MC 10122274 9999

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
VW Passat Quick Reference Specification Book • February 2014 i

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
ii VW Passat Quick Reference Specification Book • February 2014
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
VW Passat Quick Reference Specification Book • February 2014 iii

Engine Assembly – 2.0L CKRA (TDI)................................105
Fastener Tightening Specifications.......................................105
Engine Mount Tightening Specifications...............................105
Transmission Mount Tightening Specifications.....................106
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
Balance Shaft Module, with 6 Bolts, Tightening
iv VW Passat Quick Reference Specification Book • February 2014
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
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
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
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
Front Exhaust Pipe with Particulate Filter Tightening
Specifications.................................................................180
Ignition/Glow Plug System – 2.0L CKRA (TDI)..................181
Engine Mechanical – 2.5L CBTA, CBUA................... 182
Engine Number.....................................................................182
Engine Data..........................................................................183
VW Passat Quick Reference Specification Book • February 2014 v
Engine Assembly – 2.5L CBTA, CBUA..............................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
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
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
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
vi VW Passat Quick Reference Specification Book • February 2014

Fuel Supply – 2.5L CBTA, CBUA.......................................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
Fuel Rail and Injectors Overview..........................................228
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
Secondary Air Injection Pipe Tightening Specifications........235
Ignition – 2.5L CBTA, CBUA..............................................236
Ignition System Component Overview.................................236
Technical Data......................................................................238
Engine Mechanical – 3.6L CDVB............................... 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
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
Cylinder Block Overview, Transmission Side.......................252
Crankshaft Overview............................................................253
Pistons and Connecting Rod Overview................................254
VW Passat Quick Reference Specification Book • February 2014 vii

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
Vacuum Pump Overview......................................................260
Cover and Sealing Flange Overview....................................262
Control Housing Overview....................................................264
Timing Chains Overview.......................................................266
Valvetrain Overview..............................................................268
Dimensions for Intake Valve.................................................270
Dimensions for Exhaust Valve..............................................270
Specification...................................................................271
Cylinder Head Tightening Specifications.............................272
Sealing Flange to Cylinder Block Bolt Tightening
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
Fuel Supply System – 3.6L CDVB.....................................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
Fuel Rail with Injector Overview...........................................294
High Pressure Pump Overview............................................296
Exhaust System, Emission Controls – 3.6L CDVB............298
viii VW Passat Quick Reference Specification Book • February 2014

Exhaust Manifold Overview..................................................298
Exhaust Pipe with Catalytic Converter Overview.................300
Ignition/Glow Plug System – 3.6L CDVB...........................303
Ignition Technical Data.........................................................303
Ignition System Assembly Overview.....................................304
transmissions
Manual Transmission – 0A4...................................... 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
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
VW Passat Quick Reference Specification Book • February 2014 ix

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
Transmission to Engine Tightening Specifications...............343
Gears, Hydraulic Controls – 09G.......................................344
Differential Overview............................................................344
Direct Shift Gearbox (DSG) Transmission – 02E..... 347
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
x VW Passat Quick Reference Specification Book • February 2014

General Information
Information
Decimal and Metric Equivalents
General
Distance/Length
To calculate: mm x 0.03937 = in.
mm in. mm in. mm in. mm in.
0.002 0.00008 0.01 0.0004 0.1 0.004 1 0.04
0.004 0.00016 0.02 0.0008 0.2 0.008 2 0.08
0.006 0.00024 0.03 0.0012 0.3 0.012 3 0.12
0.008 0.00031 0.04 0.0016 0.4 0.016 4 0.16
0.010 0.00039 0.05 0.0020 0.5 0.020 5 0.20
0.020 0.00079 0.06 0.0024 0.6 0.024 6 0.24
0.030 0.00118 0.07 0.0028 0.7 0.028 7 0.28
0.040 0.00157 0.08 0.0031 0.8 0.031 8 0.31
0.050 0.00197 0.09 0.0035 0.9 0.035 9 0.35
0.060 0.00236 0.10 0.0039 1.0 0.039 10 0.39
0.070 0.00276 0.20 0.0079 2.0 0.079 20 0.79
0.080 0.00315 0.30 0.0118 3.0 0.118 30 1.18
0.090 0.00354 0.40 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 1.575
1.000 0.03937 5.00 0.1969 50.0 1.969
2.000 0.07874 6.00 0.2362 60.0 2.362
3.000 0.11811 7.00 0.2756 70.0 2.756
4.000 0.15748 8.00 0.3150 80.0 3.150
5.000 0.19685 9.00 0.3543 90.0 3.543
6.000 0.23622 10.00 0.3937 100.0 3.937
7.000 0.27559 20.00 0.7874
8.000 0.31496 30.00 1.1811
9.000 0.35433 40.00 1.5748
10.000 0.39370 50.00 1.9685
20.000 0.78740 60.00 2.3622
30.000 1.18110 70.00 2.7559
40.000 1.57480 80.00 3.1496
50.000 1.96850 90.00 3.5433
60.000 2.36220 100.00 3.9370
70.000 2.75591
80.000 3.14961
90.000 3.54331
100.000 3.93701
VW Passat Quick Reference Specification Book • February 2014 1

Tightening Torque
Nm-to-lb·ft (ft·lb)
To calculate: Nm x 0.738 = lb·ft
lb·ft lb·ft lb·ft
Nm Nm Nm
(ft·lb) (ft·lb) (ft·lb)
10 7 55 41 100 74
11 8 56 41 105 77
12 9 57 42 110 81
13 10 58 43 115 85
14 10 59 44 120 89
15 11 60 44 125 92
16 12 61 45 130 96
17 13 62 46 135 100
18 13 63 46 140 103
19 14 64 47 145 107
20 15 65 48 150 111
21 15 66 49 155 114
22 16 67 49 160 118
23 17 68 50 165 122
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 65 280 207
44 32 89 66 290 214
45 33 90 66 300 221
46 34 91 67 310 229
47 35 92 68 320 236
48 35 93 69 330 243
49 36 94 69 340 251
50 37 95 70 350 258
51 38 96 71 360 266
52 38 97 72 370 273
53 39 98 72 380 280
54 40 99 73 390 288
55 41 100 74 400 295
2 VW Passat Quick Reference Specification Book • February 2014

Nm-to-lb·in (in·lb), kg·cm
To calculate: Nm x 8·85 = lb·in • Nm x 10.20 = kg·cm
Information
General
lb·in lb·in
Nm kg·cm Nm kg·cm
(in·lb) (in·lb)
1 9 10 26 230 265
2 18 20 27 239 275
3 27 31 28 248 286
4 35 41 29 257 296
5 44 51 30 266 306
6 53 61 31 274 316
7 62 71 32 283 326
8 71 82 33 292 337
9 80 92 34 301 347
10 89 102 35 310 357
11 97 112 36 319 367
12 106 122 37 327 377
13 115 133 38 336 387
14 124 143 39 345 398
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
lb·in lb·in
N·cm kg·cm N·cm kg·cm
(in·lb) (in·lb)
50 4 5 250 22 25
60 5 6 300 27 31
70 6 7 350 31 36
80 7 8 400 35 41
90 8 9 450 40 46
100 9 10 500 44 51
110 10 11 550 49 56
120 11 12 600 53 61
130 12 13 650 58 66
140 12 14 700 62 71
150 13 15 750 66 76
160 14 16 800 71 82
170 15 17 850 75 87
180 16 18 900 80 92
190 17 19 950 84 97
200 18 20 1000 89 102

kg·cm-to-lb·in (in·lb), N·cm
To calculate: kg·cm x 0.868 = lb·in • kg·cm x 9.81 = N·cm
lb·in lb·in
kg·cm N·cm kg·cm N·cm
(in·lb) (in·lb)
5 4 49 110 95 1079
6 5 59 120 104 1177
7 6 69 130 113 1275
8 7 78 140 122 1373
9 8 88 150 130 1471
10 9 98 160 139 1569
20 17 196 170 148 1667
30 26 294 180 156 1765
40 35 392 190 165 1863
50 43 490 200 174 1961
60 52 588 210 182 2059
70 61 686 220 191 2157
80 69 785 230 200 2256
90 78 883 240 208 2354
100 87 981 250 217 2452
Warnings and Cautions

WARNINGS
• Some repairs may be beyond your capability. If you lack the skills,
tools and equipment, or a suitable workplace for any procedure
described in this manual, we suggest you leave such repairs to an
authorized 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 work under a lifted car unless it is solidly supported on
stands designed for the purpose. Do not support a car on cinder
blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a car that is supported solely
by a jack. Never work under the car while the engine is running.
• If you are going to work under a car on the ground, make sure
the ground is level. Block the wheels to keep the car from rolling.
Disconnect the battery negative (-) terminal (ground strap) to
prevent others from starting the car while you are under it.

• Never run the engine unless the work area is well ventilated.
Carbon monoxide kills.
Information
• Remove rings, bracelets and other jewelry so they cannot cause
General
electrical shorts, get caught in running machinery, or be crushed by
heavy parts.
• Tie back long hair. Do not wear a necktie, a scarf, loose clothing,
or a necklace when you work near machine tools or running
engines. If your hair, clothing, or jewelry were to get caught in the
machinery, severe injury could result.
• Do not attempt to work on your car if you do not feel well. You
increase the danger of injury to yourself and others if you are tired,
upset, or have taken medication or any other substance that may
keep you from being fully alert.
• Illuminate your work area adequately but safely. Use a portable
safety light for working inside or under the car. Make sure the bulb
is enclosed by a wire cage. The hot filament of an accidentally
broken bulb can ignite spilled fuel, vapors or oil.
• Use a suitable container to catch 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 protective clothing whenever the job requires working with
harmful substances.
• Greases, lubricants and other automotive chemicals contain toxic
substances, many of which are absorbed directly through the skin.
Read the manufacturer’s instructions and warnings carefully. Use
hand and eye protection. Avoid direct skin contact
• Disconnect the battery negative (-) terminal (ground strap)
whenever you work on the fuel or electrical system. Do not smoke
or work near heaters or other fire hazards. Keep an approved fire
extinguisher handy.
• Friction materials (such as brake pads or shoes or clutch discs)
contain asbestos fibers or other friction materials. Do not create
dust by grinding, sanding, or cleaning with compressed air. Avoid
breathing dust. Breathing any friction material dust can lead to
serious diseases and may result in death.
(WARNINGS cont’d on next page)

WARNINGS (cont’d)
• Batteries give off explosive hydrogen gas during charging. Keep
sparks, lighted matches and open flame away from the top of the
battery. If hydrogen gas escaping from the cap vents is ignited, it
ignites the gas trapped in the cells and causes the battery
to explode.
• Connect and disconnect battery cables, jumper cables or a battery
charger only with the ignition off. Do not disconnect the battery
while the engine is running.
• 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.
• Do not allow battery charging voltage to exceed 16.5 volts. If
the battery begins producing gas or boiling violently, reduce the
charging rate. Boosting a sulfated battery at a high charging rate
can cause an explosion.
• The A/C system is filled with chemical refrigerant, which is
hazardous. The A/C system should be serviced only by trained
technicians using approved refrigerant 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 when repairing a tire that may have been inflated using an
aerosol tire inflator. Keep sparks, open flame or other sources of
ignition away from the tire repair area. Inflate and deflate the tire at
least four times before breaking the bead from the rim. Completely
remove the tire from the rim before attempting
any repair.
• Some cars are equipped with a Supplemental Restraint System
(SRS) that automatically deploys airbags and pyrotechnic seat
belt tensioners in the event of a frontal or side impact. These
are explosive devices. Handled improperly or without adequate
safeguards, they can be accidentally activated and cause serious
injury.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals and use extreme care when
working on a car with the engine running or the ignition on.

• Place jack stands only at locations specified by manufacturer.
The vehicle lifting jack supplied with the vehicle is intended for tire
changes only. Use a heavy duty floor jack to lift the vehicle before
Information
installing jack stands.
General
• Battery acid (electrolyte) can cause severe burns. Flush contact
area with water, seek medical attention.
• Aerosol cleaners and solvents may contain hazardous or deadly
vapors and are highly flammable. Use only in a well ventilated
area. Do not use on hot surfaces (such as engines or brakes).
• Do not remove coolant reservoir or radiator cap with the engine
hot. Burns and engine damage may occur.
CAUTIONS
• If you lack the skills, tools and equipment, or a suitable workshop
for any procedure described in this manual, we suggest you leave
such repairs to an authorized dealer or other
qualified shop.
• Before starting a job, make certain that you have all the necessary
tools and parts on hand. Read all the 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 tighten fasteners to
the tightening torque specification listed.
• Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the oil. Do not
pour oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of in accordance with Federal, State and
Local laws.
• The control module for the Anti-lock Brake System (ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp in excess of 95°C (203°F) and should not be subjected to
temperatures exceeding 85°C (185°F) for more than two hours.
• Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative (-) terminal (ground strap) and the
ABS control module connector.
• Always make sure the ignition is off before disconnecting battery.
(CAUTIONS cont’d on next page)

CAUTIONS (cont’d)
• Label battery cables before disconnecting. On some models,
battery cables are not color coded.
• Disconnecting the battery may erase fault code(s) stored in control
module memory. Check for fault codes prior to disconnecting the
battery cables.
• If a normal or rapid charger is used to charge the battery,
disconnect the battery and remove it from the vehicle to 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-hour (Ah) rating.
• Do not allow battery charging voltage to exceed 16.5 volts. If
the battery begins producing gas or boiling violently, reduce the
charging rate. Boosting a sulfated battery at a high charging rate
can cause an explosion.

Vehicle Identification
Vehicle Identification Number (VIN) Location
Identification
Vehicle
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.

VIN Decoder
Series: 2014 Volkswagen VIN Decoder (except Routan)
Country of origin
K= Jetta SportWagen w/5
Restraint system
A= CC Sport w/Man Trans,
Assembly plant
Spd Man Trans
E = 2014
Passat S, Tiguan w/Auto
Trans L= Jetta SEL/TDI w/Auto
Manufacturer
Vehicle Type
B= CC Sport/Sport+ w/Auto Trans
Model (7&8)
Check digit
M= Jetta SportWagen w/6
Model year
Trans, Eos Komfort/Sport
w/Auto Trans, Jetta SE Spd Manual
w/5 Spd Man, Passat SE, N= Golf 4dr w/6 Spd Manual Sequential
Engine
Tiguan w/Auto Trans and P= Jetta SportWagen w/6 production number
Series
4-Motion Spd Auto Trans
R= Beetle TDI w/6 Spd Man,
(position 12 - 17)
C= Golf 4dr w/5 Spd Manual,
Passat SEL, Tiguan CC Exec w/Auto Trans
w/Man Trans V= Beetle R-Line w/6 Spd
D= Golf 4dr w/Auto Trans, Auto Trans
1= Jetta / S w/5 Spd Manual
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Jetta SE w/Auto Trans,
Touareg V6 FSI/TDI 2= Jetta / S w/Auto Trans W V G C V 3 A X 8 E W 5 3 2 0 1 4
3= Jetta TDI w/6 Spd Man
See back
R-Line
2014
E= Touareg V6 FSI/TDI 4= Beetle R-Line w/6 Spd A= 5 cyl 2.5L 170hp (CBTA-M) Golf
/Hybrid Manual, Jetta GLI WVW = Europe - B= 5 cyl 2.5L 170hp (CBUA-M-PZEV*) Golf
F= Beetle w/6 Spd Auto w/Auto Trans Pass. Car D= 4 cyl 2.0L 200hp (CBFA-PZEV*) GTI
Trans, Eos Lux/Exec w/ 5= Beetle Conv. 1.8T w/6 Spd 1VW = USA - Pass. Calculate per F= VR6 3.6L 280hp (CGRA) Touareg
Auto Trans Auto Trans, Beetle Conv. Car NhTSA Code G= 6 cyl 3.0L 333hp + 34 Kw (CGFA)
G= CC V6 Exec w/Auto 2.5L TDI w/6 Spd. Auto 3VW = Mexico - Touareg Hybrid
Trans and 4Motion, GTI Trans, Jetta GLI w/6 Spd Pass. Car h= 5 cyl 2.5L 170hp (CBTA-M) Passat
WVG = Europe - A3*** = Passat K= 4 cyl 2.0L 115hp (CBPA) Jetta
4dr w/Man Trans, Jetta Manual
S.U.V. Ah (1F) = Eos L= 4 cyl 2.0L TDI 140hp (CJAA) Beetle, Beetle
SEL w/5 Spd Man Trans 6= Beetle Conv. TDI w/6Spd
AJ (16/1K)**** = Golf, Convertible, Jetta, Jetta SportWagen
h= Beetle 1.8T w/5 Spd Man Man Trans, Jetta Hybrid
GTI, Jetta, M= 4 cyl 2.0L TDI 140hp (CJAA) Golf
Trans, CC V6 Exec w/Auto Trans
Jetta M= VR6 3.6L 280hp (CDVB) Passat
w/Auto Trans, Beetle 2.5L 7= Beetle Conv. R-Line w/6
SportWagen N= 4 cyl 2.0L 200hp (CCTA) CC
w/5 Spd Manual, GTI 4dr Spd Auto Trans
AN (3C) = CC N= 4 cyl 2.0L TDI 140hp (CKRA) Passat
w/Auto Trans 8= Beetle Conv. R-Line w/6
AT = Beetle, Beetle P= 4 cyl 2.0L 200hp (CBFA-PZEV*) CC
J= Beetle 1.8T w/6 Spd Auto Spd Man Trans
Conv. P= 5 cyl 2.5L 170hp (CBUA-M-PZEV*)
Trans, Beetle 2.5L TDI AX (5N) = Tiguan
w/6 Spd Auto Trans Beetle, Beetle Convertible, Jetta, Jetta
BP (7P) = Touareg SportWagen, Passat
P= V6 3.0L TDI 240hp (CNRB) Touareg
* PZEV = Partial Zero Emissions Vehicle S= 4 cyl 1.8L 170hp (CPKA) Passat
C = Chattanooga P = Mosel S= 4 cyl 2.0L 210hp (CPLA) Beetle, Beetle
** SULEV II = Super Low Emissions Vehicle D = Bratislava V = Portugal Convertible, Jetta GLI
E = Emden W = Wolfsburg T= 4 cyl 1.8L 170hp (CPRA-PZEV*) Passat
*** 7 position US model characters are M = Mexico T= 4 cyl 2.0L 210hp (CPPA-PZEV*) Beetle,
alphabetic beginning with 2010 MY. ROW Beetle Convertible, Jetta GLI
model characters, where different, are listed in U= VR6 3.6L 280hp (CNNA) CC
parenthesis (), for reference only. V= 4 cyl 2.0L 200hp (CCTA) Tiguan
W= 4 cyl 2.0L 200hp (CBFA-SULEV II**) Eos
**** Jetta and Jetta SportWagen models are X= 5 cyl 2.5L 170hp (CBTA-M) Beetle, Beetle
identified by WMI code of 3VW. GTI and Golf Convertible, Jetta, Jetta SportWagen
models are identified by WMI code of WVW. 0= 4 cyl 1.8L 170hp (CPKA) Beetle, Beetle
Convertible, Jetta
1= 4 cyl 1.8L 170hp (CPRA-PZEV*) Beetle, Beetle
Convertible, Jetta
october 30, 2013 (Rev 4) 3= 4 cyl 1.4L 150hp + 28 Kw (CNLA-PZEV*)
Jetta Hybrid
2014 Volkswagen VIN Decoder (except Routan)
J= Beetle 1.8T w/6 Spd Auto
h= Beetle 1.8T w/5 Spd Man

