K&J Automotive
21 Rosebank Close
Hollingworth
Hyde
Telephone: 07427773348
Fax:
Email: [email protected]
VAT Registration No.:
Notes Specified value Measured value
Vehicle identification
No. of cylinders Type 4/DOHC
Capacity cc 1968
Compression ratio :1 16,5
Fuel system Make Bosch
Fuel system Type EDC 17
Injection system
Air metering Type Mass
Fuel/injection pump assembly Make Bosch
Pump type Common rail
Injection sequence 1-3-4-2
Starting and charging
Battery V/RC(Ah) 12
Glow plugs
Glow plug - part no. Original equipment Beru/NGK
Glow plug - part no. Beru GE108
Glow plug - part no. NGK Y-609AS
Service checks and adjustments
Valve clearance - INLET mm Hydraulic
Valve clearance - EXHAUST mm Hydraulic
Compression pressure bar 19,0-31,0
Oil pressure bar/rpm 2,0/2000
Lubricants and capacities
Engine oil options
Ambient temperature range All temperatures
180 Engine oil grade SAE 5W/30
Engine oil classification OEM VW 507.00
Engine with filter(s) litres 4,0
Other lubricants and capacities
Manual transmission oil grade SAE 70W/75 Synthetic
Manual transmission oil classification GL-5
Manual transmission litres 2,3
Automatic transmission fluid Type G 052 182
196 Automatic transmission (drain & refill) litres 5,2
Cooling system - total capacity litres 8,0
Brake fluid Type DOT 4
Brake fluid litres 1,2
Power steering fluid Type G 004 000
Tightening torques
Cylinder head instructions
Cylinder head
Renew bolts Yes
Stage 1 Tighten 30 Nm
Stage 2 Tighten 50 Nm
Manufacturer: Volkswagen Model: Golf (08-) 2,0D GTD CR © Autodata Limited 2010
Engine code: CBBB Output: 125 (170) 4200 Valid forever. 31/03/2023
Tuned for: Year: 2009-11 V8.500-
Stage 3 Tighten 90°
Stage 4 Tighten 90°
Other engine tightening torques
Sump drain bolt 30 Nm
Injector/clamp 10 Nm
Injector pipe unions 25 Nm
Injector nozzle to holder 5 Nm
Glow plugs 18 Nm
Engine oil pressure switch 22 Nm
Oil filter 25 Nm
Chassis tightening torques
137 Front hub
1 Front hub - wheel bearing housing bolts 70 Nm+90°
265 Rear hub
1 Rear hub - wheel bearing housing bolts 70 Nm+90°
Brake disc to hub Front 4 Nm
Brake caliper to carrier Front 30 Nm
Brake caliper carrier to hub Front 190 Nm
Brake disc to hub Rear 4 Nm
1 Brake caliper to carrier Rear 35 Nm
1 Brake caliper carrier to hub Rear 90 Nm+90°
Back plate to hub Rear 12 Nm
ABS sensor Front 8 Nm
ABS sensor Rear 8 Nm
297 Road wheels 120 Nm
Brake disc and drum dimensions
264 Minimum disc thickness - ventilated Front
Minimum disc thickness Rear 8 mm
Minimum pad thickness Front 2 mm
Minimum pad thickness Rear 2 mm
Air conditioning
No. of AC service connectors 2
Air conditioning restrictor type Expansion valve
Air conditioning refrigerant Type R134a
Air conditioning refrigerant quantity grams 525±25
Air conditioning oil Type G 052 300 A2
Air conditioning oil quantity cm³ 110±10
Air conditioning oil viscosity ISO 46
Autodata Note 180
To VW specification 507.00
Low ash engine oil MUST be used to ensure long service life of diesel particulate filter (DPF).
Autodata Note 196
Fill transmission with specified amount.
Connect diagnostic equipment to check ATF temperature.
Start engine. Select each gear for 3 seconds, then return selector lever to 'P'.
Ensure ATF temperature is 35-45°C.
Remove level plug. Allow excess fluid to drain off.
If no fluid loss apparent: Top up until ATF drips from level tube.
Autodata Note 137
Use new bolts.
12 point bolt:
Tighten to 70 Nm with wheels off the ground.
Lower car to the ground and tighten a further 90°.
Hexagonal bolt:
Tighten to 200 Nm with wheels off the ground.
Manufacturer: Volkswagen Model: Golf (08-) 2,0D GTD CR © Autodata Limited 2010
Engine code: CBBB Output: 125 (170) 4200 Valid forever. 31/03/2023
Tuned for: Year: 2009-11 V8.500-
Lower car to the ground and tighten a further 180°.
Autodata Note 1
Use new bolts.
Autodata Note 265
Use new nuts/bolts.
FWD
1) Tighten to 180 Nm with wheels off the ground.
2) Lower car to the ground and tighten a further 180°.
4WD
1) Tighten to 70 Nm with wheels off the ground.
2) Lower car to the ground and tighten a further 90°.
Autodata Note 297
Do NOT lubricate bolts.
Lubricate mating surfaces between wheel centre hole and hub (use spray wax).
Autodata Note 264
FS III caliper (15") = 19 mm
FN3 caliper (15"/16") = 22 mm
Cylinder layout Tightening sequence
Manufacturer: Volkswagen Model: Golf (08-) 2,0D GTD CR © Autodata Limited 2010
Engine code: CBBB Output: 125 (170) 4200 Valid forever. 31/03/2023
Tuned for: Year: 2009-11 V8.500-
