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2004 Volkswagen Passat

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Passat.

Body PASSENGER CAR

The 2004 Volkswagen Passat is a passenger car whose lubrication requirements—5.7 quarts of 0W-40, 5W-30, or 5W-40 oil—reflect a European engine philosophy favoring heavier viscosity grades than many of its contemporaries. The model year carries a moderate reliability burden of 283 owner complaints concentrated in the Engine & Engine Cooling category, accompanied by four recalls, which together suggest buyers should scrutinize powertrain and cooling system condition closely. Within the Passat's broader complaint history spanning 1990 through 2022, the 2004 sits comfortably below the peak of 747 complaints recorded for the 2013 model year and well above the 11 logged for 2022, placing it in the middle tier of the nameplate's reliability timeline—neither a standout problem year nor a trouble-free one, making a thorough pre-purchase inspection of cooling and engine components essential for anyone considering this vintage.

Model year2022 2021 2020 2019 2018 2017 2016 2015 2004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.7 qtOEM · verified

Engine oil type0W-40 / 5W-30 / 5W-40OEM · verified

Lug nut torque89 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 48 · 540 CCA battery, OE oil filter 068115561B. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 48 · 540 CCAOEM · verified

Tail / brake / turnBRAKEOEM · verified

OE service part numbers OEM · verified

Engine oil filter	068115561B alt 078115561J
Engine air filter	058133843
Fuel filter	1H0201511A alt 441201511C
Spark plug	101000063AA alt 101000035HJ
Battery	000915105AG
Front wiper blades	3B1955426B alt 1J1955425B
Serpentine belt	038903137T alt 06B260849B
Thermostat	038121119B alt 078121113G
Cabin air filter	1H0819644B alt 8D0819165B

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length	184.3 in
Overall width	68.9 in
Overall height	59.1 in
Wheelbase	106.3 in
Curb weight	3644 lb
Track (front / rear)	59.4 / 59.4 in
Weight distribution (front / rear)	60/40

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Passat of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

6.7 sec0–60 mph (tested)quickest 6.70 sec — 2004 W8 4Motion Sedan

Year	Trim / engine	0–60	¼ mile	HP	Drivetrain
2004	W8 4Motion Sedan 4.0L W8	6.70 sec	14.90 sec	270 hp	AWD
2003	W8 4Motion Sedan 4.0L W8	6.40 sec	14.45 sec	270 hp	AWD
2003	GL 1.8T Sedan 1.8L Turbo I-4	7.60 sec	16.10 sec	170 hp	FWD
2003	GLX V6 Sedan 2.8L V6	9.20 sec	17.00 sec	190 hp	FWD
2002	W8 4Motion Sedan 4.0L W8	6.80 sec	15.20 sec	270 hp	AWD
2002	W8 4Motion Sedan 4.0L W8	6.90 sec	15.40 sec	270 hp	AWD
2002	W8 4Motion Sedan 4.0L W8	7.20 sec	15.60 sec	270 hp	AWD
2002	W8 4Motion Sedan 4.0L W8	7.70 sec	15.90 sec	270 hp	AWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.7 qt of 0W-40 / 5W-30 / 5W-40 engine oil, SYNTHETIC · 75W-90 · GL-4 in the differential, DOT 4 brake fluid. Torque lug nuts to 89 ft-lbs. The firing order is 1-4-3-6-2-5. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission Fluid	ATF
Automatic Transmission Fluid Capacity	9.5
Brake Fluid	DOT 4
Differential Gear Oil	SYNTHETIC · 75W-90 · GL-4
Differential Gear Oil Capacity	1.7 Pints
Engine Coolant	USE G012ABG-A1 COOLANT
Engine Oil	0W-40 · 5W-30 · 5W-40
Engine Oil Capacity	5.7 qt

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs	15 ft-lbs
Camshaft Bearing/Carrier Cap Bolts or Studs	7 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	18 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs	Short bolts, 7 ft-lbs, Long bolts, 15 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs	7 ft-lbs

