23

February 2014

179

Front Exhaust Pipe with Particulate
Filter Tightening Specifications

Step
1
2
3
4
5
6
7
8
9

180

Component
Position the particulate filter on the
turbocharger. Install clamp (1) so it is still loose.
Install bolts 2 through 5 hand-tight so they are
still loose. The particulate filter and bracket must
be allowed to slide back and forth.
Attach the EGR pipe, loosely secure the clamp
(6)
Tighten clamp (1)
Tighten the nuts (5)
Tighten the nuts (4)
Tighten the nut (2)
Tighten bolts (3)
Tighten the clamp (6)

VW Passat Quick Reference Specification Book

Nm
7
23
23
23
23
3.5

•

February 2014

Engine –
2.0L CKRA (TDI)

Ignition/Glow Plug System – 2.0L CKRA
(TDI)
Fastener Tightening Specifications
Component
Camshaft Position (CMP) sensor
Engine Speed (RPM) sensor
Glow plug

VW Passat Quick Reference Specification Book

Nm
10
5
18

•

February 2014

181

Engine Mechanical – 2.5L
CBTA, CBUA
General, Technical Data
Engine Number

The engine code (A) and engine number (B) (serial number) are
located on the rear side of the engine, above the cylinder block/
upper oil pan partition. The engine number consists of up to nine
characters (alphanumeric). The first part (maximum of 3 letters)
represents the engine code; the second (six digits) is the serial
number. If more than 999,999 engines with the same engine code
are produced, the first of the six characters is replaced with a letter.
In addition, a sticker with the engine code and engine number
is applied to the cylinder head cover. The engine code letters
are also located on the vehicle data label. The vehicle data label
is located in the customer’s service schedule as well as in the
spare tire wheel well or on the luggage compartment floor.
When four digit engine codes are used, the first three digits indicate
the mechanical structure of the engine and are stamped on the
engine. The fourth digit describes the engine output and torque.

182

VW Passat Quick Reference Specification Book

•

February 2014

Engine Data
CBTA
from 07.2007
TIER 2/BIN 5
(US coalition)
2480
125 @ 5700
240 @ 4250
680
approximately
6300
82.5
92.8
9.5
4
95 unleaded 2)

CBUA
from 07.2007
SULEV 1)

Displacement
cm³
2480
Output
kW at RPM
125 @ 5700
Torque
Nm at RPM
240 @ 4250
Engine idle speed 3)
RPM
680
Engine speed (RPM)
RPM
approximately
limitation
6300
Bore
diameter mm
82.5
Stroke
mm
92.8
Compression ratio
9.5
Valves per cylinder
4
Research Octane
minimum
95 unleaded 2)
Number (RON)
Fuel injection, ignition
Motronic ME 17.5 Motronic ME 17.5
Knock control
2 sensors
2 sensors
Variable valve timing
Yes
Yes
Variable intake manifold
No
No
Oxygen Sensor (O2S) regulation
2 sensors
3 sensors
Catalytic converter
Yes
Yes
Exhaust Gas Recirculation (EGR)
No
No
Turbocharger, Supercharger
No
No
Secondary Air Injection (AIR) system
No
Yes
1)
2)
3)

SULEV = Super Ultra Low Emission Vehicles.
Unleaded RON 91 is permitted but performance is reduced.
Applies to manual and automatic transmission. If voltage supply of Engine Control
Module (ECM) drops below 12 volts, idle speed is raised in stages up to 780 RPM.
Idle speed is not adjustable.

VW Passat Quick Reference Specification Book

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February 2014

183

Engine –
2.5L CBTA/CBUA

Engine codes
Manufactured
Emission values in accordance with

Engine Assembly – 2.5L CBTA, CBUA
Fastener Tightening Specifications
Component
Bolts and nuts

Fastener
size
M6
M7
M8
M10
M12

Nm
10
15
25
40
60

Engine Mount Tightening Specifications

Component
Bolts 1

Nm
40 plus an
additional 90°
(¼ turn) 1)
20 plus an
additional 90°
(¼ turn) 1)
60 plus an
additional 90°
(¼ turn) 1)

Bolts 2
Bolts 3

1)

Replace fastener(s).

184

VW Passat Quick Reference Specification Book

•

February 2014

Engine –
2.5L CBTA/CBUA

Transmission Mount Tightening Specifications

Component
Bolts A 1)

Nm
40 plus an
additional 90°
(¼ turn)
60 plus an
additional 90°
(¼ turn)

Bolt B 1)

1)

Replace fastener(s).

VW Passat Quick Reference Specification Book

•

February 2014

185

Pendulum Support Tightening Specifications

Secure the pendulum support to the transmission first and then
to the subframe. To remove, first remove bolt B, then bolts A.
Component
Bolts A 1)

Fastener
size
10.9

Bolt B 1)

-

1)

Nm
50 plus an
additional 90°
(¼ turn)
100 plus an
additional 90°
(¼ turn)

Replace fastener(s).

