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

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on exhaust system
  1
• 1.2 Safety regulations for working on fuel supply
  1
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.5 Safety precautions when working on ignition system
  2
• 1.6 Safety precautions when working on cooling system
  3
• 1.7 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 Adapting after component replacement
  6
• 3.3 General information
  7
• 3.4 General repair instructions
  7
• 3.5 Foreign objects in engine
  8
• 3.6 Contact corrosion
  9
• 3.7 Routing and attachment of lines
  9
• 3.8 Fitting radiators and condensers
  9
• 3.9 Checking vacuum system
  9
• 3.10 Nuts and bolts
  10
• 3.11 Identification labels
  10
• 3.12 Using impact drivers
  10
• 3.13 Checking fuel system for leaks
  11
• Removing and installing engine
  12
• 1 Removing and installing engine
  12
• 1.1 Removing engine
  12
• 1.2 Separating engine and gearbox
  28
• 1.3 Securing engine on engine and gearbox support
  33
• 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
  50
• 2.7 Adjusting assembly mountings
  51
• 3 Engine cover panel
  54
• 3.1 Removing and installing engine cover
  54
• Crankshaft group
  55
• 1 Cylinder block (pulley end)
  55
• 1.1 Assembly overview - cylinder block (pulley end)
  55
• 1.2 Removing and installing poly-V belt
  58
• 1.3 Removing and installing tensioner for poly V-belt
  59
• 1.4 Removing and installing vibration damper
  59
• 1.5 Removing and installing bracket for ancillaries
  68
• 1.6 Removing and installing engine support
  71
• 1.7 Renewing crankshaft oil seal - belt pulley end
  73
• 2 Cylinder block, gearbox end
  76
• 2.1 Assembly overview - cylinder block, gearbox end
  76
• 2.2 Removing and installing flywheel
  78
• 2.3 Removing and installing sealing flange on gearbox side
  79
• 3 Crankshaft
  84
• 3.1 Assembly overview - crankshaft
  84
• 3.2 Crankshaft dimensions
  87
• 3.3 Allocation of main bearing shells
  87
• 3.4 Renewing needle bearing in crankshaft
  89
• 3.5 Measuring axial clearance of crankshaft
  92
• 3.6 Measuring radial clearance of crankshaft
  93
• 3.7 Removing and installing crankshaft
  94
• 3.8 Removing and installing sender wheel
  96
• 4 Balancer shaft
  97
• 4.1 Assembly overview - balance shaft
  97
• 4.2 Removing and installing balance shaft
  99
• 4.3 Renewing oil seal for balance shaft (inlet side)
  104
• 5 Pistons and conrods
  106
• 5.1 Assembly overview - pistons and conrods
  106
• 5.2 Removing and installing pistons
  111
• 5.3 Removing and installing oil spray jets
  114
• 5.4 Checking pistons and cylinder bores
  116
• 5.5 Separating new conrod
  118
• 5.6 Checking radial clearance of conrods
  118
• Cylinder head, valve gear
  120
• 1 Cylinder head
  120
• 1.1 Assembly overview - cylinder head
  120
• 1.2 Assembly overview - vacuum pump
  124
• 1.3 Removing and installing cylinder head
  125
• 1.4 Removing and installing vacuum pump
  134
• 1.5 Checking compression
  135
• 2 Cover for timing chain
  138
• 2.1 Assembly overview - cover for timing chain
  138
• 2.2 Removing and installing timing chain cover
  141
• 3 Chain drive
  147
• 3.1 Assembly overview - camshaft timing chains
  147
• 3.2 Assembly overview - drive chain for balance shaft
  150
• 3.3 Removing and installing bearing saddle
  153
• 3.4 Removing and installing camshaft timing chain
  158
• 3.5 Checking timing chain
  168
• 3.6 Removing and installing drive chain for balance shaft
  169
• 4 Valve gear
  174
• 4.1 Assembly overview - valve gear
  174
• 4.2 Removing and installing camshaft
  178
• 4.3 Installing ball for sliding piece
  187
• 4.4 Removing and installing actuators for camshaft adjustment
  188
• 4.5 Removing and installing camshaft control valve 1 N205
  189
• 4.6 Removing and installing exhaust camshaft control valve 1 N318
  190
• 4.7 Removing and installing valve stem oil seals
  190
• 5 Inlet and exhaust valves
  203
• 5.1 Checking valve guides
  203
• 5.2 Checking valves
  204
• 5.3 Valve dimensions
  204
• Lubrication
  205
• 1 Sump, oil pump
  205
• 1.1 Assembly overview - sump/oil pump
  205
• 1.2 Engine oil:
  208
• 1.3 Removing and installing lower part of sump
  208
• 1.4 Removing and installing oil pump
  209
• 1.5 Removing and installing upper part of sump
  210
• 1.6 Removing and installing oil level and oil temperature sender G266
  215
• 2 Engine oil cooler
  216
• 2.1 Assembly overview - engine oil cooler
  216
• 2.2 Removing and installing engine oil cooler
  216
• 2.3 Removing and installing mechanical switching valve
  217
• 3 Crankcase ventilation
  218
• 3.1 Assembly overview - crankcase breather system
  218
• 3.2 Removing and installing oil separator
  219
• 3.3 Removing and installing crankcase pressure sensor G1068
  220
• 4 Oil filter, oil pressure switch
  222
• 4.1 Assembly overview - oil filter
  222
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  222
• 4.3 Removing and installing oil pressure switch F22
  224
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  224
