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

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 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 notes
  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
  15
• 1.3 Securing engine on engine and gearbox support
  17
• 1.4 Installing engine
  20
• 2 Assembly mountings
  23
• 2.1 Assembly overview - assembly mountings
  23
• 2.2 Removing and installing motor mounting
  25
• 2.3 Removing and installing gearbox mounting
  26
• 2.4 Removing and installing pendulum support
  27
• 2.5 Supporting engine in installation position
  27
• 2.6 Adjusting assembly mountings
  35
• 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  37
• 3 Motor cover
  38
• 3.1 Removing and installing engine cover
  38
• Crankshaft group
  39
• 1 Cylinder block (pulley end)
  39
• 1.1 Assembly overview - cylinder block (pulley end)
  39
• 1.2 Removing and installing poly-V belt
  40
• 1.3 Removing and installing tensioner for poly V-belt
  42
• 1.4 Removing and installing vibration damper
  42
• 1.5 Removing and installing bracket for ancillaries
  48
• 1.6 Removing and installing engine support
  50
• 2 Cylinder block, gearbox end
  52
• 2.1 Assembly overview - cylinder block, gearbox end
  52
• 2.2 Assembly overview - drive plate
  53
• 2.3 Removing and installing drive plate
  54
• 2.4 Removing and installing flywheel
  55
• 2.5 Removing and installing sealing flange on gearbox side
  56
• 3 Crankshaft
  60
• 3.1 Assembly overview - crankshaft
  60
• 3.2 Crankshaft dimensions
  61
• 3.3 Allocation of main bearing shells
  62
• 3.4 Renewing needle bearing in crankshaft
  63
• 3.5 Measuring axial clearance of crankshaft
  66
• 3.6 Measuring radial clearance of crankshaft
  67
• 3.7 Removing and installing sender wheel
  67
• 4 Balancer shaft
  69
• 4.1 Assembly overview - balance shaft
  69
• 4.2 Removing and installing balance shaft
  70
• 4.3 Renewing oil seal for balance shaft (inlet side)
  74
• 5 Pistons and conrods
  76
• 5.1 Assembly overview - pistons and conrods
  76
• 5.2 Removing and installing pistons
  77
• 5.3 Checking pistons and cylinder bores
  79
• 5.4 Separating new conrod
  80
• 5.5 Checking radial clearance of conrods
  81
• Cylinder head, valve gear
  82
• 1 Cylinder head
  82
• 1.1 Assembly overview - cylinder head
  82
• 1.2 Assembly overview - camshaft housing
  85
• 1.3 Removing and installing cylinder head
  86
• 1.4 Removing and installing vacuum pump
  90
• 1.5 Checking compression
  91
• 2 Cover for timing chain
  94
• 2.1 Assembly overview - cover for timing chain
  94
• 2.2 Removing and installing timing chain cover
  96
• 2.3 Renewing seal for vibration damper
  102
• 3 Chain drive
  105
• 3.1 Assembly overview - camshaft timing chains
  105
• 3.2 Assembly overview - drive chain for balance shaft
  106
• 3.3 Removing and installing camshaft timing chain
  109
• 3.4 Removing and installing drive chain for balance shaft
  123
• 3.5 Checking chain elongation
  123
• 3.6 Checking valve timing
  124
• 4 Valve gear
  127
• 4.1 Assembly overview - valve gear
  127
• 4.2 Removing and installing camshaft
  130
• 4.3 Removing and installing camshaft control valve 1 N205
  143
• 4.4 Removing and installing valve stem seals
  144
• 5 Inlet and exhaust valves
  152
• 5.1 Checking valve guides
  152
• 5.2 Checking valves
  153
• 5.3 Valve dimensions
  153
• Lubrication
  154
• 1 Sump, oil pump
  154
• 1.1 Assembly overview - sump/oil pump
  154
• 1.2 Engine oil:
  157
• 1.3 Removing and installing lower part of sump
  157
• 1.4 Removing and installing upper part of sump
  159
• 1.5 Removing and installing oil pump
  162
• 1.6 Removing and installing oil level and oil temperature sender G266
  164
• 2 Engine oil cooler
  166
• 2.1 Assembly overview - engine oil cooler
  166
• 2.2 Removing and installing engine oil cooler
  166
• 2.3 Removing and installing mechanical switching valve
  168
• 3 Crankcase ventilation
  169
• 3.1 Assembly overview - crankcase breather system
  169
• 3.2 Removing and installing oil separator
  170
• 4 Oil filter, oil pressure switch
  171
• 4.1 Assembly overview - oil filter
  171
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  172
• 4.3 Removing and installing piston cooling jet control valve N522
  173
• 4.4 Removing and installing oil pressure switch F1
