ReferenceQ Service Bulletin/Repair Instructions

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

12 3 4 5...21

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Last update on 2026-05-12 / Affiliate links / Images from Amazon Product Advertising API

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