NHTSA ID Number: 10122274
Manufacturer Communication Number: QRG - 2014 Passa
TSB/Document Date: 2017-11-08
Summary
2014 Volkswagen
Passat Quick Reference Specification Book This document is an overview which covers -General Information -Vehicle Identification -Sales Codes -Vehicle Lifting -ENGINES -Transmissions
2014
Passat
Quick Reference
Specification Book
2014 Volkswagen Passat
Quick Reference Specification Book
Table of Contents
General Information....................................................... 1
Decimal and Metric Equivalents............................................1
Distance/Length.....................................................................1
Tightening Torque..................................................................2
Nm-to-lb·ft (ft·lb)....................................................................2
Nm-to-lb·in (in·lb), kg·cm.......................................................3
N·cm-to-lb·in (in·lb), kg·cm....................................................3
kg·cm-to-lb·in (in·lb), N·cm....................................................4
Warnings 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
ENGINES
Engine Mechanical – 1.8L CPKA, CPRA..................... 16
General, Technical Data......................................................16
Engine Number Location........................................................16
Engine Data............................................................................17
Engine Assembly – 1.8L CPKA, CPRA...............................18
Assembly Mounts Overview...................................................18
Fastener Tightening Specifications.........................................19
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Engine Support - Tightening Specification and Sequence.....20
Install the Pendulum Support.................................................21
Crankshaft, Cylinder Block – 1.8L CPKA, CPRA.................22
Cylinder Block Overview, Belt Pulley Side..............................22
Cylinder Block Overview, Transmission Side.........................24
Drive Plate Overview..............................................................25
Crankshaft Overview..............................................................26
Balance Shaft Overview.........................................................27
Pistons and Connecting Rods Overview................................28
Accessory Assembly Bracket - Tightening Specifications
And Tightening Sequence................................................29
Ribbed Belt Transmission Side Sealing Flange Tightening Specifications and Sequence.........................30
Crankshaft, Tightening Sequence..........................................31
Crankshaft Dimensions..........................................................32
Piston and Cylinder Dimensions.............................................32
Piston Ring End Gaps............................................................32
Piston Ring Clearance............................................................32
Cylinder Head, Valvetrain – 1.8L CPKA, CPRA...................34
Cylinder Head Overview.........................................................34
Timing Chain Cover Overview................................................36
Camshaft Timing Chain Overview..........................................38
Balance Shaft Drive Chain Overview.....................................40
Valvetrain Overview................................................................42
Loosening the Cylinder Head Cover.......................................44
Cylinder Head Cover, Tightening Specifications
and Sequence..................................................................45
Cylinder Head Tightening Sequence......................................46
Timing Chain Guard Upper Cover - Tightening Sequence.....47
Timing Chain Lower Cover Tightening Sequence..................48
Timing Chain Guard Lower Section - Tightening
Sequence for 15 Bolts......................................................49
Intermediate Sprocket Tightening Sequence..........................50
Valve Dimensions...................................................................51
Compression Pressures.........................................................51
Lubrication – 1.8L CPKA, CPRA.........................................52
Oil Pan/Oil Pump Overview....................................................52
Engine Oil Cooler Overview ..................................................54
Crankcase Ventilation Overview.............................................55
Oil Filter Overview..................................................................56
Oil Pressure Switch/Oil Pressure Regulator Valve
Overview..........................................................................58
Oil Pan Lower Section - Tightening Sequence.......................60
Oil Pan Upper Section - Tightening Sequence.......................61
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Oil Separator - Tightening Sequence.....................................62
Cooling System – 1.8L CPKA, CPRA..................................64
Coolant Pump/Thermostat Overview......................................64
Electric Coolant Pump Overview............................................66
Coolant Temperature Sensor Overview..................................67
Coolant Pipes Overview.........................................................68
Radiator/Coolant Fan Overview.............................................69
Fan Shroud and Radiator Fan Overview................................70
Thermostat - Tightening Specification and Tightening
Sequence.........................................................................71
Coolant Pump - Tightening Specification and Sequence.......72
Fastener Tightening Specifications.........................................72
