4-cylinder injection engine (1.8 l, 2.0 l TFSI engine, EA888, generation III)

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• 3.3 Contact corrosion
  5
• 3.4 Routing and attachment of lines
  6
• 3.5 Fitting radiator and condensers
  6
• 3.6 Checking vacuum system
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Separating engine and gearbox
  18
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  22
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• 2.2 Removing and installing engine mounting
  28
• 2.3 Removing and installing gearbox mounting
  30
• 2.4 Removing and installing pendulum support
  31
• 2.5 Supporting engine in installation position
  32
• 2.6 Adjusting assembly mountings
  40
• 2.7 Checking adjustment of assembly mountings
  42
• 3 Engine cover panel
  43
• 3.1 Removing and installing engine cover
  43
• Crankshaft group
  44
• 1 Cylinder block (pulley end)
  44
• 1.1 Assembly overview - cylinder block (pulley end)
  44
• 1.2 Removing and installing poly-V belt
  47
• 1.3 Removing and installing tensioner for poly V-belt
  48
• 1.4 Removing and installing vibration damper
  49
• 1.5 Removing and installing bracket for ancillaries
  56
• 1.6 Removing and installing engine support
  60
• 2 Cylinder block, gearbox end
  62
• 2.1 Assembly overview - cylinder block, gearbox end
  62
• 2.2 Assembly overview - drive plate
  63
• 2.3 Removing and installing drive plate
  64
• 2.4 Removing and installing flywheel
  66
• 2.5 Removing and installing sealing flange on gearbox side
  68
• 3 Crankshaft
  73
• 3.1 Assembly overview - crankshaft
  73
• 3.2 Crankshaft dimensions
  76
• 3.3 Allocation of main bearing shells
  76
• 3.4 Renewing needle bearing in crankshaft
  78
• 3.5 Measuring axial clearance of crankshaft
  81
• 3.6 Measuring radial clearance of crankshaft
  82
• 3.7 Removing and installing sender wheel
  83
• 4 Balancer shaft
  85
• 4.1 Assembly overview - balance shaft
  85
• 4.2 Removing and installing balance shaft
  87
• 4.3 Renewing oil seal for balance shaft (inlet side)
  92
• 5 Pistons and conrods
  94
• 5.1 Assembly overview - pistons and conrods
  94
• 5.2 Removing and installing pistons
  98
• 5.3 Checking pistons and cylinder bores
  100
• 5.4 Separating new conrod
  101
• 5.5 Checking radial clearance of conrods
  102
• 5.6 Removing and installing oil spray jets
  102
• Cylinder head, valve gear
  105
• 1 Cylinder head
  105
• 1.1 Assembly overview - cylinder head
  105
• 1.2 Removing and installing cylinder head
  108
• 1.3 Assembly overview - vacuum pump
  114
• 1.4 Removing and installing vacuum pump
  115
• 1.5 Checking compression
  117
• 2 Cover for timing chain
  120
• 2.1 Assembly overview - cover for timing chain
  120
• 2.3 Removing and installing timing chain cover
  122
• 2.4 Renewing seal for vibration damper
  130
• 3 Chain drive
  134
• 3.1 Assembly overview - camshaft timing chains
  134
• 3.2 Assembly overview - drive chain for balance shaft
  137
• 3.3 Removing and installing camshaft timing chain
  140
• 3.4 Removing and installing drive chain for balance shaft
  152
• 3.5 Checking valve timing
  155
• 3.6 Checking chain elongation
  158
• 4 Valve gear
  160
• 4.1 Assembly overview - valve gear
  160
• 4.2 Removing and installing camshaft
  163
• 4.3 Installing ball for sliding piece
  172
• 4.4 Removing and installing actuators for camshaft adjustment
  173
• 4.5 Removing and installing valve stem seals
  174
• 5 Inlet and exhaust valves
  186
• 5.1 Checking valve guides
  186
• 5.2 Checking valves
  187
• 5.3 Valve dimensions
  187
• Lubrication
  188
• 1 Sump, oil pump
  188
• 1.1 Assembly overview - sump/oil pump
  188
• 1.2 Engine oil:
  191
• 1.3 Removing and installing lower part of sump
  191
• 1.4 Removing and installing upper part of sump
  197
• 1.5 Removing and installing oil pump
  202
• 1.6 Removing and installing oil level and oil temperature sender G266
  204
• 2 Engine oil cooler
  206
• 2.1 Assembly overview - engine oil cooler
  206
• 2.2 Removing and installing engine oil cooler
  206
• 2.3 Removing and installing mechanical switching valve
  208
• 3 Crankcase ventilation
  209
• 3.1 Assembly overview - crankcase breather system
  209
• 3.2 Removing and installing oil separator
  210
• 4 Oil filter, oil pressure switch
  213
• 4.1 Assembly overview - oil filter
  213
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  213
• 4.3 Removing and installing piston cooling jet control valve N522
  215
• 4.4 Removing and installing oil pressure switch F1
  216
• 4.5 Removing and installing oil pressure switch for reduced oil pressure F378
