping Plate ...

Page 199: ...Electrical System VW Golf GTI Quick Reference Specification Book January 2014 193 7 Bolt 20 Nm M8 x 35 ...

Page 200: ...Quick Reference Specification Book January 2014 Generator Overview 1 Collar Bolt 20 Nm M8 x 110 2 Phillips Head Screws 2 Nm M4 x 19 3 Washer M5 4 Phillips Head Screws 4 5 Nm M5 x 21 5 Nut 15 Nm M8 6 Flat Hex Nut M8 Nm ...

Page 201: ...Electrical System VW Golf GTI Quick Reference Specification Book January 2014 195 7 Generator Cap 8 Phillips Head Screws 2 Nm M4 x 13 9 Voltage Regulator 10 Generator 11 Ribbed Belt ...

Page 202: ...on Book January 2014 Starter Overview 1 Starter 2 Connection B Wire To Starter 3 Mounting Nut B Wire To Starter 4 Starter Bolts 80 Nm M12 5 Cap 6 Cap 7 Wiring Bracket Nuts 20 Nm M8 8 Wiring Bracket Mounting bolt air filter housing to body 10 Nm ...

Page 203: ... x 90 25 2 M8 x 90 20 3 M8 x 110 20 1 Hex bolt with washer and threaded piece for voltage regulator M4 x 20 M4 x 15 2 Lower idler pulley with bracket 23 2 Protective cap phillips head screw M5 x 21 4 5 1 Protective cap hex head nut M8 20 Ribbed belt tensioners 35 2 Ribbed belt pulley with freewheel 80 Ribbed belt pulley without freewheel 65 Starter bolts M12 75 Starter bolts M12 80 Starter wiring ...

Page 204: ...Specification Book January 2014 Windshield Wiper Washer System Rear Window Wiper System Overview 1 Cap 2 Nut 12 Nm 3 Wiper Arm 4 Gasket 5 Rear Window Wiper Motor V12 6 M6 Nut With Washer 8 Nm 7 Rubber ring 8 Spacer 9 Windshield wiper ...

Page 205: ...e 6 Windshield Wiper Motor V with Wiper Motor Control Module 7 Rubber Grommet in the Bulkhead No Illustration Bolt horn retaining plate to longitudinal member 20 Nm Screws windshield wiper motor to wiper frame and linkage 9 Nm Windshield and headlamp washer fluid reservoir to body 8 Nm Windshield wiper motor crank to windshield wiper motor shaft 18 Nm Wiper motor crank to wiper motor shaft hex nut...

Page 206: ...uary 2014 Exterior Lights Switches Fog Lamp Golf Overview 1 Front Bumper Cover 2 Fog Lamp Housing 3 Bolt 2 Nm 4 Ventilation Hose 5 Left Fog Lamp Bulb L22 Or Right Fog Lamp Bulb L23 And Left Cornering Lamp Bulb L148 And Right Cornering Lamp Bulb L149 6 Cap ...

Page 207: ...Electrical System VW Golf GTI Quick Reference Specification Book January 2014 201 Fog Lamp GTI Overview 1 Fog Lamp Housing 2 Screws 2 Nm 3 Front Bumper Cover 4 Fog Lamp Bulb Static Cornering Lamp ...

Page 208: ... Headlamp Beam Adjustment Motor V48 And Right Headlamp Beam Adjustment Motor V49 6 Left Headlamp Beam Adjustment Motor V48 And Right Headlamp Beam Adjustment Motor V49 7 Lamp Socket With Grip Piece 8 Left Low Beam Headlamp M29 And Right Low Beam Headlamp M31 9 Headlamp 10 Guide 11 Carrier Front End 12 Screws 5 Nm M6 x 20 ...

Page 209: ...High Beam Headlamp and Daytime Running Lamp Bulb And Right High Beam Headlamp and Daytime Running Lamp Bulb 14 Left Parking Lamp M1 and Right Parking Lamp M3 15 Lamp Socket With Grip Piece 16 Left Front Turn Signal Light M5 and Right Front Turn Signal Light M7 17 Lamp Socket With Grip Piece ...

Page 210: ...ng Lamp M1 and Right Parking Lamp M3 5 Headlamp Range Control Positioning Motor 6 Left High Intensity Gas Discharge Hid Lamp L13 and Right High Intensity Gas Discharge Hid Lamp L14 7 Headlamp 8 Left High Intensity Gas Discharge Hid Lamp Ballast J426 And Right High Intensity Gas Discharge Hid Lamp Ballast J427 9 Hid Headlamp Ballast Screws 1 4 Nm 10 Guide 11 Headlamp Power Output Stage Screws 1 4 N...

Page 211: ... Reference Specification Book January 2014 205 12 Left Headlamp Power Output Stage J667 or Right Headlamp Power Output Stage J668 13 Carrier Front End 14 Level Control System Sensor 15 Screws 4 Nm M6 X 20 16 Headlamp Range Control Module ...

Page 212: ...ook January 2014 Rear Lid Tail Lamps Overview 1 Nut 3 Nm 2 Bolb Holder 3 Left Tail Lamp M4 and Right Tail Lamp M2 4 Left Rear Fog Lamp L46 and Right Rear Fog Lamp L47 or Left Backup Lamp M16 and Right Backup Lamp M17 5 Tail Lamp Housing In Rear Lid ...

Page 213: ...ing Column Switch Overview 1 Steering Column Electronic Systems Control Module J527 2 Steering Column Combination Switch E595 3 Base Carrier for Steering Column Switches 4 Shear Bolts Break off torque approximately 15 Nm M8 x 20 5 Steering Lock Housing 6 Ignition Switch and Lock Cylinder ...

Page 214: ... Overview 1 Steering Column Electronic Systems Control Module J527 1 5 Nm 2 Steering Column Combination Switch E595 3 Base Carrier for Steering Column Switches 4 Shear Bolts Break off torque approximately 15 Nm M8 x 20 5 Electronic Steering Column Lock Control Module J764 6 Start System Button E378 ...

Page 215: ...GTI Quick Reference Specification Book January 2014 209 Interior Lights Switches Fastener Tightening Specification Component Nm Horn bracket to longitudinal member 20 Left footwell lamp and diagnostic socket to bracket screw 1 5 ...

Page 216: ... Wiring Left E box in Engine Compartment Fastener Tightening Specifications Component Fastener Size Nm Central Bolt E box 9 Securing nuts 1 M5 width 8 4 Securing nuts 1 M6 width 10 6 Fastener Tightening Specification Component Nm Instrument panel fuse panel bolts 4 ...

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