Fuel Supply – 1.8L CPKA, CPRA........................................73
Accelerator Pedal Mechanism Overview................................73
Fuel Tank and Attachments Overview....................................74
EVAP System Component Overview......................................76
Fuel Delivery Unit/Fuel Level Sensor Assembly Overview.....77
Turbocharger – 1.8L CPKA, CPRA......................................78
Turbocharger and Mahle Charge Pressure Actuator
-V465- Overview..............................................................78
Turbocharger and Cooper Charge Pressure Actuator
-V465- Overview..............................................................82
Charge Air System Overview..................................................86
Air Guides with Screw-Type Clamps, Installing......................87
Multiport Fuel Injection – 1.8L CPKA, CPRA.......................88
Fuel Rail with Fuel Injectors Overview...................................88
Air Filter Housing Overview....................................................90
Intake Manifold Overview.......................................................92
High Pressure Pump Overview..............................................94
Heated Oxygen Sensor Overview, 2 Heated Oxygen
Sensors............................................................................96
Exhaust System, Emission Controls – 1.8L CPKA,
CPRA...................................................................................97
Muffler Overview.....................................................................97
Emissions Control Overview...................................................98
Secondary Air Injection System Overview............................100
Ignition/Glow Plug System – 1.8L CPKA, CPRA...............102
Ignition System Overview.....................................................102
Engine Mechanical – 2.0L CKRA (TDI)..................... 103
General, Technical Data....................................................103
Engine Number Location......................................................103
Engine Data..........................................................................104
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Engine Assembly – 2.0L CKRA (TDI)................................105
Fastener Tightening Specifications.......................................105
Engine Mount Tightening Specifications...............................105
Transmission Mount Tightening Specifications.....................106
Fastener Tightening Specifications.......................................107
Pendulum Support Tightening Specifications.......................108
Direct Shift Gearbox (DSG®) to Engine, Bolt Tightening
Sequence and Specification...........................................109
Crankshaft, Cylinder Block – 2.0L CKRA (TDI)................. 110
Ribbed Belt and Tensioner Overview................................... 110
Sealing Flange Overview...................................................... 111
Dual Mass Flywheel and Sealing Flange Overview............. 112
Crankshaft Overview............................................................ 113
Pistons and Connecting Rod Overview................................ 114
Sealing Flange Bolt Tightening Sequence and
Specification................................................................... 115
Sealing Flange Bolt Tightening Sequence and
Specification................................................................... 116
Accessory Bracket Tightening Specifications....................... 117
Crankshaft Dimensions........................................................ 117
Piston and Cylinder Dimensions........................................... 118
Piston Ring End Gaps.......................................................... 118
Piston Ring Clearance.......................................................... 118
Cylinder Head, Valvetrain – 2.0L CKRA (TDI)...................120
Cylinder Head Cover Overview............................................120
Cylinder Head Overview.......................................................122
Toothed Belt Drive Overview................................................124
Valve Dimensions.................................................................126
Compression Pressures.......................................................126
Cylinder Head Cover Bolt Tightening Sequence and
Specification...................................................................127
Cylinder Head Tightening Specifications..............................128
Bearing Frame Tightening Specifications.............................129
Lubrication – 2.0L CKRA (TDI)..........................................130
Oil Filter Bracket and Oil Cooler Overview...........................130
Cylinder Head, Valvetrain – 2.0L CKRA (TDI)...................132
Oil Pan, Pump and Balance Shaft Module Overview...........132
Oil Filter Bracket Bolt Tightening Sequence and
Specification...................................................................134
Oil Pan Bolt Tightening Sequence and Specification...........135
Balance Shaft Module, with 8 Bolts, Tightening
Sequence and Specification...........................................136
Balance Shaft Module, with 6 Bolts, Tightening
Sequence and Specification...........................................137
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Cooling System – 2.0L CKRA (TDI)..................................138
Engine Preheater Overview..................................................138
Coolant Pump and Thermostat Overview.............................139
4/2-Way Valve and Thermostat Overview............................140
Charge Air Cooling Pump -V188- Overview.........................141
Coolant Pipes Overview.......................................................142