Chassis torques

Lug Nuts	89 ft-lbs
Transfer Case Fill Plug	15.0 ft-lbs
Rear Wheel Hub	85 ft-lbs

Ignition

Cylinder Firing Order	1-3-4-2
Cylinder Firing Order	1-4-3-6-2-5
Curb Idle Speed (No Load)	700 rpm
Curb Idle Speed Variance (No Load)	20 rpm
Curb Idle Speed (No Load)	800 rpm
Curb Idle Speed Variance (No Load)	60 rpm
Ignition Coil Secondary Resistance	3600-4400 ohms
Spark Plug Manufacturer	Bosch

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	Models w/Denso 7SB-16c, 1.31; models w/Denso 7SEU16 compressor, 1.13. lbs
Oil Group	PAG
Oil Type	46
Oil Capacity	Except models w/W8 engine, 8.45; models w/W8 engine, 6.76. oz
Standard BCI Group Number	48
Standard BCI Cranking Performance	540 cca
Standard BCI Group Number	94R

Service checks

Pressure Test	14.5 psi
Radiator Cap Pressure Relief	20-23 psi
Thermostat Opening Temperature	188 °F
Injector Primary Resistance	13.5-15.5 ohms
Injector Primary Resistance	14-20 ohms
Injector Primary Resistance	15-20 ohms

Brakes

Other	WITH HP2 16 inch WHEELS
Torque to Knuckle	140 ft-lbs / 89 ft-lbs
Torque Caliper to Bracket	19 ft-lbs / 18 ft-lbs
Torque Caliper to Bracket	25 ft-lbs
Torque to Knuckle	70 ft-lbs
Torque Caliper to Bracket	25 ft-lbs
Torque to Knuckle	70 ft-lbs
Minimum Pad Thickness	Front: 0.276; Rear: 0.276 specification

Multi-step torque procedures OEM · verified

Camshaft Bearing/Carrier Cap Bolts or Studs — tightening sequence 1 stages

4 ft. lbs., Step 2: 45

4 ft. lbs

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

22 ft. lbs., Step 2: 90

22 ft. lbs

Cylinder Head — tightening sequence 4 stages

1	30 ft. lbs.	30 ft. lbs
2	44 ft. lbs.	44 ft. lbs
3	90 degrees.	90 degrees
4	90 degrees.	90 degrees

Cylinder Head — tightening sequence 3 stages

1	44 ft. lbs.	44 ft. lbs
2	90 degrees.	90 degrees
3	90 degrees.	90 degrees

Cylinder Head — tightening sequence 3 stages

Prep Do not reuse old bolts. Coat bolt head washers and threads with clean engine oil

1	30.0 ft. lbs.	30 ft. lbs
2	90 degrees	90 degrees
3	90 degrees	90 degrees

Cylinder Head — tightening sequence 4 stages

Prep Do not reuse old bolts. Coat bolt head washers and threads with clean engine oil

1	22.0 ft. lbs.	22 ft. lbs
2	37.0 ft. lbs.	37 ft. lbs
3	90 degrees	90 degrees
4	90 degrees	90 degrees

Engine Flywheel Bolts — tightening sequence 1 stages

44 ft. lbs., Step 2: 90

44 ft. lbs

Engine Flywheel Bolts — tightening sequence 1 stages

74 ft. lbs., Step 2: 90

74 ft. lbs

Main Bearings — tightening sequence 1 stages

48 ft. lbs., Step 2: 90

48 ft. lbs

Main Bearings — tightening sequence 1 stages

44 ft. lbs., Step 2: 90

44 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter at 5,000 mi; spark plugs every 40,000 mi.