  217
• 4.6 Removing and installing stage 3 oil pressure switch F447
  218
• 4.7 Checking oil pressure
  220
• 4.8 Removing and installing oil pressure regulating valve N428
  224
• Cooling
  226
• 1 Cooling system/coolant
  226
• 1.1 Connection diagram - coolant hoses
  226
• 1.2 Checking cooling system for leaks
  227
• 1.3 Draining and adding coolant
  231
• 2 Coolant pump, regulation of cooling system
  240
• 2.1 Assembly overview - coolant pump, thermostat
  240
• 2.2 Assembly overview - electric coolant pump
  242
• 2.3 Assembly overview - coolant temperature sender
  243
• 2.4 Removing and installing auxiliary pump for heating V488
  244
• 2.5 Removing and installing coolant pump
  247
• 2.6 Removing and installing toothed belt for coolant pump
  248
• 2.7 Removing and installing thermostat housing
  251
• 2.8 Removing and installing coolant valve for gearbox N488
  255
• 2.9 Removing and installing actuator for engine temperature regulation N493
  256
• 2.10 Removing and installing coolant temperature sender G62
  259
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  260
• 3 Coolant pipes
  262
• 3.1 Assembly overview - coolant pipes
  262
• 3.2 Removing and installing coolant pipes
  262
• 3.3 Removing and installing upper coolant pipes
  264
• 4 Radiator, radiator fan
  266
• 4.1 Assembly overview - radiator/radiator fan
  266
• 4.2 Assembly overview – radiator cowl and radiator fan
  267
• 4.3 Removing and installing radiator
  268
• 4.4 Removing and installing radiator cowl
  269
• 4.5 Removing and installing radiator fan
  271
• 4.6 Removing and installing auxiliary radiator
  271
• Turbocharging/supercharging
  274
• 1 Turbocharger
  274
• 1.1 Assembly overview - turbocharger
  274
• 1.2 Removing and installing turbocharger
  280
• 1.3 Adjusting charge pressure positioner V465
  289
• 2 Charge air system
  292
• 2.1 Assembly overview - charge air system
  292
• 2.2 Removing and installing charge air cooler
  294
• 2.3 Removing and installing charge pressure sender G31
  295
• 2.4 Checking charge air system for leaks
  296
• Mixture preparation - injection
  299
• 1 Injection system
  299
• 1.1 Overview of fitting locations - injection system
  299
• 1.2 Releasing high pressure in fuel system
  308
• 2 Injectors
  309
• 2.1 Assembly overview - fuel rail with injectors
  309
• 2.2 Removing and installing fuel rail
  311
• 2.3 Removing and installing injectors
  311
• 2.4 Renewing seals on injectors
  316
• 2.5 Cleaning injectors
  318
• 3 Air filter
  321
• 3.1 Assembly overview - air filter housing
  321
• 3.2 Removing and installing air filter housing
  323
• 4 Intake manifold
  325
• 4.1 Assembly overview – intake manifold
  325
• 4.2 Removing and installing intake manifold
  327
• 4.3 Removing and installing throttle valve module GX3
  333
• 4.4 Cleaning throttle valve module GX3
  334
• 5 Senders and sensors
  336
• 5.1 Removing and installing fuel pressure sender G247
  336
• 5.2 Checking fuel pressure sender G247
  338
• 5.3 Removing and installing intake manifold sender GX9
  341
• 5.4 Removing and installing air mass meter G70
  342
• 6 Engine control unit
  344
• 6.1 Removing and installing engine control unit J623
  344
• 7 High-pressure pump
  348
• 7.1 Assembly overview - high-pressure pump
  348
• 7.2 Removing and installing high-pressure pump
  350
• 8 Lambda probe
  354
• 8.1 Assembly overview - Lambda probe
  354
• 8.2 Removing and installing Lambda probe GX10
  354
• 8.3 Removing and installing Lambda probe after catalytic converter GX7
  357
• Exhaust system
  359
• 1 Exhaust pipes and silencers
  359
• 1.1 Assembly overview – silencers
  359
• 1.2 Removing and installing rear silencer
  364
• 1.3 Aligning exhaust system free of stress
  367
• 1.4 Checking exhaust system for leaks
  368
• 1.5 Installation position of clamp
  368
• 2 Emission control
  371
• 2.1 Assembly overview – emission control
  371
• 2.2 Removing and installing catalytic converter
  371
• 3 Secondary air system
  376
• 3.1 Assembly overview - secondary air system
  376
• 3.2 Removing and installing secondary air pump motor V101
  378
• 3.3 Removing and installing secondary air inlet valve N112
  378
• Ignition system
  380
• 1 Ignition system
  380
• 1.1 Assembly overview - ignition system
  380
• 1.2 Test data, spark plugs
  382
• 1.3 Removing and installing ignition coils with output stage
  382
• 1.4 Removing and installing knock sensor 1 G61
  384
• 1.5 Removing and installing Hall sender G40
  385
• 1.6 Removing and installing Hall sender 3 G300
  386
• 1.7 Removing and installing engine speed sender G28
  386