Radiator and Fan Shroud Overview.....................................144
Fastener Tightening Specifications.......................................145
Fuel Supply – 2.0L CKRA (TDI).........................................146
Accelerator Pedal Mechanism Overview..............................146
Fuel Delivery Unit/Fuel Level Sensor Overview...................147
Fuel Filter Overview..............................................................148
Fuel Tank Overview..............................................................150
Turbocharger – 2.0L CKRA (TDI)......................................152
Charge Air Cooler Overview.................................................152
Turbocharger and Attachments Overview............................154
Fastener Tightening Specifications.......................................155
Diesel Fuel Injection – 2.0L CKRA (TDI)...........................156
Fuel Rail and Injector Overview............................................156
High-Pressure Pump Overview............................................158
Air Filter Housing Overview..................................................160
Intake Manifold Overview.....................................................162
Fastener Tightening Specifications.......................................164
Exhaust System, Emission Controls – 2.0L CKRA (TDI)...166
Front Exhaust Pipe with Particulate Filter Overview.............166
NOx Reduction Catalytic Converter Overview......................168
Exhaust Door Control Unit Overview....................................169
NOx sensor -G295- Overview..............................................170
Muffler and Mounts Overview...............................................171
Exhaust Temperature Control Overview...............................172
Exhaust Gas Recirculation Overview...................................174
Reducing Agent (AdBlue®) Tank Overview..........................176
Reducing Agent (AdBlue®) Delivery Module Overview........177
Reducing Agent (AdBlue®) Delivery Line Overview.............178
Fastener Tightening Specifications.......................................179
Front Exhaust Pipe with Particulate Filter Tightening
Specifications.................................................................180
Ignition/Glow Plug System – 2.0L CKRA (TDI)..................181
Fastener Tightening Specifications.......................................181
Engine Mechanical – 2.5L CBTA, CBUA................... 182
General, Technical Data....................................................182
Engine Number.....................................................................182
Engine Data..........................................................................183
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Engine Assembly – 2.5L CBTA, CBUA..............................184
Fastener Tightening Specifications.......................................184
Engine Mount Tightening Specifications...............................184
Transmission Mount Tightening Specifications.....................185
Pendulum Support Tightening Specifications.......................186
Crankshaft, Cylinder Block – 2.5L CBTA, CBUA...............187
Main Bearing Shell Allocation...............................................187
Crankshaft/Upper Bearing Shell Mark..................................187
Ribbed Belt Drive Overview..................................................188
Cylinder Block Overview, Transmission Side.......................190
Flywheel Overview...............................................................192
Crankshaft Overview............................................................193
Piston and Connecting Rod Overview..................................194
Fastener Tightening Specifications.......................................194
Crankshaft Dimensions........................................................195
Piston Ring Gap...................................................................195
Piston Ring Groove Clearance.............................................195
Piston and Cylinder Dimensions...........................................195
Cylinder Head, Valvetrain – 2.5L CBTA, CBUA.................196
Cylinder Head and Cover Overview.....................................196
Camshaft Timing Chain Overview........................................198
Valvetrain Overview..............................................................200
Fastener Tightening Specifications.......................................201
Valve Dimensions.................................................................202
Compression Pressures.......................................................202
Cylinder Head Cover Bolt Tightening Sequence and
Specification...................................................................203
Cylinder Head Bolt Tightening Sequence and
Specification...................................................................204
Guide Frame Bolt Tightening Sequence and
Specification...................................................................205
Lubrication – 2.5L CBTA, CBUA........................................206
Oil Pan and Oil Pump Overview...........................................206
Oil Filter Adapter Overview...................................................208
Fastener Tightening Specifications.......................................209
Cooling System – 2.5L CBTA, CBUA................................210
Engine Pre-Heater Overview................................................210
Coolant Pump and Thermostat Overview Part 1,
Belt Pulley Side..............................................................212
Coolant Pump and Thermostat Overview Part 2,
Transmission Side..........................................................214
Fan Shroud and Radiator Overview.....................................216
Fastener Tightening Specifications.......................................217