• 4.5 Removing and installing stage 2 oil pressure switch F446
  225
• 4.6 Removing and installing oil pressure regulating valve N428
  226
• 4.7 Removing and installing piston cooling jet control valve N522
  227
• 4.8 Checking oil pressure
  227
• Cooling
  231
• 1 Cooling system/coolant
  231
• 1.1 Connection diagram - coolant hoses
  231
• 1.2 Checking cooling system for leaks
  232
• 1.3 Draining and adding coolant
  236
• 2 Coolant pump, regulation of cooling system
  245
• 2.1 Assembly overview - coolant pump, thermostat
  245
• 2.2 Assembly overview - electric coolant pump
  247
• 2.3 Assembly overview – coolant valves
  248
• 2.4 Assembly overview - coolant temperature sender
  249
• 2.5 Removing and installing electric coolant pump
  250
• 2.6 Removing and installing coolant pump
  253
• 2.7 Removing and installing toothed belt for coolant pump
  254
• 2.8 Removing and installing actuator for engine temperature regulation N493
  256
• 2.9 Removing and installing coolant temperature sender G62
  259
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  260
• 2.11 Removing and installing coolant valves
  260
• 3 Coolant pipes
  263
• 3.1 Assembly overview - coolant pipes
  263
• 3.2 Removing and installing coolant pipes
  264
• 4 Radiator, radiator fan
  271
• 4.1 Assembly overview - radiator/radiator fan
  271
• 4.2 Assembly overview – radiator cowl and radiator fan
  272
• 4.3 Assembly overview - auxiliary radiator
  273
• 4.4 Removing and installing radiator
  274
• 4.5 Removing and installing radiator cowl
  276
• 4.6 Removing and installing radiator fan
  277
• 4.7 Removing and installing auxiliary radiator
  278
• Turbocharging/supercharging
  281
• 1 Turbocharger
  281
• 1.1 Assembly overview - turbocharger
  281
• 1.2 Removing and installing turbocharger
  286
• 1.3 Removing and installing charge pressure control module GX34
  292
• 1.4 Removing and installing turbocharger air recirculation valve
  294
• 2 Charge air system
  296
• 2.1 Assembly overview - charge air system
  296
• 2.2 Assembly overview - charge-air hose connections
  297
• 2.3 Removing and installing charge air cooler
  299
• 2.4 Removing and installing charge pressure sender G31
  301
• 2.5 Removing and installing air intake pipe
  302
• 2.6 Checking charge air system for leaks
  305
• Mixture preparation - injection
  308
• 1 Injection system
  308
• 1.1 Overview of fitting locations - injection system
  308
• 2 Vacuum system
  315
• 2.1 Connection diagram – vacuum system
  315
• 2.2 Checking vacuum system
  315
• 3 Injectors
  317
• 3.1 Assembly overview - fuel rail with injectors
  317
• 3.2 Removing and installing fuel rail
  318
• 3.3 Removing and installing injectors
  320
• 3.4 Cleaning injectors
  325
• 4 Air filter
  327
• 4.1 Assembly overview - air filter housing
  327
• 4.2 Removing and installing air filter housing
  329
• 4.3 Removing and installing air guide on lock carrier
  330
• 5 Intake manifold
  332
• 5.1 Assembly overview – intake manifold
  332
• 5.2 Removing and installing intake manifold
  334
• 5.3 Removing and installing throttle valve module GX3
  338
• 5.4 Cleaning throttle valve module GX3
  339
• 5.5 Removing and installing intake manifold flap valve N316
  340
• 5.6 Checking intake manifold change-over
  340
• 6 Senders and sensors
  343
• 6.2 Control unit for structure-borne sound and actuator for structure-borne sound
  344
• 6.3 Removing and installing intake manifold pressure sender G71
  345
• 6.4 Removing and installing fuel pressure sender G247
  345
• 6.5 Checking fuel pressure sender G247
  346
• 6.6 Removing and installing pressure differential sender for particulate filter G1037
  349
• 7 Engine control unit
  351
• 7.1 Assembly overview – engine/motor control unit
  351
• 7.2 Removing and installing engine control unit J623
  351
• 8 High-pressure pump
  353
• 8.1 Assembly overview - high-pressure pump
  353
• 8.2 Removing and installing high-pressure pump
  356
• 8.3 Removing and installing high-pressure pipe
  358
• 9 Lambda probe
  360
• 9.1 Assembly overview - Lambda probe
  360
• 9.2 Removing and installing Lambda probe
  362
• Exhaust system
  365
• 1 Exhaust pipes and silencers
  365
• 1.1 Assembly overview – silencers
  365
• 1.2 Removing and installing silencer
  366
• 1.3 Aligning exhaust system free of stress
  368
• 1.4 Checking exhaust system for leaks
  369
• 1.5 Installation position of clamp
  369
• 2 Emission control
  371
• 2.1 Assembly overview – emission control
  371
• 2.3 Removing and installing bracket for catalytic converter
  375
• 2.4 Removing and installing catalytic converter
  378
• 3 Exhaust gas temperature regulation
  388
• 3.1 Assembly overview – exhaust gas temperature regulation
  388
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  390
• Ignition system
  392
• 1 Ignition system
  392
• 1.1 Assembly overview - ignition system
  392
• 1.2 Removing and installing ignition coils
  394
• 1.3 Removing and installing knock sensor 1 G61
  396
• 1.4 Removing and installing Hall sender
  397
• 1.5 Removing and installing engine speed sender G28
  399