4-cylinder direct-injection engine (2.0l, 4V, TFSI, EA888evo4)

Chapter overview

• 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 start/stop system
  1
• 1.4 Safety precautions when working on ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Initial diagnoses
  6
• 3.3 Foreign objects in engine
  7
• 3.4 Contact corrosion
  7
• 3.5 Routing and attachment of lines
  7
• 3.6 Fitting radiator and condensers
  7
• 3.7 Checking vacuum system
  7
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  29
• 1.3 Securing engine on engine and gearbox support
  34
• 1.4 Installing engine
  36
• 2 Assembly mountings
  40
• 2.1 Assembly overview - assembly mountings
  40
• 2.2 Removing and installing engine mounting
  43
• 2.3 Removing and installing gearbox mounting
  44
• 2.4 Removing and installing pendulum support
  46
• 2.5 Supporting engine in installation position
  46
• 2.6 Checking adjustment of assembly mountings
  73
• 2.7 Adjusting assembly mountings
  73
• 3 Engine cover panel
  76
• 3.1 Removing and installing engine cover
  76
• Crankshaft group
  77
• 1 Cylinder block (pulley end)
  77
• 1.1 Assembly overview - cylinder block (pulley end)
  77
• 1.2 Removing and installing poly-V belt
  80
• 1.3 Removing and installing tensioner for poly V-belt
  81
• 1.4 Removing and installing vibration damper
  81
• 1.5 Removing and installing bracket for ancillaries
  89
• 1.6 Removing and installing engine support
  92
• 2 Cylinder block, gearbox end
  95
• 2.1 Assembly overview - cylinder block, gearbox end
  95
• 2.2 Removing and installing flywheel
  97
• 2.3 Removing and installing sealing flange on gearbox side
  99
• 3 Crankshaft
  104
• 3.1 Assembly overview - crankshaft
  104
• 3.2 Crankshaft dimensions
  107
• 3.3 Allocation of main bearing shells
  107
• 3.4 Renewing needle bearing in crankshaft
  109
• 3.5 Measuring axial clearance of crankshaft
  112
• 3.6 Measuring radial clearance of crankshaft
  113
• 3.7 Removing and installing crankshaft
  114
• 3.8 Removing and installing sender wheel
  116
• 4 Balancer shaft
  117
• 4.1 Assembly overview - balance shaft
  117
• 4.2 Removing and installing balance shaft
  119
• 5 Pistons and conrods
  126
• 5.1 Assembly overview - pistons and conrods
  126
• 5.2 Removing and installing pistons
  131
• 5.3 Removing and installing oil spray jets
  134
• 5.4 Checking pistons and cylinder bores
  136
• 5.5 Separating new conrod
  138
• 5.6 Checking radial clearance of conrods
  138
• Cylinder head, valve gear
  140
• 1 Cylinder head
  140
• 1.1 Assembly overview - cylinder head
  140
• 1.2 Removing and installing cylinder head
  144
• 1.3 Removing and installing vacuum pump
  153
• 1.4 Checking compression
  154
• 2 Cover for timing chain
  157
• 2.1 Assembly overview - cover for timing chain
  157
• 2.2 Removing and installing timing chain cover
  160
• 2.3 Renewing seal for vibration damper
  165
• 3 Chain drive
  168
• 3.1 Assembly overview - camshaft timing chains
  168
• 3.2 Assembly overview - drive chain for balance shaft
  170
• 3.3 Removing and installing camshaft timing chain
  173
• 3.4 Removing and installing bearing saddle
  196
• 3.5 Checking timing chain
  201
• 3.6 Removing and installing drive chain for balance shaft
  202
• 4 Valve gear
  207
• 4.1 Assembly overview – valve gear
  207
• 4.2 Removing and installing camshaft
  215
• 4.3 Removing and installing actuators for camshaft adjustment
  233
• 4.4 Removing and installing camshaft control valves N205/N318
  234
• 4.5 Removing and installing valve stem seals
  235
• 5 Inlet and exhaust valves
  247
• 5.1 Checking valve guides
  247
• 5.2 Checking valves
  248
• 5.3 Valve dimensions
  248
• Lubrication
  249
• 1 Sump, oil pump
  249
• 1.1 Assembly overview - sump/oil pump
  249
• 1.2 Engine oil:
  252
• 1.3 Removing and installing lower part of sump
  252
• 1.4 Removing and installing oil pump
  253
• 1.5 Removing and installing upper part of sump
  254
• 1.6 Removing and installing oil level and oil temperature sender G266
  259
• 2 Engine oil cooler
  261
• 2.1 Assembly overview - engine oil cooler
  261
• 2.2 Removing and installing engine oil cooler
  261
• 3 Crankcase ventilation
  263
• 3.1 Assembly overview - crankcase breather system
  263
• 3.2 Removing and installing oil separator
  264
• 3.3 Removing and installing crankcase pressure sensor G1068
  265
• 4 Oil filter, oil pressure switch
  267
• 4.1 Assembly overview - oil filter
  267
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  267
• 4.3 Removing and installing oil pressure switch
  269
• 4.4 Removing and installing oil pressure regulating valve N428
  271
• 4.5 Removing and installing piston cooling jet control valve N522
  272
• 4.6 Checking oil pressure