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Fuel Supply – 2.5L CBTA, CBUA.......................................218
Accelerator Pedal Mechanism Overview..............................218
Fuel Tank and Attachments Overview..................................220
EVAP System Component Overview....................................222
Fuel Delivery Unit/Fuel Level Sensor Assembly
Overview........................................................................223
Multiport Fuel Injection – 2.5L CBTA, CBUA.....................224
Engine Cover/Air Filter Housing Overview...........................224
Intake Manifold Overview.....................................................226
Fuel Rail and Injectors Overview..........................................228
Fastener Tightening Specifications.......................................229
Lower Air Filter Housing Bolt Tightening Sequence.............229
Exhaust System, Emission Controls –
2.5L CBTA, CBUA..............................................................230
Exhaust Manifold Overview..................................................230
Exhaust Pipe with Catalytic Converter Overview.................232
Muffler Overview...................................................................234
Fastener Tightening Specifications.......................................235
Secondary Air Injection Pipe Tightening Specifications........235
Ignition – 2.5L CBTA, CBUA..............................................236
Ignition System Component Overview.................................236
Muffler Overview...................................................................237
Technical Data......................................................................238
Engine Mechanical – 3.6L CDVB............................... 239
General, Technical Data....................................................239
Engine Number Location......................................................239
Engine Data..........................................................................240
Cylinder Numbering..............................................................241
Engine Assembly – 3.6L CDVB.........................................242
Engine/Transmission Mounts Overview...............................242
Tightening Specifications......................................................244
Fastener Tightening Specifications.......................................244
Crankshaft, Cylinder Block – 3.6L CDVB..........................245
Allocation of Crankshaft Bearing Shells for Cylinder
Block..............................................................................245
Cylinder Block Identification.................................................245
Crankshaft Identification.......................................................246
Cylinder Block Overview, Belt Pulley Side............................248
Ribbed Belt Drive Overview..................................................250
Cylinder Block Overview, Transmission Side.......................252
Crankshaft Overview............................................................253
Pistons and Connecting Rod Overview................................254
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Fastener Tightening Specifications.......................................254
Accessory Bracket Bolt Tightening Specifications................255
Piston Ring End Gaps..........................................................256
Piston Ring Clearance..........................................................256
Piston and Cylinder Dimensions...........................................256
Crankshaft Dimensions........................................................256
Cylinder Head, Valvetrain – 3.6L CDVB............................258
Ribbed Belt Drive Overview..................................................258
Vacuum Pump Overview......................................................260
Cover and Sealing Flange Overview....................................262
Control Housing Overview....................................................264
Timing Chains Overview.......................................................266
Valvetrain Overview..............................................................268
Compression Pressures.......................................................270
Valve Dimensions.................................................................270
Dimensions for Intake Valve.................................................270
Dimensions for Exhaust Valve..............................................270
Cylinder Head Cover Bolt Tightening Sequence and
Specification...................................................................271
Cylinder Head Tightening Specifications.............................272
Sealing Flange to Cylinder Block Bolt Tightening
Sequence and Specification...........................................273
Camshaft Bearing Cap Tightening Specifications................274
Lubrication – 3.6L CDVB...................................................276
Oil Pan/Oil Pump Overview..................................................276
Oil Filter Housing/Oil Pressure Switch Overview..................278
Cooling System – 3.6L CDVB...........................................280
Coolant Pump/Thermostat Overview....................................280
Radiator/Coolant Fan Overview...........................................282
Fastener Tightening Specifications.......................................283
Fuel Supply System – 3.6L CDVB.....................................284
Accelerator Pedal Mechanism Overview..............................284
Fuel Tank and Attachments Overview..................................286
EVAP System Component Overview....................................288
Fuel Delivery Unit/Fuel Level Sensor Assembly
Overview........................................................................289