7 = (Beetle/Beetle Conv.) Advanced Front Air Bags + Side Impact Air Bags -
2014 Restraint System:
w/6 Spd Auto Trans

Trans, Beetle 2.5L TDI
5 (Jetta only) or 7 (Jetta SportWagen/CC/Passat) = Advanced Front Air
w/Auto Trans
w/5 Spd Manual, GTI 4dr
w/Auto Trans, Beetle 2.5L 7= Beetle Conv. R-Line w/6
Trans, CC V6 Exec
SEL w/5 Spd Man Trans

4dr w/Man Trans, Jetta
Trans and 4Motion, GTI
1 Country of origin
6 Restraint system
8 (Eos only) = Advanced Front Air Bags + Side Impact Aig Bags - Front
All = Active-Dr/Pass - Front Air Bag - Dr/Pass

9 (Touareg) = Advanced Front Air Bags + Side Impact Air Bags - Front
11 Assembly plant
8 (position 7 & 8)
3 (Tiguan) = Advanced Front Air Bags + Side Impact Air Bags - Front
3 (Tiguan) = Advanced Front Air Bags + Side Impact Air Bags - Front
2 Manufacturer
+ Side Curtain Air Bags + 4 Star Crash Rated

Sequential
3 Vehicle Type
october 30, 2013 (Rev 4)
5 (Jetta only) or 7 (Jetta SportWagen/CC/Passat) = Advanced Front Air

9 Check digit
10 Model year
Bags
+ Side Impact Air Bags - Fr. + Side Curtain Air Bags
production number
7 = (Beetle/Beetle Conv.) Advanced Front Air Bags + Side Impact Air Bags - (position 12 - 17)
5 Engine
+ Side Impact Air Bags - Fr. + Side Curtain Air Bags
4 Series
7 Model
Front + 3 Star Crash Rated

+ Knee Air Bags - Front + Side Curtain Air Bags
8 (Eos only) = Advanced Front Air Bags + Side Impact Aig Bags - Front
+ Knee Air Bags - Front + Side Curtain Air Bags
+ Side Curtain Air Bags + 4 Star Crash Rated
8= Beetle Conv. R-Line w/6
6= Beetle Conv. TDI w/6Spd

All = Active-Dr/Pass - Front Air Bag - Dr/Pass
9 (Touareg) = Advanced Front Air Bags + Side Impact Air Bags - Front
+ Side Curtain Air Bags
Spd Man Trans
Spd Auto Trans
w/Auto Trans
Man Trans, Jetta Hybrid
Manual
Trans, Jetta GLI w/6 Spd
12
13
14
15
16
17
NHTSA Code
Sequential
Calculate per
models are identified by WMI code of WVW.

identified by WMI code of 3VW. GTI and Golf
**** Jetta and Jetta SportWagen models are
parenthesis (), for reference only.
model characters, where different, are listed in
alphabetic beginning with 2010 MY. ROW
*** 7 position US model characters are
** SULEV II = Super Low Emissions Vehicle
* PZEV = Partial Zero Emissions Vehicle

2014 Restraint System:
Number
Product
Front + 3 Star Crash Rated
+ Side Curtain Air Bags
1 Country of origin
S.U.V.
WVG = Europe -
Pass. Car
C = 2012
D = 2013
Y = 2000
A = 2010
B = 2011
E = 2014
M =1991
1 = 2001
2 = 2002
3 = 2003
4 = 2004
5 = 2005
6 = 2006
7 = 2007
8 = 2008
9 = 2009
N =1992
R =1994
W=1998
P =1993
S =1995
V =1997
X =1999
T =1996
2014 Volkswagen VIN Decoder (except Routan)
2 Manufacturer
Bags
M =1991 3 Vehicle Type

N =1992
4 Series
P =1993
R =1994 5 Engine
S =1995
T =1996
M = Mexico
E = Emden
D = Bratislava
C = Chattanooga P = Mosel
BP (7P)
AX (5N)
AT
AN (3C)
AJ (16/1K)**** = Golf,
Ah (1F)
A3***
6 Restraint system
V =1997 Calculate per
W=1998 NHTSA Code 7 Model
X =1999
= Touareg
= Beetle, Beetle
= Eos
= Passat
= Tiguan
= CC
Y = 2000 8 (position 7 & 8)

Conv.
SportWagen
Jetta
GTI, Jetta,
W = Wolfsburg
V = Portugal
1 = 2001
9 Check digit
2 = 2002
3 = 2003 10 Model year
4 = 2004
5 = 2005 11 Assembly plant
6 = 2006
3= 4 cyl 1.4L 150hp + 28 Kw (CNLA-PZEV*)
1= 4 cyl 1.8L 170hp (CPRA-PZEV*) Beetle, Beetle
0= 4 cyl 1.8L 170hp (CPKA) Beetle, Beetle
X= 5 cyl 2.5L 170hp (CBTA-M) Beetle, Beetle

W= 4 cyl 2.0L 200hp (CBFA-SULEV II**) Eos
V= 4 cyl 2.0L 200hp (CCTA) Tiguan
U= VR6 3.6L 280hp (CNNA) CC
T= 4 cyl 2.0L 210hp (CPPA-PZEV*) Beetle,

T= 4 cyl 1.8L 170hp (CPRA-PZEV*) Passat
S= 4 cyl 2.0L 210hp (CPLA) Beetle, Beetle

S= 4 cyl 1.8L 170hp (CPKA) Passat
P= V6 3.0L TDI 240hp (CNRB) Touareg
P= 5 cyl 2.5L 170hp (CBUA-M-PZEV*)

P= 4 cyl 2.0L 200hp (CBFA-PZEV*) CC
N= 4 cyl 2.0L TDI 140hp (CKRA) Passat
N= 4 cyl 2.0L 200hp (CCTA) CC
M= VR6 3.6L 280hp (CDVB) Passat
M= 4 cyl 2.0L TDI 140hp (CJAA) Golf
L= 4 cyl 2.0L TDI 140hp (CJAA) Beetle, Beetle

K= 4 cyl 2.0L 115hp (CBPA) Jetta
h= 5 cyl 2.5L 170hp (CBTA-M) Passat
7 = 2007 12
Convertible, Jetta
Convertible, Jetta
Convertible, Jetta, Jetta SportWagen
Beetle Convertible, Jetta GLI
Convertible, Jetta, Jetta SportWagen

Jetta Hybrid
Beetle, Beetle Convertible, Jetta, Jetta

Convertible, Jetta GLI
SportWagen, Passat
Sequential
production number
8 = 2008
(position 12 - 17)
Product 13
9 = 2009 Number
Sequential
A = 2010 14
B = 2011
C = 2012 15
D = 2013
E = 2014 16
17

VIN on Longitudinal Member Extension
Identification
Vehicle
The Vehicle Identification Number (VIN) is located

on the longitudinal member extension (Æ).

Vehicle Data Label
The vehicle data label (Æ) is located in the left rear of

the vehicle in the spare wheel well. The vehicle data
label is also in the customer’s maintenance booklet.

Sales Codes
Engine Codes
CPKA, CPRA 1.8L 4-cylinder
CKRA 2.0L 4-cylinder Turbo Diesel (TDI)
CBTA/CBUA 2.5L 5-cylinder
CDVB 3.6L 6-cylinder
Transmission Codes
0A4 5-speed manual
02Q 6-speed manual
02E 6-speed Direct Shift Gearbox (DSG)
09G 6-speed automatic
Codes
Sales

Vehicle Lifting
Hoist and Jack Mounting Points
Front
Position the support plate in the side member

vertical reinforcement area (Æ).

Rear
Position the support plate in the side member

Vehicle
Lifting
vertical reinforcement area (Æ).
! WARNING
Make sure the side member stiffener contacts the support
plate of the lifting platform at center.

Engine Mechanical – 1.8L
CPKA, CPRA
General, Technical Data
Engine Number Location
The engine number “engine code” and “serial number” are located
at the engine/transmission joint. The engine code is also printed
behind the oil filter on the cylinder block. There is also a label glued
to the timing chain cover with the “engine code” and “serial number”.
The first three digits describe the mechanical structure of the engine
and are still stamped on the engine. The fourth digit describes
the engine output and torque and depends on the engine control
module. Four-digit engine codes are found on the type plate and
vehicle data label. It can also be read via the engine control module.
Engine Data
Identification code CPRA CPKA
Emission values PZEV SULEV BIN 5 TIER 2
Displacement liter 1.8 1.8
Output kW at RPM 125 (at 4800 125 at 4800
to 6200 to 6200
Torque Nm at RPM 250 at 1500 to 4750 250 at 1500 to 4750
Bore diameter mm 82.5 82.5
Stroke mm 84.1 84.1
Valves per cylinder 4 4
Compression ratio 9.6:1 9.6:1
RON 95 unleaded (in 95 unleaded (in
exceptional cases, exceptional cases,
minimum 91 RON, minimum 91 RON,
but with reduced but with reduced
performance) performance)
Injection system/ignition TFSI/SIMOS 12 TFSI/SIMOS 12
system
Ignition sequence 1-3-4-2 1-3-4-2
Turbocharger Turbocharger Turbocharger
Variable valve timing Yes (Intake) Yes (Intake)
Secondary air injection (AIR) Yes Yes
Oil pressure control Yes Yes
1.8L CPKA, CPRA

Engine –

Engine Assembly – 1.8L CPKA, CPRA
Assembly Mounts Overview
1 - Bolt
Tightening specification see Engine support - tightening
specification and sequence below
Engine support to engine
Replace after removing
2 - Engine Mount
3 - Bolt
40 Nm + 90° turn
Engine mount to body
4 - Bracket
5 - Bolt
20 Nm + 90° turn
Bracket to engine mount and body
6 - Bolt
40 Nm + 90° turn
Engine mount to body
7 - Bolt
60 Nm + 90° turn
Engine mount to engine support
8 - Pendulum Support
9 - Bolt
Tightening specification, see Install the Pendulum Support below
10 - Bolt
Tightening specification, see Install the Pendulum Support below
11 - Bolt
60 Nm + 90° turn
Transmission mount to transmission support
Replace after removin
12 - Bolt
40 Nm + 90° turn
Transmission mount to body
13 - Transmission Mount
The illustration shows the DSG transmission version
14 - Gearbox Support
15 - Bolt
Double Bolt
Transmission support to transmission
Tightening specification, see Manual Transmission or DSG
Transmission
16 - Engine Mount
Transmission
17 - Engine Support
Fastener Tightening Specifications

Component Fastener Nm
size
1.8L CPKA, CPRA
Bolts and nuts M6 10

M7 15
Engine –
M8 20
M10 40
M12 65

Engine Support - Tightening
Specification and Sequence
Tighten the bolts in steps in the sequence -1- to -3-.

Stage Bolts Nm
1 -1- through -3- 7
2 -1- through -3- 40
3 -1- through -3- Tighten 90° additional turn

Install the Pendulum Support
Step Component Nm
1 Tighten bolts A 1) 50 plus an
additional 90°
(¼ turn)
2 Tighten bolts B 1) 50 plus an
additional 90°
(¼ turn)
3 Tighten bolts C 1) 100 plus an
additional 90°
(¼ turn)
1.8L CPKA, CPRA
Engine –

Crankshaft, Cylinder Block – 1.8L CPKA,
CPRA
Cylinder Block Overview, Belt Pulley Side
1 - Ribbed Belt
2 - Ribbed Belt Tensioning Damper
3 - Bolt
8 Nm +45° turn
4 - Bolt
150 Nm + 90° turn
Lubricate O-ring
5 - O-Ring
6 - Vibration Damper
7 - Auxiliary Components Bracket

8 - Seal
9 - Bolt
Tightening specification, see Ribbed Belt Transmission Side
Sealing Flange - Tightening Specifications and Sequence below
10 - Bolt
Tightening specification, refer to Electrical Equipment
11 - Generator
12 - Alignment Sleeves
13 - A/C Compressor
14 - Bolt
Tightening specification, refer to Heating, Ventilation and Air
Conditioning
15 - Bolt

Transmission
16 - Engine Mount
Transmission
17 - Engine Support Cylinder Block Overview,
1.8L CPKA, CPRA

Engine –

Cylinder Block Overview, Transmission Side
1 - Flywheel
2 - Alignment Sleeve
3 - Sealing Flange, Transmission Side
4 - Cylinder Block
5 - Bolt
Tightening specification and sequence, see Ribbed Belt
Transmission Side Sealing Flange - Tightening Specifications and
Sequence below
6 - Intermediate Plate
8- Bolt
60 Nm + 90° turn
For dual-mass flywheel

Drive Plate Overview
1 - Washer with Recessesg

2 - Shim
3 - Bolts
60 Nm + 90° turn (additional turning can occur in several stages).
1.8L CPKA, CPRA
Engine –

Crankshaft Overview
1 - Cylinder Block
2 - Bearing Shell for Cylinder Block
3 - Crankshaft
4 - Bearing Shell for Bearing Cap
5 - Bolt
Tightening specification and sequence, see Crankshaft, Tightening
Sequence below
6 - Bearing Cap
7 - Bolt
10 Nm + 90° turn
8 - Sensor Wheel
9 - Thrust Washers
10 - Bolt
Tightening specification and sequence, see Crankshaft, Tightening
Sequence below

Balance Shaft Overview
1 - Bolt
4 Nm + 45° turn
2 - Balance Shaft
Exhaust side
3 - Needle Bearing Rim
4 - Pipe for the Balance Shaft
5 - Cylinder Block
1.8L CPKA, CPRA
6 - Balance Shaft Seal Intake Side

7 - Balance Shaft
Engine –
Intake side
8 - Needle Bearing Rim
9 - 4 Nm + 45° turn

Pistons and Connecting Rods Overview
1 - Connecting Rod Bolts

45 Nm + 90° turn
Lubricate the thread and contact surface.
2 - Connecting Rod Bearing Cap
Exhaust side
3 - Bearing Shells
4 - Relief Valve
27 Nm
5 - Oil Spray Jet
6 - Locking Ring
7 - Piston Pin
8 - Piston
9 - Compression Rings
10 - Oil Scraping Ring
11 - Connecting Rod

Accessory Assembly Bracket - Tightening
Specifications And Tightening Sequence

Stage Bolts Nm
1 -1- through -5- Tighten by hand
2 -1- through -5- Tighten to 20 Nm
1.8L CPKA, CPRA

Engine –

Ribbed Belt Transmission Side Sealing Flange
- Tightening Specifications and Sequence

Stage Bolts Nm
2 -1- through -6- 9

Crankshaft, Tightening Sequence
Tighten the bolts in steps in the sequence -1- to -10- and -arrpw A-.
Stage Bolts Nm
3 -1- through -3- Turn another 90° using a rigid wrench.
4 -Arrows A- Tighten to 20 Nm
1.8L CPKA, CPRA
5 -Arrows A- Turn another 90° using a rigid wrench.

Engine –

Crankshaft Dimensions
Reconditioning Crankshaft bearing Connecting rod bearing
dimension 1) pin diameter pin diameter
Basic dimension 58.00 47.80
1)
The preparation of worn crankshafts is not provided.
Piston and Cylinder Dimensions

Honing dimension Piston diameter 1) Cylinder bore diameter
in mm
1)
Measurement with coating (thickness = 0.02 mm). The coating wears off.
Piston Ring End Gaps

Piston ring gap New Wear limit
dimensions in mm
Compression ring 0.20 to 0.40 0.80
Oil scraping ring 0.25 to 0.50 0.80
Piston Ring Clearance

Piston ring to New Wear limit
groove clearance
dimensions in mm
1st compression ring 0.06 to 0.09 0.20
2nd compression ring 0.03 to 0.06 0.15
Oil scraping ring Cannot be measured

1.8L CPKA, CPRA
Engine –

Cylinder Head, Valvetrain – 1.8L CPKA,
CPRA
Cylinder Head Overview
1 - Alignment Pin
2 - Cylinder Head Gasket
3 - Cylinder Head
4 - Bolt
Procedure when loosening, see Loosening the Cylinder Head
below
Tightening specification, see Cylinder Head Tightening Sequence
below
5 - Heat Shield
6 - Bolt
9 Nm

7 - Bolt
9 Nm
8 - Heat Shield
9 - Bolt
9 Nm
10 - Bolt
9 Nm
11 - Connecting Piece
12 - O-ring
13 - Cylinder Head Bolt
below
below
14 - O-ring
Coat with coolant
16 - Bolt
9 Nm
17 - Base Plate
For engine cover
18 - Engine Lifting Eye
19 - Bolt
8 Nm + 90° turn
20 - Partition Plate
21 - Ball Pin
23 - Bolt
8 Nm + 90° turn
24 - Alignment Pin
1.8L CPKA, CPRA
Engine –

Timing Chain Cover Overview
1 - Bolt
Tightening specification, see Timing Chain Guard Upper Cover -
Tightening Sequence below
2 - Timing Chain Cover Upper Section
3 - Cover
4 - Bolt
4 Nm + 45° turn
5 - Camshaft Adjustment Valve 1 -N205-
6 - Seal
7 - Seal
8 - O-ring
9 - Engine
10 - Timing Chain Cover Lower Section
11 - Shaft Seal

12 - Plug
13 - Bolt
Tightening sequence eight bolts, see Timing Chain Lower Cover
Tightening sequence 15 bolts, see Timing Chain Guard Lower
Section - Tightening Sequence for 15 Bolts below
14 - Bolt
9 Nm
15 - Oil Dipstick Tube
16 - Bolt
Tightening specification, see Assembly Mounts Overview
17 - Engine Support
1.8L CPKA, CPRA