  272
• Cooling
  276
• 1 Cooling system/coolant
  276
• 1.1 Connection diagram - coolant hoses
  276
• 1.2 Checking cooling system for leaks
  277
• 1.3 Draining and adding coolant
  281
• 2 Coolant pump, regulation of cooling system
  290
• 2.1 Assembly overview - coolant pump, thermostat
  290
• 2.2 Assembly overview - electric coolant pump
  292
• 2.3 Assembly overview – coolant valves
  293
• 2.4 Assembly overview - coolant temperature sender
  294
• 2.5 Removing and installing electric coolant pump
  295
• 2.6 Removing and installing coolant pump
  298
• 2.7 Removing and installing toothed belt for coolant pump
  299
• 2.8 Removing and installing actuator for engine temperature regulation N493
  301
• 2.9 Removing and installing coolant temperature sender G62
  304
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  305
• 2.11 Removing and installing coolant valves
  305
• 3 Coolant pipes
  308
• 3.1 Assembly overview - coolant pipes
  308
• 3.2 Removing and installing coolant pipes
  309
• 4 Radiator, radiator fan
  316
• 4.1 Assembly overview - radiator/radiator fan
  316
• 4.2 Assembly overview – radiator cowl and radiator fan
  319
• 4.3 Assembly overview - auxiliary radiator
  321
• 4.4 Removing and installing radiator
  322
• 4.5 Removing and installing radiator cowl
  328
• 4.6 Removing and installing radiator fan
  333
• 4.7 Removing and installing auxiliary radiator
  334
• Turbocharging/supercharging
  337
• 1 Turbocharger
  337
• 1.1 Assembly overview – turbocharger
  337
• 1.2 Removing and installing turbocharger
  347
• 1.3 Removing and installing charge pressure control module GX34
  353
• 2 Charge air system
  357
• 2.1 Assembly overview – charge air system
  357
• 2.2 Assembly overview - charge-air hose connections
  362
• 2.3 Removing and installing charge air cooler
  363
• 2.4 Removing and installing charge pressure sender G31
  367
• 2.6 Removing and installing air intake pipe
  368
• 2.7 Checking charge air system for leaks
  373
• Mixture preparation - injection
  376
• 1 Injection system
  376
• 1.1 Overview of fitting locations - injection system
  376
• 2 Vacuum system
  385
• 2.1 Connection diagram – vacuum system
  385
• 2.2 Checking vacuum system
  385
• 3 Injectors
  387
• 3.1 Assembly overview - fuel rail with injectors
  387
• 3.2 Removing and installing fuel rail
  388
• 3.3 Removing and installing injectors
  390
• 3.4 Cleaning injectors
  395
• 4 Air filter
  397
• 4.1 Assembly overview – air filter housing
  397
• 4.2 Removing and installing air filter housing
  399
• 4.3 Removing and installing air guide on lock carrier
  401
• 5 Intake manifold
  404
• 5.1 Assembly overview – intake manifold
  404
• 5.2 Removing and installing intake manifold
  406
• 5.3 Removing and installing throttle valve module GX3
  410
• 5.4 Cleaning throttle valve module GX3
  411
• 5.5 Removing and installing intake manifold flap valve N316
  412
• 5.6 Checking intake manifold change-over
  412
• 6 Senders and sensors
  415
• 6.3 Removing and installing intake manifold sender GX9
  419
• 6.4 Removing and installing fuel pressure sender G247
  419
• 6.5 Checking fuel pressure sender G247
  420
• 6.6 Removing and installing pressure differential sender for particulate filter G1037
  423
• 7 Engine control unit
  425
• 7.1 Removing and installing engine control unit J623
  425
• 8 High-pressure pump
  427
• 8.1 Assembly overview - high-pressure pump
  427
• 8.2 Removing and installing high-pressure pump
  430
• 8.3 Removing and installing high-pressure pipe
  432
• 9 Lambda probe
  433
• 9.1 Assembly overview - Lambda probe
  433
• 9.2 Removing and installing Lambda probe
  435
• Exhaust system
  437
• 1 Exhaust pipes and silencers
  437
• 1.1 Assembly overview – silencers
  437
• 1.2 Removing and installing silencer
  447
• 1.3 Separating exhaust pipes from silencers
  457
• 1.4 Aligning exhaust system free of stress
  464
• 1.5 Checking exhaust system for leaks
  464
• 1.6 Removing and installing bracket for catalytic converter, Tiguan
  464
• 2 Emission control
  468
• 2.1 Assembly overview – emission control
  468
• 2.3 Removing and installing catalytic converter
  475
• 2.5 Removing and installing exhaust flap control unit
  485
• 3 Exhaust gas temperature regulation
  486
• 3.1 Assembly overview – exhaust gas temperature regulation
  486
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  487
• Ignition system
  492
• 1 Ignition system
  492
• 1.1 Assembly overview - ignition system
  492
• 1.2 Removing and installing ignition coils
  494
• 1.3 Removing and installing knock sensor 1 G61
  496
• 1.4 Removing and installing Hall sender
  497
• 1.5 Removing and installing engine speed sender G28
  499