  173
• 4.5 Removing and installing oil pressure switch for reduced oil pressure F378
  174
• 4.6 Removing and installing stage 3 oil pressure switch F447
  175
• 4.7 Checking oil pressure
  177
• 4.8 Removing and installing oil pressure regulating valve N428
  180
• Cooling
  182
• 1 Cooling system/coolant
  182
• 1.1 Connection diagram - coolant hoses
  182
• 1.2 Checking cooling system for leaks
  185
• 1.3 Draining and adding coolant
  187
• 2 Coolant pump, regulation of cooling system
  194
• 2.1 Assembly overview - coolant pump, thermostat
  194
• 2.2 Assembly overview - electric coolant pump
  196
• 2.3 Assembly overview - coolant temperature sender
  199
• 2.5 Removing and installing coolant pump
  201
• 2.6 Removing and installing coolant shut-off valve N82
  202
• 2.8 Removing and installing toothed belt for coolant pump
  206
• 2.9 Removing and installing thermostat housing
  208
• 2.10 Removing and installing coolant temperature sender G62
  211
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  212
• 3 Coolant pipes
  214
• 3.1 Assembly overview - coolant pipes
  214
• 3.2 Removing and installing coolant pipes
  214
• 3.3 Removing and installing upper coolant pipes
  215
• 4 Radiator, radiator fan
  218
• 4.1 Assembly overview - radiator/radiator fan
  218
• 4.2 Assembly overview - radiator cowl and radiator fan
  219
• 4.3 Removing and installing radiator
  219
• 4.4 Removing and installing radiator cowl
  220
• 4.5 Removing and installing radiator fan
  221
• 4.6 Removing and installing auxiliary radiator
  221
• Turbocharging/supercharging
  224
• 1 Exhaust turbocharger
  224
• 1.1 Assembly overview - turbocharger
  224
• 1.2 Removing and installing turbocharger
  229
• 2 Charge air system
  236
• 2.1 Assembly overview - charge air system
  236
• 2.2 Removing and installing charge air cooler
  237
• 2.3 Removing and installing charge pressure sender G31
  238
• 2.4 Checking charge air system for leaks
  238
• Mixture preparation - injection
  241
• 1 Injection system
  241
• 1.1 Overview of fitting locations - injection system
  241
• 1.2 Releasing high pressure in fuel system
  243
• 2 Injectors
  245
• 2.1 Assembly overview - fuel rail with injectors
  245
• 2.2 Removing and installing fuel rail
  247
• 2.3 Removing and installing injectors
  248
• 2.4 Renewing seals on injectors
  250
• 2.5 Cleaning injectors
  252
• 3 Air filter
  254
• 3.1 Assembly overview - air filter housing
  254
• 3.2 Removing and installing air filter housing
  255
• 4 Intake manifold
  257
• 4.1 Assembly overview - intake manifold
  257
• 4.2 Removing and installing intake manifold
  258
• 4.3 Removing and installing throttle valve module J338
  262
• 4.4 Cleaning throttle valve module
  263
• 5 Senders and sensors
  265
• 5.3 Removing and installing fuel pressure sender G247
  266
• 5.4 Checking fuel pressure sender G247
  268
• 6 Engine (motor) control unit
  271
• 6.1 Removing and installing engine (motor) control unit J623
  271
• 7 High-pressure pump
  275
• 7.1 Assembly overview - high-pressure pump
  275
• 7.2 Removing and installing high-pressure pump
  276
• 8 Lambda probe
  280
• 8.1 Assembly overview - Lambda probe
  280
• 8.2 Removing and installing Lambda probe G39
  280
• 8.3 Removing and installing Lambda probe after catalytic converter G130
  282
• Exhaust system
  283
• 1 Exhaust pipes and silencers
  283
• 1.1 Assembly overview - silencers
  283
• 1.2 Removing and installing rear silencer
  286
• 1.3 Aligning exhaust system free of stress
  289
• 1.4 Check exhaust system for leaks
  290
• 1.5 Installation position of clamp
  290
• 2 Exhaust gas cleaning
  292
• 2.1 Assembly overview - emission control
  292
• 2.2 Removing and installing catalytic converter
  292
• 3 Secondary air system
  296
• 3.1 Assembly overview - secondary air system
  296
• 3.2 Removing and installing secondary air pump motor V101
  297
• 3.3 Removing and installing secondary air inlet valve N112
  297
• Ignition system
  299
• 1 Ignition system
  299
• 1.1 Assembly overview - ignition system
  299
• 1.2 Test data, spark plugs
  300
• 1.3 Removing and installing ignition coils with output stage
  300
• 1.4 Removing and installing knock sensor 1 G61
  302
• 1.5 Removing and installing Hall sender
  303
• 1.6 Removing and installing engine speed sender G28
  303