Engine –

Camshaft Timing Chain Overview
1 - Bolt
4 Nm + 90° turn
2 - Chain Tensioner
3 - Timing Chain Tensioning Rail
4 - Guide Pins
20 Nm
5 - Bolt
4 Nm + 180° turn
6 - Regulator Valve
35 Nm
Left thread

7 - Bolt
M6 Bolt - 8 Nm + 90° turn
M8 Bolt - 20 Nm + 90° turn
8 - Washer
9 - Bearing Bracket
10 - Camshaft Timing Chain Guide Rail
11 - Camshaft Housing
12 - Camshaft Timing Chain
13 - Camshaft Timing Chain Guide Rail
14 - Guide Pins
20 Nm
15 - Three Stage Chain Sprocket
1.8L CPKA, CPRA

Engine –

Balance Shaft Drive Chain Overview
1 - Guide Pins
20 Nm
2 - Tensioning Rail
3 - Balance Shaft
Exhaust side
4 - Guide Pins
20 Nm
5 - Guide Rail
6 - Chain Tensioner
85 Nm
Mount with locking compound see Parts Catalog.
7 - Bolt
Seal
8 - Cylinder Block
9 - O-ring
10 - Mounting Pin

11 - Intermediate Sprocket
12 - Washer
13 - Bolt
Tightening sequence, see Intermediate Sprocket Tightening
Sequence below
20 Nm
The intermediate sprocket must be replaced if the bolt is loosened.
14 - Guide Rail
15 - Guide Pins
20 Nm
16 - Balance Shaft
Intake side
17 - Three Stage Chain Sprocket
18 - Balance Shaft Drive Chain
1.8L CPKA, CPRA

Engine –

Valvetrain Overview
1 - Intake Valve
2 - Cylinder Head
3 - Valve Stem Seal
4 - Valve Spring
5 - Valve Spring Retainer
6 - Valve Retainers
7 - Hydraulic Adjusting Element
8 - Clip
9 - Roller Rocker Lever
10 - Exhaust Camshaft
11 - Cylinder Head Cover
12 - Bolt
below
below

13 - O-ring
Not installed
14 - Cam Adjustment Actuator
Not installed
15 - Bolt
Not installed
16 - Ball Pin
9 Nm
For engine cover
17 - Bracket
19 - O-ring
Coat with engine oil
20 - Plug
21 - Camshaft Position Sensor 3 -G300-
Not installed
22 - Bolt
Not installed
23 - O-ring
Not installed
24 - Oil Separator
25 - Bolt
Tightening sequence, see Oil Separator - Tightening Sequence
below
26 - Seal
27 - Intake Camshaft
28 - Alignment Pins
29 - Vacuum Pump
30 - Bolt
8 Nm + 180° turn
31 - Seal
32 - Bolt
Tightening specification, see Coolant Temperature Sensor
Overview
33 - Engine Coolant Temperature Sensor -G62-
34 - O-ring
Replace
Coat with coolant
35 - O-ring
1.8L CPKA, CPRA
36 - Camshaft Position Sensor -G40-

37 - Bolt
Engine –
Tightening sequence, see Ignition System Overview

38 - Exhaust Valve

Loosening the Cylinder Head Cover
Loosen the cylinder head cover in the following sequence: -1- to -6-.

Cylinder Head Cover, Tightening
Specifications and Sequence
Replace the bolts.

Step Bolts Tightening specification/additional turn
1 -1- through -6- Install hand-tight in several stages
2 -1- through -6- Tighten with torque wrench to 8 Nm
3 -1- through -6- Tighten 90° further using a rigid wrench.
1.8L CPKA, CPRA
Engine –

Cylinder Head Tightening Sequence
Tighten the cylinder head bolts in sequence -1- to -10- and -arrows-.
4 Bolts -arrows- Tighten to 4 Nm
5 Bolts -arrows- Tighten 90° further using a rigid wrench.

Timing Chain Guard Upper Cover
- Tightening Sequence
Tighten the bolts -1- through -6- in the sequence shown:.

1 -1- through -6- Hand tighten
1.8L CPKA, CPRA

Engine –

Timing Chain Lower Cover Tightening Sequence
Tighten the bolts -1- through -8- in 2 stages in the sequence shown:

Timing Chain Guard Lower Section -
Tightening Sequence for 15 Bolts
Tighten the bolts -1- through -15- in 2 stages in the sequence shown:
1.8L CPKA, CPRA
Engine –

Intermediate Sprocket Tightening Sequence
Tighten the bolts -1- through -6- in the sequence shown:.

1 -1- Tighten to 10 Nm
2 -1- The intermediate sprocket must not have any
play. Loosen and tighten it again if necessary.
3 -1- Tighten to 25 Nm
4 -1- Tighten 90° further using a rigid wrench.

Valve Dimensions
Dimension Intake valve Exhaust valve

Diameter a mm 33.85 ± 0.10 28.0 ± 0.1
Diameter b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45
NOTE: Intake and exhaust valves must not be
refaced by grinding. Only lapping is permitted.
Compression Pressures
New Wear limit Difference between
Bar positive pressure Bar positive pressure cylinders
Bar positive pressure
11.0 to 14.0 7.0 Maximum 3.0
1.8L CPKA, CPRA
Engine –

Lubrication – 1.8L CPKA, CPRA
Oil Pan/Oil Pump Overview
1 - Nut
9 Nm
2 - Oil Level Thermal Sensor -G266-
3 - Seal
4 - Bolt
Tightening specification, see Oil Pan Lower Section - Tightening
sequence below
5 - Seal
6 - O-ring
7 - Bolt
4 Nm + 45° turn

8 - Intake Line
9 - O-ring
10 - Oil Pump
11 - Centering Sleeve
12 - O-ring
13 - Bolt
Tightening specification, see Oil Pressure Switch/Oil Pressure
Regulator Valve Overview
14 - Oil Pressure Regulation Valve -N428
15 - Chain Tensioner
16 - Oil Pump Drive Chain
17 - Bolt
9 Nm
18 - Cylinder Block
19 - Oil Pan Upper Section
Tightening specification, see Oil Pan Upper Section - Tightening
Sequence below
20 - Bolt
Tightening specification, see Oil Pan Upper Section - Tightening
Sequence below
21 - O-ring
22 - Bolt
4 Nm + 45° turn
23 - Oil Return Pipe
24 - Bolt
8 Nm + 45° turn
25 - Oil Baffle
26 - Bolt
4 Nm + 45° turn
27 - Oil Pan Lower Section
28 - Seal or O-Ring
1.8L CPKA, CPRA
Coat O-ring with engine oil

Engine –
29 - Oil Drain Plug or Sealing Plug

Oil Drain Plug 30 Nm
Tighten sealing plug all the way

Engine Oil Cooler Overview

2 - Seal
3 - O-rings
4 - Mechanical Switch Valve
5 - Engine Oil Cooler
6 - Seal
Coat with coolant
7 - Connection
8 - Bolt
4 Nm + 45° turn

Crankcase Ventilation Overview

2 - Seal
3 - Hose
To the EVAP Canister Purge Regulator Valve 1 -N80-
4 - Oil Separator
5 - Seal
6 - Hose
1.8L CPKA, CPRA
To turbocharger
7 - Bolt
Engine –
4 Nm
8 - Seal
9 - Bolt
Tightening specification and sequence see Oil Separator -

Oil Filter Overview

2 - Seal
3 - Oil Filter
4 - O-ring
5 - Oil Filter Housing Cap
25 Nm
6 - Oil Drain Supports
7 - O-rings
8 - Bolt
Tightening specification and sequence, see Ribbed Belt
Transmission Side Sealing Flange - Tightening Specifications and
Sequence belowOil Filter Overview

1.8L CPKA, CPRA
Engine –

Oil Pressure Switch/Oil Pressure
Regulator Valve Overview
1 - Bolt
4 Nm + 90° turn
2 - Oil Pressure Regulation Valve -N428-
3 - O-ring
4 - O-ring
Not installed
5 - Bolt
Not installed
6 - Piston Cooling Nozzle Control Valve -N522-
Not installed
7 - Seal
8 - Oil Pressure Switch -F22-
20 Nm
9 - Reduced Oil Pressure Switch -F378-
20 Nm
10 - Seal
Replace the seal with the oil pressure switch.
11 - Seal
Not installed
12 - Oil Pressure Switch, Level 3 -F447-
Not installed
1.8L CPKA, CPRA

Engine –

Oil Pan Lower Section - Tightening Sequence
Tighten the bolts -1- through -20- in two stages in the sequence
shown:

Oil Pan Upper Section - Tightening Sequence
Tighten the bolts -1- through -14- in the sequence shown:

2 -1- and -2- Tighten 180° additional turn
4 -10- Tighten 180° additional turn
1.8L CPKA, CPRA
Engine –

Oil Separator - Tightening Sequence
Tighten the bolts in the sequence -1- through -7-.

Bolts Tightening specification/additional turn
-1- through -7- Tighten to 9 Nm

1.8L CPKA, CPRA
Engine –

Cooling System – 1.8L CPKA, CPRA
Coolant Pump/Thermostat Overview
1 - Connection
2 - O-ring
Coat with coolant
3 - Bolt
Tightening specification and sequence, see Thermostat - Tightening
Specification and Tightening Sequence below
4 - Centering Pin
5 - Seal
6 - Seal
7 - Coolant Pump

8 - Bolt
Tightening specification and sequence, see Coolant Pump -
Tightening Specification and Sequence below
9 - Bolt
9 Nm
10 - Toothed Belt
11 - Tothed Belt Cover
12 - Bolt
10 Nm + 90° turn
Left thread
13 - Drive Gear for Toothed Belt
14 - Balance Shaft Seal Intake Side
15 - Balance Shaft
16 - Bolt
9 Nm
18 - Thermostat
19 - O-Ring
20 - Coolant Thermostat
1.8L CPKA, CPRA

Engine –

Electric Coolant Pump Overview
1 - Bolt
5 Nm
2 - Plastic Sockets
3 - Nut
9 Nm
4 - Coolant Hose
5 - Bracket
25 Nm
6 - Spring Clamp
7 - After-Run Coolant Pump -V51-
8 - Spring Clamp
9 - Coolant Hose
10 - Connector
11 - Clip
12 - Bolt
20 Nm
13 - Bracket
Coolant Temperature Sensor Overview
1 - Clamp
2 - O-ring
3 - Engine Coolant Temperature Sensor on Radiator Outlet -G83-
4 - Connector
25 Nm
6 - O-ring
1.8L CPKA, CPRA
Coat with coolant

7 - O-rings
Engine –

Coat with coolant
8 - Bolt
4 Nm + 45° turn

Coolant Pipes Overview
1 - Front Coolant Pipe

2 - Bolt
6 Nm
3 - Upper Coolant Pipe
4 - Bolts
9 Nm
5 - Bolt
9 Nm
6 - Coolant Line
7 - Bolts
9 Nm

Radiator/Coolant Fan Overview
1 - Side Air Guide

2 - Lock Carrier
3 - Condenser
4 - Bolts
8 Nm
5 - Side Air Guide
6 - Seal
7 - Bolts
1.8L CPKA, CPRA
8 Nm
8 - Radiator
9 - Bolt
Engine –
8 Nm
10 - Shroud
11 - Charge Air Cooler

Fan Shroud and Radiator Fan Overview
1 - Fan Shroud
2 - Bolt
5 Nm
Fan shroud to radiator
3 - Bolt
Tightening specification, see Radiator/Coolant Fan Overview
4 - Coolant Fan 2 -V177-
5 - Coolant Fan -V7-
6 - Bracket
7 - Bolt
Tightening specification, see Radiator/Coolant Fan Overview
8 - Bolt
5 Nm

Thermostat - Tightening Specification
and Tightening Sequence
Tightening sequence Tightening specification

1.8L CPKA, CPRA

Engine –

Coolant Pump - Tightening
Specification and Sequence
Tightening sequence Tightening specification/additional turn


Component Nm
Auxiliary cooler nuts 25

Fuel Supply – 1.8L CPKA, CPRA
Accelerator Pedal Mechanism Overview
1 - Connector
2 - Accelerator Pedal Position Sensor -G79- / Accelerator Pedal
Position Sensor 2 -G185-
3 - Bolt
10 Nm
4 - Cap
1.8L CPKA, CPRA
Engine –

Fuel Tank and Attachments Overview
1 - Cap
2 - Bolt
Tightening specification, refer to Body Exterior
3 - Fuel Filler Door Unit with Fuel Filler Door Lock
4 - Ventilation Line
5 - Bolt
11 Nm
6 - Heat Shield
7 - Nut
2.5 Nm
8 - Bolt
25 Nm
9 - Left Tensioning Strap
10 - Bolt
25 Nm
11 - Right Tensioning Strap
12 - Seal
13 - Fuel Delivery Unit
14 - Lock Ring
110 Nm
1.8L CPKA, CPRA

Engine –

EVAP System Component Overview
1 - Connecting Hose
2 - Connecting Hose Connection
3 - Leak Detection Pump -V144-
4 - Hose Clamp
5 - Connecting Hose
6 - EVAP Canister
7 - Nut
1.8 Nm
8 - Air Filter with Connecting Hose
9 - Bolt
1.8 Nm

Fuel Delivery Unit/Fuel Level
Sensor Assembly Overview
1 - Locking Ring
110 Nm
2 - Flange
3 - Intake Line
4 - Fuel Level Sensor -G-
6 - Seal
1.8L CPKA, CPRA
Replace
Engine –

Turbocharger – 1.8L CPKA, CPRA
Turbocharger and Mahle Charge
Pressure Actuator -V465- Overview
1 - Heat Shield
2 - Bolt
9 Nm
3 - Bolt
20 Nm
4 - Bolt
9 Nm
5 - Charge Pressure Actuator -V465-
6 - Bolt
Do not remove the Charge Pressure Actuator -V465-.
Replace turbocharger after loosening bolt.
7 - Nut
7 Nm

8 - Bolt
7 Nm
9 - Bolt
10 - Turbocharger Recirculation Valve -N249-
11 - O-ring
12 - Turbocharger
13 - Spring Clip
14 - O-ring
15 - Coolant Supply Line
16 - Bolt
9 Nm
17 - Bolt
9 Nm
18 - O-ring
19 - Bolt
25 Nm
21 - O-ring
22 - O-ring
Coat with coolant
23 - Bolt
9 Nm
24 - Bolt
9 Nm
26 - Bolt
9 Nm
27 - O-ring
Coat with coolant
28 - Bolt
30 Nm
1.8L CPKA, CPRA
29 - Support Brace
30 - Bolt
Engine –
30 Nm
Lubricate the thread with hot bolt paste before loosening and
installing
31 - Heat Shield

Turbocharger and Mahle Charge Pressure
Actuator -V465- Overview (cont’d)
32 - V-Clamp
15 Nm
33 - Bolt
9 Nm
34 - O-ring
35 - Oil Supply Line
36 - O-ring
37 - Seal
38 - Nut
25 Nm
39 - Heat Shield
40 - Bolt
4.5 Nm
41 - Bolt
9 Nm

1.8L CPKA, CPRA
Engine –

Turbocharger and Cooper Charge
Pressure Actuator -V465- Overview
1 - Heat Shield
2 - Bolt
9 Nm
3 - Bolt
20 Nm
4 - Bolt
9 Nm
5 - Charge Pressure Actuator -V465-
6 - Bolt
7 - Nut
7 Nm
8 - Bolt
7 Nm

9 - Bolt
10 - Turbocharger Recirculation Valve -N249-
11 - O-ring
12 - Turbocharger
13 - Spring Clip
14 - O-ring
16 - Bolt
9 Nm
17 - Bolt
9 Nm
18 - O-ring
19 - Bolt
25 Nm
21 - O-ring
22 - O-ring
Coat with coolant
23 - Bolt
9 Nm
24 - Bolt
9 Nm
26 - Bolt
9 Nm
27 - O-ring
Coat with coolant
28 - Bolt
30 Nm
29 - Support Brace
30 - Bolt
1.8L CPKA, CPRA
30 Nm
Lubricate the thread with hot bolt paste before loosening and
Engine –
installing
31 - Heat Shield
32 - V-Clamp
15 Nm

Turbocharger and Cooper Charge Pressure
Actuator -V465- Overview (cont’d)
33 - Bolt
9 Nm
34 - O-ring
36 - O-ring
37 - Seal
38 - Nut
25 Nm
39 - Heat Shield
40 - Bolt
4.5 Nm
41 - Bolt
9 Nm

1.8L CPKA, CPRA
Engine –

Charge Air System Overview
1 - Air Guide Hose

2 - Rubber Bushing
3 - Bolt
8 Nm
5 - Rubber Bushing
6 - Bolt
8 Nm
7 - Rubber Bushing
8 - Rubber Bushing
9 - Gasket
10 - Bolt
7 Nm
11 - Air Guide Hose
12 - Spring Clip
13 - Bolt
7 Nm
14 - Air Guide Pipe
15 - Bolt
7 Nm
16 - Air Guide Pipe
17 - Bolt
7 Nm
18 - O-ring
19 - Charge Air Pressure Sensor -G31-
20 - Air Guide Hose
Air Guides with Screw-Type Clamps, Installing
Hose Width Tightening Specification

Clmap
1 -a- = 13 mm wide 5.5 Nm
2 -b- = 9 mm wide 3 Nm
1.8L CPKA, CPRA
Engine –

Multiport Fuel Injection – 1.8L CPKA,
CPRA
Fuel Rail with Fuel Injectors Overview
1 - Fuel Injector
2 - Support Ring
3 - Fuel Rail for the-Fuel Injector
9 Nm
4 - Roller Tappet
5 - Fuel Pressure Regulator Valve -N276-
6 - High Pressure Pump
7 - High Pressure Pump Bolts
8 Nm + 90° turn

8 - Fuel Supply Line Connection on the High Pressure Pump
40 Nm
9 - Fuel Supply Line Union Nut
27 Nm
10 - Fuel Supply Line Union Nut
27 Nm
11 - Connections for the Fuel Supply Line on the Fuel Rail
40 Nm
12 - Bolt
9 Nm
13 - Channel Separating Plate
14 - Seal
15 - Charge-Motion Valve Adjuster (Intake Manifold Flap)
16 - Channel Separating Plate Vacuum Diaphragm (Intake Manifold
Flaps)
17 - Intake Manifold Runner Control Valve -N316-
18 - Intake Air Temperature Sensor -G42- with Manifold Absolute
Pressure Sensor -G71-
5 Nm
19 - Throttle Valve Control Module -J338-, EPC Throttle Drive -G186-
7 Nm
20 - Bolt for the Intake Manifold
Tightening specification, see Intake Manifold Overview
21 - Intake Manifold Runner Position Sensor -G336-
22 - Intake manifold
23 - Fuel Pressure Sensor -G247-
27 Nm
1.8L CPKA, CPRA