186

VW Passat Quick Reference Specification Book

•

February 2014

Crankshaft, Cylinder Block – 2.5L CBTA,
CBUA
Main Bearing Shell Allocation

The upper bearing shells are allocated to the cylinder
block with the correct thickness from the factory.
Colored dots identify the bearing thicknesses.

Letter on cylinder block
G
B
W

Engine –
2.5L CBTA/CBUA

The letters marked on the lower sealing surface of the cylinder block
identify which bearing thickness must be installed in which location.
Color of bearing
Yellow
Blue
White

Crankshaft/Upper Bearing Shell Mark

NOTE:
• The Æ points in the direction of travel.
• If the colored marks can no longer be read, use the bearing shell
with the blue mark.
• The lower crankshaft bearing shells are always shipped as a
replacement part with the yellow mark.

VW Passat Quick Reference Specification Book

•

February 2014

187

Ribbed Belt Drive Overview

1 - Bolt

23 Nm
2 - Power Steering Pump Pulley
3 - Bolt
23 Nm
4 - Power Steering Pump
5 - Accessory Bracket
6 - Bolt
25 Nm
7 - Bolt
25 Nm
8 - Generator
9 - Bolt
25 Nm
10 - Idler Pulley with Bracket
11 - Bolt
25 Nm
188

VW Passat Quick Reference Specification Book

•

February 2014

VW Passat Quick Reference Specification Book

•

February 2014

189

Engine –
2.5L CBTA/CBUA

12 - Bushing
13 - A/C Compressor
14 - Stud Bolt
25 Nm
15 - Bolt
25 Nm
16 - Ribbed Belt, for the Generator, power Steering Pump and Coolant
Pump
17 - Ribbed Belt, for the A/C Compressor
18 - Vibration Damper
There are different versions.
19 - Bolt
50 Nm + 90° turn
Replace after removing
20 - Coolant Pump
21 - Tensioner for A/C Compressor Ribbed Belt
35 Nm
22 - Tensioninger for Ribbed Belt for Generator, Vane Pump and
Coolant Pump
35 Nm
23 - Bolt
40 Nm + 90° turn
24 - Bolt
25 Nm
25 - Bushing
26 - Engine Mount

Cylinder Block Overview, Transmission Side

1 - Vibration Damper
2 - Bolt
50 Nm + 90° turn
Always replace
3 - Bolt
10 Nm
4 - Sealing Flange, Belt Pulley Side
5 - Cylinder Block
6 - Bolt
60 Nm + 90° turn
Always replace
7 - Drive Plate/Flywheel
8 - Sensor Wheel
9 - Crankshaft Seal, Transmission Side
10 - Timing Case

190

VW Passat Quick Reference Specification Book

•

February 2014

Engine –
2.5L CBTA/CBUA

11 - O-ring
Always replace
12 - Bolt
25 Nm
13 - Alignment Sleeves
14 - Bolt
5 Nm
15 - Engine Speed Sensor -G2816 - Seal
Always replace

VW Passat Quick Reference Specification Book

•

February 2014

191

Flywheel Overview

1 - Flywheel
2 - Bolt
9 Nm
Always replace.

192

VW Passat Quick Reference Specification Book

•

February 2014

Engine –
2.5L CBTA/CBUA

Crankshaft Overview

1 - Bolt
40 Nm + 90° turn
Always replace
2 - Bearing Cap
3 - Bearing Shell for the Bearing Cap
4 - Crankshaft
5 - Thrust Washers
6 - Bearing Shell for the Cylinder Block
7 - Cylinder Block

VW Passat Quick Reference Specification Book

•

February 2014

193

Piston and Connecting Rod Overview

1 - Connecting Rod Bolt
30 Nm + 90° turn
2 - Relief Valve
27 Nm
3 - Oil Spray Jet
4 - Connecting Rod Bearing Cap
5 - Bearing Shell
6 - Connecting Rod
7 - Circlip
8 - Piston Pin
9 - Piston
10 - Piston Rings

Fastener Tightening Specifications
Component
Plug to rear of cylinder block
194

VW Passat Quick Reference Specification Book

Nm
30*
•

February 2014

Crankshaft Dimensions

1st oversize

Crankshaft bearing
pin diameter
58.00
-0.022
-0.042
57.75
-0.022

2nd oversize

57.50

Stage III

57.25

Connecting rod bearing
pin diameter
47.80
-0.022
-0.042
47.55
-0.022

-0.042
-0.022
-0.042
-0.022
-0.042

-0.042
-0.022
-0.042
-0.022
-0.042

47.30
47.05

Piston Ring Gap
Piston ring
Compression rings
Oil scraping ring

mm
mm

Gap