At 5,000 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Fuel Filter Water Separator (drain)
Every 5,000 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace)
Every 10,000 mi	Battery (inspect) · Brake Hydraulic System (inspect fluid level) · Brake Shift Interlock Solenoid (inspect) · Brake System (inspect) · Engine Oil (drain & refill) · Engine Oil Filter (replace)
At 20,000 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Fuel Filter Water Separator (drain)
Every 20,000 mi	CV Joint Boot (inspect) · Cabin Air Filter (replace) · Door Stop (lubricate) · Engine Assembly (leak inspection) · Engine Coolant System (inspect fluid level) · Exhaust System (Complete) (inspect)
At 40,000 mi	Final Drive (leak inspection)
Every 40,000 mi	Accessory Drive Belt (inspect) · Engine Air Filter Element (replace) · Power Steering System (inspect fluid level) · Spark Plugs (replace) · Sunroof Assembly (inspect)
At 60,000 mi	Timing Belt (inspect)
Every 80,000 mi	Timing Belt (inspect)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Volkswagen Passat occupies a brief lull in a generation otherwise characterized by massive federal complaint spikes, sitting between the 1998-2003 peak (reaching 675 complaints in 1999) and a subsequent surge starting in 2006. Compared to 2003, the 2004 model saw complaints drop by more than half to 283, with recalls falling to 4 and investigations to 3, suggesting late-cycle refinements temporarily tempered earlier flaws. However, the 2004 model still carries notable risks, with Engine & Engine Cooling (49), Seats (28), Power Train (28), and Fuel System, Gasoline (25) leading the complaints, alongside 25 fire complaints where the data does not specify root causes. While it fares better than the troubled 1998-2003 models, its elevated fire complaint rate and position just before another major reliability downturn mean it is not an unequivocally strong choice. Ultimately, the 2004 Passat is a mediocre year to buy; it is superior to its immediate predecessors but demands rigorous inspection of the engine and fuel systems to mitigate documented fire risks.

Open recalls

NHTSA campaigns

249

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

283

Owner complaints

9 involved a crash · 25 a fire

Owner complaints by model year NHTSA · this generation & adjacent

’90 ’91 ’92 ’93 ’94 ’95 ’96 ’97 ’98 ’99 ’00 ’01 ’02 ’03’04’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12 ’13 ’14 ’15 ’16 ’17 ’18 ’19 ’20 ’22

Owner complaints filed with NHTSA, by component

All 283 complaints on record, top 8 components.

Engine & Engine Cooling49

Seats28

Power Train28

Fuel System, Gasoline25

Fuel/Propulsion System22

Engine12

Visibility9

Structure8

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

14E007000Engine And Engine Cooling:EngineReported 07/03/2014

The Gates Corporation (Gates) is recalling certain aftermarket Tru-Flow Water Pumps, part number TFW 41127, sold at certain NAPA Auto Parts and/or installed by automotive service technicians after November 1, 2013 (and… Remedy: Gates will notify owners, and dealers will replace the water pump, free of charge. The recall began during May 2014. Owners may contact The Gates Corporation at 1-303-744-1911.

08V156000Fuel System, Gasoline:DeliveryReported 07/04/2008

VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME… Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY…

Technical service bulletins NHTSA · verified

Showing 5 of 249 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
V171901201285565	2023-08-21	Engine And Engine Cooling	Update to Volkswagen engine oil standards
V171901201285562	2023-05-30	Engine And Engine Cooling	Volkswagen Engine oil quality standards, update to attachments.
V171901201285560	2023-04-24	Engine And Engine Cooling	Engine oil quality standards, update to attachments.
V941901201152119	2022-12-12	Equipment	Update model year applicability to include 2023.
V271901201189422	2022-12-06	Electrical System	Battery testing and charging using special tools VAS6161 & GRX3000VAS Charger. Updated to…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Passat. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 48 battery Vehicles taking 5.7 qt Engine oil filter 068115561B Engine air filter 058133843 Fuel filter 1H0201511A Spark plug 101000063AA

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2004 Passat take?

5.7 qt of 0W-40, 5W-30 OR 5W-40 MEETING VW SPECIFICATION 502.00, per the factory manual.

Does the 2004 Passat have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.