Engine –

Air Filter Housing Overview
1 - Bolt
1.5 Nm
2 - Air Filter Housing Upper Section
3 - Filter
4 - Snow Screen
5 - Air Filter Housing Lower Section
Bolt 8 Nm
6 - Rubber Buffer
7 - Water Drain Hose
8 - Air Guide
9 - Bolt
3 Nm
10 - Intake Air Guide

12 - Spring Clamp
13 - Spring Clamp
14 - Connecting Pipe
15 - Bolt
5 Nm
16 - Spring Clamp
17 - Air Guide Hose
1.8L CPKA, CPRA

Engine –

Intake Manifold Overview
1 - Intake Manifold
2 - Intake Manifold Runner Position Sensor -G336-t
3 - Bolt
5 Nm
4 - Intake Air Temperature Sensor -G42- with Manifold Absolute
Pressure Sensor -G71-
5 Nm
5 - O-ring
6 - Bolt for the Intake Manifold
9 Nm
7 - Threaded Pin for Outer Intake Manifold
9 Nm
8 - Seal
9 - Channel Separating Plate Vacuum Diaphragm (Intake Manifold
Flaps)
10 - Fuel Injector Fuel Rail
11 - Fuel Injectors
12 - Bolt
9 Nm
High pressure line to intake manifold
13 - Bracket
14 - Bolt
5 Nm
15 - Bolt
20 Nm
For the intake manifold bracket
16 - Bolt for Throttle Valve Control Module -J338-
7 Nm
17 - Nut for the Intake Manifold Support
10 Nm
18 - Intake Manifold Support
19 - Rubber Bushing
5 Nm
20 - Throttle Valve Control Module -J338-, EPC Throttle Drive -G186-,
21 - Seal
23 - Bolts
9 Nm
Fuel rail to cylinder head
1.8L CPKA, CPRA

Engine –

High Pressure Pump Overview
1 - Connector
2 - High Pressure Pump Bolt
Tighten by hand
8 Nm + 90° turn
4 - O-ring
5 - Roller Tappet
6 - High Pressure Pump Bolt
Tighten by hand
8 Nm + 90° turn
7 - Fuel Supply Line Connection
30 Nm

8 - Bolt
27 Nm
Lubricate the fuel supply line ball with engine oil
9 - Spring Clamp
10 - Fuel Supply Line
1.8L CPKA, CPRA

Engine –

Heated Oxygen Sensor Overview,
2 Heated Oxygen Sensors
1 - Connector
2 - Heated Oxygen Sensor -G39- with Oxygen Sensor Heater -Z19-
55 Nm
3 - Bracket
4 - Oxygen Sensor after Three Way Catalytic Converter -G130- with
Heater or Oxygen Sensor 1 after Catalytic Converter -Z29-
5 - Connector
6 - Underbody Trim

Exhaust System, Emission Controls – 1.8L
CPKA, CPRA
Muffler Overview
1 - Exhaust Pipe with Rear Muffler

2 - Bolt
25 Nm
3 - Separating Point
1.8L CPKA, CPRA
4 - Mounting Strap
5 - Bolt
Engine –
Tightening specification, refer to Fuel Supply System

6 - Bolt
7 - Rear Tunnel Bridge
8 - Nut
20 Nm

Emissions Control Overview
1 - Bracket
2 - Catalytic Converter
3 - V-clamp
Tightening specification, refer to Turbocharger Overview
4 - Seal
5 - Turbocharger
6 - Front Clamping Sleeve
30 Nm
7 - Bolt
23 Nm

1.8L CPKA, CPRA
Engine –

Secondary Air Injection System Overview
1 - Air Filter Housing

2 - O-ring
3 - Connecting Line
4 - Bracket
5 - Nut
8 Nm
6 - Bracket
7 - Bolt
9 Nm
8 - Seal
9 - Secondary Air Injection Solenoid Valve
10 - Nut
8 Nm
11 - Bracket
12 - Rubber Bushing
13 - Secondary Air Injection Pump Motor
14 - Connecting Line
15 - Bracket
16 - Protection
1.8L CPKA, CPRA

Engine –

Ignition/Glow Plug System – 1.8L CPKA,
CPRA
Ignition System Overview
1 - Bolt
10 Nm
2 - Ignition Coil with Power Output Stage
3 - Spark Plug
30 Nm
4 - Bolt
20 Nm
5 - Knock Sensor 1 -G61-
7 - Bolt
9 Nm
8 - Engine Speed Sensor -G28-
9 - Bolt
10 Nm

2.0L CKRA (TDI)

CKRA (TDI)
Engine –
The engine number (engine code and serial number) (arrow)

is located at the front of the engine/transmission joint. There
is also a label on the toothed belt guard that shows the engine
code and serial number. Engine codes beginning with C are
four digits. The first 3 digits of the engine code indicate the
displacement and the mechanical structure of the engine. They
are stamped in the cylinder block, including the serial number.
The fourth digit describes the engine output and torque.

Engine Data
Identification code CKRA
Emission values in accordance with BIN 5/LEV 2
Displacement liter 2.0
Output kW at RPM 103 @ 4000
Torque Nm at RPM 320 @ 1500 to 2500
Bore diameter mm 81.0
Stroke mm 95.5
Valves per cylinder 4
Compression ratio 16.5
Fuel Diesel
Ignition sequence 1-3-4-2
Balance shaft module Yes
Catalytic converter Yes
Exhaust Gas Recirculation (EGR) Yes
Turbocharger, Supercharger Yes
Charge Air Cooler (CAC) Yes
Particulate filter Yes

Engine Assembly – 2.0L CKRA (TDI)
2.0L CKRA (TDI)

Engine –
size
M7 15
M8 25
M10 40
M12 1) 65
1)
Tightening specification for a M12 collar bolt is 75 Nm.
Engine Mount Tightening Specifications
Step Component Nm
additional 90°
(¼ turn)
additional 90°
(¼ turn)
additional 90°
(¼ turn)
1)
Replace fastener(s).

Transmission Mount Tightening Specifications
Step Component Nm
1 Tighten bolts 1 1) 40 plus an
additional 90°
(¼ turn)
2 Tighten bolts 2 1) 60 plus an
additional 90°
(¼ turn)
1)

2.0L CKRA (TDI)

Component Nm
Accessory bracket-to-belt tensioner bolt 1) 35
Engine –
Accessory bracket-to-high pressure fuel pump bolt 1) 20 plus an
additional 90°
(¼ turn)
Air conditioning compressor-to-accessory bracket bolt 45
Connecting rod cap-to-connecting rod bolt 1) 3) 30 plus an
additional 90°
(¼ turn)
Crankshaft bearing cap-to-cylinder block bolt 1) 65 plus an
additional 90°
(¼ turn)
Crankshaft toothed belt gear-to-crankshaft bolt 1) 2) 120 plus an
additional 90°
(¼ turn)
Dual mass flywheel-to-crankshaft bolt 1) 60 plus an
additional 90°
(¼ turn)
Engine speed sensor-to-sealing flange bolt 5
Generator-to-accessory bracket bolt 25
Oil spray jet-to-cylinder block bolt 27
Ribbed Belt Tensioner 35
Toothed belt idler pulley-to-cylinder block bolt 1) 50 plus an
additional 90°
(¼ turn)
Toothed belt idler roller-to-cylinder block nut 20
Vibration damper-to-crankshaft bolt 1) 10 plus an
additional 90°
(¼ turn)

Pendulum Support Tightening Specifications
Step Component Nm
additional 90°
(¼ turn)
additional 90°
(¼ turn)
additional 90°
(¼ turn)
1)

Direct Shift Gearbox (DSG®) to Engine, Bolt
Tightening Sequence and Specification
2.0L CKRA (TDI)

Engine –
Item Bolt Nm
1, 3 and 10 M12 x 65 80
5 M12 x 65 80
6, 7 and 8 M10 x 50 40
9 M12 x 70 80
2 and 4 For starter, refer to Electrical Equipment
A Alignment sleeves for centering
1)

Crankshaft, Cylinder Block – 2.0L CKRA
(TDI)
Ribbed Belt and Tensioner Overview
1 - Bolt
120 Nm + 90° turn
2 - Crankshaft Toothed Belt Gear
3 - Seal
4 - Sealing Flange
5 - Cylinder Block
6 - Alignment Pin
7 - Bolt
Tightening sequence and specification, see Sealing Flange Bolt
Tightening Sequence and Specification below

Sealing Flange Overview
2.0L CKRA (TDI)

Engine –
1 - Air Filter Housing

2 - O-ring
3 - Connecting Line
4 - Bracket
5 - Nut
8 Nm
6 - Bracket
7 - Bolt
9 Nm
8 - Seal
9 - Secondary Air Injection Solenoid Valve
10 - Nut
8 Nm
11 - Bracket
12 - Rubber Bushing

Dual Mass Flywheel and Sealing Flange Overview
1 - Bolt
60 Nm + 90° turn
2 - Dual Mass Flywheel
3 - Sensor Wheel
5 - Bolt
5 Nm
6 - Alignment Pin
7 - Intermediate Plate
8 - Sealing Flange, Flywheel Side
9 - Bolt
Tightening sequence and specification, see Sealing Flange Bolt

Crankshaft Overview
2.0L CKRA (TDI)

Engine –
1 - Bearing Shell
2 - Bolt
65 Nm + 90° turn
3 - Bearing Cap
4 - Thrust Washer
5 - Needle Bearing
6 - Crankshaft
7 - Thrust Washer

Pistons and Connecting Rod Overview
1 - Piston Rings
2 - Piston
3 - Piston Pin
4 - Lock Ring
5 - Connecting rod
6 - Bearing Shell
7 - Cylinder Block
9 - Oil Spray Jet
10 - Nut
25 Nm
Install without sealant
11 - Bolt
30 Nm + 90° turn

2.0L CKRA (TDI)

Sealing Flange Bolt Tightening
Engine –
Sequence and Specification
Step Component Nm
1 1 through 10 Hand-tighten
2 1 through 6 Tighten diagonally in steps to at least
15 Nm
3 7 through 10 Tighten to 15 Nm

Sealing Flange Bolt Tightening
Step Component Nm
1 1 through 6 Hand-tighten
2 1 through 6 Tighten diagonally in steps to at least
15 Nm

Accessory Bracket Tightening Specifications
2.0L CKRA (TDI)

Engine –
Step Component Nm
1 Tighten bolts 1 through 6 in sequence Hand-tighten
2 Tighten bolts 1 through 6 in sequence 40
3 Tighten bolts 3 and 4 an additional
45° (⅛ turn)
4 Tighten bolts 1, 2, 5 and 6 in sequence an additional
90° (¼ turn)
Honing dimension Crankshaft bearing Connecting rod bearing
in mm pin diameter pin diameter
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042

Honing dimension Piston diameter 1) Cylinder bore diameter
in mm
1)
Measurement with coating (thickness = 0.02 mm). The coating wears off.

Piston ring gap New Wear limit
dimensions in mm

Piston ring to New Wear limit
groove clearance
dimensions in mm

2.0L CKRA (TDI)
Engine –

Cylinder Head, Valvetrain – 2.0L CKRA (TDI)
Cylinder Head Cover Overview
1 - Gasket
3 - O-ring
Always replace
4 - Hose
5 - Sealing Bushing
6 - Bracket
7 - Grommet
8 - Tensioning Bracket
9 - Bolt
8 Nm
10 - Fuel Rail (high-pressure reservoir)
11 - Bolt
22 Nm

12 - Bolt
8 Nm +180° turn
2.0L CKRA (TDI)

13 - Fuel Return Line
Engine –
14 - O-ring
Always replace
15 - Fuel Injector
16 - O-ring
Always replace
17 - Heat Protection Seal
18 - Seal
19 - Cap
20 - Gasket
21 - Grommet
22 - Bracket
23 - Bolt
Tightening specification and sequence, see Cylinder Head Cover
Bolt Tightening Sequence and Specification below

Cylinder Head Overview

Always replace
2 - Bolt
10 Nm
Install using locking compound, refer to the Parts Catalog
4 - Cylinder Head
5 - Washer
6 - Bolt
Loosening sequence, see Cylinder Head Bolt Loosening Sequence
below
Tightening sequence and specification, see Cylinder Head Bolt
Always replace
20 Nm

8 - Seal
Always replace
2.0L CKRA (TDI)

9 - Bolt
20 Nm
Engine –
11 - Seal
Always replace
12 - Bolt
20 Nm
13 - Gasket
Always replace
14 - Vacuum Pump
15 - Bolt
10 Nm
17 - Bolt
9 Nm
18 - Gasket
Always replace
19 - Bolt
20 Nm

Toothed Belt Drive Overview
1 - Toothed Belt
2 - Bolt
120 Nm + 90° turn
3 - Crankshaft Toothed Belt Gear
4 - Nut
20 Nm
5 - Idler Roller
6 - Nut
20 Nm + 45° turn
7 - Tensioning Roller
8 - Bolt
20 Nm + 45° turn
9 - Camshaft Sprocket

10 - Bolt
20 Nm
2.0L CKRA (TDI)

11 - Bolt
100 Nm
Engine –
12 - Hub
13 - Rear Toothed Belt Guard
14 - Bolt
20 Nm
15 - Bolt
20 Nm
16 - Idler roller
17 - Bolt
50 Nm + 90° turn
18 - Hub
19 - Nut
95 Nm
20 - High-Pressure Pump Toothed Belt Gear
21 - Bolt
20 Nm
22 - Coolant Pump
23 - Bolt
15 Nm
24 - Upper Toothed Belt Guard
25 - Lower Toothed Belt Guard
26 - Center Toothed Belt Guard
27 - Bolt
10 Nm
28 - Bolt
10 Nm + 90° turn
30 - Bolt
5 Nm
31 - Protective Plate
32- Bolt
40 Nm + 180° turn
33 - Engine Mount Bracket

Valve Dimensions

Diameter a mm 28.10 26.00
Diameter b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45
Bar positive pressure Bar positive pressure cylinders
Bar positive pressure
25.0 to 31.0 19.0 Maximum 5.0

Cylinder Head Cover Bolt Tightening
2.0L CKRA (TDI)

Engine –
Step Component Nm

Cylinder Head Tightening Specifications
Step Component Nm
3 Tighten bolts 1 through 10 in sequence an additional
90° (¼ turn)
90° (¼ turn)

Bearing Frame Tightening Specifications
2.0L CKRA (TDI)

Engine –
Step Component Nm
1 Tighten bolts and nuts 1 through 24 in Hand-tighten
sequence 1)
2 Tighten bolts and nuts 1 through 24 in sequence 10
1)
The guide frame must be in contact with the entire contact surface of the cylinder
head.

Lubrication – 2.0L CKRA (TDI)
Oil Filter Bracket and Oil Cooler Overview
1 - Cap
25 Nm
2 - O-ring
Always replace
3 - O-ring
Always replace
4 - O-ring
Always replace
5 - Oil Filter Element
7 - Bolt
11 Nm
8 - Seal
Always replace

9 - Bolt
Always replace
2.0L CKRA (TDI)

10 - Oil Filter Housing
11 - Seal
Engine –
Always replace

Cylinder Head, Valvetrain – 2.0L CKRA (TDI)
Oil Pan, Pump and Balance Shaft Module Overview
1 - Bolt
30 Nm
2 - Rear Coolant Pipe
3 - Nut
25 Nm
4 - Bolt
9 Nm
5 - Connection
6 - O-ring
Always replace
7 - Oil Pump
8 - Drive Axle
9 - Lock Ring
10 - Alignment Bushing

11 - Balance Shaft Module
12 - Spur Gear
2.0L CKRA (TDI)

13 - Bolt
20 Nm + 90° turn
Engine –
Always replace
14 - Bolt
90 Nm + 90° turn
Always replace
15 - Axial Bearing Disc
Always replace
16 - Intermediate Sprocket
Always replace
17 - Axial Bearing Disc
Always replace
18 - Crankcase
19 - Bolt
M7 tighten to 13 Nm + 90° turn
M8 tighten to 20 Nm + 90° turn
Always replace
21 - Bolt
9 Nm
22 - Oil Pipe
23 - Bolt
9 Nm
24 - Bolt
Tightening sequence and specification, see Oil Pan Bolt Tightening
Sequence and Specification below
Always replace

Oil Filter Bracket Bolt Tightening
Note: Replace the oil filter bracket bolts. Install the upper left
bolt and the lower right bolt. Tighten the bolts in 2 steps:
Step Bolts Nm
1 -Arrows- Tighten to 14 Nm in a diagonal
sequence
2 -Arrows- Tighten an additional 90° (1/4) turn, in a
diagonal sequence

Oil Pan Bolt Tightening Sequence and Specification
2.0L CKRA (TDI)

Engine –
Note: Replace the oil pan bolts. Tighten the bolt in 3 steps:
Step Bolts Nm
1 -1 through 20- Tighten to 5 Nm, in a diagonal sequence
2 -Arrows- Tighten to 40 Nm
3 -1 through 20- Tighten to 15 Nm, diagonally and in

steps

Balance Shaft Module, with 8 Bolts,
Step Bolts Nm
1 -1 through 8- Hand tighten
2 -1 through 8- Tighten in sequence to 6 Nm
3 -1 through 4- Tighten to 20 Nm.
4 -5- Tighten to 13 Nm.
8 -1 through 8- Tighten an additional 90° (1/4) turn in
sequence using a ratchet

Balance Shaft Module, with 6 Bolts,
2.0L CKRA (TDI)

Engine –
Step Bolts Nm
1 -1 through 6- Hand tighten
2 -1 through 6- Tighten in sequence to 6 Nm
3 -1 through 4- Tighten to 20 Nm.
4 -5 and 6- Tighten to 13 Nm.
5 -1 through 6- Tighten an additional 90° (1/4) turn in
sequence with a ratchet

Cooling System – 2.0L CKRA (TDI)
Engine Preheater Overview
1 - Rubber Protector
2 - Engine Preheating Element -Z97-
3 - Clip
4 - Bolt
8 Nm
5 - Bracket
6 - Connecting Cable
7 - Bracket
8 - Bracket
9 - Air Grille

Coolant Pump and Thermostat Overview
2.0L CKRA (TDI)

Engine –
1 - Coolant Pump
2 - Bolt
15 Nm
3 - O-ring
Always replace
4 - O-ring
Always replace
5 - Bolt
15 Nm
6 - 4/2-Way Valve with Thermostat

4/2-Way Valve and Thermostat Overview
1 - Housing Cover
2 - Bolt
5 Nm
3 - O-ring
Always replace
5 - Housing
6 - Bushing
7 - O-ring
9 - O-ring
Always replace
11 - Spring Clip