Multiport Fuel Injection – 3.6L CDVB................................290
Air Filter Housing Overview..................................................290
Intake Manifold Overview.....................................................292
Fuel Rail with Injector Overview...........................................294
High Pressure Pump Overview............................................296
Exhaust System, Emission Controls – 3.6L CDVB............298
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Exhaust Manifold Overview..................................................298
Exhaust Pipe with Catalytic Converter Overview.................300
Muffler Overview...................................................................301
Fastener Tightening Specifications.......................................302
Ignition/Glow Plug System – 3.6L CDVB...........................303
Ignition Technical Data.........................................................303
Ignition System Assembly Overview.....................................304
transmissions
Manual Transmission – 0A4...................................... 306
General, Technical Data....................................................306
Transmission Identification...................................................306
Codes Letters, Transmission Allocation and Capacities.......308
Clutch – 0A4......................................................................310
Clutch Hydraulic System Overview......................................310
Pedal Cluster Overview........................................................312
Clutch Release Mechanism Overview..................................314
Clutch Overview, with Dual Mass Flywheel, LuK..................315
Clutch Overview, with Single Flywheel.................................316
Fastener Tightening Specifications.......................................317
Controls, Housing – 0A4....................................................318
Shift Lever and Housing Overview.......................................318
Shift and Selector Cables Overview.....................................320
Engine and Transmission Mounts Overview........................322
Transmission Cover and 5th Gear Overview........................324
Transmission Housing and Gear Shift Unit Overview...........326
Gear Shift Unit Overview......................................................328
Input Shaft, Output Shaft, Differential and Shift Rods
Overview........................................................................330
Selector Fork Overview........................................................331
Transmission Housing and Clutch Housing Overview..........332
Transmission to Engine Tightening Specifications...............333
Gears, Shafts – 0A4..........................................................334
Fastener Tightening Specification........................................334
Determining Shim Thickness................................................334
Adjustment Shim Table.........................................................335
Rear Final Drive, Differential – 0A4........................... 336
Differential Overview............................................................336
Automatic Transmission – 09G................................. 338
General, Technical Data....................................................338
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Identification on Transmission..............................................338
Engine and Transmission Allocation.....................................339
Controls, Housing – 09G...................................................340
Selector Mechanism Overview.............................................340
ATF Cooler, Round Version..................................................341
ATF Cooler, Rectangular Version.........................................342
Fastener Tightening Specifications.......................................343
Transmission to Engine Tightening Specifications...............343
Gears, Hydraulic Controls – 09G.......................................344
Differential Overview............................................................344
Fastener Tightening Specifications.......................................346
Direct Shift Gearbox (DSG) Transmission – 02E..... 347
General, Technical Data....................................................347
Identification on Transmission..............................................347
Identification on Transmission..............................................348
Transmission Allocation Codes.............................................349
Controls, Housing (DSG) – 02E........................................350
Transmission Component Overview.....................................350
Selector Mechanism Overview.............................................352
Engine and Transmission Mounts Overview........................354
Mechatronic Tightening Specifications.................................356
Oil Pump Tightening Specifications Without
Countersunk Bolt............................................................357
Transmission to Engine Tightening Specifications
Diesel Engine.................................................................358
Gas Engine...........................................................................359
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General
Information
General Information
Decimal and Metric Equivalents
Distance/Length
To calculate: mm x 0.03937 = in.
mm
0.002
0.004
0.006
0.008
0.010
0.020
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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TSB/Document ID: QRG - 2014 Passa
Replacement Service Bulletin Number:
MFR Communication Date: 2014-02-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
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