Charge Air Cooling Pump -V188- Overview
2.0L CKRA (TDI)

Engine –
1 - Bolt
1.5 Nm
2 - Rubber Grommet with Sleeve
3 -Bolt
8 Nm
M6 x 12
4 - Bracket
5 - Bolt
40 Nm
6 - Charge Air Cooling Pump -V188-
7 - Colant Hose

Coolant Pipes Overview
1 - Bolt
20 Nm
3 - Nut
25 Nm
4 - O-ring
Always replace
6 - O-ring
Always replace
8 - Bolt
9 Nm
9 - Retaining Clip
10 - Bolt
9 Nm

12 - Nut
9 Nm
2.0L CKRA (TDI)

13 - Engine Preheating Element -Z97-
14 - Bolt
Engine –
8 Nm
15 - Bolt
9 Nm
16 - Left Coolant Pipe
17 - Bolt
8 Nm
18 - O-ring
Always replace

Radiator and Fan Shroud Overview
1 - Expansion Tank
2 - Bolts
5 Nm
3 - Connector
4 - Coolant Hose
5 - Clip
6 - Coolant Hose
8 - O-ring
9 - Radiator
10 - Coolant Hose
11 - O-ring
12 - Radiator
13 - Bracket
14 - Bolt
10 Nm
15 - Radiator Mount

16 - O-ring
17 - Coolant Hose
2.0L CKRA (TDI)

18 - Radiator
19 - Bolt
Engine –
5 Nm
20 - O-ring
21 - Coolant Hose
22 - Nut
10 Nm
23 - Fan Shroud
24 - Bolt
5 Nm
26 - Right Coolant Fan -V35-

size
A/C Condenser to the Radiator for the - 5
Charged Air Coolant Circuit Bolts
4/2 way valve housing cover-to-housing - 5
bolt
4/2 way valve with thermostat-to-cylinder - 15
block bolt
Charge air cooling pump-to-bracket bolt - 1.5
Charge air cooling pump-to-bracket bolt M6 8
M10 40
Coolant pipe to engine bolts - 9
Coolant pump-to-cylinder block bolt - 15
Engine preheating element bracket bolt - 8
Intake manifold support-to-engine bolt - 40
Intake manifold support-to-throttle valve - 8
control module bolt

Fuel Supply – 2.0L CKRA (TDI)
1 - Connector
2 - Accelerator Pedal Module
3 - Bolts
5 Nm
4 - Cap

Fuel Delivery Unit/Fuel Level Sensor Overview
2.0L CKRA (TDI)

Engine –
1 - Locking Ring
110 Nm
2 - Supply Line to Fuel Filter
3 - Return Line
4 - Supply Line for Auxiliary Heater
Not available in the US or Canada
5 - Flange
8 - Seal
Replace

Fuel Filter Overview
1 - Supply Line
From the fuel tank
2 - Supply Line
To the high pressure pump
3 - Return Line
4 - Bolt for Fuel Filter Upper Section
10 Nm
5 - Replacement Filter
6 - Fuel Filter Lower Section
7 - Bolt
10 Nm

2.0L CKRA (TDI)
Engine –

Fuel Tank Overview
1 - Fuel Filler Door Unit

2 - Cap
3 - Bolt
4 - Fuel Flap Lock
5 - Ground Connection
6 - Bolt
8 Nm + 90° turn
7 - Fuel Filler Tube
8 - Fuel Tank
9 - Heat Shield
10 - Bolt
2.5 Nm
11 - Bolt
20 Nm + 90° turn

12 - Mounting Strap
13 - Fuel Lines
2.0L CKRA (TDI)

14 - Seal
Replace
Engine –
16 - Locking Ring
110 Nm

Turbocharger – 2.0L CKRA (TDI)
Charge Air Cooler Overview

2 - Bolt
8 Nm
3 - Bolt
5 Nm
4 - Charge Air Pressure Sensor -G31-/Intake Air Temperature
Sensor G42-
5 - Windshield Washer Fluid Hose
6 - Bolt
8 Nm
7 - Support
8 - Bolt
8 Nm
9 - Clamp
5.5 Nm
10 - Air Guide Hose
11 - Clamp
2.0L CKRA (TDI)

5.5 Nm
12 - Bolt
Engine –
8 Nm
13 - Charge Air Pipe
14 - Bolt
5.5 Nm
15 - Air Guide Hose
16 - Clip
5.5 Nm

Turbocharger and Attachments Overview
1 - Bolt
8 Nm
2 - Connection
3 - O-ring
4 - Bolt
15 Nm
5 - Ground Connection
6 - Gasket
Always replace
7 - Turbocharger
8 - Nut
24 Nm
9 - Bolt
10 Nm
10 - Support

11 - Banjo Bolt
60 Nm
2.0L CKRA (TDI)

12 - O-ring
Engine –
Always replace
13 - Bolt
15 Nm
14 - Gasket
Always replace
15 - Oil Return Line
16 - O-ring
Always replace
17 - Bolt
20 Nm
18 - Banjo Bolt
30 Nm
19 - Seal
Always replace
Tighten union nuts to 22 Nm
21 - Bolt
10 Nm
22 - Exhaust Gas Recirculation (EGR) Pipe
23 - Heat Shield
24 - Nut
24 Nm
25 - Exhaust Gas Temperature Sensor 1 -G235-
26 - O-ring
Always replace
27 - Pulsation Damper
28 - Bolt
9 Nm

Component Nm
Charge Air Cooler (CAC)-to-cylinder block bolt 8
Charge air hose clamp (9 mm wide) 3
Charge air hose clamp (13 mm wide) 5.5
Charge air pressure sensor/intake air temperature 5
sensor-to-Charge Air Cooler (CAC) bolt
Coolant pipe to engine bolt 9

Diesel Fuel Injection – 2.0L CKRA (TDI)
Fuel Rail and Injector Overview
1 - Seal
2 - Copper Washer
Always replace
3 - O-ring
Always replace
4 - Fuel Injector
5 - O-ring
Always replace
To fuel tank
7 - Bolt
8 Nm + 180° turn.
Always replace
8 - Tensioning Bracket

9 - High-Pressure Line
28 Nm
2.0L CKRA (TDI)

10 - Bolt
22 Nm
Engine –
11 - Fuel Rail (high-pressure reservoir)
12 - Fuel Return Hose
13 - Fuel Pressure Regulator Valve -N276-
80 Nm
14 - O-ring
Always replace
16 - O-ring
8 Nm
100 Nm
18 - Grommet

High-Pressure Pump Overview
1 - Accessory Bracket
2 - Bolt
20 Nm + 180° turn
3 - Hub
4 - High-Pressure Pump Toothed Belt Gear
5 - Bolt
20 Nm
6 - Nut
95 Nm
7 - Bolt
20 Nm + 45° turn
8 - High-Pressure Pump
9 - Fuel Supply Hose
10 - Fuel Return Hose
28 Nm
2.0L CKRA (TDI)
Engine –

1 - Hose Connection
2 - Air Guide Pipe
3 - Bolt
1.5 Nm
4 - Mass Airflow Sensor -G70-
5 - O-ring
Always replace
6 - Screw
1.5 Nm
7 - Bolt
8 Nm
8 - Sleeve
9 - Washer
10 - Upper Air Filter Housing
11 - Air Filter Element
12 - Grille
13 - Lower Air Filter Housing

14 - Water Drain Hose
2.0L CKRA (TDI)

16 - Adjusting Element
17 - Bolt
Engine –
1.5 Nm
18 - Preheating Intake Manifold
8 Nm
19 - Connecting Hose
20 - Spring Clamps
21 - Seal
22 - Bolt
8 Nm
23 - Hose Clamp
5.5 Nm

1 - Intake Manifold
2 - Gasket
Always replace
3 - Connecting Pipe
4 - Bolt
20 Nm
5 - Gasket
Always replace
6 - Bolt
20 Nm
7 - EGR Vacuum Regulator Solenoid Valve -N18- with EGR
Potentiometer -G212-
8 - Bolt
8 Nm
9 - Seal
Always replace
10 - Throttle Valve Control Module -J338-

11 - Bolt
10 Nm
2.0L CKRA (TDI)

12 - Gasket
Engine –
Always replace
13 - Bolt
10 Nm
14 - Bolt
10 Nm
15 - Stud Bolt
40 Nm
16 - Support
17 - Guide Tube
18 - Clip
19 - Bolt
10 Nm
20 - Seal
Always replace
21 - Gasket
Always replace
22 - Bolt
8 Nm
24 - Bolt
8 Nm

size
Connecting tube bolts - 20
Differential Pressure Sensor -G505- on the - 4
Mount
Mount on the Engine Mount Bolts - 20
Exhaust Pressure Sensor 1 -G450- on the - 4
Mount
Fuel Pressure Regulator Valve -N276 - 80
Heated oxygen sensor -G39- - 50
Intake manifold-to-cylinder head bolt - 8
Lower air filter housing-to-body bolt - 8
Lower support bolts on the engine - 40
Lower support bolts on the engine - 40
Oil dipstick guide tube bolt - 10
Throttle valve control module support bolt - 10
Toothed Belt Sprocket to Hub Bolts - 20
Upper support bolts on the throttle valve - 10
control module -j338-
1)
Only grease the threads with Hot Bolt Paste -G 052 112 A3-. Do not allow the Hot
Bolt Paste -G 052 112 A3- to enter the slits on the sensor body.

2.0L CKRA (TDI)
Engine –

CKRA (TDI)
Front Exhaust Pipe with Particulate Filter Overview
1 - Differential Pressure Sensor -G505-

45 Nm
3 - Nut
9 Nm
4 - Shield
5 - Heated Oxygen Sensor -G39-
50 Nm
6 - Front Exhaust Pipe with Particulate Filter
7 - Gasket
Always replace
8 - Clamp
7 Nm

9 - Nut
25 Nm
2.0L CKRA (TDI)

10 - Clamp
3.5 Nm
Engine –
12 - Gasket
13 - Bracket
14 - Control Line
45 Nm
15 - Control Line
16 - Clip
17 - Exhaust Pressure Sensor 1 -G450-
45 Nm
20 - Bracket
21 - Bolt
23 Nm
22 - Nut
23 Nm

NOx Reduction Catalytic Converter Overview
1 - Gasket
Always replace
2 - Nuts
23 Nm
3 - NOx Sensor -G295-
4 - Bolt
25 Nm
5 - NOx Reduction Catalytic Converter
6 - Clamp
5 Nm
7 - Gasket
Always replace
8 - Reducing Agent Injector -N474-

Exhaust Door Control Unit Overview
2.0L CKRA (TDI)

Engine –
1 - Exhaust Pipe with NOx Sensor -G295-

2 - Clamp
7 Nm
3 - Seal
Always replace
4 - Exhaust Door Control Unit -J883-

NOx sensor -G295- Overview
1 - Wiring Harness
2 - NOx sensor -G295-
52 Nm
3 - Exhaust Door Control Unit -J883-
5 - NOx Sensor Control Module -J583-
6 - Connector
7 - Nut
6 Nm
8 - Bracket
9 - Bracket

Muffler and Mounts Overview
2.0L CKRA (TDI)

Engine –
1 - Clamping Sleeve
2 - From the NOx Reduction Catalytic Converter
3 - Bolts
25 Nm
4 - Bracket
5 - Suspended Mount
6 - Rear Muffler
7 - Clamping Sleeve
8 - Bracket
9 - Rear Subframe

Exhaust Temperature Control Overview

45 Nm
45 Nm
3 - Heated Oxygen Sensor -G39- with Oxygen Sensor Heater -Z19-
50 Nm
45 Nm
45 Nm
6 - Turbocharger
7 - Gasket
8 - EGR Temperature Sensor -G98-
10 - Particulate Filter

2.0L CKRA (TDI)
Engine –

Exhaust Gas Recirculation Overview
1 - Bolt
1.5 Nm
3 - EGR Temperature Sensor -G98-
4 - Gasket
5 - Gasket
Always replace
6 - Gasket
Always replace
7 - Bolt
9 Nm
8 - Gasket
Always replace
10 - Bolt
9 Nm
11 - Exhaust Gas Recirculation (EGR) Cooler

12 - Gasket
Always replace
2.0L CKRA (TDI)

14 - Clamp
Engine –
5 Nm
15 - Bolt
9 Nm
16 - Control Line

Reducing Agent (AdBlue®) Tank Overview
1 - Cap
2 - Gasket
3 - Sound Insulation
4 - Reducing Agent Tank
5 - Bolt
25 Nm

Reducing Agent (AdBlue®) Delivery Module Overview
2.0L CKRA (TDI)

Engine –
1 - Wiring Harness
2 - Delivery Line
3 - Bolt
5 Nm
4 - Reducing Agent Pump -V437-
5 - Seal
Always replace
6 - Gasket
Always replace
7 - Lock Ring
80 Nm
8 - Delivery Module
9 - Gasket
10 - Filter
11 - Seal
12 - Cap

Reducing Agent (AdBlue®) Delivery Line Overview
1 - Delivery Line Connector

2 - Delivery Line Connector
3 - Electrical Harness Connectors
4 - Reducing Agent Tank
5 - Reducing Agent Delivery Line
6 - Clamp
Always replace
7 - Gasket
Always replace
8 - Reducing Agent Injector -N474-
10 - NOx Sensor -G295-

2.0L CKRA (TDI)

Component Nm
Coolant Pipe on the Engine Control 9
Engine –
Exhaust Gas Recirculation Temperature Sensor to 20
Exhaust Gas Recirculation Pipe
Heat Shield Nuts 9
Tunnel Bridge to Underbody Bolt 23

Front Exhaust Pipe with Particulate
Filter Tightening Specifications
Step Component Nm
1 Position the particulate filter on the -
turbocharger. Install clamp (1) so it is still loose.
2 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.
3 Attach the EGR pipe, loosely secure the clamp -
(6)
4 Tighten clamp (1) 7
5 Tighten the nuts (5) 23
6 Tighten the nuts (4) 23
7 Tighten the nut (2) 23
8 Tighten bolts (3) 23
9 Tighten the clamp (6) 3.5

Ignition/Glow Plug System – 2.0L CKRA
2.0L CKRA (TDI)

(TDI)
Engine –
Component Nm
Camshaft Position (CMP) sensor 10
Engine Speed (RPM) sensor 5
Glow plug 18

CBTA, CBUA
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.

Engine Data
Engine codes CBTA CBUA
Manufactured from 07.2007 from 07.2007
Emission values in accordance with TIER 2/BIN 5 SULEV 1)
(US coalition)
Displacement cm³ 2480 2480
Output kW at RPM 125 @ 5700125 @ 5700
Torque Nm at RPM 240 @ 4250240 @ 4250
Engine idle speed 3) RPM 680 680
Engine speed (RPM) RPM approximately
approximately
2.5L CBTA/CBUA
limitation 6300 6300
Bore diameter mm 82.5 82.5
Engine –
Stroke mm 92.8 92.8
Compression ratio 9.5 9.5
Research Octane minimum 95 unleaded 2)
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)
SULEV = Super Ultra Low Emission Vehicles.
2)
Unleaded RON 91 is permitted but performance is reduced.
3)
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.

Engine Assembly – 2.5L CBTA, CBUA
size
M7 15
M8 25
M10 40
M12 60
Engine Mount Tightening Specifications
Component Nm
Bolts 1 40 plus an
additional 90°
(¼ turn) 1)
Bolts 2 20 plus an
additional 90°
(¼ turn) 1)
Bolts 3 60 plus an
additional 90°
(¼ turn) 1)
1)

Transmission Mount Tightening Specifications
2.5L CBTA/CBUA
Engine –
Component Nm
Bolts A 1) 40 plus an
additional 90°
(¼ turn)
Bolt B 1) 60 plus an
additional 90°
(¼ turn)
1)

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.
size
Bolts A 1) 10.9 50 plus an
additional 90°
(¼ turn)
Bolt B 1) - 100 plus an
additional 90°
(¼ turn)
1)

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.
The letters marked on the lower sealing surface of the cylinder block
identify which bearing thickness must be installed in which location.
2.5L CBTA/CBUA
Letter on cylinder block Color of bearing
G Yellow
Engine –
B Blue
W 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.

Ribbed Belt Drive Overview
1 - Bolt
23 Nm
2 - Power Steering Pump Pulley
3 - Bolt
23 Nm
4 - Power Steering Pump
6 - Bolt
25 Nm
7 - Bolt
25 Nm
8 - Generator
9 - Bolt
25 Nm
10 - Idler Pulley with Bracket
11 - Bolt
25 Nm

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
There are different versions.
2.5L CBTA/CBUA
19 - Bolt
50 Nm + 90° turn
Engine –
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

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

11 - O-ring
Always replace
12 - Bolt
25 Nm
13 - Alignment Sleeves
14 - Bolt
5 Nm
16 - Seal
Always replace
2.5L CBTA/CBUA
Engine –

Flywheel Overview
1 - Flywheel
2 - Bolt
9 Nm
Always replace.

Crankshaft Overview
2.5L CBTA/CBUA
Engine –
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

Piston and Connecting Rod Overview
1 - Connecting Rod Bolt

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

Component Nm
Plug to rear of cylinder block 30*

Honing dimensions Crankshaft bearing Connecting rod bearing
in mm pin diameter pin diameter
Basic dimension 58.00 -0.022 47.80 -0.022
-0.042 -0.042
1st oversize 57.75 -0.022 47.55 -0.022
-0.042 -0.042
2nd oversize 57.50 -0.022 47.30 -0.022
-0.042 -0.042
Stage III 57.25 -0.022 47.05 -0.022
2.5L CBTA/CBUA
-0.042 -0.042
Engine –
Piston Ring Gap
Piston ring Gap
New Wear limit
Compression rings mm 0.20 to 0.40 0.8
Oil scraping ring mm 0.25 to 0.50 0.8
Piston Ring Groove Clearance

Piston ring Ring to groove clearance
New Wear limit
Compression rings mm 0.06 to 0.09 0.20
Oil scraping ring mm 0.03 to 0.06 0.15

Honing dimension Piston diameter Cylinder bore diameter
in mm
Basic dimension 82.465 1) 82.51
1)
Measurement does not include the graphite coating (thickness = 0.02 mm). The
graphite coating wears away.

Cylinder Head, Valvetrain – 2.5L CBTA,
CBUA
Cylinder Head and Cover Overview
1 - Bolt
10 Nm
Tightening sequence, see Cylinder Head Cover Bolt Tightening
Sequence below
3 - Cylinder Head Cover Gasket
4 - Crankcase Ventilation Hose
5 - Oil Fill Cap
6 - Seal
7 - Bolt
10 Nm
8 - Wire Bracket
9 - Seal
10 - Wire Bracket
11 - Timing Chain Cover
12 - Bolt
2 Nm
14 - O-ring
15 - Bolt
10 Nm
17 - Transport Strap
18 - Bolt
2.5L CBTA/CBUA
25 Nm
Engine –
Always replace
20 - Cylinder Head
21 - Cap
22 - Gasket
Always replace
23 - Bolt
40 Nm + 180° turn
Always replace
24 - Wire Bracket

Camshaft Timing Chain Overview
1 - Intake Camshaft Adjuster

2 - Exhaust Camshaft Sprocket
3 - Cylinder Head
4 - Tensioning Rail
5 - Double Sprocket
7 - Oil Strainer
Always replace
8 - Bolt
10 Nm
9 - Chain Tensioner
10 - Gasket
Always replace
11 - Bolt
Always replace

12 - Bolt
60 Nm + 90° turn
Always replace
13 - Bolt
60 Nm + 90° turn
Always replace
2.5L CBTA/CBUA
Engine –

Valvetrain Overview
1 - Bolt
8 Nm + 90° turn
Always replace
2 - Guide Frame
3 - Exhaust Camshaft Sprocket
4 - Bolt
60 Nm + 90° turn
Always replace
5 - Bolt
60 Nm + 90° turn
Always replace
7 - Seals
8 - Timing Chain
9 - Cylinder Head

10 - Hydraulic Lash Adjuster
11 - Valve Retainers
12 - Spring Seat
13 - Valve Spring
14 - Valve Stem Seal
15 - Valve Guide
16 - Intake Valve
17 - Exhaust Valve
18 - Sealing Plug
Always replace
19 - Intake Camshaft
2.5L CBTA/CBUA
Engine –
Component Nm
AIR pipe at cylinder head bolt 10
Coolant pipe to bracket bolt 10
Flange to timing chain cover bolt 10
Timing chain cover to cylinder head bolt 10
Vacuum pump to timing case bolt 10

Valve Dimensions

Diameter a mm 26.80 to 27.00 29.80 to 30.00
Diameter b mm 5.95 to 5.97 5.94 to 5.95
c mm 104.84 to105.34 103.64 to 104.14
α ∠° 45 45
Bar positive Bar positive pressure cylinders
pressure Bar positive pressure
9.0 to 13.0 8.0 Maximum 3.0

2.5L CBTA/CBUA
Engine –
Step Component Nm

Cylinder Head Bolt Tightening
Step Component Nm
90° (¼ turn)
90° (¼ turn)
4 Tighten bolts 13 10

Guide Frame Bolt Tightening
2.5L CBTA/CBUA
Engine –
Step Component Nm
1 Tighten bolts 1 through 7 in sequence 1) 8
90° (¼ turn)
1)

Lubrication – 2.5L CBTA, CBUA
Oil Pan and Oil Pump Overview
1 - Cylinder Block
20 Nm
Only installed on vehicles with engine codes CBTA and CBUA.
20 Nm
5 - Oil Pump Timing Chain
6 - Bolt
20 Nm + 90° turn
Always replace
7 - Oil Pump Sprocket
8 - Oil Pump
9 - Bolt
25 Nm
10 - Bolt
25 Nm
11 - Oil Filter Adapter
12 - Oil Dipstick
13 - Circlip
14 - Guide Tube
15 - Engine Pre-Heater
16 - Bolt
25 Nm
17 - O-ring
Always replace
2.5L CBTA/CBUA
18 - Seal
Always replace
Engine –
19 - Bracket
20 - Bolt
10 Nm
21 - Lower Oil Pan
22 - Bolt
10 Nm
23 - Oil Drain Plug
30 Nm
24 - Decoupling Element
10 Nm
25 - Oil Intake Pipe
26 - Bolt
25 Nm
27 - Upper Oil Pan
28 - O-ring
Always replace

Oil Filter Adapter Overview
1 - Bolt
25 Nm
2 - Oil Filter Adapter
3 - Gasket
Always replace
20 Nm
20 Nm
6 - O-ring
8 - Bolt
9 Nm
9 - from Connecting Pipe
10 - Vent Tube
11 - Cap

25 Nm
13 - Seal
15 - Gasket
Always replace
17 - Bolt
25 Nm
18 - to the Thermostat Housing
19 - Gasket
2.5L CBTA/CBUA
Always replace
Engine –
Component Nm
Oil intake pipe-to-oil pump bolt 10
Oil intake pipe-to-upper oil pan bolt 10
Upper oil pan-to-cylinder block bolt 25

Cooling System – 2.5L CBTA, CBUA
Engine Pre-Heater Overview
Not installed on all vehicles.

1 - Guide Tube
2 - Left Cover
3 - Bracket
4 - Connecting Cable
5 - Retainer
6 - from the Oil Cooler
8 - to the Coolant Thermostat Housing
9 - Bolt
25 Nm
10 - Adhesive Foil
11 - Bracket with Clamp

2.5L CBTA/CBUA
Engine –

Coolant Pump and Thermostat
Overview Part 1, Belt Pulley Side
1 - Cylinder Block
3 - Bolt
25 Nm
4 - Bolt/Nut
10 Nm
5 - to the Heater Core, Bottom Connection
6 - Guide Tube
8 - Bolt
25 Nm
9 - O-ring
Always replace
10 - Circlip
13 - Cover
14 - to the Radiator, Lower Connection
15 - Bolt
5 Nm
16 - O-ring
Always replace
18 - Seal
Always replace
19 - Bolt
25 Nm
2.5L CBTA/CBUA
20 - Coolant Thermostat Housing
21 - Seal
Engine –
Always replace
23 - O-ring
Always replace
24 - Bolt
9 Nm
25 - Coolant Hose
26 - Bolt
25 Nm
27 - Coolant Pump

Coolant Pump and Thermostat Overview
Part 2, Transmission Side
1 - Coolant Pipe Connection

2 - Lock Ring
3 - Seal
4 - to the Expansion Tank, Top Connection
6 - Bracket
7 - Bolt/Nut
10 Nm
8 - Heat Shield
9 - to the Heater Core, Top Connection
10 - Supply Hose
11 - Bypass Thermostat
Only for vehicles with a automatic transmission.
12 - to the Transmission Oil Cooler

13 - from the Heater Core, Bottom Connection
14 - from the Transmission Oil Cooler
15 - Return Hose
16 - Coolant Pipe
17 - to the Flange
18 - Flange
19 - to the Radiator, Upper Connection
20 - to the Radiator, Upper Connection
21 - Supply Hose
2.5L CBTA/CBUA
23 - O-ring
Always replace
Engine –
24 - Retaining Clip

Fan Shroud and Radiator Overview
1 - Coolant Hose
2 - Radiator
3 - Upper Seal
4 - Cap
5 - Expansion Tank
6 - Connector
7 - Bolt
2 Nm
8 - Bolt
5 Nm
9 - Mount
10 - Mount
11 - Lower Seal
12 - Fan Shroud
13 - Nut
5 Nm

14 - Bolt
5 Nm
16 - Connector
18 - Lower Coolant Hose
20 - O-ring
Always replace
21 - Retaining Clip
22 - Upper Coolant Hose
2.5L CBTA/CBUA
Engine –
Component Nm
A/C condenser to radiator 5
Coolant fan to fan shroud 5
Coolant pump to cylinder block 10
Cover to coolant thermostat housing 5
Radiator mount to lock carrier 7

Fuel Supply – 2.5L CBTA, CBUA
1 - Connector
2 - Accelerator Pedal Position Sensor -G79- with Accelerator Pedal
3 - Bolt
10Nm
4 - Cap

2.5L CBTA/CBUA
Engine –

1 - Cap
2 - Bolt
5 - Bolt
11 Nm
6 - Heat Shield
7 - Nut
2.5 Nm
8 - Bolt
25 Nm
10 - Bolt
25 Nm
Always replace

12 - Seal
Always replace
14 - Lock Ring
110 Nm
2.5L CBTA/CBUA
Engine –

1 - Connecting Hose
4 - Hose Clamp
5 - Connecting Hose
6 - EVAP Canister
7 - Nut
1.8 Nm
9 - Bolt
1.8 Nm

2.5L CBTA/CBUA
Engine –
1 - Locking Ring
110 Nm
2 - Flange
3 - Intake Line
6 - Seal
Replace

Multiport Fuel Injection – 2.5L CBTA,
CBUA
Engine Cover/Air Filter Housing Overview
1 - Spring Clamp
2 - Connecting Pipe
3 - Bolt
3 Nm
5 - Engine Cover/Upper Air Filter Housing
6 - Rubber Bushing
7 - Filter Element
9 - Bolt
2 Nm

2.5L CBTA/CBUA
Engine –

1 - Crankcase Ventilation Vent Hose

2 - Connecting Hose
3 - EVAP Canister Purge Regulator Valve 1 -N80-
4 - Fuel Rail
5 - Bolt
9 Nm
7 - Seal
Always replace
8 - Intake Manifold
9 - Bracket
10 - Bolt
16 Nm
11 - Bolt
25 Nm
12 - Bracket

13 - O-ring
14 - Manifold absolute pressure sensor -G71- with intake air
temperature sensor -G42-
15 - Bolt
3.5 Nm
16 - Bolt
6.5 Nm
18 - Seal
2.5L CBTA/CBUA
Engine –

Fuel Rail and Injectors Overview
1 - Bolt
3.5 Nm
2 - Fuel Rail
4 - O-ring
Always replace
5 - Retaining Clip
6 - Fuel Injector -N30, N31, N32, N33, N83-
7 - Intake Manifold
8 - Cap
9 - Valve

Component Nm
Fuel rail-to-intake manifold bolt 3.5*
Intake manifold support-to-cylinder block bolt 25*
Oil dipstick guide tube-to-cylinder block bolt 25*
Transport strap to cylinder head 25*
Lower Air Filter Housing Bolt Tightening Sequence
2.5L CBTA/CBUA
Engine –
Step Component Nm

Exhaust System, Emission Controls –
2.5L CBTA, CBUA
Exhaust Manifold Overview
1 - Nut
23 Nm
Always replace
2 - Exhaust Manifold
3 - Clip
4 - Bolt
10 Nm
5 - Heat Shield
55 Nm
When reusing an old oxygen sensor, only use hot bolt paste -G 052
112 A3- to grease the threads, do not let the paste get onto the slits
of the oxygen sensor body.

7 - Bolt
10 Nm
8 - Bracket
9 - Gasket
Always replace
2.5L CBTA/CBUA
Engine –

Exhaust Pipe with Catalytic Converter Overview
2 - Gasket
Always replace
3 - Nut
23 Nm
Always replace
4 - Exhaust Pipe with Catalytic Converter
5 - Clamp
6 - Nut
23 Nm
7 - Nut
20 Nm
8 - Tunnel Brace
9 - Oxygen Sensor after Three Way Catalytic Converter -G130-
55 Nm
10 - Connector
11 - Bolt
23 Nm
12 - Suspended Mount
2.5L CBTA/CBUA
Engine –

Muffler Overview
1 - from the Exhaust Pipe with Catalytic Converter

2 - Bolt
26 Nm
Always replace
3 - Suspended Mount
4 - Bolt
23 Nm
5 - Center Muffler
6 - Retaining Ring
7 - Rear Muffler
8 - Nut
23 Nm
9 - Repair Clamp
10 - Suspended Mount
11 - Bolt
23 Nm

12 - Nut
23 Nm
13 - Tunnel Brace
14 - Front Muffler

Component Nm
Clamp 25
Suspended mount to subframe 25*
2.5L CBTA/CBUA
Secondary Air Injection Pipe
Engine –
Tightening Specifications
Step Component Nm
1 Tighten bolts 1 through 3 in sequence Hand-tighten

Ignition – 2.5L CBTA, CBUA
Ignition System Component Overview
1 - Knock Sensor 2 Connector

5 - Bolt
20 Nm
6 - Ignition Coil with Power Output Stage -N70, N127, N291, N292,
N323-
7 - Spark Plug
25 Nm
8 - Bolt
10 Nm
10 - O-ring

Muffler Overview
2.5L CBTA/CBUA
Engine –
1 - Cylinder Block
2 - Plug
30 Nm
4 - Bolt
20 Nm
5 - Bolt
10 Nm
6 - Cover
7 - Bayonet Connection
8 - Wire Clip
10 - Wire Bracket

Technical Data
Engine codes CBTA and CBUA
Ignition sequence 1-2-4-5-3
Spark plugs Refer to the Parts Catalog
Electrode gap 1.0 to 1.1 mm
Tightening specification 25 Nm
Change intervals Refer to Maintenance Intervals Rep. Gr. 03

Engine Mechanical – 3.6L CDVB
3.6L CDVB
Engine –
The engine number (engine code and serial number) (Æ) is
located on the cylinder block next to the vibration damper.

Engine Data
Engine code CDVB
Manufactured From 01.2011
Emission values in accordance with BIN 5/ULEV 2 2)
Displacement cm3 3597
Output kW at RPM 206 @ 6200
Torque Nm at RPM 350 @ 2500-5000
Engine idle speed 3) RPM 640 to 760
Engine speed (RPM) RPM approximately 6700
limitation
Bore diameter mm 89.0
Stroke mm 96.4
Cylinder angle 10.6°
Compression ratio 11.4
Valves per cylinder 4
Research Octane minimum 95 unleaded 1)
Number (RON)
Fuel injection, ignition Motronic MED 17.1.6
Knock control 2 knock sensors
Oxygen Sensor (O2S) regulation 4 sensors
Catalytic converter Yes
Leak detection system No
Exhaust Gas Recirculation (EGR) Internal
1)
In exceptional circumstances a minimum 91 RON, however with reduced
performance.
2)
ULEV 2: Ultra Low Emission Vehicles 2.
3)
Idle speed is not adjustable.

Cylinder Numbering
NOTE: Cylinder 1 is located opposite the fuel supply side.
3.6L CDVB
Engine –
Ignition sequence 1-5-3-6-2-4

Engine Assembly – 3.6L CDVB
Engine/Transmission Mounts Overview
1 - Bolt
Tightening specification, refer to DSG® Transmission
2 - Bolt
50 Nm + 90° turn
Always replace
3 - Bolt
50 Nm + 90° turn
Always replace
5 - Bolt
40 Nm + 180° turn
Always replace
6 - Bolt
40 Nm + 90° turn
Always replace

7 - Bolt
40 Nm + 90° turn
Always replace
8 - Support
9 - Bolt
20 Nm + 90° turn
Always replace
10 - Bolt
40 Nm + 90° turn
Always replace
11 - Bolt
40 Nm + 90° turn
Always replace
13 - Bolt
100 Nm + 90° turn
Always replace
14 - Bolt
40 Nm + 90° turn
Always replace
16 - Bolt
Tightening specification, refer to DSG® Transmission
3.6L CDVB
Engine –
17 - Transmission Mount Bracket
18 - Bolt
60 Nm + 90° turn
Always replace

Tightening Specifications
Bolt Tightening Specifications

-A- 1) 20 Nm + an additional 90° (1/4) turn
-B- 1) 40 Nm + an additional 90° (1/4) turn
-C- 1) 60 Nm + an additional 90° (1/4) turn
1)
Always replace

size
M7 15
M8 25
M10 40
M12 60

Crankshaft, Cylinder Block – 3.6L CDVB
Allocation of Crankshaft Bearing
Shells for Cylinder Block
The main bearing shells with the correct thickness are
allocated to the cylinder block and crankshaft in the
factory. Colored dots identify the bearing thickness.
Allocate the bearing shells if the cylinder block
or crankshaft are being replaced.
The bearing shell for the cylinder block (upper bearing
shell) is always marked with a yellow dot.
Using the letters on the cylinder block and crankshaft,
determine the correct color identification for the bearing
shell in the bearing cap (lower bearing shell). The first letter
is for bearing cap 1, the second for bearing cap 2, etc.
Cylinder Block Identification
3.6L CDVB
Engine –
The letters are located on the oil pan sealing surface.

Crankshaft Identification
The letters are located on the outer crankshaft

counterweight for cylinder 1.
Note the letters and then match it to the
color identification in the table.
Letter on the Letter on the Bearing Bearing
cylinder block crankshaft shell color shell color
counterweight identification for identification
the bearing cap for the cylinder
block
A, B, C, D, E R Red Yellow
A, B, C, D, E G Red Yellow
A, B, C, D, E B Yellow Yellow
A, B, C, D, E V Blue Yellow
G, H, I R Red Yellow
G, H, I G Red Yellow

Letter on the Letter on the Bearing Bearing
cylinder block crankshaft shell color shell color
counterweight identification for identification
the bearing cap for the cylinder
block
G, H, I B Yellow Yellow
G, H, I V Blue Yellow
K, L, M R Red Yellow
K, L, M G Yellow Yellow
K, L, M B Blue Yellow
K, L, M V Purple Yellow
Example:
Bearing Cap 1 2 3 4 5 6 7
Letter on the G H H H G E G
cylinder block
Letter on the G B B V B B G
crankshaft
counterweight
Bearing Red Yellow Yellow Blue Yellow Yellow Red
shell color
3.6L CDVB
Engine –
identification for
the bearing cap

Cylinder Block Overview, Belt Pulley Side
1 - Ribbed Belt
3 - Bolt
4 - Bolt
10 Nm
5 - Bolt
20 Nm
6 - Coolant Pump Pulley
7 - Bolt
50 Nm
8 - Ribbed Belt Tensioner
9 - Sealing Flange
10 - Bolt
8 Nm
11 - Coolant Pump
12 - Cylinder Block

13 - Bolt
25 Nm
14 - Generator
16 - Bolt
25 Nm
17 - Bolt
25 Nm
18 - A/C Compressore
19 - Bolt
23 Nm
20 - Idler Roller
21 - Bolt
40 Nm
3.6L CDVB
Engine –

1 - Bolt
60 Nm + 180° turn
3 - Ribbed Belt
4 - Bolt
20 Nm
5 - Coolant Pump
6 - Bolt
25 Nm
7 - Bolt
50 Nm
8 - Ribbed Belt Tensioner
9 - Bolt
25 Nm
10 - Bolt
25 Nm

11 - Generator
13 - Bolt
25 Nm
14 - A/C Compressor
15 - Bolt
23 Nm
M8 x 100
16 - Idler Roller
40 Nm
3.6L CDVB
Engine –

1 - Cylinder Block
2 - Alignment Pin
3 - Sealing Flange
4 - Bolt
60 Nm + 90° turn
Always replace
5 - Flywheel
6 - Needle Bearing
7 - Seal

Crankshaft Overview
3.6L CDVB
Engine –
1 - Bearing Cap
2 - Bolt
30 Nm + 180° turn
Always replace
3 - Bearing Shells, 1 through 7
4 - Thrust Washer
5 - Bolt
10 Nm + 90° turn
Always replace
6 - Sensor Wheel
Always replace
7 - Needle Bearing
8 - Crankshaft
9 - Oil Spray Jet
40 Nm + 90° turn
Always replace

Pistons and Connecting Rod Overview
1 - Piston Rings
2 - Piston
3 - Lock Ring
4 - Connecting Rod
5 - Bearing Shell
7 - Bolt
40 Nm + 90° turn
Always replace
7 - Piston Pin

size
Sensor wheel-to-crankshaft screw 1) - 10 plus an
additional 90°
(¼ turn)
1)

Accessory Bracket Bolt Tightening Specifications
Step Component Nm
1 Tighten bolts 2 and 4 Hand-tighten
3.6L CDVB
Engine –
2 Tighten bolts 1, 3 and 5 Hand-tighten
3 Tighten bolts 1 through 5 in a diagonal 25
sequence

Piston ring Gap
dimensions in mm New Wear limit
Stepped 0.30 to 0.50 1.0
compression ring

Piston ring Ring to groove clearance
dimensions in mm New Wear limit
Stepped 0.03 to 0.06 0.15
compression ring

Honing dimension Piston diameter Cylinder bore diameter
in mm
Reconditioning Crankshaft bearing pin Connecting rod bearing
dimension in mm diameter pin diameter
Basic dimension 59.958 to 59.978 53.958 to 53.978

3.6L CDVB
Engine –

Cylinder Head, Valvetrain – 3.6L CDVB
1 - Bracket
2 - Bolt
10 Nm
3 - Cap
5 - Bolt
10 Nm
6 - Cylinder Head Cover Gasket
7 - Lifting Eye
8 - Bolt
23 Nm
9 - Intake Manifold Support
10 - Bolt
23 Nm

11 - Bolt
10 Nm
12 - Bolt
10 Nm
13 - Water Connection
14 - Seal Ring
Always replace
15 - Chain Tensioner
50 Nm
16 - Cover
17 - Seal
18 - Bolt
8 Nm
19 - Bolt
8 Nm
20 - Coolant Pipe
21 - Bolt
23 Nm
22 - Guide Rail
23 - Bolt
23 Nm
Install using liquid locking fluid -D 000 600 A2-.
3.6L CDVB
Engine –
25 - O-ring
Always replace
26 - Seal
Always replace
Always replace
28 - Cylinder Head
29 - Bolt
Always replace
Before installing, coat the bolts with liquid locking fluid -D 197 300
A2-.
Follow the instructions and sequence when loosening see below
Follow the instructions and sequence when tightening see below

Vacuum Pump Overview
1 - Drive Shaft
2 - Cover
3 - Bolt
8 Nm
Short
4 - Bolt
8 Nm
Long
5 - Vacuum Pump
6 - Gasket
Always replace
7 - Seal

3.6L CDVB
Engine –

Cover and Sealing Flange Overview
1 - Seal
2 - Sealing Flange
3 - Bolt
23 Nm
4 - Bolt
8 Nm
Tighten in a diagonal sequence and in steps.
5 - Seal
6 - Bolt
8 Nm
7 - Camshaft Position (CMP) Sensor
8 - O-ring
Always replace
9 - Alignment Pin
10 - Cover
12 - Alignment Pin
13 - Bolt
10 Nm
3.6L CDVB
Engine –

Control Housing Overview
1 - Gasket
Replace
3 - Guide Track: Clipped to the Control Housing
5 - Bolt
3.8 Nm
6 - Exhaust Camshaft Adjustment Valve 1 -N318-
7 - Bolt
8 Nm + 180° turn
Replace

3.6L CDVB
Engine –

Timing Chains Overview
1 - Control Housing
2 - Seal
Always replace
3 - Oil Pump
4 - Bolt
8 Nm
Install using liquid locking fluid -D 000 600 A2-.
5 - Chain Tensioner
50 Nm
6 - Seal
7 - Tensioning Rail
8 - Pin
10 Nm
9 - Chain Sprocket

11 - Bolt
60 Nm + 90° turn
Always replace
12 - Exhaust Camshaft Adjuster
13 - Bolt
60 Nm + 90° turn
Always replace
15 - Bolt
10 Nm
16 - Chain Tensioner with Tensioning Rail
17 - Drive Sprocket
18 - Pin
10 Nm
19 - Oil Pump Timing Chain
20 - Pin
10 Nm
21 - Bolt
23 Nm
22 - Guide Rail
23 - Guide Rail
24 - High Pressure Pump Sprocket
3.6L CDVB
Engine –

Valvetrain Overview
1 - Intake Camshaft
2 - Camshaft Bearing Cap
4 - Nut
5 Nm + 45° turn
5 - Seal
6 - Control Housing
7 - Bolt
8 Nm + an 90° (1/4) turn
Replace
10 - Bolt
60 Nm + 90° turn
Always replace

11 - Cylinder Head Height
12 - High Pressure Pump Sprocket
13 - Drive Shaft
14 - Valves
16 - Cylinder Head
17 - Cam Follower
18 - Hydraulic Lash Adjuster
19 - Valve Stem Seal
21 - Clip
22 - Roller Rocker Arm
23 - Valve Spring
24 - Valve Spring Retainer
25 - Valve Retainer
3.6L CDVB
Engine –

Bar positive Bar positive pressure cylinders
pressure Bar positive pressure
11.0 to 13.0 8.0 Max. 3.0
Valve Dimensions
Dimensions for Intake Valve

Dimension Short valve Long valve
c mm 102.46 136.36
α ∠° 44° 40´ 44° 40´
Dimensions for Exhaust Valve

Dimension Short valve Long valve
c mm 102.20 136.20
α ∠° 44° 40´ 44° 40´

3.6L CDVB
Engine –
Step Component Nm

Cylinder Head Tightening Specifications
Step Component Nm
90° (¼ turn)
90° (¼ turn)

Sealing Flange to Cylinder Block Bolt
3.6L CDVB
Engine –
Step Component Nm
1 Tighten bolts 1 5

Camshaft Bearing Cap Tightening Specifications
Step Component Nm
A - Intake Camshaft
1 Alternately tighten bearing caps 5 and 9 and in 5 plus an
a diagonal sequence additional 45°
(⅛ turn)
2 Alternately tighten bearing caps 1 and 13 in a 5 plus an
diagonal sequence additional 45°
(⅛ turn)
3 Tighten bearing cap 7 5 plus an
additional 45°
(⅛ turn)
(⅛ turn)
B - Exhaust Camshaft
(⅛ turn)
(⅛ turn)
3 Tighten bearing cap 8 5 plus an
additional 45°
(⅛ turn)
(⅛ turn)

3.6L CDVB
Engine –

Lubrication – 3.6L CDVB
Oil Pan/Oil Pump Overview
1 - Bolt
6 Nm
2 - Guide Tube
3 - Cylinder Block
4 - O-ring
Always replace
5 - Oil Pump
6 - Chain Sprocket
7 - Bolt
60 Nm + an 90° turn
Replace
8 - Bolt
8 Nm
9 - Seal
Always replace

10 - Oil Spray Jet
11 - Seal
12 - Oil Suction Pipe
13 - Bolt
8 Nm
Install using liquid locking fluid.
14 - Oil Pipe
15 - Bolt
8 Nm
Install using liquid locking fluid.
16 - Baffle Plate
17 - Oil Drain Plug
30 Nm
Always replace
18 - Oil Pan
19 - Oil Level Thermal Sensor -G266-
20 - Bolt
10 Nm
21 - Bolt
12 Nm
22 - Bolt
10 Nm
3.6L CDVB
Engine –
24 - Bolt
23 Nm
25 - Oil Pressure Switch
26 - Seal
Always replace
Coat with oil before installing
27 - Seal
Always replace

Oil Filter Housing/Oil Pressure Switch Overview
1 - Seal
Always replace
3 -Seal
Always replace
4 - Plate
6 - Bolt
8 Nm
7 - Coolant Hose
8 - Coolant Hose
9 - Hose Clamp
10 - Bolt
23 Nm

20 Nm
12 - Oil Drain Plug
10 Nm
13 - O-ring
Always replace
14 - Cap
25 Nm
15 - O-ring
Always replace
17 - O-ring
Always replace
3.6L CDVB
Engine –

Cooling System – 3.6L CDVB
Coolant Pump/Thermostat Overview
1 - to the Expansion Tank Upper Connection

3 - Nut
20 Nm
4 - from the Heater Core
5 - to the Heater Core
6 - Coolant Pipe
7 - Bolt
10 Nm
8 - from the Transmission Oil Cooler
9 - Coolant Pipe, Side, Top
10 - Bolt
10 Nm

12 - O-ring
Always replace
13 - Clip
14 - Bolt
10 Nm
15 - to the Radiator Upper Connection
16 - from the Auxiliary Cooler
If installed
17 - to the Auxiliary Cooler
If installed
18 - from the Radiator Lower Connection
19 - Check Valve
20 - Coolant Pipe, Side, Bottom
21 - Bolt
25 Nm
22 - to the Transmission Oil Cooler
23 - Recirculation Pump -V55-
24 - Bolt
8 Nm
26 - Coolant Pipe
27 - Seal
Always replace
3.6L CDVB
Engine –
28 - Bolt
8 Nm
29 - Pulley
30 - Bolt
20 Nm
31 - Coolant Pump
32 - Gasket
Always replace
34 - Bolt
10 Nm
35 - from the Expansion Tank Lower Connection

Radiator/Coolant Fan Overview
1 - Coolant Hose
2 - Radiator
3 - Upper Seal
4 - Cap
5 - Coolant Expansion Tank
6 - Connector
7 - Bolt
2 Nm
8 - Bolt
5 Nm
9 - Mount
10 - Mount
11 - Lower Seal
12 - Fan Shroud
13 - Nut
5 Nm

14 - Bolt
5 Nm
16 - Connector
18 - Lower Coolant Hose
20 - O-ring
Always replace
21 - Clamp
22 - Upper Coolant Hose

Component Nm
A/C condenser to radiator 5
Radiator mount to lock carrier 7
3.6L CDVB
Engine –

Fuel Supply System – 3.6L CDVB
1 - Connector
2 - Accelerator Pedal Position Sensor -G79- with Accelerator Pedal
3 - Bolt
10Nm
4 - Cap

3.6L CDVB
Engine –

1 - Cap
2 - Bolt
5 - Bolt
11 Nm
6 - Heat Shield
7 - Nut
2.5 Nm
8 - Bolt
25 Nm
Always replace
10 - Bolt
25 Nm
Always replace

12 - Seal
Always replace
14 - Lock Ring
110 Nm
3.6L CDVB
Engine –

1 - Connecting Hose
4 - Hose Clamp
5 - Connecting Hose
6 - EVAP Canister
7 - Nut
1.8 Nm
9 - Bolt
1.8 Nm

3.6L CDVB
Engine –
1 - Locking Ring
110 Nm
2 - Flange
3 - Intake Line
6 - Seal
Replace

Multiport Fuel Injection – 3.6L CDVB
1 - Regulator Flap
2 - Bolt
2 Nm
3 - Connecting Pipe
4 - Air Filter Element
5 - Mass Airflow Sensor -G70-
6 - Seal
7 - Upper Air Filter Housing
8 - Bolt
2 Nm
9 - Connection
10 - Nut
8 Nm
11 - Intake Air Duct Cover

12 - Intake Air Duct
13 - Bolt
5 Nm
14 - Gasket
15 - Rubber Bushing
16 - Bolt
10 Nm
17 - Bracket
18 - Connection
3.6L CDVB
Engine –

1 - Bolt
10 Nm
2 - Upper Intake Manifold
3 - Bolt
10 Nm
4 - Grommet
5 - to the Brake Booster
6 - from EVAP Canister Purge Regulator Valve 1 -N80-
7 - Intake Manifold Rear Support
8 - Bolt
20 Nm
9 - Bolt
7 Nm
11 - Seal
Always replace

12 - Bolt
3.5 Nm
13 - Vent Hose
14 - Seal
15 - Intake Manifold Front Support
16 - Gasket
17 - Gasket
Always replace
18 - Lower Intake Manifold
19 - Fuel Rail
20 - Bolt
30 Nm + 90° turn
Always replace
21 - Bolt
8 Nm
22 - Gasket
3.6L CDVB
Engine –

Fuel Rail with Injector Overview
1 - Low Fuel Pressure Sensor -G410-

15 Nm
2 - Fuel Supply Hose
3 - Bolt
8 Nm
4 - Bracket
5 - Bolt
8 Nm
6 - O-ring
Always replace
7 - Seal
Always replace
8 - Spring
9 - Cylinder 1 Fuel Injector -N30-
10 - Low Pressure Fuel Hose
11 - Spring Clamp

12 - High Pressure Fuel Pipe
28 Nm
13 - Pressure Relief Valve
14 - Fuel Rail
16 - Connecting Pipe
18 - Fuel Rail
22 Nm
20 - Plug
22 Nm
22 - Bolt
30 Nm + 90° turn
Always replace
23 - Cylinder 2 Fuel Injector -N31-
24 - Support Washer
25 - Spring
26 - Bolt
30 Nm + 90° turn
Always replace
27 - Spring Clamp
3.6L CDVB
Engine –

High Pressure Pump Overview
1 - High Pressure Pipe

28 Nm
2 - Low Pressure Hose
3 - Spring Clamp
4 - Cam Follower
5 - O-ring
Always replace
7 - Bolt
10 Nm

3.6L CDVB
Engine –

CDVB
Exhaust Manifold Overview
1 - Intake Manifold Front Support

2 - Bolt
20 Nm
3 - Bolt
20 Nm
4 - Gasket
Always replace
6 - Nut
25 Nm
Always replace
7 - Heat Shield

8 - Bolt
20 Nm
9 - Intake Manifold Rear Support
11 - Gasket
Always replace
3.6L CDVB
Engine –

Exhaust Pipe with Catalytic Converter Overview
1 - Exhaust Pipe with Catalytic Converters

2 - Bolt
25 Nm
3 - Tunnel Brace
4 - Bolt
25 Nm
5 - Suspended Mount
6 - Oxygen Sensor after Three Way Catalytic Converter -G130-
50 Nm
50 Nm
8 - Heated Oxygen Sensor 2 -G108-
50 Nm
9 - Oxygen Sensor 2 after Catalytic Converter -G131-
50 Nm

Muffler Overview
3.6L CDVB
Engine –
1 - Center Muffler
2 - Clamping Sleeve
M8 nut - 25 Nm
M10 nut - 40 Nm
3 - Bolt
23 Nm
4 - Suspended Mount
5 - Retaining Loop
6 - Left Rear Muffler
7 - Bolt
25 Nm
8 - Tunnel Brace
9 - Suspended Mount
10 - Bolt
23 Nm

size
Center muffler bracket-to-underbody bolt - 23
Clamping Sleeve - 25
Front exhaust pipe-to-exhaust manifold nut - 40
1)
Heat shield bracket-to-cylinder head bolt - 20

Heat shield bracket-to-heat shield bolt - 20
Suspended mount to subframe - 25
Tunnel brace to body - 25
1)

Ignition/Glow Plug System – 3.6L CDVB
Ignition Technical Data
Engine code CDVB
Ignition sequence 1-5-3-6-2-4
Spark plugs 1)
VW/Audi 101 905 622 A
Electrode gap 0.8 to 0.9 mm
Tightening specification 18 Nm
Change intervals Refer to Maintenance Procedures Rep. Gr. 03
Maintenance Procedures
1)
Use the spark plug removal tool (3122B) to remove or install spark plugs.
3.6L CDVB
Engine –

Ignition System Assembly Overview
1 - Ignition Coil with Power Output Stage -N70, N127, N291, N292,
N323, N324-
2 - Connector
3 - Bracket
4 - Bolt
20 Nm
5 - Retaining Loop
7 - Bolt
20 Nm
9 - Cover
10 - Connector
11 - Bolt
10 Nm
12 - Camshaft Position Sensor 2 -G163-

13 - Seal
Always replace
16 - Connector
18 - Spark Plug
10 Nm
19 - Control Housing
3.6L CDVB
Engine –

Manual Transmission – 0A4
Transmission Identification
Code letters and build date (1) manual transmission 0A4 (2).
Manual transmission 0A4 (2).

Transmission code letters and build date.
Example:
LPU 22 07 0
Identification code Day Month Year (2010)
of manufacture
NOTE: The transmission code letters are also
included on the vehicle data label.
Manual Trans. –
0A4

Codes Letters, Transmission
Allocation and Capacities
Manual transmission 5 Speed Manual Transmission 0A4
Identification code LPU
Manufactured from from 06.2011
through
Allocation Type Passat from MY 2012
Engine 2.5 L - 125 kW
Ratio: Z2: Z1 Final drive 62:17 = 3.647
Manual transmission capacity Refer to the Fluid Capacity Tables
(transmission completely Rep. Gr. 03
disassembled)
Refer to the Electronic Parts Catalog (ETKA) for the following information:
• Individual gear ratios
• Transmission fluid specifications
• Clutch disc and pressure plate allocation

Manual Trans. –
0A4

Clutch – 0A4
Clutch Hydraulic System Overview
1 - Brake Fluid Reservoir

2 - Seal
3 - Supply Hose
4 - Clutch Master Cylinder
5 - Clip
6 - Mount
7 - Clutch Pedal
8 - Nut
25 Nm
9 - Seal/O-ring
10 - Hose/Line Assembly
11 - Bracket
12 - Seal/O-ring
13 - Clip
14 - Clutch Slave Cylinder

15 - Boltt
20 Nm
16 - Vent Valve
4.5 Nm
17 - Cap
18 - Transmission
19 - Bracket
20 - Bolt
20 Nm
Manual Trans. –
0A4

Pedal Cluster Overview
1 - Bulkhead
2 - Gasket
3 - Mounting Bracket
4 - Bolt
5 - Over-Center Spring
6 - Bushing
7 - Pin
8 - Clutch Pedal
9 - Base Plate
10 - Gasket
11 - Clutch Master Cylinder
12 - Clutch Position Sensor -G476-
13 - Clip
14 - Supply Hose

15 - Nut
25 Nm
16 - Nut
25 Nm
17 - Jounce Bumper
Manual Trans. –
0A4

Clutch Release Mechanism Overview
1 - Transmission
2 - Ball Stud
25 Nm
3 - Input Shaft Seal
4 - Guide Sleeve
5 - Spring
6 - Bolt
20 Nm
7 - Clutch Release Lever
8 - Release Bearing
9 - Bolt
20 Nm
10 - Clutch Slave Cylinder
11 - Plunger
12 - Assembly Bolt

Clutch Overview, with Dual Mass Flywheel, LuK
Manual Trans. –
1 - Flywheel
2 - Clutch Plate
0A4
3 - SAC Pressure Plate

4 - Bolt
M6: 13 Nm
M7: 20 Nm

Clutch Overview, with Single Flywheel
1 - Flywheel
2 - Clutch Plate
3 - Pressure Plate
4 - Bolt
M6: 13 Nm
M7: 20 Nm

size
Crash bolster to mounting bracket/steering - 20
column 1)
1)
Replace the impact bolster bolt.
Manual Trans. –
0A4

Controls, Housing – 0A4
Shift Lever and Housing Overview
1 - Base Plate
2 - Gasket
3 - Shift Lever
4 - Washer
5 - Lock Washer
6 - Selector Cable
7 - Bushing
8 - Shift Cable
9 - Sound Insulation
10 - Bearing Shell
11 - Bushing
12 - Lock Washer
13 - Pressure Spring
14 - Bushing

15 - Shift Lever Guide
16 - Nut
8 Nm
17 - Gasket
18 - Shift Housing
Manual Trans. –
0A4

Shift and Selector Cables Overview
1 - Gear Shift Unit

2 - Slding Shoe
3 - Relay Lever
4 - Cable Retainer
5 - Shift Lever, Transmission
6 - Nut
25 Nm
7 - Cable Retainer
8 - Lock Washer
9 - Lock Washer
10 - Selector Cable
11 - Shift Housing
12 - Lock Washer
13 - Shift Cable

14 - Cable Bracket
15 - Bolt
20 Nm
16 - Grommet
17 - Spacer
18 - Clip
Manual Trans. –
0A4

Engine and Transmission Mounts Overview
1 - Bolt
20 Nm + 90° turn
2 - Transmission Support
3 - Engine Mount with Engine Mount Bracket
4 - Bolt
Tightening specification, refer to Suspension, Wheels, Steering,
Front Suspension
6 - Bolt
Front Suspension
7 - Bolt
Front Suspension

8 - Bolt
40 Nm + 90° turn
11 - Bolt
Tightening specification, refer to Engine Mechanical, Fuel Injection
and Ignition, Engine Assembly
12 - Bolt
60 Nm + 90° turn
Manual Trans. –
0A4

Transmission Cover and 5th Gear Overview
1 - Bolt
18 Nm
2 - Transmission Cover
3 - Gasket
4 - Bolt
80 Nm + 90° turn
5 - Concave Washer
6 - Bolt
25 Nm
7 - Base for Selector Fork
8 - 5th Gear Selector Fork
9 - Spring
10 - 5th Gear Locking Collar
11 - Locking Pieces

12 - Synchronizer Hub with Gear and 5th Gear Synchronizer Ring
13 - Needle Bearing
14 - 5th Gear
Manual Trans. –
0A4

Transmission Housing and Gear Shift Unit Overview
1 - Countersunk Bolt
25 Nm
2 - Flange Shaft with Pressure Spring
3 - Inner TORX® Bolt
25 Nm
4 - Bolt
5 - O-ring
6 - Support Pin
7 - Pin
8 - Bolt
25 Nm
9 - Sealing Cap
10 - Bolt
25 Nm

11 - Bolt
5 Nm
Not available in the US/Canadian market.
12 - Transmission Neutral Position Sensor -G701-
Not available in the US/Canadian market
13 - Transmission Housing
14 - Clutch Housing
15 - Bolt
25 Nm + 90° turn
16 - Gear Shift Unitg
17 - Bolt
25 Nm
Manual Trans. –
0A4

Gear Shift Unit Overview
1 - Gear Shift Unit

2 - Backup Lamp Switch -F4-
25 Nm
3 - Locking Pin
4 - Relay Lever
5 - Clip
6 - Seal
7 - Nut
23 Nm
8 - Shift Lever
9 - Cap
10 - Sealing Cap
11 - Spring

Manual Trans. –
0A4

Input Shaft, Output Shaft, Differential
and Shift Rods Overview
1 - Differential
2 - Seal
3 - Output Shaft
4 - Reverse Gear Shaft Support
5 - Reverse Gear Shaft
6 - Input Shaft
7 - Reverse Gear Selector Fork
8 - Inner TORX® Bolt
25 Nm
9 - Selector Fork with Rail
10 - Clutch Housing
11 - Nut
25 Nm + 90° turn
12 - Flange Shaft with Pressure Spring
25 Nm
Selector Fork Overview
Manual Trans. –
1 - 5th Gear Shift Segment

2 - Lock Washer
0A4
3 - 5th Gear Selector Fork

4 - Bolt
25 Nm
5 - 5th Gear Shift Jaw
6 - Ball Bearing
7 - Selector Fork with Rail
8 - 1st/2nd Gear Shift Segment
9 - 3rd/4th Gear Shift Segment
10 - Gliding Piece
11 - Spring
12 - Reverse Gear Selector Fork
13 - Support for the Reverse Gear Selector Fork
14 - Lock Ring

Transmission Housing and Clutch Housing Overview
2 - Needle Bearing
3 - Fill Plug
35 Nm
4 - Outer Race/Tapered Roller Bearing
5 - Adjusting Shim
6 - Adjusting Shim
9 - Needle Sleeve
11 - Clutch Housing
12 - Guide Sleeve
13 - Bolt
20 Nm
14 - Seal and Sleeve, One Piece

15 - Drain Plug
35 Nm
17 - Magnet
18 - Oil Guide
19 - Jounce Bumper
20 - Jounce Bumper
21 - Jounce Bumper
Manual Trans. –
Item Fastener Quantity Nm

1 M 12 x 50 2 80
0A4
2 M 12 x 150 Also starter to transmission 2 80

3 M 10 x 55 3 80
4 M 12 x 60 1 80
5 M 6 x 8 (Not present on all) 1 40
1)
Also starter to transmission


Gears, Shafts – 0A4
Fastener Tightening Specification
Component Nm
Output shaft bearing support-to-clutch housing nut 1) 25 plus an
additional 90°
(¼ turn)
1)
Determining Shim Thickness

Example Bearing clearance Adjustment shim thickness
measured value according to the table
0.850 mm 1.000 mm

Adjustment Shim Table
Bearing play Adjusting shim
Measured value (mm) Thickness (mm)
0.671 to 0.699 0.650
0.700 to 0.724 0.675
0.725 to 0.749 0.700
0.750 to 0.774 0.725
0.775 to 0.799 0.750
0.800 to 0.824 0.775
0.825 to 0.849 0.800
0.850 to 0.874 0.825
0.875 to 0.899 0.850
0.900 to 0.924 0.875
0.925 to 0.949 0.900
0.950 to 0.974 0.925
0.975 to 0.999 0.950
1.000 to 1.024 0.975
1.025 to 1.049 1.000
1.050 to 1.074 1.025
1.075 to 1.099 1.050
1.100 to 1.124 1.075
1.125 to 1.149 1.100
1.150 to 1.174 1.125
1.175 to 1.199 1.150
1.200 to 1.224 1.175
1.225 to 1.249 1.200
1.250 to 1.274 1.225
1.275 to 1.229 1.250
1.300 to 1.324 1.275
1.325 to 1.349 1.300
Manual Trans. –
1.350 to 1.374 1.325

1.375 to 1.399 1.350
1.400 to 1.424 1.375
0A4
1.425 to 1.449 1.400

1.450 to 1.474 1.425
1.475 to 1.499 1.450
1.500 to 1.524 1.475
1.525 to 1.549 1.500
1.550 to 1.574 1.525
1.575 to 1.599 1.550
1.600 to 1.624 1.575
1.625 to 1.649 1.600
1.650 to 1.674 1.625
1.675 to 1.699 1.650
1.700 to 1.724 1.675
NOTE: Refer to the Electronic Parts Catalog
(ETKA) for the correct shims.
Rear Final Drive, Differential – 0A4
Differential Overview
2 - Adjusting Shim
4 - Bearing Inner Race/Taper Roller Bearing
5 - Differential Housing
6 - Bearing Inner Race/Taper Roller Bearing
8 - Clutch Housing
9 - Seal
25 Nm
11 - Flange Shaft
12 - Flange Shaft Pressure Spring
13 - Thrust Washer

14 - Tapered Ring
15 - Lock Ring
16 - Thrust Washer Union
17 - Large Differential Bevel Gear
18 - Threaded Piece
19 - Differential Taper Axle
20 - Adapter Sleeve
21 - Small Differential Bevel Gear
22 - Large Differential Bevel Gear
23 - Seal
Manual Trans. –
0A4

Automatic Transmission – 09G
Identification on Transmission
Code letters (Æ).

Code letter (1) indicates 6-speed automatic transmission 09G (2).
Example:
MAN 24 06 10
Identification codes Day Month Year (2010) of manufacture
The transmission code letters are also
included on the vehicle data labels.
Engine and Transmission Allocation

If original replacement parts are needed for a repair,
always pay attention to the transmission codes.
6-Speed automatic transmission 09G
Transmission code MAN NTJ
Engine 2.5L -125 kW 1.8L -125 kW
Auto Trans. – 09G

Controls, Housing – 09G
Selector Mechanism Overview
1 - Selector Handle With Cover

2 - Center Console Cover
3 - Selector Mechanism
4 - Bolt
8 Nm
5 - Nut
8 Nm
6 - Gearshift Housing
7 - Bracket
8 - Selector Lever Cable
9 - Transmission
10 - Tunnel/Body

ATF Cooler, Round Version
2 - O-ring
Always replace
3 - Automatic Transmission Fluid (ATF) Cooler
4 - O-ring
Always replace
5 - Washer
6 - Plate Spring
7 - Bolt
Auto Trans. – 09G
36 Nm

ATF Cooler, Rectangular Version
2 - O-ring
Always replace
3 - ATF Cooler
4 - Bolt
20 Nm
M8 x 25

Component Nm
Multifunction transmission range switch-to-transmission 6
bolt
Multifunction transmission range switch-to-transmission 7
nut
Selector lever cable adjustment bolt 13
Selector lever-to-selector shaft nut 13
Transmission oil pan inspection plug 27
Auto Trans. – 09G
size
Drive plate-to-converter - 60
Bolts M12 80 or 65, if
using T10179
Bolts located in the lower flange M10 40
Alignment (arrow) pins for centering

Gears, Hydraulic Controls – 09G
Differential Overview
1 - Inspection Plug
Tightening specification, see Fastener Tightening Specifications
below
2 - Seal
Always replace
3 - Overflow Tube
below
4 - Transmission Fluid Pan
5 - Bolt
Tighten the pan bolts diagonally and in several steps.
below
6 - Gasket
7 - Magnet

8 - Bolt
Always replace
below
9 - Bolt
below
10 - Transmission Fluid Filter
11 - Valve Body
12 - Bolt
below
13 - Bolt
below
14 - Transmission Input Speed Sensor -G182-
15 - Bolt
below
16 - Transmission Output Speed Sensor -G195-
18 - Vent
19 - Multifunction Transmission Range Switch -F125-
20 - Transmission Fluid Temperature Sensor -G93-
21 - Bolt
below
22 - Bolt
below
23 - Sensor Wiring Harness
24 - Seal
Always replace
25 - Drain Plug
below
26 - Selector Shaft Lever
27 - Washer
28 - Nut
below
Auto Trans. – 09G
29 - Spring
30 - Piston
31 - Solenoid Valve Wiring Harness
32 - Bolt
below


Direct Shift Gearbox (DSG)
Transmission – 02E
DSG Trans. –
02E
Example:
GFK 10 05 10
Identification codes Day Month Year (2002) of manufacture

The transmission code letters can be found on the transmission near

the selector lever cable (Æ) or under the transmission mount bracket.

DSG Trans. –
02E
To read the transmission code letters under the transmission
mount bracket, support the engine and transmission and
remove the transmission mount bracket (A). Refer to ElsaWeb
for the transmission mount bracket removal procedure.
Transmission Allocation Codes

Direct Shift Gearbox (DSG®) 02E
Identification codes MTA, NJH, NLW MSV, NJK, NLP
Engine 3.6L - 206 kW FSI 2.0L - 103 kW TDI
Common Rail

Controls, Housing (DSG) – 02E
Transmission Component Overview
1 - Transmission Cover
2 - Gasket
Always replace
3 - Bolt
5 Nm + 90° turn
Always replace
4 - DSG Transmission Mechatronic -J743-
5 - Bolt
16 Nm
Always replace
6 - Clutch End Cover for the Direct Shift Gearbox (DSG®)
7 - Dual Clutch
8 - Vent Tube
Always replace after removing.
9 - Cover

10 - Nut
20 Nm
Always replace
DSG Trans. –
11 - Gear Shift Lever
12 - Seal
02E
13 - Bolt
20 Nm + 90° turn
Always replace
14 - Transmission Oil Cooler
15 - O-rings
Always replace
16 - Cable Bracket
17 - Bolt
20 Nm + 90° turn
Always replace
20 Nm
19 - O-ring
Always replace
21 - Transmission Input Speed Sensor -G182- and Clutch Oil
Temperature Sensor -G509-
22 - Bolt
10 Nm
Always replace
23 - Alignment Pin
24 - Gasket
Always replace
25 - Transmission Oil Pump
26 - Transmission Oil Pump Cover
Always replace
27 - Bolt
8 Nm
Always replace
28 - Bolt
Always replace
There are different bolts for the transmission oil pump.
29 - Overflow Tube
3 Nm
30 - Seal
Always replace
31 - Oil Drain and Check Plug
45 Nm

Selector Mechanism Overview
1 - Selector Handle with Cover

2 - Center Console Cover
3 - Selector Mechanism with Selector Lever Cable
4 - Bolt
8 Nm
5 - Nut
8 Nm
6 - Selector Housing
7 - Bolt
20 Nm + 90° turn
Always replace
8 - Cable Bracket
9 - Lock Washer
Always replace after removing
10 - Lock Washer
Always replace after removing
11 - Tunnel/Body

DSG Trans. –
02E

Engine and Transmission Mounts Overview
1 - Bolt
40 Nm + 90° turn
Always replace
2 - Bolt
Front Suspension
4 - Bolt
5 - Engine Mount
6 - Bolt
7 - Support

8 - Bolt
DSG Trans. –
9 - Bolt
02E
10 - Bolt
11 - Bolt
13 - Bolt
Front Suspension
14 - Bolt
60 Nm + 90° turn
Always replace
15 - Bolt
17 - Bolt
40 Nm + 90° turn
Always replace
18 - Bolt
40 Nm + 90° turn
Always replace

Mechatronic Tightening Specifications
Step Component Nm
1 Tighten bolts 1 through 10 in sequence 1) Hand-tighten
90° (¼ turn)
1)

Oil Pump Tightening Specifications
Without Countersunk Bolt
DSG Trans. –
02E
Component Nm
Oil pump bolts (Æ) with flat heads 5 plus an
additional 90°
(¼ turn)

Diesel Engine
Item Fastener Nm
1 M12 x 55 80
2 M10 x 45 1) 40
3 M12 x 55 2) 80
4 M10 x 45 or M10 x 40 1) 40
5 M12 x 65 or M12 x 70 80
6 M10 x 50 40
7 M10 x 50 40
8 M10 x 50 40
9 M12 x 65 or M12 x 70 80
10 M12 x 55 80
1)
Also starter to transmission.
2)
Is accessible only through the opening for the starter.

Gas Engine
DSG Trans. –
02E
Item Fastener Nm
1 M12 x 55 80
2 M10 x 45 1) 40
3 M12 x 55 80
4 M10 x 45 1) 40
5 M12 x 55 2) 80
6 M12 x 55 80
7 M10 x 50 40
8 M10 x 50 40
9 M10 x 45 2) 40
10 M12 x 65 2) 80
1)
Also starter to transmission.
2)
Installed from the engine side.

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2014

VW Passat Quick Reference Specification Book • February 2014 i

VW Passat Quick Reference Specification Book • February 2014 iii

vi VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 vii

viii VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 ix

x VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 1

2 VW Passat Quick Reference Specification Book • February 2014

N·cm-to-lb·in (in·lb), kg·cm

VW Passat Quick Reference Specification Book • February 2014 3

Warnings and Cautions

4 VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 5

6 VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 7

8 VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 9

2014 Volkswagen VIN Decoder (except Routan)

J= Beetle 1.8T w/6 Spd Auto

h= Beetle 1.8T w/5 Spd Man

2014 Restraint System:

w/6 Spd Auto Trans

SEL w/5 Spd Man Trans

All = Active-Dr/Pass - Front Air Bag - Dr/Pass

+ Side Curtain Air Bags + 4 Star Crash Rated

october 30, 2013 (Rev 4)

5 (Jetta only) or 7 (Jetta SportWagen/CC/Passat) = Advanced Front Air

Front + 3 Star Crash Rated

8= Beetle Conv. R-Line w/6

6= Beetle Conv. TDI w/6Spd

Spd Man Trans

Spd Auto Trans

models are identified by WMI code of WVW.

** SULEV II = Super Low Emissions Vehicle

* PZEV = Partial Zero Emissions Vehicle

+ Side Curtain Air Bags

2014 Volkswagen VIN Decoder (except Routan)

M =1991 3 Vehicle Type

Y = 2000 8 (position 7 & 8)

1= 4 cyl 1.8L 170hp (CPRA-PZEV*) Beetle, Beetle

0= 4 cyl 1.8L 170hp (CPKA) Beetle, Beetle

X= 5 cyl 2.5L 170hp (CBTA-M) Beetle, Beetle

T= 4 cyl 2.0L 210hp (CPPA-PZEV*) Beetle,

S= 4 cyl 2.0L 210hp (CPLA) Beetle, Beetle

P= 5 cyl 2.5L 170hp (CBUA-M-PZEV*)

L= 4 cyl 2.0L TDI 140hp (CJAA) Beetle, Beetle

Convertible, Jetta, Jetta SportWagen

Beetle Convertible, Jetta GLI

Convertible, Jetta, Jetta SportWagen

Beetle, Beetle Convertible, Jetta, Jetta

10 VW Passat Quick Reference Specification Book • February 2014

The Vehicle Identification Number (VIN) is located

VW Passat Quick Reference Specification Book • February 2014 11

The vehicle data label (Æ) is located in the left rear of

12 VW Passat Quick Reference Specification Book • February 2014

VW Passat Quick Reference Specification Book • February 2014 13

Position the support plate in the side member